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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 997 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Valve Rocker Arm Cover Replacement - Upper Left >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Loosen the outlet duct clamp at the upper intake manifold cover.
  2. Remove the upper intake manifold cover from the outlet duct.
  3. Remove the upper intake manifold cover.
    4. Fig 1: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  4. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  5. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  6. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  7. Remove the charged air cooler inlet duct from the turbocharger.
    8. Fig 2: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  8. Remove the battery cable to generator nut.
  9. If equipped, remove the battery cable to the auxiliary generator.
  10. Remove the battery cable harness clip from the bracket.
  11. Remove the battery cable junction block bolt from the power steering pump.
    12. Fig 3: View Of Upper Engine
    GM666693Courtesy of GENERAL MOTORS CORP.
  12. Move and secure the battery cables out of the way.
  13. Disconnect the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6L.
  14. Remove the fuel hose bracket nut.
    15. Fig 4: View Of Fuel Hose Bracket & Nut
    GM674616Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel injection control module electrical connectors. Lift up on the latch in order to disconnect the connectors.
  16. Remove the fuel injection control module wiring harness clip from the bracket.
    17. Fig 5: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  17. Remove the engine-to-chassis harness connector bolts (1).
  18. Remove the engine-to-chassis harness bracket bolts (2).
    19. Fig 6: View Of Engine-To-Chassis Harness Connector & Bracket Bolts
    GM674680Courtesy of GENERAL MOTORS CORP.
  19. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LB7) Engine) in Engine Cooling.
  20. Remove the glow plug relay bracket. Refer to Glow Plug Relay Replacement (Federal Emissions) or Glow Plug Relay Replacement (California Emissions) in Engine Controls - 6.6L.
  21. Remove the auxiliary generator, if equipped. Refer to Generator Replacement - Auxiliary (6.6L (LB7) Engine) in Engine Electrical.
  22. Disconnect the positive crankcase ventilation (PCV) hose from the upper valve rocker arm cover.
    23. Fig 7: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  23. Remove the sleeve nut plate bolts and plates.
  24. Remove the fuel injector feed pipes.
    25. Fig 8: View Of Fuel Injector Feed Pipes (Left)
    GM798893Courtesy of GENERAL MOTORS CORP.
  25. Remove the upper valve rocker arm cover bolts.
    26. IMPORTANT: The valve rocker arm cover uses sealer. Pry only at the location shown in order to avoid damage to the sealing surfaces.
  26. Using a suitable tool at the prying location, loosen the upper valve rocker arm cover.
    27. Fig 9: View Of Upper Valve Rocker Arm Cover Prying Location
    GM665256Courtesy of GENERAL MOTORS CORP.
  27. Remove the upper valve rocker arm cover.
    28. Fig 10: View Of Upper Valve Rocker Arm Cover
    GM660467Courtesy of GENERAL MOTORS CORP.
  28. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper .
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