- Apply a 2-3 mm (1/8 in)
wide, by 0.5-1.5 mm (1/16 in) high bead of sealant, GM P/N 97720043
(Canadian P/N 88901148), or equivalent to the upper valve rocker
arm cover.
- Apply a bead of sealant GM P/N 97720043 (Canadian P/N 88901148),
or equivalent to the area under the injector wire harness on the lower valve rocker
arm cover.
- Install the upper valve rocker arm cover.
- Install the upper valve rocker arm cover
bolts. Install bolts 1 and 2 first, they are used to position the cover.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Tighten the upper valve rocker arm cover bolts in the sequence shown.
Tighten
- Tighten the bolts a first pass to 8 N·m (71 lb in).
- Tighten the bolts a final pass to 8 N·m (71 lb in).
- Install the fuel injector feed pipes.
Tighten
Tighten the pipes to 41 N·m (30 lb ft).
- Install the sleeve nut plates and bolts.
Tighten
Tighten the bolts to 4 N·m (35 lb in).
- Connect the PCV hose to the upper valve rocker arm cover.
- Install the engine-to-chassis harness connector
bracket bolts (2).
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
- Install the engine-to-chassis harness electrical connectors
bolts (1).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Connect the fuel injection control module
electrical harness connectors.
- Install the fuel injection control module wiring harness to the retainer.
- Install the water outlet tube. Refer to
Water Outlet Tube Replacement
in Engine Cooling.
- Install the glow plug relay bracket. Refer to
Glow Plug Relay Replacement
in Engine Controls - 6.6L.
- Install the auxiliary generator, if equipped. Refer to
Auxiliary Generator Replacement
in Engine Electrical.
- Connect the fuel lines. Refer to
Metal Collar Quick Connect Fitting Service
in Engine
Controls - 6.6L.
- Install the fuel hose bracket nut.
Tighten
Tighten the nut to 21 N·m (15 lb ft).
- Position the generator positive cable.
- Install the generator positive cable in the clip on the engine front
cover.
- Install the generator positive cable and nut.
Tighten
Tighten the nut to 9 N·m (80 lb in).
- Install the positive battery cable junction block bracket and bolt to
the power steering pump.
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- Remove the tape from the turbocharger openings.
- Install the charged air cooler inlet duct to the turbocharger.
- Align the mark on the duct (2) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N·m (53 lb in).
- Install the upper intake manifold cover.
- Install the upper intake manifold cover to the outlet duct.
- Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten
Tighten the clamp to 6 N·m (53 lb in).
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.