GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Valve Rocker Arm Cover Replacement - Upper Right Side

Removal Procedure

    Object Number: 813243 Size: SH
  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. Object Number: 813244 Size: SH

    Important: After removing the turbocharger air ducts, cover the turbocharger openings with tape to prevent entry of objects.

  4. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
  5. Remove the outlet duct from the turbocharger.

    6. Object Number: 877275 Size: SH
  6. Loosen the charged air cooler outlet duct to intake hose clamp (1).

    7. 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 outlet duct from the intake.

    8. Object Number: 665386 Size: SH
  8. Remove the heater outlet hose bolt (2) and nut (1).
  9. Remove the fuel filter mounting bolts. Refer to Fuel Filter Replacement .
  10. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  11. Remove the exhaust gas recirculation (EGR) cooler tube, if equipped. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  12. Position the heater outlet hose out of the way.

    13. Object Number: 687021 Size: SH
  13. Disconnect positive crankcase ventilation (PCV) hose from the valve rocker arm cover.

    14. Object Number: 798894 Size: SH
  14. Remove the sleeve nut plate bolts and plates.
  15. Remove the fuel injector feed pipes.

    16. Object Number: 665256 Size: SH
  16. Remove the upper valve rocker arm cover bolts.

    17. Note the location of any wire harness clips.

    Important: The valve rocker arm cover uses sealer. Pry only at the location shown in order to avoid damage to the sealing surfaces.

  17. Using a suitable tool at the prying location, loosen the upper valve rocker arm cover.

    18. Object Number: 660467 Size: SH
  18. Remove the upper valve rocker arm cover.
  19. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper .

Installation Procedure

    Object Number: 663817 Size: SH
  1. 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.
  2. 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.

    3. Object Number: 660467 Size: SH
  3. Install the upper valve rocker arm cover.

    4. Object Number: 663904 Size: SH

    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.

  4. Install the upper valve rocker arm cover bolts. Install bolts 1 and 2 first, they are used to position the cover.

    5. Tighten the bolts in the sequence shown.

    Tighten

    1. Tighten the bolts a first pass to 8 N·m (71 lb in).
    2. Tighten the bolts a final pass to 8 N·m (71 lb in).

    Object Number: 798894 Size: SH
  5. Install the fuel injector feed pipes.

    6. Tighten
    Tighten the pipes to 41 N·m (30 lb ft).

  6. Install the sleeve nut plates and bolts.

    7. Tighten
    Tighten the bolts to 4 N·m (35 lb in).


    Object Number: 687021 Size: SH
  7. Connect PCV hoses to the upper valve rocker arm cover.

    8. Object Number: 665386 Size: SH
  8. Position the heater outlet hose.
  9. Install the EGR cooler tube, if equipped. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  10. Install the fuel filter mounting bolts. Refer to Fuel Filter Replacement .
  11. Install the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  12. Install the heater hose bracket bolt (2) and nut (1).

    13. Tighten

        • Tighten the nut to 9 N·m (80 lb in).
        • Tighten the bolt to 21 N·m (15 lb ft).

    Object Number: 877275 Size: SH
  13. Remove the tape from the turbocharger openings.
  14. Install the charged air cooler outlet duct to the intake.
  15. Align the mark on the duct (3) to the mark on the intake
  16. Position the clamp (1) as shown for proper clearance.

    17. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 813246 Size: SH
  17. Install the outlet duct to the turbocharger.
  18. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).

    19. Object Number: 813244 Size: SH

    Important: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.

  19. Install the outlet duct to the MAF/IAT sensor.
  20. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.

    21. Tighten
    Tighten the clamps to 6 N·m (53 lb ft).


    Object Number: 813243 Size: SH
  21. Install the upper intake manifold cover.
  22. Install the upper intake manifold cover to the outlet duct.
  23. Tighten the outlet duct clamp at the upper intake manifold cover.

    24. Tighten
    Tighten the clamp to 6 N·m (53 lb ft).