GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 GMC K Sierra - 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
  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 and MAF/IAT sensor.

    6. Object Number: 664851 Size: SH

    Important: After removing the turbocharger air ducts, hoses cover the turbocharger, the air inlet duct, and the charged air cooler openings with tape to prevent entry of objects.

  6. Loosen both hose clamps for the charged air cooler outlet duct to intake manifold tube hose.

    7. Important: Do not use a screwdriver or other prying tool to remove the hose. The hose can be damaged.

  7. Using a twisting motion remove the hose from the intake manifold tube and the pipe.
  8. Cover the opening on the pipe and the intake manifold tube with tape.

    9. Object Number: 665386 Size: SH
  9. Remove the bolt (2) retaining the outlet heater hose to the generator mounting bracket.
  10. Remove the fuel filter mounting bolts. Refer to Fuel Filter Replacement in Engine Controls - 6.6 L.
  11. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.
  12. Position the outlet heater hose out of the way.

    13. Object Number: 687021 Size: SH
  13. Disconnect PCV hose from the valve rocker arm cover.

    14. Object Number: 1336209 Size: SH
  14. Before removing the fuel injector lines, use compressed air to blow any debris from the injector lines and fittings (1, 2). Wipe the fittings clean of debris.
  15. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line fittings (1, 2) to assist in containing any debris during removal.
  16. Remove the injector line(s).

    17. Object Number: 665256 Size: SH
  17. Remove the 11 bolts from the upper valve rocker arm cover.

    18. Note the location of any wire harness clips.

    Important: The upper valve rocker arm cover uses sealer. Pry only at the locations shown. Avoid damage to the sealing surfaces.

  18. Using a gasket scraper or other suitable tool at the prying locations, loosen the upper valve rocker arm cover.

    19. Object Number: 660467 Size: SH
  19. Remove the upper valve rocker arm cover.

    20. Object Number: 1336205 Size: SH

    Notice: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.

  20. Immediately after removal of the cover, use a vacuum source to remove any contamination in the fuel injector inlet (1).

    21. Object Number: 663628 Size: SH
  21. If replacing the upper valve rocker arm cover, remove the grommets for the injector line fittings.

    22. Object Number: 663733 Size: SH
  22. If replacing the upper valve rocker arm cover, remove the screws, PCV diaphragm, and spring.
  23. Inspect the PCV diaphragm for damage.
  24. Replace the PCV diaphragm if damage is found.
  25. Clean the sealer from the sealing surfaces on the upper valve rocker arm cover and the lower valve rocker arm cover.
  26. Clean the upper valve rocker arm cover in suitable cleaning solvent.
  27. Inspect for cracking and other damage on the upper valve rocker arm cover.
  28. Replace the upper valve rocker arm cover if any damage.

Installation Procedure

    Object Number: 663733 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.

  1. If removed, install the PCV diaphragm, spring, and screws.

    2. Tighten
    Tighten the screws to 4 N·m (35 lb in).


    Object Number: 663628 Size: SH
  2. If removed, install NEW grommets for the injector line fittings.

    3. Object Number: 665277 Size: SH
  3. Apply a 2-3 mm (1/8 in) wide to 0.5-1.5 mm (1/16 in) high bead of sealant GM P/N United States 97720043, GM P/N Canada 88901148, or equivalent to the upper valve rocker arm cover sealing surface.
  4. Apply a bead of sealant GM P/N United States 97720043, GM P/N Canada 88901148, or equivalent to the area under the injector wire harness on the lower valve rocker arm cover.

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

    6. Object Number: 663904 Size: SH
  6. Install the upper valve rocker arm cover bolts.

    7. Use the bolt tightening sequence. Bolts number 1 and 2 are used to position the valve rocker arm cover.

    Tighten

    1. Tighten the bolts to 8 N·m (71 lb in) in the sequence shown.
    2. Tighten the bolts again to 8 N·m (71 lb in) in the sequence shown.

    Object Number: 1336209 Size: SH

    Notice: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

  7. Install the fuel injector line(s).

    8. Tighten
    Tighten the fittings (1, 2) to 41 N·m (30 lb ft).


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

    9. Object Number: 665386 Size: SH
  9. Position the outlet heater hose.
  10. Install the fuel filter mounting bolts. Refer to Fuel Filter Replacement in Engine Controls - 6.6 L.
  11. Install the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.
  12. Install the bolt (2) retaining the heater hose bracket to the generator bracket.

    13. Tighten
    Tighten the bolt to 21 N·m (15 lb ft).


    Object Number: 664851 Size: SH
  13. Remove the tape from the charged air cooler outlet duct to charge air cooler pipe opening and the intake manifold tube opening.
  14. Position the hose on the pipe and the intake manifold tube.

    15. The hose is marked ENG for the intake manifold tube end and DUCT for the pipe end.

  15. Install the clamps and position as shown in order to allow the proper clearances.

    16. Tighten
    Tighten the clamps to 6 N·m (53 lb in).

  16. Install the charged air cooler inlet duct to the turbocharger.

    17. Object Number: 813246 Size: SH

    Important: The outlet duct must be fully seated against the positive stop feature on the turbocharger inlet.

  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).