GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Mechanical - 6.6L (LLY) 🢒 Valve Rocker Arm Cover Replacement - Upper Right Side

Removal Procedure

    Object Number: 1334381 Size: SH
  1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.

    2. Important: After removing the air cleaner outlet duct, cover the turbocharger opening with tape to prevent entry of objects.

  2. Remove the air cleaner. Refer to Air Cleaner Replacement in Engine Controls.
  3. Loosen the charged air cooler outlet duct to intake hose clamp.

    4. 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.

  4. Remove the charged air cooler outlet duct from the intake.
  5. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls.
  6. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement in Engine Controls.
  7. Remove the fuel injectors. Refer to Fuel Injector Replacement .
  8. Remove the heater outlet hose bolt and nut.
  9. Position the heater outlet hose out of the way.

    10. Object Number: 1335454 Size: SH
  10. Reposition the right positive crankcase ventilation (PCV) hose clamp at the resonator tee.
  11. Remove the PCV hose from the tee.

    12. Object Number: 1335456 Size: SH
  12. Remove the right PCV pipe bolt.
  13. Remove the right PCV pipe.

    14. Object Number: 1335653 Size: SH
  14. Remove the upper valve rocker arm cover bolts.
  15. Remove the upper valve rocker arm cover.
  16. Remove and discard the upper valve rocker arm cover gasket.
  17. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper .

Installation Procedure
  1. Inspect the upper valve rocker arm cover gasket for damage. If the upper valve rocker arm cover gasket is not damaged, reuse the gasket.

    2. Object Number: 1335653 Size: SH
  2. Install the upper valve rocker arm cover gasket.
  3. Install the upper valve rocker arm cover.
  4. Install the upper valve rocker arm cover bolts.

    5. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 663904 Size: SH
  5. Tighten the upper valve rocker arm cover bolts in the sequence shown.

    6. Tighten
    Tighten the bolts to 8 N·m (71 lb in).

  6. Install the fuel injectors. Refer to Fuel Injector Replacement .

    7. Object Number: 1335456 Size: SH
  7. Install the right PCV pipe.
  8. Install the right PCV pipe bolt.

    9. Tighten
    Tighten the bolt to 18 N·m (13 lb ft).


    Object Number: 1335454 Size: SH
  9. Install the PCV hose to the tee.
  10. Position the right PCV hose clamp at the resonator tee.
  11. Position the heater outlet hose.
  12. Install the heater hose bracket bolt and nut.

    13. Tighten

        • Tighten the nut to 9 N·m (80 lb in).
        • Tighten the bolt to 21 N·m (15 lb ft).
  13. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement in Engine Controls.
  14. Install the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls.

    15. Object Number: 1334381 Size: SH

    Important: Lubricate the end of the duct prior to installation.

  15. Install the charged air cooler outlet duct to the intake.
  16. Tighten the charged air cooler outlet duct to intake hose clamp.

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

  17. Install the air cleaner. Refer to Air Cleaner Replacement in Engine Controls.
  18. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.