Valve Rocker Arm Cover Replacement - Upper Right Side LBZ, LLY

1. Remove the engine cover. Refer to Engine Cover Replacement .

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 .
3. Loosen the charged air cooler outlet duct to intake hose clamp.

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 glow plug control module. Refer to Glow Plug Control Module Replacement .
6. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
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. Reposition the right positive crankcase ventilation (PCV) hose clamp at the resonator tee.
11. Remove the PCV hose from the tee.



12. Remove the right PCV pipe bolt.
13. Remove the right PCV pipe.



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 .

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. 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.

Notice: Refer to Fastener Notice in the Preface section.




5. Tighten the upper valve rocker arm cover bolts in the sequence shown.

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

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



7. Install the right PCV pipe.
8. Install the right PCV pipe bolt.

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




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.

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 .
14. Install the glow plug control module. Refer to Glow Plug Control Module Replacement .




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.

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

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

Valve Rocker Arm Cover Replacement - Upper Right Side LMM

1. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
2. Remove the engine harness bracket bolt (1) and retainer.



3. Remove the fuel rail pressure sensor electrical connector bracket bolt and nut.
4. Remove the bracket from the stud.




Notice: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.

5. Disconnect the engine harness electrical connectors from the fuel injectors.



6. Remove the heater pipe bracket clamp (1) and bolts (2).
7. Position heater pipe aside.



8. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
9. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to Adhesives, Fluids, Lubricants, and Sealers .

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.

10. Remove the right fuel injector pipes.



11. Remove the upper valve rocker arm cover bolts.
12. Remove the upper valve rocker arm cover.
13. Remove the upper valve rocker arm cover gasket.
14. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

1. Install the upper valve rocker arm cover gasket.
2. Install the upper valve rocker arm cover.
3. Install the upper valve rocker arm cover bolts.

Notice: Refer to Fastener Notice in the Preface section.




4. Tighten the upper valve rocker arm cover bolts.

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





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.

5. Install the fuel injector pipes.

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

6. After installing the fuel injector pipes, clean the injector pipes and apply sealant at the fittings to prevent moisture and debris from collecting between the line and fitting. Refer to Adhesives, Fluids, Lubricants, and Sealers .



7. Position the heater pipe in place.
8. Install the heater pipe bracket clamp (1) and bolts (2).

Tighten
Tighten the bolts to 24 N·m (18 lb ft).




9. Install the fuel rail pressure sensor electrical connector bracket to the stud.
10. Install the bracket bolt and nut.

Tighten
Tighten the bolt/nut to 10 N·m (89 lb in).




11. Connect the engine harness electrical connectors to the fuel injectors.



12. Install the engine harness bracket bolt (1) and retainer.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

13. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .