GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Valve Rocker Arm Cover Replacement - Upper Left 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. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    6. Object Number: 877281 Size: SH
  6. Loosen the charged air cooler inlet duct to turbocharger 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 inlet duct from the turbocharger.

    8. Object Number: 666693 Size: SH
  8. Remove the battery cable to generator nut.
  9. If equipped, remove the battery cable to the auxiliary generator.
  10. Remove the battery cable harness clip from the bracket.
  11. Remove the battery cable junction block bolt from the power steering pump.
  12. Move and secure the battery cables out of the way.

    13. Object Number: 674616 Size: SH
  13. Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 6.6L.
  14. Remove the fuel hose bracket nut.

    15. Object Number: 674653 Size: SH
  15. Disconnect the fuel injection control module electrical connectors. Lift up on the latch in order to disconnect the connectors.
  16. Remove the fuel injection control module wiring harness clip from the bracket.

    17. Object Number: 674680 Size: SH
  17. Remove the engine-to-chassis harness connector bolts (1).
  18. Remove the engine-to-chassis harness bracket bolts (2).
  19. Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
  20. Remove the glow plug relay bracket. Refer to Glow Plug Relay Replacement in Engine Controls - 6.6L.
  21. Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement in Engine Electrical.

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

    23. Object Number: 798893 Size: SH
  23. Remove the sleeve nut plate bolts and plates.
  24. Remove the fuel injector feed pipes.

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

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

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

    27. Object Number: 660467 Size: SH
  27. Remove the upper valve rocker arm cover.
  28. 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
  4. Install the upper valve rocker arm cover bolts. Install bolts 1 and 2 first, they are used to position the cover.

    5. 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.

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

    6. 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: 798893 Size: SH
  6. Install the fuel injector feed pipes.

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

  7. Install the sleeve nut plates and bolts.

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


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

    9. Object Number: 674680 Size: SH
  9. Install the engine-to-chassis harness connector bracket bolts (2).

    10. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).

  10. Install the engine-to-chassis harness electrical connectors bolts (1).

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


    Object Number: 674653 Size: SH
  11. Connect the fuel injection control module electrical harness connectors.
  12. Install the fuel injection control module wiring harness to the retainer.
  13. Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
  14. Install the glow plug relay bracket. Refer to Glow Plug Relay Replacement in Engine Controls - 6.6L.
  15. Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement in Engine Electrical.

    16. Object Number: 674616 Size: SH
  16. Connect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 6.6L.
  17. Install the fuel hose bracket nut.

    18. Tighten
    Tighten the nut to 21 N·m (15 lb ft).


    Object Number: 666693 Size: SH
  18. Position the generator positive cable.
  19. Install the generator positive cable in the clip on the engine front cover.
  20. Install the generator positive cable and nut.

    21. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  21. Install the positive battery cable junction block bracket and bolt to the power steering pump.

    22. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 877281 Size: SH
  22. Remove the tape from the turbocharger openings.
  23. Install the charged air cooler inlet duct to the turbocharger.
  24. Align the mark on the duct (2) with the mark on the turbocharger.
  25. Position the clamp (1) as shown for proper clearance.

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


    Object Number: 813243 Size: SH
  26. Install the upper intake manifold cover.
  27. Install the upper intake manifold cover to the outlet duct.
  28. Tighten the outlet duct clamp at the upper intake manifold cover.

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

  29. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.