Valve Cover: Service and Repair
Removal Procedures1. Disconnect the battery negative cables from the batteries.
^ For the front battery, refer to Battery Cable Replacement (Battery Cable Negative) in Starting and Charging.
^ For the auxiliary battery, refer to Battery Cable Replacement (Battery Cable Aux. Negative) in Starting and Charging.
^ Remove the CDR valve and hose (right side).
2. Remove the upper intake manifold from the turbo charger.
3. Remove the lower intake manifold from the cylinder head.
4. Mark the fuel line retaining clips and the stud in order to ensure proper reinstallation.
Important: Do not bend the fuel injector lines in order to ease in the removal of the valve rocker arm cover.
5. Remove the fuel injection lines from the fuel nozzles.
6. Remove the engine oil level indicator and tube from the engine block.
7. Remove the transmission oil level indicator and tube.
8. Remove the fuel return line clip at the valve rocker arm cover stud.
9. Remove the wiring harness at the valve rocker arm cover and move aside (left side).
10. Remove the electrical connectors at the valve rocker arm cover and move aside (left side).
11. Remove the rear generator support bracket.
12. Remove the valve rocker arm cover bolts.
Notice: Prying on the valve rocker arm cover may cause damage to the sealing surfaces. Use a block of wood against the side of the valve rocker arm cover and strike with a hammer in a sideways direction to shear the RTV sealant.
13. Remove the valve rocker arm cover from the cylinder head.
14. Clean the oil and grease from the sealing surfaces on the valve rocker arm and the cylinder head.
Use a suitable solvent.
Installation Procedure
Notice: Do not allow the RTV sealant into the valve rocker arm cover bolt holes. This may cause a "valve lock" condition, when the bolts are tightened, damaging the cylinder head casting.
1. Apply a 5 mm (3/16 inch) bead of RTV sealant GM P/N 12345739 to the valve rocker arm covers, inboard of the bolt holes. The sealer must be wet to the touch when the bolts are tightened.
2. Install the valve rocker arm cover to the cylinder head.
Notice: Refer to Fastener Notice in Service Precautions.
3. Install the valve rocker arm cover bolts.
^ Tighten the bolts to 22 Nm (16 ft. lbs.).
4. Install the fuel injection lines and clips.
5. Install the wiring harness and all the electrical connectors at the valve rocker arm cover from the clips and move aside (left side).
6. Install the engine oil level indicator and tube.
7. Install the transmission oil level indicator tube and bracket.
8. Install the lower intake manifold to the cylinder head.
9. Install the CDR valve and hose.
10. Install the rear generator support bracket.
11. Install the upper intake manifold to the lower intake manifold.
12. Connect the battery negative cables from the batteries.