Valve Rocker Arm Cover Replacement - Upper Left

Valve Rocker Arm Cover Replacement - Upper Left
Removal Procedure
1. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill).
2. Disconnect the negative battery cable.

Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

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.

3. Remove the left charged air cooler hose.





4. Remove the battery cable to generator nut.
5. If equipped, remove the battery cable to the auxiliary generator.
6. Remove the battery cable harness clip from the bracket.
7. Remove the battery cable junction block bolt (1) from the power steering pump.
8. Move and secure the battery cables out of the way.





9. Disconnect the fuel lines.
10. Remove the fuel hose bracket nut.





11. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
12. Open the harness clip (2).
13. Remove the main engine electrical harness connectors.





14. Remove the main engine electrical harness connector hold down bolts.





15. Remove the main electrical connector harness bracket bolts.
16. Remove the main electrical connector harness bracket.
17. Remove the water outlet tube.
18. Remove the auxiliary generator, if equipped.
19. Remove the positive crankcase ventilation (PCV) hose/pipe.





20. 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.
21. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.

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.

22. Remove the left fuel injector pipes.





23. Remove the upper valve rocker arm cover bolts.
24. Remove the upper valve rocker arm cover.
25. Remove the upper valve rocker arm cover gasket.
26. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
27. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper.

Installation Procedure





1. Install the 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 Service Precautions.

4. Tighten the upper valve rocker arm cover bolts in the sequence shown.
Tighten the bolts to 8 Nm (71 inch lbs.).





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 left fuel injector pipes.
Tighten the pipes to 41 Nm (30 ft. lbs.).
6. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
7. Install the water outlet tube.
8. Install the auxiliary generator, if equipped.
9. Install the PCV hose/pipe.





10. Install the main electrical connector harness bracket.
11. Install the main electrical connector harness bracket bolts.
Tighten the bolts to 21 Nm (15 ft. lbs.).





12. Install the main engine electrical harness connector hold down bolts.
Tighten the bolts to 10 Nm (89 inch lbs.).





13. Connect the main engine electrical harness connectors.
14. Push down on the latches (1) in order to connect the connectors.
15. Close the harness clip (2).





16. Connect the fuel lines.
17. Install the fuel hose bracket nut.
Tighten the nut to 21 Nm (15 ft. lbs.).





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.
Tighten the nut to 9 Nm (80 inch lbs.).
21. Install the positive battery cable junction block bracket and bolt (1) to the power steering pump.
Tighten the bolt to 9 Nm (80 inch lbs.).
22. Remove the tape from the turbocharger openings.

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

23. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill).
24. Connect the negative battery cable.