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Home >> Chevy Truck >> 2009 >> Express 3500 V8-6.6L DSL Turbo >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Valve Cover >> Service and Repair >> Valve Rocker Arm Cover Replacement - Upper Left Side

Valve Rocker Arm Cover Replacement - Upper Left Side




Valve Rocker Arm Cover Replacement - Upper Left Side

Special Tools

J-46594 Fuel Injector Puller

Removal Procedure




1. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Service and Repair).
2. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement (Auxiliary Generator Replacement).
4. Remove the glow plug control module. Refer to Glow Plug Control Module Replacement (Service and Repair).
5. Remove the glow plug module bracket bolts (1) and bracket.





Caution: 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.

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




7. Remove the engine wiring harness bracket bolt (1).




8. Disconnect the left side main engine harness electrical connector.
9. Remove the wiring harness clip from the main connector bracket.
10. Remove the connector bracket bolts (1).
11. Remove the glow plug wire harness retaining bolts at the lower part of the upper left valve cover.
12. Reposition the engine wiring harness out of the way.




13. Remove the fuel injector return line clip (1) from the injector.
14. Remove the fuel injector return line fitting (2) from the injector.
15. Perform the above 2 steps for the other 3 fuel injectors.
16. Reposition the injector return line out of the way.




17. 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.
18. 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 (Specifications).

Caution: 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.

19. Remove the left fuel injector pipes.
20. Remove No. 8 fuel injector bracket bolt.
21. Install the J-46594 into injector No. 8 bracket bolt hole.
22. Using the J-46594 pull injector No. 8 until it releases.
23. Remove the J-46594 .
24. Remove No. 8 fuel injector and bracket.




25. Remove the upper valve rocker arm cover bolts.
26. Remove the upper valve rocker arm cover.
27. Remove the upper valve rocker arm cover gasket.
28. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.

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.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Tighten the upper valve rocker arm cover bolts in the sequence shown to 8 Nm (71 lb in).
5. Install No. 8 fuel injector and bracket.
6. Install No. 8 fuel injector bracket bolt.





Caution: 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.

7. Install the left fuel injector pipes and tighten to 41 Nm (30 lb ft).
8. 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 (Specifications).




9. Position the injector return line to the injectors.
10. Install the fuel injector return line clip (1) to the injector.
11. Install the fuel injector return line fitting (2) to the injector.
12. Perform the above 2 steps for the other 3 fuel injectors.




13. Position the engine wiring harness.
14. Install the glow plug wire harness retaining bolts at the lower part of the left upper valve cover.
15. Install the connector bracket bolts (1) and tighten to 10 Nm (89 lb in).
16. Install the wiring harness clip to the main connector bracket.
17. Connect the left side main engine harness electrical connector.




18. Install the engine wiring harness bracket bolt (1) and tighten to 10 Nm (89 lb in).




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




20. Install the glow plug module bracket and bolts (1) and tighten to 10 Nm (89 lb in).
21. Install the glow plug control module. Refer to Glow Plug Control Module Replacement (Service and Repair).
22. Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement (Auxiliary Generator Replacement).
23. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
24. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (Service and Repair).

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