Avalanche, Express, Savana 2006-2007

Valve Covers

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Removal & Installation



4.3L Engine
Left Side
  1. Remove the engine wiring harness bracket nuts.
  2.  
  3. Remove the engine wiring harness bracket.
  4.  
  5. Remove the engine wiring harness clip bolt.
  6.  
  7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  8.  
  9. Reposition the engine wiring harness and bracket.
  10.  
  11. Disconnect the power brake booster vacuum hose from the vacuum fitting.
  12.  
  13. Remove the positive crankcase ventilation (PCV) valve hose from the valve cover and rocker cover.
  14.  
  15. Remove the rocker arm cover bolts.
  16.  
  17. Remove and discard the rocker arm cover bolt grommets, if necessary.
  18.  
  19. Remove the rocker arm cover.
  20.  
  21. Remove and discard the rocker arm cover gasket.
  22.  
  23. Clean and inspect the rocker arm cover, if necessary.
  24.  

To install:


NOTE
Do not reuse the rocker cover gasket or the rocker arm cover bolt grommets.

  1. Install a NEW rocker arm cover gasket to the cover.
  2.  
  3. Install NEW rocker arm cover bolt grommets to the cover, if necessary.
  4.  
  5. Install the rocker arm cover.
  6.  
  7. Install the rocker arm cover bolts.
    1. Tighten the bolts to 106 inch lbs. (12 Nm).
    2.  

  8.  
  9. Install the PCV valve hose to the valve cover and rocker cover.
  10.  
  11. Connect the power brake booster vacuum hose to the vacuum fitting.
  12.  
  13. Position the engine wiring harness and bracket.
  14.  
  15. Connect the ECT sensor electrical connector.
  16.  
  17. Install the engine wiring harness clip bolt.
    1. Tighten the bolt to 80 inch lbs. (9 Nm).
    2.  

  18.  
  19. Install the engine wiring harness bracket.
  20.  
  21. Install the engine wiring harness bracket nuts.
    1. Tighten the nuts to 106 inch lbs. (12 Nm).
    2.  

  22.  

Right Side
  1. Loosen the air cleaner outlet duct clamp at the mass airflow/intake air temperature (MAF/IAT) sensor.
  2.  
  3. Remove the positive crankcase ventilation (PCV) hose.
  4.  
  5. Remove the air cleaner adapter nut.
  6.  
  7. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
  8.  
  9. Remove the heater outlet hose from the clip.
  10.  
  11. Move and secure the heater hoses out of the way.
  12.  
  13. Disconnect the following electrical connectors:
    1. The ignition coil
    2.  
    3. The ignition coil drive
    4.  
    5. The alternator
    6.  

  14.  
  15. Disconnect the engine wiring harness clips.
  16.  
  17. Reposition the engine wiring harness.
  18.  
  19. Remove the rocker arm cover bolts.
  20.  
  21. Remove and discard the rocker arm cover bolt grommets, if necessary.
  22.  
  23. Remove the rocker arm cover.
  24.  
  25. Remove and discard the rocker arm cover gasket.
  26.  
  27. Clean and inspect the rocker arm cover, if necessary.
  28.  

To install:


NOTE
Do not reuse the cover gasket or the valve rocker arm cover bolt grommets.

  1. Install a NEW rocker arm cover gasket.
  2.  
  3. Install NEW rocker arm cover bolt grommets, if necessary.
  4.  
  5. Install the rocker arm cover.
  6.  
  7. Install the rocker arm cover bolts.
    1. Tighten the bolts to 106 inch lbs., (12 Nm).
    2.  

  8.  
  9. Position the engine wiring harness.
  10.  
  11. Connect the engine wiring harness clips.
  12.  
  13. Connect the following electrical connectors:
    1. The ignition coil
    2.  
    3. The ignition coil drive
    4.  
    5. The alternator
    6.  

  14.  
  15. Position the heater hoses.
  16.  
  17. Install the heater outlet to the hose clip.
  18.  
  19. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
  20.  
  21. Install the air cleaner adapter nut.
  22.  
  23. Install the positive crankcase ventilation (PCV) hose.
  24.  
  25. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
    1. Tighten the clamp to 35 inch lbs. (4 Nm).
    2.  

  26.  

4.8L, 5.3L & 6.0L Engines
Left Side
  1. Remove the engine sight shield, if required.
  2.  
  3. Remove the connector position assurance (CPA) lock.
  4.  
  5. Disconnect the main electrical connector to the ignition coil wire harness.
  6.  
  7. Remove the harness clips.
  8.  
  9. Reposition the engine harness, if necessary.
  10.  
  11. Remove the spark plug wires from the ignition coils.
  12.  
  13. Remove the ignition coil bracket studs.
  14.  
  15. Remove the ignition coil bracket.
  16.  
  17. Remove the positive crankcase ventilation (PCV) hose.
  18.  
  19. Loosen the valve rocker arm cover bolts.
  20.  
  21. Remove the valve rocker arm cover.
  22.  
  23. Remove and discard the old gasket.
  24.  
  25. If required, clean and inspect the rocker arm cover.
  26.  

To install:


NOTE
All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT reuse the valve rocker arm cover gasket. If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly.

  1. Install a NEW rocker cover gasket.
  2.  
  3. Install the valve rocker arm cover.
  4.  
  5. Tighten the rocker arm cover bolts.
    1. Tighten the bolts to 106 inch lbs. (12 Nm).
    2.  

  6.  
  7. Install the PCV hose.
  8.  
  9. Apply threadlock to the threads of the bracket bolts.
  10.  
  11. Install the ignition coil bracket.
  12.  
  13. Install the ignition coil bracket studs.
    1. Tighten the studs to 106 inch lbs. (12 Nm).
    2.  

  14.  
  15. Install the spark plug wires to the ignition coils.
  16.  
  17. Position the engine harness, if necessary.
  18.  
  19. Install the harness clips.
  20.  
  21. Connect the main electrical connector to the ignition coil wire harness.
  22.  
  23. Install the CPA lock.
  24.  
  25. Install the engine sight shield, if required.
  26.  

Right Side
  1. Remove the engine sight shield, if required.
  2.  
  3. Remove the connector position assurance (CPA) lock.
  4.  
  5. Disconnect the main electrical connector to the ignition coil wire harness.
  6.  
  7. Remove the harness clips.
  8.  
  9. Reposition the engine harness, if necessary.
  10.  
  11. Remove the spark plug wires from the ignition coils.
  12.  
  13. Reposition the surge tank/heater hoses from the heater hose bracket.
  14.  
  15. Remove the heater hose bracket nut and bracket.
  16.  
  17. Remove the ignition coil bracket studs.
  18.  
  19. Remove the ignition coil bracket.
  20.  
  21. Remove the positive crankcase ventilation (PCV) hose.
  22.  
  23. Loosen the valve rocker arm cover bolts.
  24.  
  25. Remove the valve rocker arm cover.
  26.  
  27. Remove and discard the old gasket.
  28.  
  29. Remove the oil fill tube from the rocker cover, if required.
  30.  
  31. If required, clean and inspect the rocker arm cover.
  32.  

To install:


NOTE
All gasket surfaces should be free of oil or other foreign material during assembly. DO NOT reuse the valve rocker arm cover gasket. If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly.

  1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
  2.  
  3. Insert the NEW oil fill tube into the rocker arm cover. Rotate the tube clockwise until locked in the proper position.
  4.  
  5. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position.
  6.  
  7. Install a NEW rocker cover gasket into the valve rocker arm cover lip.
  8.  
  9. Install the valve rocker arm cover.
  10.  
  11. Tighten the rocker arm cover bolts.
    1. Tighten the bolts to 106 inch lbs. (12 Nm).
    2.  

  12.  
  13. Install the PCV hose.
  14.  
  15. Apply threadlock to the threads of the bracket bolts.
  16.  
  17. Install the ignition coil bracket.
  18.  
  19. Install the ignition coil bracket studs.
    1. Tighten the studs to 106 inch lbs. (12 Nm).
    2.  

  20.  
  21. Install the heater hose bracket and nut.
    1. Tighten the nut to 80 inch lbs. (9 Nm).
    2.  

  22.  
  23. Position the surge tank/heater hoses to the heater hose bracket.
  24.  
  25. Install the spark plug wires to the ignition coils.
  26.  
  27. Position the engine harness, if necessary.
  28.  
  29. Install the harness clips.
  30.  
  31. Connect the main electrical connector feeding the ignition coils.
  32.  
  33. Install the CPA lock.
  34.  
  35. Install the engine sight shield, if required
  36.  

6.6L Engine
Lower Left Side
  1. Remove the upper left valve rocker arm cover.
  2.  
  3. Remove the fuel injectors.
  4.  
  5. Remove the lower valve rocker arm cover bolts.
  6.  
  7. Remove the lower valve rocker arm cover.
  8.  
  9. Remove the gasket from the lower valve rocker arm cover.
  10.  
  11. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
  12.  
  13. If required, clean and inspect the lower valve rocker arm cover.
  14.  

To install:

  1. Install the lower valve rocker arm cover gasket.
  2.  
  3. Install the lower valve rocker arm cover.
  4.  
  5. Install the lower valve rocker arm cover bolts.
  6.  
  7. Tighten the lower valve rocker arm cover bolts in the sequence shown.
    1. Tighten the bolts to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Tighten the lower valve cover bolts in the sequence shown-6.6L engines

    2.  

  8.  
  9. Install the fuel injectors.
  10.  
  11. Install the upper left valve rocker arm cover.
  12.  

Lower Right Side
  1. Remove the upper right valve rocker arm cover.
  2.  
  3. Remove the fuel injectors.
  4.  
  5. Remove the lower valve rocker arm cover bolts.
  6.  
  7. Remove the lower valve rocker arm cover.
  8.  
  9. Remove the gasket from the lower valve rocker arm cover.
  10.  
  11. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
  12.  
  13. If required, clean and inspect the lower valve rocker arm cover.
  14.  

To install:

  1. Install the lower valve rocker arm cover gasket.
  2.  
  3. Install the lower valve rocker arm cover.
  4.  
  5. Install the lower valve rocker arm cover bolts.
  6.  
  7. Tighten the bolts in the sequence shown.
    1. Tighten the bolts to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Tighten the lower valve cover bolts in the sequence shown-6.6L engines

    2.  

  8.  
  9. Install the fuel injectors.
  10.  
  11. Install the right upper valve rocker arm cover.
  12.  

Upper Left Side
  1. Remove the intake manifold cover.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

  6.  
  7. Loosen the charged air cooler inlet duct connector to turbocharger clamp.
    NOTE
    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.

  8.  
  9. Remove the charged air cooler inlet duct connector from the turbocharger.
  10.  
  11. Remove the battery cable to alternator nut.
  12.  
  13. If equipped, remove the battery cable to the auxiliary alternator.
  14.  
  15. Remove the battery cable harness clip from the bracket.
  16.  
  17. Remove the battery cable junction block bolt from the power steering pump.
  18.  
  19. Move and secure the battery cables out of the way.
  20.  
  21. Disconnect the fuel lines.
  22.  
  23. Remove the fuel hose bracket nut.
  24.  
  25. Disconnect the main engine electrical harness connectors. Lift up on the latches in order to disconnect the connectors.
  26.  
  27. Open the harness clip.
  28.  
  29. Remove the main engine electrical harness connectors.
  30.  
  31. Disconnect the barometric pressure sensor electrical connector.
  32.  
  33. Remove the main engine electrical harness connector hold down bolts.
  34.  
  35. Remove the main electrical connector harness bracket bolts.
  36.  
  37. Remove the main electrical connector harness bracket.
  38.  
  39. Remove the water outlet tube.
  40.  
  41. Remove the auxiliary alternator, if equipped.
  42.  
  43. Remove the positive crankcase ventilation (PCV) hose/pipe.
  44.  
  45. 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.
  46.  
  47. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    WARNING
    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.

  48.  
  49. Remove the left fuel injector pipes.
  50.  
  51. Remove the upper valve rocker arm cover bolts.
  52.  
  53. Remove the upper valve rocker arm cover.
  54.  
  55. Remove the upper valve rocker arm cover gasket.
  56.  
  57. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
  58.  
  59. If required, clean and inspect the upper valve rocker arm cover.
  60.  

To install:

  1. Install the valve rocker arm cover gasket.
  2.  
  3. Install the upper valve rocker arm cover.
  4.  
  5. Install the upper valve rocker arm cover bolts.
  6.  
  7. Tighten the upper valve rocker arm cover bolts in the sequence shown.
    1. Tighten the bolts to 71 inch lbs. (8 Nm).
      WARNING
      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.



      Click image to see an enlarged view

      Fig. Upper valve cover tightening sequence-6.6L engines

    2.  

  8.  
  9. Install the left fuel injector pipes.
    1. Tighten the pipes to 30 ft. lbs. (41 Nm).
    2.  

  10.  
  11. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, or equivalent at the fittings to prevent moisture and debris from collecting between the line and fitting.
  12.  
  13. Install the water outlet tube.
  14.  
  15. Install the auxiliary alternator, if equipped.
  16.  
  17. Install the PCV hose/pipe.
  18.  
  19. Install the main electrical connector harness bracket.
  20.  
  21. Install the main electrical connector harness bracket bolts.
    1. Tighten the bolts to 15 ft. lbs. (21 Nm).
    2.  

  22.  
  23. Install the main engine electrical harness connector hold down bolts.
    1. Tighten the bolts to 89 inch lbs. (10 Nm).
    2.  

  24.  
  25. Connect the barometric pressure sensor electrical connector.
  26.  
  27. Connect the main engine electrical harness connectors.
  28.  
  29. Push down on the latches in order to connect the connectors.
  30.  
  31. Close the harness clip.
  32.  
  33. Connect the fuel lines.
  34.  
  35. Install the fuel hose bracket nut.
    1. Tighten the nut to 15 ft. lbs. (21 Nm).
    2.  

  36.  
  37. Position the alternator positive cable.
  38.  
  39. Install the alternator positive cable in the clip on the engine front cover.
  40.  
  41. Install the alternator positive cable and nut.
    1. Tighten the nut to 80 inch lbs. (9 Nm).
    2.  

  42.  
  43. Install the positive battery cable junction block bracket and bolt to the power steering pump.
    1. Tighten the bolt to 80 inch lbs. (9 Nm).
    2.  

  44.  
  45. Remove the tape from the turbocharger openings.
    NOTE
    Lubricate the end of the duct prior to installation.

  46.  
  47. Install the charged air cooler inlet duct connector to the turbocharger.
  48.  
  49. Tighten the charged air cooler inlet duct connector to turbocharger clamp.
    1. Tighten the clamp to 53 inch lbs. (6 Nm).
    2.  

  50.  
  51. Fill the cooling system.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Install the intake manifold cover.
  56.  

Upper Right Side
  1. Remove the intake manifold cover.
  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Loosen the charged air cooler outlet duct to intake hose clamp.
    WARNING
    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.

  6.  
  7. Remove the charged air cooler outlet duct from the intake.
  8.  
  9. Remove the fuel injection control module.
  10.  
  11. Remove the Exhaust Gas Recirculation (EGR) cooler tube.
  12.  
  13. Remove the heater outlet hose bolt from the bracket.
  14.  
  15. Position the heater outlet hose out of the way.
  16.  
  17. Remove the fuel filter bracket bolts.
  18.  
  19. Reposition the fuel filter with bracket.
  20.  
  21. Remove the positive crankcase ventilation (PCV) hose/pipe.
  22.  
  23. 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.
  24.  
  25. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    WARNING
    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.

  26.  
  27. Remove the right fuel injector pipes.
  28.  
  29. Remove the upper valve rocker arm cover bolts.
  30.  
  31. Remove the upper valve rocker arm cover.
  32.  
  33. Remove the upper valve rocker arm cover gasket.
  34.  
  35. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
  36.  
  37. If required, clean and inspect the upper valve rocker arm cover.
  38.  

To install:

  1. Install the upper valve rocker arm cover gasket.
  2.  
  3. Install the upper valve rocker arm cover.
  4.  
  5. Install the upper valve rocker arm cover bolts.
  6.  
  7. Tighten the upper valve rocker arm cover bolts in the sequence shown.
    1. Tighten the bolts to 71 inch lbs. (8 Nm).
      NOTE
      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.



      Click image to see an enlarged view

      Fig. Upper valve cover tightening sequence-6.6L engines

    2.  

  8.  
  9. Install the fuel injector pipes.
    1. Tighten the pipes to 30 ft lbs. (41 Nm).
    2.  

  10.  
  11. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, or equivalent at the fittings to prevent moisture and debris from collecting between the line and fitting.
  12.  
  13. Install the PCV hose/pipe.
  14.  
  15. Position the fuel filter with bracket to the rocker cover.
  16.  
  17. Install the fuel filter bracket bolts.
    1. Tighten the bolts to 15 ft. lbs. (21 Nm).
    2.  

  18.  
  19. Position the heater outlet hose.
  20.  
  21. Install the heater hose bracket bolt to the bracket.
    1. Tighten the bolt to 15 ft. lbs. (21 Nm).
    2.  

  22.  
  23. Install the EGR cooler tube.
  24.  
  25. Install the fuel injection control module.
    NOTE
    Lubricate the end of the duct prior to installation.

  26.  
  27. Install the charged air cooler outlet duct to the intake.
  28.  
  29. Tighten the charged air cooler outlet duct to intake hose clamp.
    1. Tighten the clamp to 53 inch lbs. (6 Nm).
    2.  

  30.  
  31. Install the air cleaner outlet duct.
  32.  
  33. Install the intake manifold cover.
  34.  

8.1L Engine
Left Side
  1. Remove the engine sight shield.
  2.  
  3. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  4.  
  5. Disconnect the ignition coil harness electrical connector.
  6.  
  7. Remove the spark plug wires from the spark plugs and ignition coils.
  8.  
  9. Remove the valve rocker arm cover bolts.
  10.  
  11. Remove the valve rocker arm cover.
    NOTE
    Valve rocker arm cover gaskets are reusable. Replace the gasket only if damaged.

  12.  
  13. Inspect the valve rocker arm cover gasket for cuts or damage.
  14.  
  15. Clean and inspect the valve rocker arm cover.
  16.  

To install:

  1. Install a new valve rocker arm cover gasket if the gasket was removed from the rocker arm cover.
  2.  
  3. Install the valve rocker arm cover.
  4.  
  5. Install the valve rocker arm cover bolts.
  6.  
  7. Tighten the valve rocker arm cover bolts in the sequence shown, using two passes as shown.
    1. Tighten the bolts a first pass to 53 inch lbs. (6 Nm).
    2.  
    3. Tighten the bolts a final pass to 106 inch lbs. (12 Nm).
      NOTE
      Fully install the spark plug wire by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

    4.  

  8.  
  9. Install the spark plug wires to the spark plugs and ignition coils.
  10.  
  11. Connect the ignition coil harness electrical connector.
  12.  
  13. Install the CPA retainer to the ignition coil electrical connector.
  14.  
  15. Install the engine sight shield.
  16.  

Right Side
  1. Remove the engine sight shield.
  2.  
  3. Loosen the clamps at the throttle body and air cleaner.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  8.  
  9. Disconnect the ignition coil harness electrical connector.
  10.  
  11. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  12.  
  13. Remove the spark plug wires from the ignition coils.
  14.  
  15. Loosen the valve rocker arm cover bolts.
  16.  
  17. Remove the valve rocker arm cover.
    NOTE
    The valve rocker arm cover gasket may be reused if not removed from the valve rocker arm cover.

  18.  
  19. Replace the valve rocker arm cover gasket if it is cut or damaged.
  20.  
  21. Clean and inspect the valve rocker arm cover.
  22.  

To install:

  1. Install a NEW valve rocker arm cover gasket, if necessary.
  2.  
  3. Install the valve rocker arm cover.
  4.  
  5. Tighten the valve rocker arm cover bolts in sequence using two passes as shown.
    1. Tighten the bolts a first pass to 53 inch lbs. (6 Nm).
    2.  
    3. Tighten the bolts a final pass to 106 inch lbs. (12 Nm).
    4.  

  6.  
  7. Install the spark plug wires to the ignition coils.
  8.  
  9. Connect the ECT sensor electrical connector.
  10.  
  11. Connect the ignition coil harness electrical connector.
  12.  
  13. Install the CPA retainer to the ignition coil electrical connector.
  14.  
  15. Install the air cleaner outlet duct.
  16.  
  17. Tighten the clamps at the throttle body and air cleaner.
    1. Tighten the clamps to 35 inch lbs. (4 Nm).
    2.  

  18.  
  19. Install the engine sight shield.
  20.  

 
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