Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Timing Gear Cover, Gears & Seal

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Removal & Installation



6.6L Engine

NOTE
The 6.6L engine uses gears in place of a timing chain. For removal and installation, please see the Camshaft and Lifters procedure. This procedure covers the removal of the front cover and seal.

  1. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then lift the shield off the rear bracket.
    4.  

  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not bend the turbocharger outlet pipe.



    Negative battery cables
     
    Right front wheel
     
    Right front fender splash shield
     
    Upper fan shroud
     
    Fan clutch
     
    Drive belt
     
    Oil dipstick tube
     
    Thermostat housing crossover
     
    Crankshaft balancer
     
    Crankshaft front oil seal
     
    Water pump
     
    Camshaft sensor electrical connector
     
    Camshaft sensor bolt and sensor
     
    Crankshaft Position (CKP) sensor connector, bolt and sensor
     
    CKP sensor spacer bolts and spacer
     
    5 bolts securing the upper oil pan to the front cover
     
    Bracket bolts and the bracket for the turbocharger outlet coolant pipe
     
    Engine front cover bolts
     
    Use a suitable seal cutter to separate the front cover from the cylinder block and upper oil pan
     
    O-ring from the front cover
     
    Oil pressure relief valve from the front cover
     



    Click image to see an enlarged view

    Fig. Engine front cover-6.6L engine

  6.  

To install:

  1. Clean and inspect all sealing surfaces.
  2.  
  3. Install or connect the following:
    NOTE
    The CKP sensor spacers are machined with different timing positions. If you have to replace a spacer, make sure it has the same part number.



    Oil pressure relief valve with a new O-ring. Tighten to 30 ft. lbs. (41 Nm).
     
    Apply a 1 / 8 in. (2-3mm) wide to 1 / 16 in. (0.5-1.5mm) high bead of sealant to the front cover sealing surfaces to the engine block and oil pan.
     
    New front cover O-ring after lubricating it with engine oil
     
    Front cover and bolts. Tighten to 18 ft. lbs. (25 Nm).
     
    Upper oil pan-to-front cover bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Turbocharger coolant outlet pipe bracket and bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Camshaft sensor and bolt. Tighten to 80 inch lbs. (9 Nm).
     
    Camshaft sensor connector
     



    CKP sensor spacer and spacer bolts. Tighten to 89 inch lbs. (10 Nm).
     
    CKP sensor and bolt. Tighten to 89 inch lbs. (10 Nm).
     
    Water pump
     
    Crankshaft front oil seal
     
    Crankshaft balancer
     
    Thermostat housing crossover
     
    Oil fill tube
     
    Drive belt
     
    Upper fan shroud
     
    Right front fender splash shield and wheel
     
    Negative battery cables
     

  4.  
  5. Refill the cooling system with the proper type and quantity of antifreeze.
  6.  
  7. Inspect the engine for leaks.
  8.  


NOTE
The 6.6L engine uses gears in place of a timing chain. For removal and installation, please see the Camshaft and Lifters procedure. This procedure covers the removal of the front cover and seal.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then left the shield off the rear bracket.
    4.  

  4.  
  5. Remove or disconnect the following:
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Do not bend the turbocharger outlet pipe.



    Negative battery cables
     
    Right front wheel
     
    Right front fender splash shield
     
    Upper fan shroud
     
    Fan clutch
     
    Drive belt
     
    Oil dipstick tube
     
    Thermostat housing crossover
     
    Crankshaft balancer
     
    Crankshaft front oil seal
     
    Water pump
     
    Camshaft sensor electrical connector
     
    Camshaft sensor bolt and sensor
     
    Crankshaft Position (CKP) sensor connector, bolt and sensor
     
    CKP sensor spacer bolts and spacer
     
    5 bolts securing the upper oil pan to the front cover
     
    Bracket bolts and the bracket for the turbocharger outlet coolant pipe
     
    Engine front cover bolts
     
    Use a suitable seal cutter to separate the front cover from the cylinder block and upper oil pan
     



    O-ring from the front cover

    Click image to see an enlarged view

    Fig. Engine front cover-6.6L engine

     
    Oil pressure relief valve from the front cover
     

  10.  

To install:

  1. Clean and inspect all sealing surfaces.
  2.  
  3. Install or connect the following:
    NOTE
    The CKP sensor spacers are machined with different timing positions. If you have to replace a spacer, make sure it has the same part number.



    Oil pressure relief valve with a new O-ring. Tighten to 30 ft. lbs. (41 Nm)
     
    Apply a 1 / 8 in. (2-3mm) wide to 1 / 16 in. (0.5-1.5mm) high bead of sealant to the front cover sealing surfaces to the engine block and oil pan.
     
    New front cover O-ring after lubricating it with engine oil
     
    Front cover and bolts. Tighten to 15 ft. lbs. (20 Nm)
     
    Upper oil pan-to-front cover bolts. Tighten to 15 ft. lbs. (20 Nm)
     
    Turbocharger coolant outlet pipe bracket and bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Camshaft sensor and bolt. Tighten to 80 inch lbs. (9 Nm)
     
    Camshaft sensor connector
     



    CKP sensor spacer and spacer bolts. Tighten to 89 inch lbs. (10 Nm)
     
    CKP sensor and bolt. Tighten to 89 inch lbs. (10 Nm)
     
    Water pump
     
    Crankshaft front oil seal
     
    Crankshaft balancer
     
    Thermostat housing crossover
     
    Oil fill tube
     
    Drive belt
     
    Upper fan shroud
     
    Right front fender splash shield and wheel
     
    Negative battery cables
     

  4.  
  5. Refill the cooling system with the proper type and quantity of antifreeze.
  6.  
  7. Inspect the engine for leaks.
  8.  


NOTE
The 6.6L engine uses gears in place of a timing chain. For removal and installation of the gears, please see the Camshaft and Lifters procedure. This procedure covers the removal of the front cover and seal.

  1. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then lift the shield off the rear bracket.
    4.  

  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not bend the turbocharger outlet pipe.



    Negative battery cables
     
    Right front wheel
     
    Right front fender splash shield
     
    Upper fan shroud
     
    Fan clutch
     
    Drive belt
     
    Oil dipstick tube
     
    Thermostat housing crossover
     
    Crankshaft balancer
     
    Crankshaft front oil seal
     
    Water pump
     
    Camshaft sensor electrical connector
     
    Camshaft sensor bolt and sensor
     
    Crankshaft Position (CKP) sensor connector, bolt and sensor
     
    CKP sensor spacer bolts and spacer
     
    5 bolts securing the upper oil pan to the front cover
     
    Bracket bolts and the bracket for the turbocharger outlet coolant pipe
     
    Engine front cover bolts
     
    Use a suitable seal cutter to separate the front cover from the cylinder block and upper oil pan
     
    O-ring from the front cover
     
    Oil pressure relief valve from the front cover
     



    Click image to see an enlarged view

    Fig. Engine front cover-6.6L engines

  6.  

To install:

  1. Clean and inspect all sealing surfaces.
  2.  
  3. Install or connect the following:
    NOTE
    The CKP sensor spacers are machined with different timing positions. If you have to replace a spacer, make sure it has the same part number.



    Oil pressure relief valve with a new O-ring. Tighten to 30 ft. lbs. (41 Nm).
     
    Apply a 1 / 8 in. (2-3mm) wide to 1 / 16 in. (0.5-1.5mm) high bead of sealant to the front cover sealing surfaces to the engine block and oil pan.
     
    New front cover O-ring after lubricating it with engine oil
     
    Front cover and bolts. Tighten to 18 ft. lbs. (25 Nm).
     
    Upper oil pan-to-front cover bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Turbocharger coolant outlet pipe bracket and bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Camshaft sensor and bolt. Tighten to 80 inch lbs. (9 Nm).
     
    Camshaft sensor connector
     



    CKP sensor spacer and spacer bolts. Tighten to 89 inch lbs. (10 Nm).
     
    CKP sensor and bolt. Tighten to 89 inch lbs. (10 Nm).
     
    Water pump
     
    Crankshaft front oil seal
     
    Crankshaft balancer
     
    Thermostat housing crossover
     
    Oil fill tube
     
    Drive belt
     
    Upper fan shroud
     
    Right front fender splash shield and wheel
     
    Negative battery cables
     

  4.  
  5. Refill the cooling system with the proper type and quantity of antifreeze.
  6.  
  7. Inspect the engine for leaks.
  8.  


NOTE
The 6.6L engine uses gears in place of a timing chain. For removal and installation of the gears, please see the Camshaft and Lifters procedure. This procedure covers the removal of the front cover and seal.

  1. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then lift the shield off the rear bracket.
    4.  

  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not bend the turbocharger outlet pipe.



    Negative battery cables
     
    Right front wheel
     
    Right front fender splash shield
     
    Upper fan shroud
     
    Fan clutch
     
    Drive belt
     
    Oil dipstick tube
     
    Thermostat housing crossover
     
    Crankshaft balancer
     
    Crankshaft front oil seal
     
    Water pump
     
    Camshaft sensor electrical connector
     
    Camshaft sensor bolt and sensor
     
    Crankshaft Position (CKP) sensor connector, bolt and sensor
     
    CKP sensor spacer bolts and spacer
     
    5 bolts securing the upper oil pan to the front cover
     
    Bracket bolts and the bracket for the turbocharger outlet coolant pipe
     
    Engine front cover bolts
     
    Use a suitable seal cutter to separate the front cover from the cylinder block and upper oil pan
     
    O-ring from the front cover
     
    Oil pressure relief valve from the front cover
     



    Click image to see an enlarged view

    Fig. Engine front cover-6.6L engines

  6.  

To install:

  1. Clean and inspect all sealing surfaces.
  2.  
  3. Install or connect the following:
    NOTE
    The CKP sensor spacers are machined with different timing positions. If you have to replace a spacer, make sure it has the same part number.



    Oil pressure relief valve with a new O-ring. Tighten to 30 ft. lbs. (41 Nm).
     
    Apply a 1 / 8 in. (2-3mm) wide to 1 / 16 in. (0.5-1.5mm) high bead of sealant to the front cover sealing surfaces to the engine block and oil pan.
     
    New front cover O-ring after lubricating it with engine oil
     
    Front cover and bolts. Tighten to 18 ft. lbs. (25 Nm).
     
    Upper oil pan-to-front cover bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Turbocharger coolant outlet pipe bracket and bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Camshaft sensor and bolt. Tighten to 80 inch lbs. (9 Nm).
     
    Camshaft sensor connector
     



    CKP sensor spacer and spacer bolts. Tighten to 89 inch lbs. (10 Nm).
     
    CKP sensor and bolt. Tighten to 89 inch lbs. (10 Nm).
     
    Water pump
     
    Crankshaft front oil seal
     
    Crankshaft balancer
     
    Thermostat housing crossover
     
    Oil fill tube
     
    Drive belt
     
    Upper fan shroud
     
    Right front fender splash shield and wheel
     
    Negative battery cables
     

  4.  
  5. Refill the cooling system with the proper type and quantity of antifreeze.
  6.  
  7. Inspect the engine for leaks.
  8.  

 
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