Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

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

NOTE
Do not remove the ignition coils from the valve rocker arm cover unless required. Do not remove the oil fill tube from the cover unless service is required. If the oil fill tube has been removed from the cover, install a NEW tube during assembly.

On the right side:

  1. Remove or disconnect the following:

    Ignition coil bracket bolts from the rocker arm cover (if required)
     
    Ignition coil and bracket assembly from the cover
     
    Valve rocker arm cover bolts
     
    Valve rocker arm cover
     
    Gasket from the cover. Discard the gasket. The bolt grommets may be reused if not damaged.
     
    Oil fill cap from the oil fill tube
     
    Oil fill tube (if required). Discard the oil fill tube.
     

  2.  

On the left side:


NOTE
Do not remove the Positive Crankcase Ventilation (PCV) valve grommet from the cover unless service is required.

  1. Remove or disconnect the following:

    Ignition coil bracket bolts from the rocker arm cover (if required)
     
    Ignition coil and bracket assembly from the cover
     
    Valve rocker arm cover bolts
     
    Valve rocker arm cover
     
    Gasket from the cover. Discard the gasket. The bolt grommets may be reused if not damaged.
     

  2.  

To install:


NOTE
The valve rocker arm cover bolt grommets may be reused. If the oil fill tube has been removed from the valve rocker arm cover, install a NEW oil fill tube during assembly.

  1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
  2.  
  3. Install or connect the following:

    NEW oil fill tube into the rocker arm cover and rotate the tube clockwise until locked in the proper position
     
    Oil fill cap into the tube and rotate clockwise until locked in the proper position
     
    NEW cover gasket into the valve rocker arm cover
     
    Valve rocker arm cover onto the cylinder head
     
    Cover bolts with grommets and tighten to 106 inch lbs. (12 Nm)
     

  4.  
  5. Apply threadlock GM P/N 12345382 or equivalent to the threads of the bracket bolts.

    Ignition coil and bracket assembly and bolts. Tighten to 106 inch lbs. (12 Nm).
     

  6.  

On the left side:


NOTE
DO NOT reuse the valve rocker arm cover gasket. The valve rocker arm cover bolt grommets may be reused. If the vapor vent grommet has been removed from the valve rocker arm cover, install a NEW vapor vent gourmet during assembly.

  1. Install or connect the following:

    NEW cover gasket (1) into the valve rocker arm cover
     
    Valve rocker arm cover onto the cylinder head
     
    Cover bolts with grommets and tighten to 106 inch lbs. (12 Nm)
     

  2.  
  3. Apply threadlock GM P/N 12345382 or equivalent to the threads of the bracket bolts.

    Ignition coils and bracket assembly and bolts. Tighten the bolts to 106 inch lbs. (12 Nm).
     

  4.  

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.  

4.8L, 5.3L, 6.0L & 6.2L 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.  

5.0L & 5.7L Engines
  1. Disconnect the negative battery cable. Remove the air cleaner.
  2.  
  3. Tag, disconnect and reposition as necessary any vacuum or PCV hoses that obstruct the cylinder head covers.
  4.  
  5. If necessary, remove the air cleaner box and the intake duct.
  6.  
  7. Disconnect electrical wire(s) (spark plug, etc.) from the cylinder head cover clips. You may also have to remove or move the alternator brace and PCV pipe.
  8.  
  9. Unbolt and remove the cover(s).
    NOTE
    Do not pry the covers off if they seem stuck. Instead, gently tap around each cover with a rubber mallet until the old gasket or sealer breaks loose.



    Click image to see an enlarged view

    Fig. Unfasten and remove the cover bolts



    Click image to see an enlarged view

    Fig. Remove the old gasket material

  10.  

To install:

  1. Install a new gasket or apply RTV (or any equivalent) sealer to the cover prior to installation. If using sealer, follow directions on the tube.
  2.  
  3. Install the cover and mounting bolts. Tighten the bolts to 106 inch lbs. (12 Nm)
  4.  
  5. Attach and reposition all vacuum and PCV hoses, and reconnect electrical and/or spark plug wires at the cover clips. Install the air cleaner.
  6.  
  7. If removed, install the air cleaner box and the intake duct.
  8.  
  9. Reconnect the battery cable.

    Click image to see an enlarged view

    Fig. Cylinder head cover-5.0L and 5.7L engines



    Click image to see an enlarged view

    Fig. Correct RTV application on the cylinder head cover

  10.  

5.7L Engine
  1. Disconnect the spark plug wires from the spark plugs.
  2.  
  3. Disconnect the wiring harness from the clips, and move the harness aside.
  4.  
  5. Remove the air cleaner intake duct for access to the right valve rocker arm cover.
  6.  
  7. Remove the bolts and oil level indicator tube bracket.
  8.  
  9. Remove the AIR check valve (crossover), if so equipped.
  10.  
  11. Remove the PCV tube.
  12.  
  13. Remove the following components for access to the left valve rocker arm cover:

    The air conditioning (A/C) compressor, if equipped, and lay the A/C compressor aside
     
    The EGR valve inlet pipe
     
    The PCV and the hose
     
    The vacuum brake booster pipe, if equipped, and move it aside
     

  14.  
  15. Remove the valve rocker arm cover and the gasket.
  16.  
  17. Clean all traces of old gasket from the valve rocker arm cover and the cylinder head.
  18.  

To install:

  1. Install the valve rocker arm cover. Torque to 106 inch lbs. (12 Nm).
  2.  
  3. Install the components as follows for the left valve rocker arm cover:

    The air conditioning compressor
     
    The EGR valve pipe
     
    The PCV and the hose
     
    The vacuum brake booster pipe
     
    The AIR check valve (crossover) pipe, if equipped
     

  4.  
  5. Install the components as follows for the right valve rocker arm cover:

    The air cleaner intake duct
     
    The crankcase ventilation hose
     
    The oil level indicator tube
     

  6.  
  7. Install the wiring harnesses to the valve rocker arm cover clips.
  8.  
  9. Install the spark plug wires.
  10.  

6.5L Engine
  1. Remove the intake manifold cover.
    NOTE
    Do not bend the fuel lines to facilitate valve cover removal as this may damage the lines.

  2.  
  3. Mark the fuel line clips an brackets to ensure proper installation.
  4.  
  5. Remove the fuel injection lines and clips.
  6.  
  7. If removing the right side cover, remove the CDR valve, CDR hose and the long pencil brace to the turbocharger.
  8.  
  9. Remove the ground strap.
  10.  
  11. If removing the right side valve cover, remove the heater hose.
  12.  
  13. If removing the left side valve cover, remove the oil level indicator tube and bracket.
  14.  
  15. Remove the fuel return line clip from the valve cover stud.
  16.  
  17. Remove the wiring harness at the rear of the valve cover from the clips and set the harness aside.
  18.  
  19. If removing the right side cover, remove the turbocharger heat shield.
  20.  
  21. Unfasten the valve cover retainers.
    1. Unfasten the valve cover retainers and remove the cover.
    2.  
    3. Remove the RTV sealer from the valve, then clean any RTV sealer residue from the valve cover mating surfaces.
    4.  
    5. Inspect the valve cover and its sealing surfaces for distortion. Replace as necessary.
    6.  

  22.  

To install:


NOTE
Do not allow and RTV sealant to enter the valve cover bolt holes. This will cause a condition referred to as valve lock, and when the bolts are tightened the cylinder head casing could be damaged.

  1. Apply a 3 / 16 inch (5mm) bead of RTV sealant to the valve covers, inboard of the bolt holes. The sealer must be wet to the touch when the cover bolts are tightened.

    Click image to see an enlarged view

    Fig. Apply a bead of RTV sealant to the valve covers, inboard of the bolt holes-6.5L Diesel engine

  2.  
  3. Install the valve cover and the bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the wiring harness.
  6.  
  7. If installing the right side valve cover, install the turbocharger heat shield.
  8.  
  9. Install the fuel return lines.
  10.  
  11. If installing the left side valve cover, install the oil level dipstick tube and its bracket.
  12.  
  13. If installing the right side valve cover, install the heater hose.
  14.  
  15. Install the ground strap.
  16.  
  17. If installing the right side valve cover, install the long pencil brace to the turbocharger, the CDR valve and the CDR hose.
  18.  
  19. Install the fuel injection lines and clips to their original position marked during removal.
  20.  
  21. Install the intake manifold.
  22.  

  1. Disconnect both the battery negative cables from the batteries.
  2.  
  3. Remove the CDR valve from the valve rocker arm cover.
  4.  
  5. Remove the upper intake manifold from the lower intake manifold .
  6.  
  7. Remove the lower intake manifold from the cylinder head (s).
  8.  
  9. Remove the heat shield between the turbocharger and the valve rocker arm cover (right side only).
  10.  
  11. Remove the engine wiring harness from the rear of the right valve rocker arm cover and move to the side (for removing the right side valve rocker arm cover only).
    NOTE
    It is not necessary to disconnect the glow plug electrical connector to perform this service procedure.

  12.  
  13. Remove the engine wiring harness from the left side of the engine and move to the side (for removing the left valve rocker arm cover only).
    NOTE
    Mark the fuel injection line retaining clips and brackets in order to ensure proper reinstallation.

  14.  
  15. Remove the upper intake manifold from the lower intake manifold.
  16.  
  17. Remove the braces from the turbocharger.
  18.  
  19. Remove the lower intake manifold from the cylinder head.
    NOTE
    The turbocharger heat shield must be removed from the turbocharger to ensure that the fuel injectors are not damaged during the removal process.

  20.  
  21. Remove the fuel injection lines from the fuel injectors and the fuel injection pump.
  22.  
  23. Remove the oil level indicator and tube from the engine block.
  24.  
  25. Remove the heater hose from heater core inlet.
  26.  
  27. Remove the rear heater hose from the connector (if the vehicle is equipped with rear heat).
  28.  
  29. Remove the valve rocker arm cover bolts from the cylinder head.
    WARNING
    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.

  30.  
  31. Remove the valve rocker arm cover from the cylinder head.
  32.  
  33. Remove the RTV from the valve rocker arm cover.
  34.  
  35. Remove all oil and grease from the sealing surfaces.
  36.  

To install:


WARNING
Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.

  1. Apply a 5mm ( 3 / 16 inch) bead of RTV sealant GM P/N 12345739 to the valve rocker arm cover, inboard of the bolt holes. The sealer must be wet to the touch when the bolts are tightened.
  2.  
  3. Install the valve rocker arm cover to the cylinder head.
  4.  
  5. Install the valve rocker arm cover bolts to the cylinder head. Tighten the bolts to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the fuel injection lines to the fuel injection pump and fuel injectors.
  8.  
  9. Install the lower intake manifold on the cylinder heads.
  10.  
  11. Install the heater hose to heater core inlet.
  12.  
  13. Install the rear heater hose to the connector if the vehicle is equipped with rear heat.
  14.  
  15. Install the engine wiring harness to the right rear or the lower intake manifold (if installing the right side valve rocker arm cover only).
  16.  
  17. Install the engine wiring harness to the left of the lower intake manifold (if installing the left side valve rocker arm cover only).
  18.  
  19. Install the CDR valve to the valve rocker arm cover.
  20.  
  21. Install the heat shield to the turbocharger.
  22.  
  23. Install the upper intake manifold to the lower intake manifold.
  24.  
  25. Install the oil level indicator and tube.
  26.  
  27. Install the braces to the turbocharger.
  28.  
  29. Connect both the battery negative cables to the batteries.
  30.  

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 engine

    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 engine

    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 engine

    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 engine

    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.  

7.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. If removing the right side cover, perform the following steps:
    1. Remove the air cleaner assembly.
    2.  
    3. Tag and disconnect the spark plug wires from the spark plugs and move the wires aside so that they will not interfere with the valve cover removal.
    4.  
    5. Remove the vent tube from the valve cover.
    6.  
    7. Remove the throttle body unit and the throttle body studs.
    8.  
    9. Unfasten the valve cover retainers and remove the cover.
    10.  
    11. Remove the old valve cover gasket, then clean any gasket residue from the gasket mating surfaces.
    12.  
    13. Inspect the valve cover and its sealing surfaces for distortion. Replace as necessary.
    14.  

  4.  
  5. If removing the left side cover, perform the following steps:
    1. Remove the PCV valve, tube and the EGR inlet tube.
    2.  
    3. Tag and disconnect the spark plug wires from the spark plugs and move the wires aside so that they will not interfere with the valve cover removal.
    4.  
    5. Unfasten the valve cover retainers and remove the cover.
    6.  
    7. Remove the old valve cover gasket, then clean any gasket residue from the gasket mating surfaces.
    8.  
    9. Inspect the valve cover and its sealing surfaces for distortion. Replace as necessary.
    10.  

  6.  

To install:

  1. If installing the right side cover, perform the following steps:
    1. Install a new valve cover gasket.
    2.  
    3. Install the valve cover and its retainers. Tighten the retainers to 72 inch lbs. (8 Nm).
    4.  
    5. Install the throttle body studs in the upper intake manifold. Tighten the studs to 108 inch lbs. (12 Nm).
    6.  
    7. Install the throttle body assembly.
    8.  
    9. Attach the vent tube to the valve cover and the spark plug wires to the spark plugs.
    10.  
    11. Install the air cleaner assembly.
    12.  

  2.  
  3. If installing the left side cover, perform the following steps:
    1. Install a new valve cover gasket.
    2.  
    3. Install the valve cover and its retainers. Tighten the retainers to 72 inch lbs. (8 Nm).
    4.  
    5. Attach the spark plug wires to the spark plugs.
    6.  
    7. Install the EGR inlet tube, the PCV valve and the PCV tube.
    8.  

  4.  
  5. Connect the negative battery cable.
  6.  


NOTE
Valve rocker arm cover gaskets are reusable. Replace the valve rocker arm cover gasket only if damaged.

  1. Remove the intake air resonator.
  2.  
  3. Remove the air cleaner intake duct from the throttle body.
  4.  
  5. Remove the spark plug wires from the spark plugs.
  6.  
  7. Remove the PVC valve from then valve rocker arm cover if necessary.
  8.  
  9. Remove the engine vent tube from the throttle body if necessary.
  10.  
  11. Remove the throttle body from the intake manifold if necessary.
  12.  
  13. Remove the valve rocker arm cover bolts.
  14.  
  15. Remove the valve rocker arm cover from the cylinder head.
  16.  

To install:

  1. Install the valve rocker cover gasket to the cylinder head.
  2.  
  3. Install the valve rocker arm cover to the cylinder head.
  4.  
  5. Install the valve rocker arm cover bolts. Tighten the bolts to 71 inch lbs. (8 Nm).
  6.  
  7. Install the throttle body to the upper intake manifold.
  8.  
  9. Install the engine vent tube to the throttle body if necessary.
  10.  
  11. Install the PVC valve to the valve rocker arm cover if necessary.
  12.  
  13. Install the spark plug wires to the spark plugs.
  14.  
  15. Install the intake air resonator to the throttle body.
  16.  
  17. Install the air cleaner intake duct.
  18.  

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.  

  1. Remove the engine sight shield.
  2.  
  3. Remove the secondary air injection (AIR) pipe nut at the fuel rail, if equipped.
  4.  
  5. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
  6.  
  7. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
  8.  
  9. Remove the AIR pipe, if equipped.
  10.  
  11. Remove and discard the AIR pipe gasket, if equipped.
  12.  
  13. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  14.  
  15. Disconnect the ignition coil harness electrical connector.
    WARNING
    Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

  16.  
  17. Remove the spark plug wires from the spark plugs and ignition coils.
  18.  
  19. Remove the CPA retainers at the ignition coil electrical connectors.
  20.  
  21. Remove the ignition coil wiring harness bolts.
  22.  
  23. Remove the ignition coil wiring harness from the rocker cover.
  24.  
  25. Remove the valve rocker arm cover bolts.
  26.  
  27. Remove the valve rocker arm cover.
    NOTE
    Valve rocker arm cover gaskets are reusable. Replace the valve rocker arm cover gasket only if damaged.

  28.  
  29. Inspect the valve rocker arm cover gasket for cuts or damage.
  30.  
  31. Clean and inspect the valve rocker arm cover.

    Click image to see an enlarged view

    Fig. Rocker cover torque sequence-8.1L engine

  32.  

To install:

  1. Install a new valve rocker arm cover 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 sequence, using two passes as shown.

    Step 1: 53 inch lbs. (6 Nm).
     
    Step 2: 106 inch lbs. (12 Nm).
     

  8.  
  9. Install the ignition coil wiring harness to the rocker cover.
  10.  
  11. Install the ignition coil wiring harness bolts. Tighten the ignition coil harness bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install the CPA retainers at the ignition coil electrical connectors.
    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.

  14.  
  15. Install the spark plug wires to the spark plugs and ignition coils.
  16.  
  17. Connect the ignition coil harness electrical connector.
  18.  
  19. Install the CPA retainer to the ignition coil electrical connector.
  20.  
  21. Install a NEW AIR pipe gasket, if equipped.
  22.  
  23. Install the AIR pipe, if equipped.
  24.  
  25. Connect the AIR pipe to the AIR pump pipe, if equipped.
  26.  
  27. Install the AIR pipe bolts at the exhaust manifold, if equipped.
  28.  
  29. Install the AIR pipe nut at the fuel rail, if equipped. Tighten the AIR pipe bolts to 18 ft. lbs. (25 Nm). Tighten the AIR pipe nut to 106 inch lbs. (12 Nm).
  30.  
  31. Install the engine sight shield.
  32.  

  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.  

  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. Reposition the AIR pump pipe hose clamp.
  8.  
  9. Disconnect the AIR pump pipe hose from the pump pipe.
  10.  
  11. Remove the secondary air injection (AIR) pipe nut at the fuel rail, if equipped.
  12.  
  13. Remove the AIR pipe bolts at the exhaust manifold, if equipped.
  14.  
  15. Disconnect the AIR pipe from the AIR pump pipe, if equipped.
  16.  
  17. Remove the AIR pipe, if equipped.
  18.  
  19. Remove and discard the AIR pipe gasket, if equipped.
  20.  
  21. Remove the AIR pump pipe bolt at the cylinder head, if equipped.
  22.  
  23. Disconnect the left AIR pipe from the AIR pump pipe, if equipped.
  24.  
  25. Remove the AIR pump pipe, if equipped.
  26.  
  27. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  28.  
  29. Disconnect the ignition coil harness electrical connector.
  30.  
  31. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    WARNING
    Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

  32.  
  33. Remove the spark plug wires from the spark plugs and ignition coils.
  34.  
  35. Remove the CPA retainers at the ignition coils.
  36.  
  37. Remove the ignition coil wiring harness bolts.
  38.  
  39. Remove the ignition coil wiring harness.
  40.  
  41. Remove the valve rocker arm cover bolts.
  42.  
  43. 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.

  44.  
  45. Replace the valve rocker arm cover gasket if it is cut or damaged.
  46.  
  47. Clean and inspect the valve rocker arm cover.
  48.  

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

  8.  
  9. Install the ignition coil wiring harness (left side shown, right side similar).
  10.  
  11. Install the ignition coil wiring harness bolts. Tighten the ignition coil wire harness bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install the CPA retainers at the ignition coils.
    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 the spark plug by using the metal heat shield.

  14.  
  15. Install the spark plug wires to the spark plugs and ignition coils.
  16.  
  17. Connect the ECT sensor electrical connector.
  18.  
  19. Connect the ignition coil harness electrical connector.
  20.  
  21. Install the CPA retainer to the ignition coil electrical connector.
  22.  
  23. Install the AIR pump pipe, if equipped.
  24.  
  25. Connect the left AIR pipe to the AIR pump pipe, if equipped.
  26.  
  27. Install the AIR pump pipe bolt at the cylinder head, if equipped. Tighten the AIR pump pipe bolt to 37 ft. lbs. (50 Nm).
  28.  
  29. Install a NEW AIR pipe gasket, if equipped.
  30.  
  31. Install the AIR pipe, if equipped.
  32.  
  33. Connect the AIR pipe to the AIR pump pipe, if equipped.
  34.  
  35. Install the AIR pipe bolts at the exhaust manifold, if equipped.
  36.  
  37. Install the AIR pipe nut at the fuel rail, if equipped. Tighten the AIR pipe bolts to 18 ft. lbs. (25 Nm). Tighten the AIR pipe nut to 106 inch lbs. (12 Nm).
  38.  
  39. Connect the AIR pump pipe hose to the pump pipe.
  40.  
  41. Reposition the AIR pump pipe hose clamp.
  42.  
  43. Install the air cleaner outlet duct.
  44.  
  45. Tighten the clamps at the throttle body and air cleaner. Tighten the air cleaner outlet duct clamp to 35 inch lbs. (4 Nm).
  46.  
  47. Install the engine sight shield.
  48.  

  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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