Home » Duramax LLY » Duramax LLY – ROCKER ARM COVER SERVICE – Left Side Cover Removal

Duramax LLY – ROCKER ARM COVER SERVICE – Left Side Cover Removal

1. Remove front console and engine cover.

2. Drain engine coolant.

3. Remove driver side splash shield.

4. Remove air inlet hose and air horn.

5. Disconnect radiator upper hoses at thermostat housing and radiator. Then remove hoses and inlet tube as assembly.

6. Disconnect fuel pump, remove it from clamp and move pump aside for working clearance.

7. Remove nuts attaching harness and sensor brackets to intake manifold studs.

8. Remove nuts attaching water valve and bracket. Then move valve and bracket aside for working clearance.

9. Remove nuts and washers attaching fuel injection line clamps to manifold studs. Remove and retain clamps and fasteners.

10. Remove studs and bolts attaching intake manifold to cylinder heads. Remove manifold and gaskets. Cover cylinder head intake ports with shop towels to prevent dirt entry (Figure 2-35).

11. Remove screws attaching oil dipstick and tube to cover.
Then rotate tube away from engine for working clearance.

12. Disconnect fuel lines at driver side injectors. Then loosen (or remove) lines at pump. Rotate lines aside for working clearance. Cover lines and injectors to prevent dirt entry.
CAUTION: Do not bend the fuel injector lines. The internal coating could fracture, peel off, and clog the injectors.

13. Remove rocker arm cover attaching bolts and studs. Then tap cover with rubber mallet to break sealer bead. Do not pry cover loose.

14. Remove rocker arm cover.

15. Clean cover in parts cleaning solvent and scrape all traces of old silicone sealer off cover seal surfaces. Final clean cover seal surfaces with brake or contact cleaner. This is necessary to remove residue from cleaning solvent, and ensure proper adhesion of new sealer.

16. Clean gasket surfaces of intake manifold and cylinder heads. Be sure surfaces are clean and smooth. Remove minor nicks or scratches with 220 grit emery cloth.

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