Corvette 1997-2005

Valve Covers

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Removal & Installation



5.7L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the fuel feed hose.
  6.  
  7. Disconnect the generator electrical connector.
  8.  
  9. Remove the engine wiring harness generator lead nut and lead.
  10.  
  11. Remove the Secondary Air Injection (AIR) hose clamp.
  12.  
  13. Disconnect the AIR hose from the check valve.
  14.  
  15. On non-high output engines, remove the positive crankcase ventilation (PCV) valve pipe from the left rocker cover.
  16.  
  17. Disconnect the spark plug wires from the ignition coils.
  18.  
  19. Disconnect the ignition coil wire harness main electrical connector.
  20.  
  21. Remove the evaporative emission (EVAP) canister purge tube from the intake manifold.
  22.  
  23. Remove the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  24.  
  25. Remove the EVAP canister purge tube.
  26.  
  27. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  28.  
  29. Disconnect the EVAP canister purge tube from the fuel feed pipe.
  30.  
  31. Remove the EVAP canister purge tube.
  32.  
  33. Disconnect the EVAP canister purge solenoid valve electrical connector.
  34.  
  35. Remove the EVAP canister purge solenoid valve from the bracket.
  36.  
  37. Remove the ignition coil bracket studs.
  38.  
  39. Remove the ignition coil bracket.
  40.  
  41. Loosen the valve rocker arm cover bolts.
  42.  
  43. Remove the valve rocker cover.
  44.  
  45. Remove the gasket from the rocker cover. Discard the OLD gasket.
  46.  
  47. Clean and inspect the rocker arm cover.
  48.  

To install:

  1. Install a NEW rocker cover gasket into the valve rocker cover lip.
  2.  
  3. Install the rocker arm cover and tighten the bolts to 106 inch lbs. (12 Nm).
  4.  
  5. Install the ignition coil bracket.
  6.  
  7. Apply threadlock to the threads of the ignition coil bracket studs.
  8.  
  9. Install the ignition coil bracket studs and tighten to 106 inch lbs. (12 Nm)..
  10.  
  11. Install the EVAP canister purge solenoid valve to the bracket.
  12.  
  13. Connect the EVAP canister purge solenoid valve electrical connector.
  14.  
  15. Install the EVAP canister purge tube.
  16.  
  17. Connect the EVAP canister purge tube to the fuel feed pipe.
  18.  
  19. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  20.  
  21. Install the EVAP canister purge tube.
  22.  
  23. Install the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  24.  
  25. Install the evaporative emission (EVAP) canister purge tube to the intake manifold.
  26.  
  27. Connect the ignition coil wire harness main electrical connector.
  28.  
  29. Connect the spark plug wires from the ignition coils.
  30.  
  31. On non-high output engines, install the positive crankcase ventilation (PCV) valve pipe to the left rocker cover.
  32.  
  33. Connect the AIR hose from the check valve.
  34.  
  35. Install the Secondary Air Injection (AIR) hose clamp.
  36.  
  37. Install the engine wiring harness generator lead nut and lead.
  38.  
  39. Connect the generator electrical connector.
  40.  
  41. Install the fuel feed hose.
  42.  
  43. Connect the negative battery cable.
  44.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the right fuel rail cover.
  6.  
  7. Remove the Secondary Air Injection (AIR) hose clamp.
  8.  
  9. Remove the AIR hose from the check valve.
  10.  
  11. Remove the AIR pipe bolts at the exhaust manifold.
  12.  
  13. Loosen, DO NOT remove the AIR pipe bolt at the rear of the left cylinder head.
  14.  
  15. Slide the AIR pipe up and out from behind the bolt.
  16.  
  17. Reposition the AIR pipe.
  18.  
  19. Remove the AIR pipe gasket from the exhaust manifold.
  20.  
  21. Remove the Throttle Position (TP) sensor harness clip from the PCV tube.
  22.  
  23. Remove the PCV tube from the throttle body and rocker arm cover.
  24.  
  25. On non-high output engine, remove the PCV valve pipe strap nut.
  26.  
  27. Remove the PCV valve pipe from the right rocker arm cover and intake manifold.
  28.  
  29. Disconnect the spark plug wires from the ignition coils.
  30.  
  31. Disconnect the ignition coil wire harness main electrical connector.
  32.  
  33. Remove the ignition coil bracket studs.
  34.  
  35. Remove the ignition coil bracket.
  36.  
  37. Loosen the valve rocker arm cover bolts.
  38.  
  39. Remove the valve rocker arm cover.
  40.  
  41. Remove the gasket from the rocker cover. Discard the OLD gasket.
  42.  
  43. Remove the oil fill cap from the oil fill tube.
  44.  
  45. Remove the oil fill tube, if required.
  46.  
  47. Discard the oil fill tube.
  48.  
  49. Clean and inspect the valve rocker arm cover.
  50.  

To install:

  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 gasket into the valve rocker cover lip.
  8.  
  9. Install the valve rocker arm cover onto the cylinder head.
  10.  
  11. Install the rocker arm cover and tighten the bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install the ignition coil bracket.
  14.  
  15. Apply threadlock to the threads of the ignition coil bracket studs.
  16.  
  17. Install the ignition coil bracket studs and tighten to 106 inch lbs. (12 Nm)..
  18.  
  19. Connect the ignition coil wire harness main electrical connector.
  20.  
  21. Connect the spark plug wires from the ignition coils.
  22.  
  23. Install the PCV valve pipe to the right rocker arm cover and intake manifold.
  24.  
  25. On non-high output engine, install the PCV valve pipe strap nut.
  26.  
  27. Install the PCV tube to the throttle body and rocker arm cover.
  28.  
  29. Install the Throttle Position (TP) sensor harness clip to the PCV tube.
  30.  
  31. Install the AIR pipe gasket to the exhaust manifold.
  32.  
  33. Reposition the AIR pipe.
  34.  
  35. Slide the AIR pipe down and in behind the bolt.
  36.  
  37. Tighten the AIR pipe bolt at the rear of the left cylinder head.
  38.  
  39. Install the AIR pipe bolts at the exhaust manifold.
  40.  
  41. Install the AIR hose to the check valve.
  42.  
  43. Install the Secondary Air Injection (AIR) hose clamp.
  44.  
  45. Install the right fuel rail cover.
  46.  
  47. Connect the negative battery cable.
  48.  

6.0L Engines
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the left engine sight cover.
  6.  
  7. Disconnect the generator electrical connector.
  8.  
  9. Remove the engine wiring harness generator lead nut and lead.
  10.  
  11. Remove the ignition coil assembly.
  12.  
  13. Loosen the valve rocker arm cover bolts.
  14.  
  15. Remove the valve rocker cover.
  16.  
  17. Remove the gasket from the rocker cover. Discard the OLD gasket.
  18.  

To install:

  1. Install a NEW rocker cover gasket into the valve rocker cover lip.
  2.  
  3. Install the rocker arm cover and tighten the bolts to 106 inch lbs. (12 Nm).
  4.  
  5. Install the ignition coil assembly.
  6.  
  7. Connect the generator electrical connector.
  8.  
  9. Install the engine wiring harness generator lead and nut.
  10.  
  11. Install the left engine sight cover.
  12.  
  13. Connect the negative battery cable.
  14.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine sight cover.
  4.  
  5. Remove the crankcase ventilation hoses/pipes.
  6.  
  7. Remove the ignition coil assembly.
  8.  
  9. Remove the oil fill tube.
  10.  
  11. Loosen the valve rocker arm cover bolts.
  12.  
  13. Remove the valve rocker arm cover.
  14.  

To install:

  1. Install a NEW rocker cover gasket into the valve rocker cover lip.
  2.  
  3. Install the rocker arm cover and tighten the bolts to 106 inch lbs. (12 Nm).
  4.  
  5. Install the oil fill tube.
  6.  
  7. Install the ignition coil assembly.
  8.  
  9. Install the crankcase ventilation hoses/pipes.
  10.  
  11. Install the engine sight cover.
  12.  
  13. Connect the negative battery cable.
  14.  

Left Side
  1. Remove the left engine sight cover.
  2.  
  3. Disconnect the alternator electrical connector.
  4.  
  5. Remove the engine wiring harness alternator lead nut and lead.
  6.  
  7. Remove the ignition coil assembly.
  8.  
  9. Loosen the valve rocker arm cover bolts.
  10.  
  11. Remove the valve rocker cover.
  12.  
  13. Remove the gasket from the rocker cover. Discard the OLD gasket.
  14.  

To install:


NOTE
Important:



All gasket surfaces should be free of oil and other foreign material during assembly.
 
DO NOT reuse the valve rocker arm cover gasket.
 
The valve rocker arm cover bolt grommets may be reused.
 
If the positive crankcase ventilation (PCV) valve grommet has been removed from the rocker arm, install a NEW grommet during assembly.
 

  1. Install a NEW rocker cover gasket into the valve rocker cover lip.
  2.  
  3. Install the valve rocker arm cover.
  4.  
  5. Tighten the valve rocker cover bolts to 106 in lbs.(12 Nm).
  6.  
  7. Install the ignition coil assembly.
  8.  
  9. Connect the alternator electrical connector.
  10.  
  11. Install the engine wiring harness alternator lead and nut Tighten to 115 inch lbs.(13 Nm).
  12.  
  13. Install the left engine sight cover.
  14.  

Right Side
  1. Remove the engine sight cover.
  2.  
  3. Remove the crankcase ventilation hoses/pipes.
  4.  
  5. Remove the ignition coil assembly.
  6.  
  7. Loosen the valve rocker arm cover bolts.
  8.  
  9. Remove the valve rocker arm cover.
  10.  
  11. Remove the gasket from the rocker cover. Discard the OLD gasket.
    NOTE
    Important:



    All gasket surfaces should be free of oil and other foreign material during assembly.
     
    DO NOT reuse the valve rocker arm cover gasket.
     
    The valve rocker arm cover bolt grommets may be reused.
     
    If the positive crankcase ventilation (PCV) valve grommet has been removed from the rocker arm, install a NEW grommet during assembly.
     

  12.  
  13. Install a NEW rocker cover gasket into the valve rocker cover lip.
  14.  
  15. Install the valve rocker arm cover.
  16.  
  17. Tighten the rocker arm cover bolts to 106 inch lbs.(12 Nm).
  18.  
  19. Install the oil fill tube into the rocker arm cover.
  20.  
  21. Install the ignition coil assembly.
  22.  
  23. Install the crankcase ventilation hoses/pipes.
  24.  
  25. Install the engine sight cover.
  26.  

 
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