GM Corvette 1984-1996 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



5.7L (VIN 8) Engine
1984 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. To remove the right side rocker arm (valve) cover, perform the following:
    1. Disconnect the AIR hose from the exhaust check valve.
    2.  
    3. Disconnect the fuel inlet and return lines at the TBI units.
    4.  
    5. Remove the two rear A/C compressor braces.
    6.  
    7. Remove the A/C compressor lower mounting bolt.
    8.  
    9. Unfasten the idler pulley bracket nuts at the water pump, then slide the A/C compressor mounting bracket forward.
    10.  
    11. Disconnect the wiring from the compressor.
    12.  
    13. Remove the upper A/C compressor mounting bolts, then position the compressor aside. Do NOT disconnect the refrigerant lines!
    14.  

  8.  
  9. To remove the left side rocker arm (valve) cover bolts, perform the following:
    1. Disconnect the PCV valve and hose from the intake manifold and rocker arm cover.
    2.  
    3. Disconnect the brake vacuum pipe from the intake manifold.
    4.  
    5. Remove the radiator hose bracket from the alternator brace.
    6.  
    7. Unbolt the alternator and position it aside, out of the way.
    8.  
    9. Tag and disconnect the spark plug wires from the spark plugs.
    10.  

  10.  
  11. Remove the rocker arm (valve) cover bolts.
  12.  
  13. If necessary, bend the bracket at the rear of the cylinder head, then remove the cover. If the cover sticks to the cylinder head, shear it off by carefully bumping the end of the rocker arm cover with palm of your hand or a rubber mallet. If the cover still will not come loose, CAREFULLY pry until loose. DO NOT DISTORT THE SEALING FLANGE.
  14.  

To install:
  1. Clean the sealing surface of the cylinder head and rocker cover. Make sure no oil or old gasket is present when applying the new gasket.
  2.  


WARNING
When applying the RTV sealant, make sure to keep the sealant out of the bolt holds, as could cause a "hydraulic" condition and damage the head casting.

  1. Place a 1 / 8 in. (3mm) bead of RTV sealant around the perimeter of the cover sealing surface. When going around the attaching bolt holes, always flow the RTV sealant on the inboard side of the holes.
  2.  
  3. Install the cover and secure with the mounting bolts, while the RTV is still wet. Tighten the bolts to 50 inch lbs. (6 Nm). The remainder of installation is the reverse of the removal procedure.
  4.  
  5. Connect the negative battery cable.
  6.  

1985-88 VEHICLES

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. To remove the right side rocker arm (valve) cover, as follows:
    1. Remove the right side exhaust manifold and EGR pipe assembly.
    2.  
    3. Remove the fresh air pipe.
    4.  
    5. Loosen the spark plug retainer from the back of the right side cylinder head, then remove the other wire retainers.
    6.  
    7. Remove the injector harness retaining nuts, then position the harness aside.
    8.  
    9. Disconnect the heater control valve harness vacuum hose from the intake.
    10.  

  4.  
  5. To remove the left side rocker arm (valve) cover, as follows:
    1. Disconnect the PCV valve from the rocker arm cover.
    2.  
    3. Detach the injector harness from the intake.
    4.  
    5. Disconnect the canister hose from the pipe.
    6.  
    7. Detach the brake booster vacuum hose at the pipe, and the brake booster pipe from the plenum.
    8.  
    9. Loosen the AIR pump pulley bolts, then remove the serpentine belt from the AIR pump.
    10.  
    11. Remove the AIR pump pulley, and the pump lower mounting bolt.
    12.  

  6.  
  7. Unfasten the rocker arm cover mounting bolts, then remove the cover and gasket.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the rocker arm cover

To install:
  1. Clean the sealing surface of the cylinder head and rocker cover. Make sure no oil or old gasket is present when applying the new gasket.
  2.  
  3. Place a new gasket in proper position.
  4.  
  5. Install the cover and secure with the mounting bolts. Tighten the bolts to 80-120 inch lbs. (9-13 Nm) for 1985-87 vehicles or to 60-90 inch lbs. (7-10 Nm) for 1988 vehicles.
  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  
  9. Connect the negative battery cable.
  10.  

1989-91 vehicles

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. To remove the right side rocker arm (valve) cover, perform the following:
    1. Drain the engine coolant into a suitable container.
    2.  
    3. Disconnect the EGR valve and the crankcase vent pipes.
    4.  
    5. Tag and disconnect the spark plug wires from the spark plugs and the wire retainers from the brackets. Set the wiring harness aside.
    6.  
    7. Unfasten the nuts securing the injector harness, then set the harness aside.
    8.  
    9. Disconnect the engine cooling air bleed pipe assembly.
    10.  
    11. Detach the heater core-to-plenum coolant hose.
    12.  
    13. Disconnect the AIR hoses at the control valve.
    14.  
    15. Unbolt the A/C compressor and position it aside. Do NOT disconnect the refrigerant lines from the compressor.
    16.  

  4.  
  5. To remove the left side rocker arm (valve) cover, perform the following:
    1. Remove the PCV valve and hose.
    2.  
    3. Unfasten the nuts securing the injector harness, then position the harness aside.
    4.  
    5. Tag and disconnect the spark plug wires from the spark plugs and the wire retainers from the brackets. Set the wiring harness aside.
    6.  
    7. Remove the serpentine drive belt from the AIR pump pulley.
    8.  
    9. Remove the AIR pump pulley and the pump lower mounting bolt.
    10.  

  6.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the rocker arm (valve) cover assembly

  1. Unfasten the rocker arm cover mounting bolts, then remove the cover and gasket.
  2.  

To install:
  1. Clean the sealing surface of the cylinder head and rocker cover. Make sure no oil or old gasket is present when applying the new gasket.
  2.  
  3. Place a new gasket in proper position. Install the rocker arm cover and secure with the retaining bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  4.  
  5. If installing the left side rocker arm cover, perform the following:
    1. Install the AIR pump lower mounting bolt and pulley.
    2.  
    3. Install the serpentine drive belt.
    4.  
    5. Install the spark plug wire retainers, and connect the wires to the plugs, as tagged during removal.
    6.  
    7. Install the nuts securing the injector harness.
    8.  
    9. Install the PCV valve and hose.
    10.  

  6.  
  7. If installing the right side rocker arm cover, perform the following:
    1. Place the A/C compressor in position and secure with the mounting bolts.
    2.  
    3. Attach the AIR hoses to the control valve.
    4.  
    5. Connect the heater core-to-plenum coolant hose.
    6.  
    7. Install the engine cooling air bleed pipe assembly.
    8.  
    9. Install the nuts retaining the injector harness.
    10.  
    11. Install the spark plug wire retainers, then connect the wires to the plugs, as tagged during removal.
    12.  
    13. Connect the crankcase and EGR pipes.
    14.  
    15. Refill the engine coolant.
    16.  

  8.  
  9. Connect the negative battery cable.
  10.  

5.7L (VIN P) Engines

See Figures 3, 5, 4 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel rail cover(s).
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Unfasten the necessary retainers, then remove the fuel rail cover(s)

  1. To remove the right side rocker arm cover, perform the following:
    1. Remove the fuel rail retaining bolts/screws.
    2.  
    3. Disconnect the fuel pressure regulator vacuum tube assembly.
    4.  
    5. Unfasten the retainers, then remove the fuel rail from the intake manifold.
    6.  
    7. Remove the fuel rail cover studs, then position the wiring harness aside.
    8.  
    9. Disconnect the secondary air injection pipe and check valve assemblies from the exhaust and intake manifold assemblies.
    10.  

  2.  



Click image to see an enlarged view

Fig. Fig. 4: Remove the secondary air injection check valve pipe from the exhaust manifold

  1. Detach the crankcase vent hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Disconnect the crankcase vent hose

  1. On 1992-95 vehicles, if removing the left side rocker arm cover perform the following:
    1. Unfasten the alternator brace bolts/screws, then remove the brace.
    2.  
    3. Remove the alternator mounting bolts, then position the alternator aside.
    4.  
    5. Disconnect the secondary air injection diverter valve hose from the check valve assembly.
    6.  
    7. Position the wiring harness aside.
    8.  

  2.  
  3. On 1996 vehicles, if removing the left side rocker arm cover perform the following:
    1. Disconnect the brake booster vacuum hose from the intake manifold.
    2.  
    3. Detach the distributor vent hose from the intake manifold.
    4.  
    5. Remove the fuel rail cover attaching studs.
    6.  
    7. Disconnect the secondary air injection diverter valve hose from the check valve assembly.
    8.  
    9. Loosen the secondary air injection check valve tube at the exhaust manifold. Pivot the check valve away from the rocker arm cover.
    10.  
    11. Remove the air intake duct.