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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1302 (Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1 >> On-Vehicle Repair Instructions >> Valve Rocker Arm Cover Replacement - Right >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
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 oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly.
    Fig 1: View Of Oil Fill Cap & Tube
    GM260110Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil.
  2. Insert the NEW oil fill tube into the rocker arm cover.

    Rotate the tube clockwise until locked in the proper position.

  3. Install the oil fill cap into the tube.

    Rotate the cap clockwise until locked in the proper position.

    4. Fig 2: Rocker Arm Cover Gasket
    GM490696Courtesy of GENERAL MOTORS CORP.
  4. Install a NEW gasket (1) into the valve rocker cover lip.
    5. Fig 3: View Of Valve Rocker Arm Cover & Bolts (Right)
    GM260084Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the valve rocker arm cover onto the cylinder head.
  6. Tighten the rocker arm cover bolts.

    Tighten:  Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).

    7. Fig 4: Ignition Coil Bracket & Studs
    GM697216Courtesy of GENERAL MOTORS CORP.
  7. Install the ignition coil bracket.
  8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket studs.
  9. Install the ignition coil bracket studs.

    Tighten:  Tighten the ignition coil bracket studs to 12 N.m (106 lb in).

    10. Fig 5: Spark Plug Wire
    GM74069Courtesy of GENERAL MOTORS CORP.
  10. Connect the ignition coil wire harness main electrical connector.
  11. Install the spark plug wires to the ignition coils.
    12. Fig 6: Right Rocker Arm Cover & PCV Valve Pipe
    GM379367Courtesy of GENERAL MOTORS CORP.
  12. If equipped with the RPO LS1 engine, install the PCV valve pipe to the right rocker arm cover and intake manifold.
  13. Install the PCV valve pipe strap nut.

    Tighten:  Tighten the PCV valve strap nut to 12 N.m (106 lb in).

    14. Fig 7: PCV Tube & Rocker Arm Cover
    GM551464Courtesy of GENERAL MOTORS CORP.
  14. Install the PCV tube to the throttle body and rocker arm cover.
  15. Connect the TP sensor harness clip to the PCV tube.
    16. Fig 8: AIR Pipe Gasket, Exhaust Manifold & Bolts
    GM651878Courtesy of GENERAL MOTORS CORP.
  16. Position the AIR pipe into place.
  17. Slide the AIR pipe behind the bolt on the rear of the left cylinder head.
    18. Fig 9: AIR Pipe & Bolts
    GM651877Courtesy of GENERAL MOTORS CORP.
  18. Install the AIR pipe gasket to the exhaust manifold.
  19. Install the AIR pipe to the exhaust manifold.
  20. Install the AIR pipe bolts at the exhaust manifold.
  21. Tighten the AIR pipe bolts.

    Tighten:  Tighten the AIR pipe bolts to 20 N.m (15 lb ft).

    22. Fig 10: AIR Hose Clamp & Check Valve
    GM651875Courtesy of GENERAL MOTORS CORP.
  22. Connect the AIR hose (1) to the check valve.
  23. Install the AIR hose clamp.
    24. Fig 11: Right Fuel Injection Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  24. Install the right fuel injection rail cover.
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