GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Engine 🢒 Engine Mechanical - 8.1L 🢒 Valve Rocker Arm Cover Replacement - Left Side

Removal Procedure

    Object Number: 745786 Size: SH
  1. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  2. Disconnect the ignition coil harness electrical connector (3).

    3. Object Number: 470666 Size: SH

    Important: 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.

  3. Remove the spark plug wires from the ignition coils.

    4. Object Number: 470890 Size: SH
  4. Remove the valve rocker arm cover bolts.
  5. Remove the valve rocker arm cover.

    6. Important: Valve rocker arm cover gaskets are reusable. Replace the valve rocker arm cover gasket only if damaged.

  6. Inspect the valve rocker arm cover gasket for cuts or damage.

    7. Object Number: 745856 Size: SH
  7. If replacing the valve rocker arm cover, remove the CPA retainers at the ignition coils.
  8. Remove the ignition coil wiring harness bolts.
  9. Disconnect the ignition coil electrical connectors.
  10. Remove the ignition coil wiring harness.

    11. Object Number: 470887 Size: SH
  11. If replacing the valve rocker arm cover, remove the ignition coil bolts.
  12. Remove the ignition coil.

Installation Procedure

    Object Number: 470887 Size: SH
  1. If replacing the valve rocker arm cover, install the ignition coil.

    2. Notice: This bolt is a self-tapping bolt. If installing this bolt into a new component, installation of the bolt may be difficult. Ensure that the bolt is not over-torqued during the initial installation (thread cutting). Failure to limit torque can lead to bolt failure.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the ignition coil bolts.

    3. Tighten
    Tighten the ignition coil bolts to 12 N·m (106 lb in).


    Object Number: 745856 Size: SH
  3. If replacing the valve rocker arm cover, install the ignition coil wiring harness.
  4. Connect the ignition coil electrical connectors.
  5. Install the ignition coil wiring harness bolts.

    6. Tighten
    Tighten the ignition coil wiring harness bolts to 12 N·m (106 lb in).

  6. Install the CPA retainers at the ignition coils.

    7. Object Number: 470890 Size: SH
  7. Install a NEW valve rocker arm cover gasket if the gasket was removed from the rocker arm cover.
  8. Install the valve rocker arm cover.
  9. Install the valve rocker arm cover bolts.

    10. Object Number: 677858 Size: SH
  10. Tighten the valve rocker arm cover bolts in sequence using two passes.

    11. Tighten

    1. Tighten the valve rocker arm cover bolts to 6 N·m (53 lb in) a first pass.
    2. Tighten the valve rocker arm cover bolts to 12 N·m (106 lb in) a final pass.

    Object Number: 470666 Size: SH

    Important: Fully install the spark plug wires 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.

  11. Install the spark plug wires to the ignition coils.

    12. Object Number: 745786 Size: SH
  12. Connect the ignition coil harness electrical connector (3).
  13. Install the CPA retainer at the ignition coil electrical connector.