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 - Right Side

Removal Procedure

    Object Number: 745788 Size: SH
  1. Remove the connector position assurance (CPA) retainer from the ignition coil electrical connector.
  2. Disconnect the ignition coil harness electrical connector (2).
  3. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).

    4. Object Number: 742645 Size: SH
  4. Remove the ECT sensor bracket bolt.
  5. Reposition the ECT sensor and bracket.

    6. Object Number: 470704 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.

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

    7. Object Number: 470897 Size: SH
  7. Remove the valve rocker arm cover bolts.
  8. Remove the valve rocker arm cover.

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

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

    10. Object Number: 745856 Size: SH
  10. If replacing the valve rocker arm cover, remove the CPA retainers at the ignition coils.
  11. Remove the ignition coil wiring harness bolts. (Left side shown, right side similar).
  12. Disconnect the ignition coil electrical connectors.
  13. Remove the ignition coil wiring harness.

    14. Object Number: 470887 Size: SH
  14. If replacing the valve rocker arm cover, remove the ignition coil bolts. (Left side shown, right side similar).
  15. Remove the ignition coils.

Installation Procedure

    Object Number: 470887 Size: SH
  1. If replacing the valve rocker arm cover, install the ignition coils. (Left side shown, right side similar).

    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 CPA retainers at the ignition coils.
  4. Install the ignition coil wiring harness bolts. (Left side shown, right side similar).

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

  5. Connect the ignition coil electrical connectors.
  6. Install the ignition coil wiring harness.

    7. Object Number: 470897 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) on the first pass.
    2. Tighten the valve rocker arm cover bolts to 12 N·m (106 lb in) on the final pass.

    Object Number: 470704 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 the spark plug by using the metal heat shield.

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

    12. Object Number: 742645 Size: SH
  12. Position the ECT sensor and bracket.
  13. Install the ECT sensor bracket bolt.

    14. Tighten
    Tighten the ECT bracket bolt to 50 N·m (37 lb ft).


    Object Number: 745788 Size: SH
  14. Connect the ECT sensor electrical connector (1).
  15. Connect the ignition coil harness electrical connector (2).
  16. Install the CPA retainer to the ignition coil electrical connector.