XSR1 C5, C6 Valve Cover Instructions

 

"the name says it all"


INSTRUCTION MANUAL PARTS & TOOL LIST

This kit has been designed to fit 1999-2004 Corvette LS-1 & LS-6 motors. Please take a few moments to review your manual thoroughly before you begin. A quick inventory of your kit is a good way to get started. If you find any damage or shortage, please notify us immediately. Take a moment to look at exactly what this install consist of in terms of time, tools, and skill level. Make sure that you understand all the procedures thoroughly before starting.

PARTS LIST

: LS-1 EXSTREME STREET billet valve covers (2)
: Valves cover mounting hardware kit.
: Fuel rail covers. (2)
: Fuel rail mounting hardware kit.
: Secondary air injection tube and hardware kit.
: Coil relocate kit and hardware drivers? side.
: Coil relocate kit and hardware passenger side.
: Evap. Solenoid mounting bracket and hardware.

REQUIRED TOOLS & MATERIALS

: Safety glasses
: Shop towels
: Electrical tape
: Utility knife
: Small flat head screwdriver
: 6 inch wire dykes
: Fuel line removal tool (optional)
: 3.mm allen wrench
: 4.mm allen wrench
: 5.mm allen wrench
: 7/8 inch combination wrench
: 1 inch combination wrench

: 8.mm combination wrench
: 10.mm combination wrench
: 13.mm combination wrench
: 15.mm combination wrench
: 3/8 drive socket wrench
: 1/4 drive socket wrench
: 6 inch 1/4 drive extension
: 8.mm 1/4 drive socket
: 10.mm deep 1/4 drive socket
: 13.mm 3/8 drive socket
: 15.mm 3/8 drive socket

Pg. 1

C-5 CORVETTE LS-1 BILLET VALVE COVER INSTALLATION INSTRUCTIONS

DRIVERS SIDE

STEP 1. Remove plastic engine/coil covers. Installation of the drivers side valve cover is easier with the fuel feed hose disconnected and out of the way. The valve cover will fit under the fuel feed hose for installation but covering the fuel feed hose with tape or a rag is a good idea to avoid scratching the valve cover. Removing the fuel feed hose will require a special fuel line removal tool and depressurizing of the fuel system. Steps 2, 3, & 4 will show this procedure but they are optional except for battery cable removal. Battery cable must stay disconnected until entire install is complete.



STEP 2. (OPTIONAL) Remove fuel pump relay from fuse relay center under hood. It should be in location # 35. With the relay removed start the engine and let the remaining fuel burn off. Once this is achieved turn off ignition and remove the positive battery cable. Removal of the battery cable is NOT optional.



Pg. 2

DRIVERS SIDE.

STEP 3. (OPTIONAL) As a precaution to make sure system pressure is relieved, wearing safety glasses and having a shop towel handy depress the Schrader valve at the end of the fuel rail on the drivers side. Any excess pressure remaining should be relieved at this time. If any fuel is spilled make sure to absorb it immediately and dispose of shop towel properly.(WHEN WORKING AROUND OPEN FUEL SYSTEMS MAKE SURE AREA IS WELL VENTILATED AND THE PROPER FIRE EXTINGUISHER IS AVAILABLE.



STEP 4. (OPTIONAL) Remove safety clip and disconnect fuel feed hose and rotate out of the way.

NOTE: Valve cover will slide under fuel feed hose if necessary but installation is easier with the fuel feed hose out of the way.



It will require a fuel line disconnect tool to remove the fuel feed hose.

Pg.3

DRIVERS SIDE.

STEP 5. Disconnect coil wiring harness main connector at valve cover.



STEP 6. Disconnect the (EVAP) canister purge solenoid valve electrical terminal.



STEP 7. Unhook wiring harness from fuel rail then disconnect fuel injector terminals.



Pg.4

STEP 8. Disconnect alternator electrical connector and main alternator lead.



STEP 9. Remove serpentine belt from alternator pulley, then remove alternator.



STEP 10. Disconnect water temp electrical connector. Once this is done lay the wiring harness across the other side of the motor so it is out of the way.



Pg.5

STEP 11.Remove the secondary air injection hose clamp and remove the check valve and tubing from the exhaust manifold.



STEP 12. Disconnect spark plug wires from coils



STEP 13.Remove the spark plug wire from cyl. No. 7 (cyl. closest to fire wall) and replace with GM-88894394 spark plug wire provided.



Pg.6

DRIVERS SIDE

STEP 14. Disconnect and remove (EVAP) canister purge tube from solenoid and intake manifold.



STEP 15.Disconnect and remove (EVAP) canister purge tube from solenoid valve and fuel feed pipe.



STEP 16. Remove the (EVAP) canister purge solenoid valve and bracket. Bracket will not be reused.



Pg.7

DRIVERS SIDE

STEP 17.Remove PCV valve pipe from valve cover.



STEP 18. Remove coil bracket from valve cover with coils attached.



STEP.19 Remove secondary air injection hose clamp from remaining check valve and remove remaining hose and tubing.



Pg 8

DRIVERS SIDE

STEP 20. Separate the coil pack and fuel injector wiring as far back as possible, from the wiring harness that was attached to the fuel rail. Re-tape coil and fuel injector wires separate from main harness.



STEP 21. Remove coils from factory bracket and install on new bracket provided. A diagram is provided to show spacer location for coil bracket assembly.



STEP 22. Remove valve cover bolts and grommets but leave valve cover in place.



Pg. 9

DRIVERS SIDE

STEP 23.Remove grommets from factory valve cover bolts and install on new valve cover pacers. (Dish soap is very helpful in both removal and installation of grommets.)



STEP 24. Remove check valve from secondary air injection tubing and reinstall on new tubing provided.



STEP25. Reinstall secondary air injection system using the new tubing and hoses provided. Clamps from the old system may be reused.



Pg.10

DRIVERS SIDE

STEP 26. Remove the original valve cover and carefully remove gasket and PCV grommet. Clean and inspect both items, they are reusable if in good shape. If new gasket is needed it is GM part # GM10108625.



STEP 27.Install valve cover gasket and grommet in new valve cover. It is very important to make sure that gasket is completely seated in valve cover receiver groove.



STEP 28.Make sure gasket seating area on the cyl. Head is clean and clear of all hoses and electrical wires.



Pg. 11

DRIVERS SIDE

STEP 29.Install the new valve cover using the longer spacers and bolts provided. Position valve cover and hold in place, insert bolt and spacer with grommet attached. Start and hand tighten all four bolts before completely tightening bolts to 106 inch Lbs. Work from the center out when tightening down bolts.



STEP 30. Push PCV valve pipe back in valve cover. Make sure pipe is seated squarely.



STEP 31. Wire tie the main wiring harness to the intake manifold and run wiring along gap between intake and valve cover. Keep fuel injector and coil harness separate.



Pg 12.

DRIVERS SIDE

STEP 32. Using the new bracket provided Reconnect the (EVAP) solenoid valve and hoses. The new bracket slides in from the top instead of the bottom like the original. The bracket will be bolted to the fuel rail wear the main wiring harness was previously attached. When in place reconnect solenoid valve terminal.



STEP 33. Reconnect the fuel injector harness. To create more clearance for the (EVAP) system we rotated injectors 1,3, & 5 to the inside of the fuel rail.



STEP 34.Remove the nut from master cyl. stud and attach new coil assembly.



Pg. 13

DRIVERS SIDE

STEP 35.Reconnect the coil wiring harness in the correct firing order to each coil, and then reconnect to main wiring harness. It may be necessary to re-tape the coil wiring harness to obtain the best look and fit.



STEP 36.Reconnect spark plug wires to coils. Make sure all the spark plug wires clear header and secondary air injection tubes.



STEP 37.Install coil cover over coil assembly.



Pg. 14

DRIVERS SIDE

STEP 38.Reconnect water temp electrical connector.

STEP 39.Reinstall alternator and belt.

STEP 40.Reconnect alternator electrical connector and main lead.

STEP 41.Install fuel rail cover spacers on fuel rail mounting studs.



STEP 42. Install fuel rail covers, and reconnect fuel line.



Driver's side is complete, but do not reconnect battery cable or fuel pump relay until both sides are complete.

Pg.15

PASSENGER SIDE

NOTE: Some procedures not pictured are the same as the driver's side.

STEP 1.Disconnect spark plug wires from coils. Remove spark plug wire No. 8 completely (plug wire closest to fire wall) and replace with GM-88894394.

STEP 2.Disconnect coil wiring harness main connector.

STEP 3. Remove coil bracket from valve cover with coils attached.

STEP 4.Disconnect PCV hoses from valve cover.

STEP 5. Separate coil pack wiring harness from main harness attached to fuel rail and re-tape separately

STEP 6. Remove coils from factory bracket and assemble on new brackets according to diagram provided.



STEP 7. Remove plastic battery shroud and battery for easier coil bracket installation.



Pg. 16

PASSENGER SIDE

STEP 8. Install coil bracket assembly utilizing the 6mm. stud located on the fire wall and the engine coolant fill reservoir stud on fender well.



STEP 9. It may be necessary to remove the long bracket witch attaches to the fire wall and install it separately first. This may make installation easier. Once coil assembly in place and tight reconnect spark plug wires. (Make sure wires clear all header tubes)



STEP 10. Reinstall battery shroud and battery but do not reconnect cables yet. Note the location of the main wiring harness in step 9. The wiring harness goes over the coil mounting bracket. Battery shroud will need to be trimmed to allow harness to clear.



Pg. 17

PASSENGER SIDE

STEP 11. Remove valve cover bolts and grommets but leave valve cover in place. Transfer grommets over to the new valve cover spacers.

STEP 12.Remove the original valve cover. Clean and inspect gasket, it may be reused if in good condition. Remove the PCV tubes and transfer them over to the new valve cover. The new valve cover bores for the tubes are a light press fit for easier installation, for this reason we recommend a light coat of high strength Loctite be applied to the tubes before installation. Be very careful when tapping PCV tubes into place so as not to damage valve cover To remove the original valve cover PCV tubes lightly clamp them in a vise with soft jaws and twist valve cover , once the tube brakes loose it can be twisted out quite easily.



STEP 13. With PCV tubes in place, install valve cover gasket in valve cover. Make sure gasket is completely seated in receiver groove.

STEP 14. Make sure gasket seating area on cyl. head is clean and clear of all hoses and electrical wires.

STEP 15. Install the new valve cover using the longer spacers and bolts provided. Position valve cover and hold in place, insert bolt and spacer with grommet attached. Start and hand tighten all four bolts before completely tightening bolts to 106 inch Lbs. Work from the center out when tightening down bolts.

STEP 16. Reconnect PCV hoses to valve cover.

STEP 17. Reconnect the coil pack wiring harness to the coils. Make sure they are in the correct firing order. Re-taping the harness for the best fit may be necessary. With coils plugged in reconnect main connector to harness.

Pg. 18

PASSENGER SIDE

STEP 18. Install coil cover over coil assembly.



STEP 19. Install fuel rail cover spacers on fuel rail mounting studs.

STEP 20. Install fuel rail covers.

STEP 21. Reconnect battery and fuel pump relay.

STEP 22. Step back and take a look???.. Its drive time! If everything is connected right she should just fire right up. If this is the case take it for a drive and check or smell for oil leaks. You will know if you have one. No leaks, cool now go SHOW IT OFF.



Pg. 19

 
www.vettepieces.com.