Chevrolet 5.7L Corvette 2004 Shop Manual Download

Page: 419 / 1000

Fig. 295: Right Fuel Injection Rail Cover

Courtesy of GENERAL MOTORS CORP.

1. Recover the air conditioning (A/C) refrigerant. Refer to

Refrigerant Recovery and Recharging

Heating, Ventilation and Air Conditioning.

2. Remove the radiator. Refer to

Radiator Replacement

in Engine Cooling.

3. Remove the break pressure modulator valve (BPMV) bracket. Refer to

Brake Pressure Modulator

Valve (BPMV) Bracket Replacement

in Antilock Brake System.

4. Reposition the brake pipes.

5. Remove the accessory drive belt. Refer to

Drive Belt Replacement - Accessory

6. Remove the right fuel injection rail cover.

7. Relieve the fuel system pressure. Refer to

Fuel Pressure Relief Procedure

in Engine Controls - 5.7 L.

8. Disconnect the EVAP emission canister purge hose at the fuel line.

9. Remove the fuel feed hose. Refer to

Fuel Hose/Pipes Replacement - Engine Compartment

in Engine

Controls - 5.7 L.

2004 Chevrolet Corvette

2004 ENGINE PERFORMANCE Engine Mechanical (Repair Instructions 1 Of 3) - 5.7L - Corvette

Helpmelearn

December-24-07 10:58:47 AM

Page 319

Summary of Contents for 5.7L Corvette 2004

Page 1: ...Final Pass 75 degrees Coolant Temperature Gage Sensor 20 N m 15 lb ft Crankshaft Balancer Bolt Installation Pass to Ensure the Balancer is Completely Installed 330 N m 240 lb ft Crankshaft Balancer Bolt First Pass Install a NEW Bolt After the Installation Pass and Tighten as Described in the First and Final Passes 50 N m 37 lb ft Crankshaft Balancer Bolt Final Pass 140 degrees Crankshaft Bearing C...

Page 2: ...Drain Plugs 60 N m 44 lb ft Engine Block Heater 40 N m 30 lb ft Engine Block Oil Gallery Plugs 60 N m 44 lb ft Engine Coolant Air Bleed Pipe and Cover Bolts and Studs 12 N m 106 lb in Engine Flywheel Bolts First Pass 20 N m 15 lb ft Engine Flywheel Bolts Second Pass 50 N m 37 lb ft Engine Flywheel Bolts Final Pass 100 N m 74 lb ft Engine Flywheel Hub Collar Bolt Automatic Transmission 130 N m 96 l...

Page 3: ...Cover Bolt Left Side 12 N m 106 lb in Oil Pan Closeout Cover Bolt Right Side 12 N m 106 lb in Oil Pan Cover Bolts 12 N m 106 lb in Oil Pan Drain Plug 25 N m 18 lb ft Oil Pan Lower Bolts 12 N m 106 lb in Oil Pan M8 Bolts Oil Pan to Engine Block and Oil Pan to Front Cover 25 N m 18 lb ft Oil Pan M6 Bolts Oil Pan to Rear Cover 12 N m 106 lb in Oil Pressure Sensor 20 N m 15 lb ft Oil Pump Cover Bolts ...

Page 4: ...ess Clip Bolt near the Oil Pan 25 N m 18 lb ft Valve Lifter Guide Bolts 12 N m 106 lb in Valve Rocker Arm Bolts 30 N m 22 lb ft Valve Rocker Arm Cover Bolts 12 N m 106 lb in Water Inlet Housing Bolts 15 N m 11 lb ft Water Pump Bolts First Pass 15 N m 11 lb ft Water Pump Bolts Final Pass 30 N m 22 lb ft Water Pump Cover Bolts 15 N m 11 lb ft Application Specification Metric English General z Engine...

Page 5: ...s Measured Within a 152 4 mm 6 0 in Area 0 08 mm 0 003 in z Cylinder Head Deck Surface Flatness Measuring the Overall Length of the Block Deck 0 22 mm 0 008 in z Valve Lifter Bore Diameter 21 417 21 443 mm 0 843 0 844 in Camshaft z Camshaft End Play 0 025 0 305 mm 0 001 0 012 in z Camshaft Journal Diameter 54 99 55 04 mm 2 164 2 166 in z Camshaft Journal Out of Round 0 025 mm 0 001 in z Camshaft L...

Page 6: ...2 558 in z Crankshaft Main Journal Out of Round Production 0 003 mm 0 000118 in z Crankshaft Main Journal Out of Round Service 0 008 mm 0 0003 in z Crankshaft Main Journal Taper Production 0 01 mm 0 0004 in z Crankshaft Main Journal Taper Service 0 02 mm 0 00078 in z Crankshaft Rear Flange Runout 0 05 mm 0 002 in z Crankshaft Reluctor Ring Runout Measured 1 0 mm 0 04 in Below Tooth Diameter 0 7 mm...

Page 7: ...ton Ring End Gap First Compression Ring Measured in Cylinder Bore Service 0 23 0 5 mm 0 009 0 0196 in z Piston Ring End Gap Second Compression Ring Measured in Cylinder Bore Production 0 44 0 7 mm 0 017 0 027 in z Piston Ring End Gap Second Compression Ring Measured in Cylinder Bore Service 0 44 0 76 mm 0 0173 0 03 in z Piston Ring End Gap Oil Control Ring Measured in Cylinder Bore Production 0 18...

Page 8: ...Press Fit Pin Clearance to Piston Pin Bore Production 0 01 0 02 mm 0 0004 0 00078 in z Pin First Design Press Fit Pin Clearance to Piston Pin Bore Service 0 01 0 022 mm 0 0004 0 00086 in z Pin First Design Press Fit Pin Diameter 23 997 24 0 mm 0 9447 0 9448 in z Pin Second Design Full Floating Pin Fit in Connecting Rod Bore Production 0 007 0 02 mm 0 00027 0 00078 in z Pin Second Design Full Float...

Page 9: ...alve Stem to Guide Clearance Production Exhaust 0 025 0 066 mm 0 001 0 0026 in z Valves Valve Stem to Guide Clearance Service Exhaust 0 093 mm 0 0037 in z Rocker Arms Valve Rocker Arm Ratio 1 70 1 z Valve Springs Valve Spring Free Length 52 9 mm 2 08 in z Valve Springs Valve Spring Installed Height 45 75 mm 1 8 in z Valve Springs Valve Spring Load Closed 340 N at 45 75 mm 76 lb at 1 8 in z Valve S...

Page 10: ...asuring from the Centerline of Crankshaft to the Deck Face 234 57 234 82 mm 9 235 9 245 in z Cylinder Head Deck Surface Flatness Measured Within a 152 4 mm 6 0 in Area 0 08 mm 0 003 in z Cylinder Head Deck Surface Flatness Measuring the Overall Length of the Block Deck 0 22 mm 0 008 in z Valve Lifter Bore Diameter 21 417 21 443 mm 0 843 0 844 in Camshaft z Camshaft End Play 0 025 0 305 mm 0 001 0 ...

Page 11: ...in z Crankshaft Main Journal Diameter Production 64 992 65 008 mm 2 558 2 559 in z Crankshaft Main Journal Diameter Service 64 992 mm 2 558 in z Crankshaft Main Journal Out of Round Production 0 003 mm 0 000118 in z Crankshaft Main Journal Out of Round Service 0 008 mm 0 0003 in z Crankshaft Main Journal Taper Production 0 01 mm 0 0004 in z Crankshaft Main Journal Taper Service 0 02 mm 0 00078 in ...

Page 12: ...Surface 0 0 0 25 mm 0 0 0 01 in Piston Rings z Piston Ring End Gap First Compression Ring Measured in Cylinder Bore Production 0 23 0 44 mm 0 009 0 017 in z Piston Ring End Gap First Compression Ring Measured in Cylinder Bore 0 23 0 5 mm 0 009 0 0196 in z Piston Ring End Gap Second Compression Ring Measured in Cylinder Bore Production 0 44 0 7 mm 0 017 0 027 in z Piston Ring End Gap Second Compres...

Page 13: ...t 0 074 mm 0 0029 in z Pin First Design Press Fit Pin Fit in Connecting Rod Bore 0 02 0 043 mm Interference 0 00078 0 00169 in Interference z Pin First Design Press Fit Pin Clearance to Piston Pin Bore Production 0 01 0 02 mm 0 0004 0 00078 in z Pin First Design Press Fit Pin Clearance to Piston Pin Bore Service 0 01 0 022 mm 0 0004 0 00086 in z Pin First Design Press Fit Pin Diameter 23 997 24 0 ...

Page 14: ... Production Exhaust 0 025 0 066 mm 0 001 0 0026 in z Valves Valve Stem to Guide Clearance Service Exhaust 0 093 mm 0 0037 in z Valve Rocker Arm Valve Rocker Arm Ratio 1 70 1 z Valve Springs Valve Spring Free Length 53 4 mm 2 1 in z Valve Springs Valve Spring Installed Height 45 75 mm 1 8 in z Valve Springs Valve Spring Load Closed 400 N at 45 75 mm 90 lb at 1 8 in z Valve Springs Valve Spring Load...

Page 15: ...382 10953489 Ignition Coil and Bracket Assembly Bolts Threadlock 12345382 10953489 Intake Manifold Bolt Threads Threadlock 12345382 10953489 Oil Pan Surface at Front and Rear Covers Sealant 12378190 Oil Pressure Sensor Threads Sealant 12346004 10953480 Thread Repair Component Cleaner Cleaner 12346139 10953463 Thread Repair Component Cleaner Cleaner 12377981 10953463 Thread Repair Cutting Oil Lubri...

Page 16: ...0 M10 x 1 5 J 42385 215 J 42385 211 J 42385 212 J 42385 213 J 42385 214 Thru Thru 11 13 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 14 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 Thru 18 0 0 708 15 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 16 M8 x 1 25 J 42385 210 J 42385 206...

Page 17: ...42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 5 6 M10 x 1 5 J 42385 215 J 42385 211 J 42385 212 J 42385 213 J 42385 214 27 0 1 06 21 5 0 846 7 13 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 14 16 M10 x 1 5 J 42385 215 J 42385 211 J 42385 212 J 42385 213 J 42385 214 27 0 1 06 21 5 0 846 2004 Chevrolet Corvette 2004 ENGINE PERFORM...

Page 18: ...um mm in Tap Depth Maximum mm in J 42385 1 M28 x 1 25 N A N A N A N A N A N A N A 2 M8 x 1 25 210 206 207 208 209 28 5 1 122 23 0 0 905 3 M8 x 1 25 210 206 207 208 209 21 5 0 846 16 0 0 629 4 M10 x 1 25 215 211 212 213 214 29 0 1 141 23 0 0 905 5 M10 x 1 5 215 211 212 213 214 27 0 1 062 21 5 0 846 6 M16 x 1 5 N A N A N A N A N A N A N A 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechan...

Page 19: ...les 7 second design and 8 have a 30 mm 1 18 in counterbore included in the 69 0 mm 2 72 in drill depth Use sleeve J 42385 315 with the drill and tap z Bolt holes 7 first design have a 85 mm 3 34 in counterbore included in the 124 0 mm 4 88 in drill depth Hole Thread Size Insert Drill Counterbore Tool Tap Driver Drill Depth Maximum mm in Tap Depth Maximum mm in 2004 Chevrolet Corvette 2004 ENGINE P...

Page 20: ...esign 108 105 N A 106 107 124 0 4 88 115 0 4 52 7 M11 x 2 0 Second Design 108 105 N A 106 107 69 0 2 72 60 0 2 36 z Bolt holes 7 second design and 3 have a 30 mm 1 18 in counterbore included in the 69 0 mm 2 72 in drill depth Use sleeve J 42385 315 with the drill and tap z Bolt holes 7 first design have a 85 mm 3 34 in counterbore included in the 124 0 mm 4 88 in drill depth 2004 Chevrolet Corvett...

Page 21: ...385 101 J 42385 102 J 42385 103 53 5 2 10 44 0 1 73 6 M16 x 1 5 7 N A 8 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 9 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 31 0 1 22 25 5 1 0 10 11 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 53 5 2 10 44 0 1 73 12 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 31 0 1 22 25...

Page 22: ...J 42385 104 J 42385 101 J 42385 102 J 42385 103 53 5 2 10 44 0 1 73 25 26 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 22 5 0 885 17 5 0 688 27 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 31 0 1 22 25 5 1 0 28 29 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 53 5 2 10 44 0 1 73 30 M10 x 2 0 J 42385 104 J 42385 101 J 42385 102 J 42385 103 31 0 1 22...

Page 23: ...29 and 34 have a 20 5 mm 0 807 in counterbore included in the 53 5 mm 2 10 in drill depth z Bolt holes 1 4 9 12 17 20 23 27 30 and 35 have a 1 5 mm 0 059 in counterbore included in the 31 0 mm 1 22 in drill depth Use sleeve J 42385 316 with the drill and tap z Bolt holes 13 and 14 have a 11 5 mm 0 452 in counterbore included in the 42 5 mm 1 67 in drill depth Use sleeve J 42385 311 with the drill ...

Page 24: ... 207 J 42385 208 J 42385 209 26 5 1 04 19 0 0 784 8 M10 x 1 5 J 42385 216 J 42385 211 J 42385 212 J 42385 213 J 42385 214 22 5 0 885 17 0 0 669 9 10 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 26 5 1 04 19 0 0 784 11 M10 x 1 5 J 42385 216 J 42385 211 J 42385 212 J 42385 213 J 42385 214 22 5 0 885 17 0 0 669 12 14 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J...

Page 25: ... 26 5 1 04 19 0 0 784 6 9 M6 x 1 0 J 42385 205 J 42385 201 J 42385 202 J 42385 203 J 42385 204 20 05 0 789 16 05 0 632 10 12 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 26 5 1 04 19 0 0 784 Hole Thread Size Insert Drill Counterbore Tool Tap Driver Drill Depth Maximum mm in Tap Depth Maximum mm in J J J J 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical In...

Page 26: ...5 212 J 42385 213 J 42385 214 28 0 1 10 20 0 0 787 Hole Thread Size Insert Drill Counterbore Tool Tap Driver Drill Depth Maximum mm in Tap Depth Maximum mm in 1 2 M10 x 1 5 J 42385 215 J 42385 211 J 42385 212 J 42385 213 J 42385 214 28 0 1 10 20 0 0 787 3 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 21 0 0 826 16 0 0 629 4 M14 x 1 25 5 M8 x 1 25 J 42385 J 42385 J 42385 207...

Page 27: ...85 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 21 0 0 826 16 0 0 629 11 M14 x 1 25 12 M8 x 1 25 J 42385 210 J 42385 206 J 42385 207 J 42385 208 J 42385 209 21 0 0 826 16 0 0 629 13 M12 x 1 5 14 15 M10 x 1 5 J 42385 215 J 42385 211 J 42385 212 J 42385 213 J 42385 214 28 0 1 10 20 0 0 787 Thread Counterbore Drill Depth Maximum mm Tap Depth Maximum mm 2004 Chevrolet Corvette 2004 ENGINE PERFO...

Page 28: ...u 3 4 M6 x 1 0 J 42385 205 J 42385 201 J 42385 202 J 42385 203 J 42385 204 22 5 0 885 15 0 0 688 5 7 M6 x 1 0 J 42385 205 J 42385 201 J 42385 202 J 42385 203 J 42385 204 Thru Thru 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 28 2005 Mitchell Repair Information Company LLC ...

Page 29: ...e 308 Engine Coolant Air Bleed Pipe Cover Gasket 308 Engine Coolant Air Bleed Pipe Cover Gasket 309 Engine Coolant Air Bleed Pipe Stud 310 Engine Coolant Air Bleed Hose Clamp 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 29 2005 Mitchell Repair Information Company LLC ...

Page 30: ... Gaskets 520 Knock Sensor Oil Seals 550 Fuel Rail Ground Strap 555 Valley Cover 556 Valley Cover Gasket 708 EVAP Purge Valve 712 Fuel Rail Stop Bracket 713 Intake Manifold Bolt 714 MAP Sensor 715 MAP Sensor Grommet 716 PCV Hose 717 Knock Sensor Wire Harness 718 Knock Sensor 729 EVAP Purge Valve Hose 730 EVAP Purge Valve Bracket 731 EVAP Purge Valve Hose 2004 Chevrolet Corvette 2004 ENGINE PERFORMA...

Page 31: ...Valve Lifter Guide 211 Valve Lifter Guide Bolt 212 Pushrod 213 Rocker Arm 214 Rocker Arm Bolt 215 Rocker Arm Pedestal 216 Expansion Plug 217 Cylinder Head Gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 31 2005 Mitchell Repair Information Company LLC ...

Page 32: ...sket 504 Valve Cover Gasket 505 Valve Cover 505 Valve Cover 515 Valve Cover Bolt Grommet 516 Valve Cover Bolt 557 Valve Cover Grommet 558 Valve Cover Grommet Plug 600 Exhaust Manifold 601 Exhaust Manifold Gasket 602 Exhaust Manifold Bolt 603 Exhaust Manifold Heat Shield 604 Exhaust Manifold Heat Shield Bolt 605 Takedown Pipe Stud 700 Fresh Air Hose 719 Ignition Coil and Bracket Assembly 720 Igniti...

Page 33: ...t Balancer 139 Crankshaft Balancer Bolt 140 Crankshaft Front Oil Seal 143 Balance Weight Manual Transmission 200 Camshaft 201 Camshaft Bearings 202 Camshaft Sprocket Locating Pin 203 Camshaft Retainer Plate 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 33 2005 Mitchell Repair Information Company LLC ...

Page 34: ...Screen 408 Oil Pump Cover Bolt 409 Oil Pump Cover 410 Drive Gear 411 Oil Pump Bolt 412 Driven Gear 413 Oil Pump Assembly 414 Pressure Relief Valve 415 Pressure Relief Valve Spring 416 Plug 417 Oil Level Indicator O Ring 418 Oil Level Indicator 419 Oil Level Indicator Tube Bolt 420 Oil Level Indicator Tube 421 Oil Level Indicator Tube O Ring 501 Engine Front Cover Bolt 502 Engine Front Cover 503 En...

Page 35: ...h Disc Manual Transmission 136 Pressure Plate Manual Transmission 137 Pressure Plate Bolt Manual Transmission 141 Crankshaft Rear Oil Seal 142 Pressure Plate Locating Pin Manual Transmission 144 Balance Weight Manual Transmission 517 Rear Cover Bolt 518 Rear Cover 519 Rear Cover Gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December...

Page 36: ...100 Engine Block 102 Connecting Rod Bolt 103 Connecting Rod Cap 104 Connecting Rod Bearings 105 Connecting Rod 106 Piston Pin 107 Piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 36 2005 Mitchell Repair Information Company LLC ...

Page 37: ...Oil Pan Gasket 429 Oil Pan Drain Plug O Ring 430 Oil Pan Drain Plug 431 Closeout Cover Left 432 Closeout Cover Bolt Left 433 Oil Pan Cover Gasket 434 Oil Pan Cover 435 Oil Pan Cover Bolts 436 Oil Filter Bypass Valve 437 Oil Filter 438 Oil Filter Fitting 439 Oil Pan Bolt 453 Oil Pan Gasket Lower 454 Oil Pan Lower 455 Oil Pan Bolt Lower 700 Crankshaft Position Sensor Bolt 701 Crankshaft Position Sen...

Page 38: ... Block Rear Oil Gallery Plug O Ring 110 Engine Block Rear Oil Gallery Plug O Ring 111 Engine Block Rear Oil Gallery Plug 111 Engine Block Rear Oil Gallery Plug 112 Oil Gallery Plug 113 Oil Gallery Plug Washer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 38 2005 Mitchell Repair Information Company LLC ...

Page 39: ...oolant Drain Plug Right 700 Crankshaft Position Sensor Bolt 701 Crankshaft Position Sensor 702 Crankshaft Position Sensor O Ring 703 Camshaft Position Sensor 704 Camshaft Position Sensor O Ring 705 Camshaft Position Sensor Bolt 706 Oil Pressure Sensor 707 Oil Pressure Sensor Washer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 ...

Page 40: ...ar 412 Driven Gear 413 Oil Pump 414 Pressure Relief Valve 415 Pressure Relief Valve Spring 416 Plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 08 AM Page 40 2005 Mitchell Repair Information Company LLC ...

Page 41: ...MECHANICAL Strategy Based Diagnostics 1 Perform the Diagnostic System Check Engine Controls in Engine Controls 5 7L before using the symptom tables if applicable 2 Review the system operations in order to familiarize yourself with the system functions Refer to Disassembled Views Engine Component Description Lubrication Description New Product Information and Drive Belt System Description All diagn...

Page 42: ...sumption z Engine Compression Test z Engine Noise on Start Up but Only Lasting a Few Seconds z Upper Engine Noise Regardless of Engine Speed z Lower Engine Noise Regardless of Engine Speed z Engine Noise Under Load z Engine Will Not Crank Crankshaft Will Not Rotate z Coolant in Combustion Chamber z Coolant in Engine Oil z Oil Consumption Diagnosis z Oil Pressure Diagnosis and Testing z Oil Leak Di...

Page 43: ...lled or damaged vacuum hoses Repair or replace as required Improper sealing between the intake manifold and cylinder heads or throttle body Replace the intake manifold gaskets cylinder heads and or throttle body as required Improperly installed or damaged MAP sensor The sealing grommet of the MAP sensor should not be torn or damaged Repair or replace the MAP sensor as required Damage to the MAP se...

Page 44: ...cylinder leak down and compression testing to identify the cause Refer to Cylinder Leakage Test z Repair or replace as required A damaged crankshaft reluctor wheel A damaged crankshaft reluctor wheel can result in different symptoms depending on the severity and location of the damage z Systems with electronic communications DIS or coil per cylinder and severe reluctor ring damage may exhibit peri...

Page 45: ...gine Flywheel Replacement or Crankshaft Balancer Replacement Worn piston rings Oil consumption may or may not cause the engine to misfire z Inspect the spark plugs for oil deposits Refer to Spark Plug Inspection in Engine Controls 5 7L z Inspect the cylinders for a loss of compression Refer to Engine Compression Test z Perform cylinder leak down and compression testing to determine the cause Refer...

Page 46: ...for spark plugs saturated by coolant Refer to Spark Plug Inspection in Engine Controls 5 7L z Perform a cylinder leak down test Refer to Cylinder Leakage Test z Inspect the cylinder heads and engine block for damage to the coolant passages and or a faulty head gasket Refer to Coolant in Combustion Chamber z Repair or replace as required Cause Correction Worn valves valve guides and or valve stem o...

Page 47: ...iagnosis and Testing z Repair or replace as required Loose and or worn valve rocker arm attachments z Inspect the valve rocker arm bolt and pedestal z Repair or replace as required Worn or damaged valve rocker arm z Inspect the rocker arm for wear or missing needle bearings z Replace the valve rocker arms as required Bent or damaged push rod Inspect the following components and replace as required...

Page 48: ... cause the valve to stay open Inspect the following components and repair as required z The valves z The valve guides Cause Correction Low oil pressure z Perform an oil pressure test Refer to Oil Pressure Diagnosis and Testing z Repair or replace damaged components as required Worn accessory drive components Abnormalities such as severe cracking bumps or missing areas in the accessory drive belt a...

Page 49: ...kshaft journals Incorrect piston piston pin and connecting rod installation Pistons must be installed with the mark or dimple on the top of the piston facing the front of the engine Piston pins must be centered in the connecting rod pin bore z Verify the pistons piston pins and connecting rods are installed correctly Refer to Piston Connecting Rod and Bearing Installation z Repair as required Caus...

Page 50: ...e crankshaft by hand at the crankshaft balancer or flywheel location 3 Repair or replace the components as required Seized driveline propshaft assembly Corvette automatic transmission application 1 Separate the engine flywheel from the input shaft of the propshaft 2 Confirm that the engine will rotate Rotate the crankshaft by hand at the crankshaft balancer or flywheel location 3 Repair or replace...

Page 51: ... on compression stroke will push fluid from the combustion chamber 2 Inspect for failed broken head gaskets Refer to Coolant in Combustion Chamber 3 Inspect for a cracked engine block or cylinder head 4 Inspect for a sticking fuel injector 5 Repair or replace the components as required Material in the cylinder z Broken valve z Broken piston rings z Piston material z Foreign material z Inspect the ...

Page 52: ...ylinder head to the proper flatness if applicable and replace the cylinder head gasket Refer to Cylinder Head Cleaning and Inspection Cracked cylinder head Replace the cylinder head and gasket Cracked cylinder liner or engine block Replace the components as required Cylinder head or engine block porosity Replace the components as required Cause Correction DEFINITION Foamy or discolored oil or an e...

Page 53: ...s but does not reach normal Compression improves considerably when you add oil z Valves Leaking Compression is low on the first stroke Compression usually does not build up on the following strokes Compression does not improve much when you add oil z If 2 adjacent cylinders have lower than normal compression and injecting oil into the cylinders does not increase the compression the cause may be a ...

Page 54: ...removal and installed to the original position Refer to Engine Flywheel Removal z Existing flywheel clutch and pressure plate onto a new engine Remove balance weights if applicable from the flywheel z New flywheel clutch and pressure plate assembly onto an existing engine Do not transfer or install balance weights z New flywheel clutch and pressure plate assembly onto a new engine Do not install b...

Page 55: ...t system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring z Air leakage noise from the crankcase oil level indicator tube or oil fill tube that may indicate worn piston rings a damaged piston a worn or scored cylinder bore a damaged engine block or a CAUTION Refer to Battery Disconnect Caution in Cautions and Notices IMPORTANT A leakage test may be performed in ord...

Page 56: ...roper reading of the oil level indicator With the vehicle on a level surface run the engine for a few minutes allow adequate drain down time of 2 3 minutes and check for the correct engine oil level z Improper oil viscosity Refer to the vehicle owners manual and use the recommended SAE grade and viscosity for the prevailing temperatures z Continuous high speed driving and or severe usage z Crankca...

Page 57: ...ll on the oil level indicator 3 Run the engine briefly 10 15 seconds and verify low or no oil pressure on the vehicle gauge or light 4 Listen for a noisy valve train or a knocking noise 5 Inspect for the following conditions z Oil diluted by water or glycol antifreeze z Foamy oil 6 Remove the oil filter and install the J 42907 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Intro...

Page 58: ...d oil galleries z Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation z Broken valve lifters Repair as necessary 11 If the oil pressure reading on the J 21867 or equivalent is within specifications inspect for the following conditions z Plugged or incorrect oil filter and or malfunctioning oil bypass valve z Malfunctioning oil pressure gage or sensor Repair a...

Page 59: ...ds 3 Park the vehicle on a level surface over a large sheet of paper or other clean surface 4 Wait 15 minutes 5 Identify the type of fluid and the approximate location of the leak Can you identify the type of fluid and the approximate location of the leak Go to Step 10 Go to Step 5 5 1 Visually inspect the suspected area Use a small mirror to assist in looking at hard to see areas 2 Check for leak...

Page 60: ...see areas 2 Check for leaks at the following locations z Sealing surfaces z Fittings z Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak Go to Step 10 System OK 10 1 Inspect the engine for mechanical damage Special attention should be shown to the following areas z Higher than recommended fluid levels z Higher than recommended fluid pressures...

Page 61: ...l leak oil Step 1 OK Concern Action External oil leak Inspect for any of the following conditions z Plugged positive crankcase ventilation PCV valve z Plugged or kinked PCV hose s z Damaged or incorrectly installed PCV valve or hose s z Excessive crankcase pressure Rough Idle Inspect for any of the following conditions z Plugged PCV valve z Plugged or kinked PCV hose s z Leaking damaged PCV valve ...

Page 62: ...incorrect bolt nut spacer or washer was installed 12 Inspection the accessory drive pulley s should include inspecting for bends dents or other damage to the pulley s that would prevent the drive belt s from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley 14 Replacing the drive belt s when it is not damage...

Page 63: ...ulley s replaced and or repaired Go to Step 15 8 Inspect for a bent or cracked accessory drive bracket s Did you find any bent or cracked accessory drive bracket s Go to Step 9 Go to Step 10 9 Replace the bent and or cracked accessory drive bracket s Was the bent and or cracked accessory drive bracket s replaced Go to Step 15 10 Inspect for incorrect loose and or missing fasteners Were there any i...

Page 64: ...drive belt s removed 4 This test is to verify that an accessory drive component s does not have a seized bearing With the belt s removed test the bearings in the accessory drive components for smooth operation Also test the accessory drive component s with the engine operating by varying the load on the accessory drive component s to verify that the component s is operating properly 5 This test is...

Page 65: ...e belt s such as an A C compressor engagement snapping the throttle or slipping on a seized pulley or a faulty accessory drive component NOTE Refer to Belt Dressing Notice in Cautions and Notices 1 Did you review the Symptoms Engine Mechanical diagnostic information and perform the necessary inspections Go to Step 2 Go to Symptoms Engine Mechanical 2 Verify that there is a squealing noise Does the...

Page 66: ...on should include checking the drive belt tensioner and the drive belt idler pulley bearings The drive belt s may have to be installed and the accessory drive components operated separately by varying their loads Refer to the suspected accessory drive component for the proper removal and installation procedure Drive Belt Whine Diagnosis Did you find and correct the condition Go to Step 9 Go to Ste...

Page 67: ...agnostic Aids 3 1 Remove the drive belt s Refer to Drive Belt Replacement Accessory or Drive Belt Replacement Air Conditioning 2 Operate the engine for no longer than 30 to 40 seconds Does the whining noise still exist Go to Engine Noise on Start Up but Only Lasting a Few Seconds Upper Engine Noise Regardless of Engine Speed or Lower Engine Noise Regardless of Engine Speed Go to Step 4 4 1 Inspect...

Page 68: ...t s to ensure that the drive belt s is not the cause of the noise Small cracks across the ribs of the drive belt s will not cause the noise Belt separation is identified by the plys of the belt separating this may be seen at the edge of the belt or felt as a lump in the belt 5 Small amounts of pilling is a normal condition and acceptable When the pilling is severe the drive belt s does not have a ...

Page 69: ...Speed Go to Step 4 4 Inspect the drive belt s for damage separation or sections of missing ribs Were any of these conditions found Go to Step 7 Go to Step 5 5 Inspect for severe pilling of more than 1 3 of the drive belt groove depth Do the drive belt grooves have pilling Go to Step 6 Go to Step 7 6 1 Clean the drive belt pulleys using a suitable wire brush 2 Reinstall the drive belt Refer to Driv...

Page 70: ...eration Inspect for a bent fan shaft or a bent mounting flange 9 Inspect the water pump drive shaft for being bent Also inspect the water pump bearings for smooth operation and excessive play Compare the water pump with a known good water pump 10 Accessory drive component brackets that are bent cracked or loose may put an extra strain on that accessory component causing it to vibrate Drive Belt Vi...

Page 71: ...ment Accessory or Drive Belt Replacement Air Conditioning Did you complete the replacement Go to Step 11 6 Inspect for incorrect loose or missing fasteners Were any of these conditions found Go to Step 7 Go to Step 8 7 1 Replace the incorrect or missing fasteners 2 Tighten any loose fasteners Refer to Fastener Tightening Specifications Were the fasteners replaced and or tightened Go to Step 11 8 I...

Page 72: ...alignment of the accessory component bracket s Drive Belt Falls Off Diagnosis Step Action Yes No DEFINITION The drive belt s falls off the pulleys or may not ride correctly on the pulleys NOTE Refer to Belt Dressing Notice in Cautions and Notices 1 Did you review the Symptoms Engine Mechanical diagnostic information and perform the necessary inspections Go to Step 2 Go to Symptoms Engine Mechanica...

Page 73: ...body while the engine is operating There should be sufficient clearance when the drive belt accessory drive components load varies The drive belt s should not come in contact with an engine or a body component when snapping the throttle Drive Belt Excessive Wear Diagnosis 9 Test the drive belt tensioner for correction operation Refer to Drive Belt Tensioner Diagnosis Does the drive belt tensioner ...

Page 74: ...e necessary inspections Go to Step 2 Go to Symptoms Engine Mechanical 2 Inspect the drive belt s for the proper installation Refer to Drive Belt Replacement Accessory or Drive Belt Replacement Air Conditioning Did you find this condition Go to Step 5 Go to Step 3 3 Inspect for the proper drive belt Did you find this condition Go to Step 5 Go to Step 4 4 Inspect for the drive belt rubbing against a...

Page 75: ...ained passively lateral accelerations the outboard cover may fill with oil The dual draw system passively switches allowing the PCV valve to draw on the rocker cover with the least resistance This results in the system drawing on the air filled or inboard rocker cover and eliminates oil pullover due to drawing on the oil filled outboard rocker cover The PCV valve is connected to the PCV valve pipe...

Page 76: ...e belt may be used to drive the different accessory drive components When the back side of the drive belt is used to drive a pulley the pulley is smooth The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping The drive belt tensione...

Page 77: ...shaft timing chain The crankshaft sprocket is splined and drives the oil pump driven gear A retaining plate mounted to the front of the engine block maintains camshaft location Crankshaft The crankshaft is cast nodular iron The crankshaft is supported by 5 crankshaft bearings The bearings are retained by crankshaft bearing caps which are machined with the engine block for the proper alignment and ...

Page 78: ...throttle body The intake manifold is sealed to the cylinder heads by eight separate nonreusable silicone sealing gaskets which press into the grooves of the intake housing The drive by wire throttle body assembly bolts to the front of the intake manifold The throttle body is sealed to the intake manifold by a one piece push in place silicone gasket The fuel rail assembly with eight separate fuel i...

Page 79: ...he valve lifter guides position and retain the valve lifters The valve rocker arms for each bank of cylinders are mounted on pedestals or pivot supports Each rocker arm is retained on the pivot support and cylinder head by a bolt Valve lash is net build For the LS6 application both the intake and exhaust valves are of a hollow stem design The exhaust valve stem is sodium filled for improved coolin...

Page 80: ...sed in order to resolve a system condition The diagnostic flow is the place to start when repairs are necessary For a detailed explanation refer to Diagnostic Starting Point Engine Mechanical New Special Tools Required Angle Meter J 45059 has been developed to provide technicians with a convenient method to tighten bolts that require the torque angle tightening strategy See Special Tools and Equip...

Page 81: ...moved A bypass valve is incorporated into the oil pan which will permit oil flow in the event the filter becomes restricted At the rear of the block oil is then directed to the upper main oil galleries which are drilled just above the camshaft assembly From there oil is then directed to the crankshaft and camshaft bearings Oil that has entered the upper main oil galleries also pressurizes the valv...

Page 82: ...y stated z When any internal engine parts are serviced care and cleanliness is important z When components are removed for service they should be marked organized or retained in a specific Callout Component Name 408 Cover Bolt 409 Cover 410 Drive Gear 412 Driven Gear 413 Oil Pump 414 Pressure Relief Valve 415 Pressure Relief Valve Spring 416 Plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Eng...

Page 83: ...mmended Stamping the connecting rod or cap near the bearing bore may affect component geometry z Crankshaft main and connecting rod bearings z Camshaft and valve lifters z Valve lifters lifter guides pushrods and rocker arm assemblies z Valve to the valve guide z Valve spring and shim to the cylinder head location z Engine block main bearing cap location and direction z Oil pump drive and driven g...

Page 84: ... methods of cleaning can cause damage to the component sealing surfaces Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil This grit is abrasive and has been known to cause internal engine damage Assembling Components z When assembling components use only the sealant specified or equivalent in the service procedure z Sealing surfaces should be clean and free of d...

Page 85: ...bled together z Do not use RTV sealant in areas where extreme temperatures are expected These areas include exhaust manifold head gasket or other surfaces where a gasket eliminator is specified z Follow all safety recommendations and directions that are on the container To remove the sealant or the gasket material refer to Replacing Engine Gaskets z Apply RTV to a clean surface Use a bead size as ...

Page 86: ...lish the operations for which they are intended The use of these special tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection of certain critical components Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners To properly service the engine assembly the following items should be rea...

Page 87: ...er J 6125 1B Slide Hammer J 7872 Magnetic Base Dial Indicator Set J 8037 Piston Ring Compressor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 10 AM Page 87 2005 Mitchell Repair Information Company LLC ...

Page 88: ...er Bore Gage J 8089 Carbon Removing Brush J 8433 1 Puller Bar 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 10 AM Page 88 2005 Mitchell Repair Information Company LLC ...

Page 89: ...J 9666 Valve Spring Tester J 21867 Pressure Gage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 89 2005 Mitchell Repair Information Company LLC ...

Page 90: ...Bore Ridge Reamer J 25033 C Power Steering Pump Pulley Installer J 25034 C Power Steering Pump Pulley Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 90 2005 Mitchell Repair Information Company LLC ...

Page 91: ...ak Detector Kit J 33049 Camshaft Bearing Service Set 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 91 2005 Mitchell Repair Information Company LLC ...

Page 92: ...parator J 37378 1 Valve Guide Reamer J 38606 Valve Spring Compressor Head On Vehicle 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 92 2005 Mitchell Repair Information Company LLC ...

Page 93: ...80 Engine Support Table J 39580 500 Engine Support Table Top 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 93 2005 Mitchell Repair Information Company LLC ...

Page 94: ...1479 Crankshaft Rear Oil Seal Installer J 41480 Front and Rear Cover Alignment at Oil Pan Surface J 41556 Connecting Rod Guide 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 94 2005 Mitchell Repair Information Company LLC ...

Page 95: ... J 41712 Oil Pressure Switch Socket J 41798 Engine Lifting Brackets J 41816 Crankshaft Balancer Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 95 2005 Mitchell Repair Information Company LLC ...

Page 96: ...aring Cap Remover J 42188 Ball Joint Separator J 42203 Driveline Support 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 96 2005 Mitchell Repair Information Company LLC ...

Page 97: ...5 200 Common Thread Repair Kit J 42385 300 Fixtures and Hardware Kit 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 97 2005 Mitchell Repair Information Company LLC ...

Page 98: ... Pressure Testing Tool J 43276 Clutch Pilot Bearing Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 98 2005 Mitchell Repair Information Company LLC ...

Page 99: ...00 Rod Bearing Checking Tool Adapter Kit J 45059 Angle Meter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 99 2005 Mitchell Repair Information Company LLC ...

Page 100: ...299 Engine Preluber 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Introduction 5 7L Corvette Helpmelearn December 24 07 10 50 11 AM Page 100 2005 Mitchell Repair Information Company LLC ...

Page 101: ...er to Air Cleaner Assembly Replacement in Engine Controls 5 7 L 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 31 AM Page 1 2005 Mitchell Repair Information Company LLC Helpmelearn December 24 07 10 5...

Page 102: ...rive belt tensioner bolt 7 Clean and inspect the drive belt surfaces of all the pulleys Installation Procedure Fig 2 Accessory Drive Belt Courtesy of GENERAL MOTORS CORP 1 Route the accessory drive belt around all the pulleys except the water pump pulley and tensioner 2 Install a breaker bar with hex head socket to the drive belt tensioner bolt 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engin...

Page 103: ...bly Replacement in Engine Controls 5 7 L 9 Inspect the accessory drive belt for correct alignment DRIVE BELT REPLACEMENT AIR CONDITIONING Removal Procedure Fig 3 Accessory Drive Belt Breaker Bar Courtesy of GENERAL MOTORS CORP 1 Remove the accessory drive belt Refer to Drive Belt Replacement Accessory 2 Install a breaker bar with hex head socket to the air conditioning A C drive belt tensioner bol...

Page 104: ...MOTORS CORP 1 Install the A C drive belt around the crankshaft balancer 2 Install a breaker bar with hex head socket to the A C drive belt tensioner bolt 3 Rotate the A C drive belt tensioner clockwise in order to relieve tension on drive belt tensioner 4 Install the A C drive belt under the idler pulley 5 Install the A C drive belt over the A C compressor pulley 6 Slowly release tension on the A ...

Page 105: ...Procedure Fig 5 Accessory Drive Belt Idler Pulley Bolt Courtesy of GENERAL MOTORS CORP 1 Loosen the accessory drive belt idler pulley bolt 2 Remove the accessory drive belt Refer to Drive Belt Replacement Accessory 3 Remove the accessory drive belt idler pulley 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 5...

Page 106: ...eplacement Accessory IMPORTANT Ensure that the idler pulley and dust shield are fully seated against the shoulder on the bracket before tightening the bolt CAUTION Refer to Battery Disconnect Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 6 2005 Mitchell Repair In...

Page 107: ... Idler Pulley Courtesy of GENERAL MOTORS CORP 1 Loosen the air conditioning A C drive belt idler pulley bolt 2 Remove the A C drive belt Refer to Drive Belt Replacement Air Conditioning 3 Remove the A C drive belt idler pulley 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 7 2005 Mitchell Repair...

Page 108: ...r to Drive Belt Replacement Air Conditioning IMPORTANT Ensure that the idler pulley is fully seated against the shoulder on the bracket before tightening the bolt NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 8 2005 Mitchell Repair Informati...

Page 109: ... Courtesy of GENERAL MOTORS CORP 1 Remove the accessory drive belt Refer to Drive Belt Replacement Accessory 2 Remove the accessory drive belt tensioner bolts 3 Remove the accessory drive belt tensioner Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 9 2005 Mitchell Repair ...

Page 110: ...37 lb ft starting with the lower bolt first 3 Install the accessory drive belt Refer to Drive Belt Replacement Accessory DRIVE BELT TENSIONER REPLACEMENT AIR CONDITIONING Removal Procedure NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 10 200...

Page 111: ...port the vehicle Refer to Lifting and Jacking the Vehicle in General Information 3 Loosen the A C drive belt tensioner bolt 4 Remove the A C drive belt tensioner Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 11 2005 Mitchell Repair Information Company LLC ...

Page 112: ...tensioner bolt to 50 N m 37 lb ft 3 Lower the vehicle 4 Install the A C drive belt Refer to Drive Belt Replacement Air Conditioning NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 12 2005 Mitchell Repair Information Company LLC ...

Page 113: ...eck cracks cover the rubber cushion surface z The rubber cushion is separated from the metal plate of the mount z There is a split through the rubber cushion ENGINE MOUNT BRACKET REPLACEMENT LEFT Removal Procedure NOTE Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components When a single mount breaks the remaining mounts are subjected to abnormally hi...

Page 114: ... Mount Replacement Left 2 Remove the engine mount bracket bolts 3 Remove the engine mount bracket Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 14 2005 Mitchell Repair Information Company LLC ...

Page 115: ... 50 N m 37 lb ft 3 Install the left engine mount Refer to Engine Mount Replacement Left ENGINE MOUNT BRACKET REPLACEMENT RIGHT Removal Procedure NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 15 2005 Mitchell Repair Information Company LLC ...

Page 116: ... Mount Replacement Right 2 Remove the engine mount bracket bolts 3 Remove the engine mount bracket Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 16 2005 Mitchell Repair Information Company LLC ...

Page 117: ...cket bolts to 50 N m 37 lb ft 3 Install the right engine mount Refer to Engine Mount Replacement Right ENGINE MOUNT REPLACEMENT LEFT NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 17 2005 Mitchell Repair Information Company LLC ...

Page 118: ...ove the front suspension crossmember Refer to Crossmember Replacement Front Suspension in Front Suspension 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 18 2005 Mitchell Repair Information Company LLC ...

Page 119: ...shield from the engine mount if necessary Installation Procedure Fig 18 Engine Mount To Engine Mount Bracket Nuts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 32 AM Page 19 2005 Mitchell Repair Information Company LLC ...

Page 120: ...8 lb ft 4 Install the front suspension crossmember Refer to Crossmember Replacement Front Suspension in Front Suspension ENGINE MOUNT REPLACEMENT RIGHT Removal Procedure NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 20 2005 Mitchell Repair I...

Page 121: ...ent Front Suspension in Front Suspension 2 Remove the engine mount to engine mount bracket nut 3 Remove the engine mount left side shown right side similar 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 21 2005 Mitchell Repair Information Company LLC ...

Page 122: ...rocedure Fig 20 Engine Mount To Engine Mount Bracket Nuts Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 22 2005 Mitchell Repair Information Company LLC ...

Page 123: ...ent Front Suspension in Front Suspension POSITIVE CRANKCASE VENTILATION PCV VALVE REPLACEMENT LS1 ENGINE Removal Procedure Fig 21 PCV Tube Rocker Arm Cover Courtesy of GENERAL MOTORS CORP IMPORTANT When installing the engine mount be sure to have the locating dowel in the correct position NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine M...

Page 124: ...Left Rocker Arm Cover PCV Valve Pipe Courtesy of GENERAL MOTORS CORP 2 Remove the PCV valve pipe from the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 24 2005 Mitchell Repair Information Company LLC ...

Page 125: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 25 2005 Mitchell Repair Information Company LLC ...

Page 126: ...CV valve pipe from the right rocker arm cover and intake manifold 5 Remove the PCV valve from the valve pipe Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 26 2005 Mitchell Repair Information Company LLC ...

Page 127: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 27 2005 Mitchell Repair Information Company LLC ...

Page 128: ...r and intake manifold 3 Install the PCV valve pipe strap nut Tighten Tighten the PCV valve pipe strap nut to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 28 2005 Mitchell Repair Information Company LLC ...

Page 129: ...OTORS CORP 4 Install the PCV valve pipe to the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 29 2005 Mitchell Repair Information Company LLC ...

Page 130: ...er and intake manifold if necessary POSITIVE CRANKCASE VENTILATION PCV VALVE REPLACEMENT LS6 ENGINE Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 30 2005 Mitchell Repair Information Company LLC ...

Page 131: ...emove the positive crankcase ventilation PCV valve hose 1 from the valley cover 3 Remove the PCV valve from the valve hose Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 31 2005 Mitchell Repair Information Company LLC ...

Page 132: ...he valley cover 3 Install the PCV valve hose 1 to the intake manifold CRANKCASE VENTILATION HOSES PIPES REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 32 2005 Mitchell Repair Information Company LLC ...

Page 133: ...he positive crankcase ventilation PCV tube 2 Remove the PCV tube from the right rocker arm cover and throttle body if necessary 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 33 2005 Mitchell Repair Information Company LLC ...

Page 134: ...e regular production option RPO LS1 engine remove the PCV valve pipe from the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 34 2005 Mitchell Repair Information Company LLC ...

Page 135: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 35 2005 Mitchell Repair Information Company LLC ...

Page 136: ... PCV valve from the pipe Fig 32 PCV Valve Hose Courtesy of GENERAL MOTORS CORP 7 If equipped with the RPO LS6 engine remove the PCV valve hose 1 from the valley cover and intake manifold 8 If replacing the PCV valve hose remove the PCV valve from the hose Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn De...

Page 137: ... PCV valve to the hose if necessary 2 Install the PCV valve hose 1 to the valley cover and intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 37 2005 Mitchell Repair Information Company LLC ...

Page 138: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 38 2005 Mitchell Repair Information Company LLC ...

Page 139: ...e to the right rocker arm cover and intake manifold 5 Install the PCV valve pipe strap nut Tighten Tighten the PCV strap nut to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 39 2005 Mitchell Repair Information Company LLC ...

Page 140: ...uipped with the RPO LS1 engine install the PCV valve pipe to the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 40 2005 Mitchell Repair Information Company LLC ...

Page 141: ...EPLACEMENT Removal Procedure IMPORTANT The intake manifold throttle body fuel injection rail and injectors may be removed as an assembly If not servicing the individual components remove the manifold as a complete assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 41 2005 Mitchell Repair In...

Page 142: ... z Remove the throttle body Refer to Throttle Body Assembly Replacement in Engine Controls 5 7 L z Remove the fuel injectors Refer to Fuel Injector Replacement in Engine Controls 5 7 L 3 Remove the right fuel rail cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 42 2005 Mitchell Repair Infor...

Page 143: ...AL MOTORS CORP 4 Remove the left fuel rail cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 43 2005 Mitchell Repair Information Company LLC ...

Page 144: ...vaporative emission EVAP canister purge tube from the intake manifold 7 Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve 8 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 33 AM Page 44 2005 Mitchell Repair Information Company LLC ...

Page 145: ...rge solenoid valve 10 Disconnect the EVAP canister purge tube from the fuel feed pipe 11 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 45 2005 Mitchell Repair Information Company LLC ...

Page 146: ...electrical connector 13 Remove the coolant air bleed hose Refer to Coolant Air Bleed Hose Replacement in Engine Cooling 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 46 2005 Mitchell Repair Information Company LLC ...

Page 147: ...at the throttle body 15 Remove the throttle body heater outlet hose from the throttle body 16 Remove the throttle body heater outlet hose 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 47 2005 Mitchell Repair Information Company LLC ...

Page 148: ...t the EVAP canister purge solenoid valve electrical connector 2 19 Disconnect the electronic throttle control ETC electrical connector 3 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 48 2005 Mitchell Repair Information Company LLC ...

Page 149: ... from the bracket 21 Disconnect the harness clips at the fuel rails 22 Reposition the intake manifold branches of the wiring harness 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 49 2005 Mitchell Repair Information Company LLC ...

Page 150: ...3 Disconnect the power brake booster vacuum hose at the booster 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 50 2005 Mitchell Repair Information Company LLC ...

Page 151: ...RS CORP 24 Remove the knock sensor wire harness 1 clip from the fuel rail stop bracket 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 51 2005 Mitchell Repair Information Company LLC ...

Page 152: ...the positive crankcase ventilation PCV tube 26 Remove the PCV tube from the right rocker arm cover and throttle body 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 52 2005 Mitchell Repair Information Company LLC ...

Page 153: ...he regular production option RPO LS1 engine remove the PCV valve pipe from the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 53 2005 Mitchell Repair Information Company LLC ...

Page 154: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 54 2005 Mitchell Repair Information Company LLC ...

Page 155: ...rocker arm cover and intake manifold Fig 50 PCV Valve Hose Courtesy of GENERAL MOTORS CORP 30 If equipped with the RPO LS6 engine remove the PCV valve hose 1 from the valley cover and intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 55 2005 Mitchell Repair Information Company LLC ...

Page 156: ...the intake manifold bolts 1 and fuel rail stop bracket 2 32 Position the intake manifold forward 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 56 2005 Mitchell Repair Information Company LLC ...

Page 157: ...ct the manifold absolute pressure MAP sensor vacuum hose 34 Disconnect the MAP sensor 3 electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 57 2005 Mitchell Repair Information Company LLC ...

Page 158: ...L MOTORS CORP 35 Remove the intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 58 2005 Mitchell Repair Information Company LLC ...

Page 159: ...ifold Refer to Intake Manifold Cleaning and Inspection Installation Procedure IMPORTANT DO NOT reuse the intake manifold gaskets Install NEW intake manifold gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 59 2005 Mitchell Repair Information Company LLC ...

Page 160: ...CORP 1 Install NEW intake manifold gaskets 1 to the manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 60 2005 Mitchell Repair Information Company LLC ...

Page 161: ...nstall intake manifold 3 Position the intake manifold forward 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 61 2005 Mitchell Repair Information Company LLC ...

Page 162: ...AP sensor vacuum hose 5 Connect the MAP sensor 3 electrical connector 6 Position the intake manifold into place 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 62 2005 Mitchell Repair Information Company LLC ...

Page 163: ...ngine assembly The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash If the fuel rail stop bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 63 2005 Mitchell Repair Information Company LLC ...

Page 164: ... manifold bolts Tighten 1 Tighten the intake manifold bolts a first pass in sequence to 5 N m 44 lb in is not installed and the vehicle is involved in a frontal crash fuel could be sprayed possibly causing a fire and personal injury from burns NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corv...

Page 165: ...AL MOTORS CORP 11 If equipped with the RPO LS6 engine install the PCV valve hose 1 to the valley cover and intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 65 2005 Mitchell Repair Information Company LLC ...

Page 166: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 66 2005 Mitchell Repair Information Company LLC ...

Page 167: ...o the right valve rocker arm cover and intake manifold 13 Install the PCV pipe strap nut Tighten Tighten the PCV pipe strap nut to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 67 2005 Mitchell Repair Information Company LLC ...

Page 168: ...uipped with the RPO LS1 engine install the PCV valve pipe to the left rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 34 AM Page 68 2005 Mitchell Repair Information Company LLC ...

Page 169: ...V tube to the right rocker arm cover 16 Install the TP sensor harness clip to the PCV tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 69 2005 Mitchell Repair Information Company LLC ...

Page 170: ...OTORS CORP 17 Install the knock sensor wire harness 1 to the fuel rail stop bracket 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 70 2005 Mitchell Repair Information Company LLC ...

Page 171: ...18 Connect the power brake booster vacuum hose to the booster 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 71 2005 Mitchell Repair Information Company LLC ...

Page 172: ...e wiring harness 20 Connect the harness clips at the fuel rails 21 Install the EVAP canister purge solenoid valve from the bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 72 2005 Mitchell Repair Information Company LLC ...

Page 173: ...he EVAP canister purge solenoid valve electrical connector 2 24 Connect all the fuel injector electrical connectors 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 73 2005 Mitchell Repair Information Company LLC ...

Page 174: ...ottle body 27 Position the throttle body heater outlet hose clamp at the throttle body 28 Install the coolant air bleed hose Refer to Coolant Air Bleed Hose Replacement in Engine Cooling 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 74 2005 Mitchell Repair Information Company LLC ...

Page 175: ...L MOTORS CORP 29 Connect the TP sensor electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 75 2005 Mitchell Repair Information Company LLC ...

Page 176: ...ister purge tube to the fuel feed pipe 32 Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 76 2005 Mitchell Repair Information Company LLC ...

Page 177: ...d valve 35 Connect the EVAP canister purge tube to the intake manifold 36 Install the fuel feed hose Refer to Fuel Hose Pipes Replacement Engine Compartment in Engine Controls 5 7 L 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 77 2005 Mitchell Repair Information Company LLC ...

Page 178: ...L MOTORS CORP 37 Install the left fuel rail cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 78 2005 Mitchell Repair Information Company LLC ...

Page 179: ...ine Controls 5 7 L z Install the fuel injectors Refer to Fuel Injector Replacement in Engine Controls 5 7 L 40 Fill the cooling system Refer to Draining and Filling Cooling System in Engine Cooling ENGINE VALLEY COVER REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 7...

Page 180: ...Manifold Replacement 2 Gently pry up the rubber grommets 3 Disconnect the knock sensor wire harness electrical connectors 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 80 2005 Mitchell Repair Information Company LLC ...

Page 181: ...ENERAL MOTORS CORP 4 Remove the knock sensors 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 81 2005 Mitchell Repair Information Company LLC ...

Page 182: ...pped with the 5 7 L regular production option RPO LS1 engine remove the engine valley cover bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 82 2005 Mitchell Repair Information Company LLC ...

Page 183: ...ine remove the engine valley cover bolts 7 Remove the engine valley cover and gasket 8 Discard the engine valley cover gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 83 2005 Mitchell Repair Information Company LLC ...

Page 184: ...over Refer to Engine Valley Cover Cleaning and Inspection Installation Procedure IMPORTANT All gasket surfaces should be free of oil or other foreign material during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 84 2005 Mitchell Repair Information Company LLC ...

Page 185: ...ck sensor oil seals 1 into the valley cover 2 Lubricate the seal surfaces with clean engine oil 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 85 2005 Mitchell Repair Information Company LLC ...

Page 186: ...f equipped with the 5 7 L RPO LS6 engine install the engine valley cover and a NEW gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 86 2005 Mitchell Repair Information Company LLC ...

Page 187: ...EW gasket 4 Install the engine valley cover bolts Tighten Tighten the engine valley cover bolts to 25 N m 18 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 87 2005 Mitchell Repair Information Company LLC ...

Page 188: ...l the knock sensors Tighten Tighten the knock sensors to 20 N m 15 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 88 2005 Mitchell Repair Information Company LLC ...

Page 189: ...r grommets into the valley cover 8 Install the intake manifold Refer to Intake Manifold Replacement VALVE ROCKER ARM COVER REPLACEMENT LEFT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 89 2005 Mitchell Repair Information Company LLC ...

Page 190: ...placement Engine Compartment in Engine Controls 5 7 L 2 Disconnect the generator electrical connector 1 3 Remove the engine wiring harness generator lead nut 3 and lead 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 90 2005 Mitchell Repair Information Company LLC ...

Page 191: ...ondary air injection AIR hose clamp 5 Disconnect the AIR hose 3 from the check valve 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 35 AM Page 91 2005 Mitchell Repair Information Company LLC ...

Page 192: ...duction option RPO LS1 engine remove the positive crankcase ventilation PCV valve pipe from the left rocker cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 92 2005 Mitchell Repair Information Company LLC ...

Page 193: ...2 turn z Pull only on the boot in order to remove the wire from the ignition coil 8 Disconnect the ignition coil wire harness main electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 93 2005 Mitchell Repair Information Company LLC ...

Page 194: ...ntake manifold 10 Remove the EVAP canister purge tube from the EVAP canister purge solenoid valve 11 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 94 2005 Mitchell Repair Information Company LLC ...

Page 195: ...rge solenoid valve 13 Disconnect the EVAP canister purge tube from the fuel feed pipe 14 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 95 2005 Mitchell Repair Information Company LLC ...

Page 196: ...connect the EVAP canister purge solenoid valve electrical connector 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 96 2005 Mitchell Repair Information Company LLC ...

Page 197: ...TORS CORP 16 Remove the EVAP canister purge solenoid valve from the bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 97 2005 Mitchell Repair Information Company LLC ...

Page 198: ...emove the ignition coil bracket studs 18 Remove the ignition coil bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 98 2005 Mitchell Repair Information Company LLC ...

Page 199: ... Loosen the valve rocker arm cover bolts 20 Remove the valve rocker cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 99 2005 Mitchell Repair Information Company LLC ...

Page 200: ...on Installation Procedure IMPORTANT z All gasket surfaces should be free of oil and other foreign material during assembly z DO NOT reuse the valve rocker arm cover gasket z The valve rocker arm cover bolt grommets may be reused 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 100 2005 Mitchell Re...

Page 201: ...rocker cover lip z If the PCV valve grommet has been removed from the rocker arm install a NEW grommet during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 101 2005 Mitchell Repair Information Company LLC ...

Page 202: ...cover bolts Tighten Tighten the valve rocker arm cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 102 2005 Mitchell Repair Information Company LLC ...

Page 203: ...ivalent to the threads of the ignition coil bracket studs 6 Install the ignition coil bracket studs Tighten Tighten the ignition coil bracket studs to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 103 2005 Mitchell Repair Information Company LLC ...

Page 204: ...TORS CORP 7 Remove the EVAP canister purge solenoid valve from the bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 104 2005 Mitchell Repair Information Company LLC ...

Page 205: ...nnect the EVAP canister purge solenoid valve electrical connector 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 105 2005 Mitchell Repair Information Company LLC ...

Page 206: ...rge solenoid valve 10 Disconnect the EVAP canister purge tube from the fuel feed pipe 11 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 106 2005 Mitchell Repair Information Company LLC ...

Page 207: ...fold 13 Remove the EVAP canister purge tube from the EVAP canister purge solenoid valve 14 Remove the EVAP canister purge tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 107 2005 Mitchell Repair Information Company LLC ...

Page 208: ...e harness main electrical connector 16 Install the spark plug wires to the ignition coils 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 108 2005 Mitchell Repair Information Company LLC ...

Page 209: ...equipped with the RPO LS1 engine install the PCV valve pipe to the left rocker cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 109 2005 Mitchell Repair Information Company LLC ...

Page 210: ...Connect the AIR hose 3 to the check valve 19 Install the AIR hose clamp 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 110 2005 Mitchell Repair Information Company LLC ...

Page 211: ...ten Tighten the engine wiring harness generator lead nut to 13 N m 115 lb in 22 Install the fuel feed hose Refer to Fuel Hose Pipes Replacement Engine Compartment in Engine Controls 5 7 L VALVE ROCKER ARM COVER REPLACEMENT RIGHT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 111 2005 Mitchell Re...

Page 212: ...rtesy of GENERAL MOTORS CORP 1 Remove the right fuel rail cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 36 AM Page 112 2005 Mitchell Repair Information Company LLC ...

Page 213: ...econdary air injection AIR hose clamp 3 Remove the AIR hose 1 from the check valve 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 113 2005 Mitchell Repair Information Company LLC ...

Page 214: ...RP 4 Remove the AIR pipe bolts at the exhaust manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 114 2005 Mitchell Repair Information Company LLC ...

Page 215: ...ylinder head 6 Slide the AIR pipe up and out from behind the bolt 7 Reposition the AIR pipe 8 Remove the AIR pipe gasket from the exhaust manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 115 2005 Mitchell Repair Information Company LLC ...

Page 216: ...ip from the positive crankcase ventilation PCV tube 10 Remove the PCV tube from the throttle body and rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 116 2005 Mitchell Repair Information Company LLC ...

Page 217: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 117 2005 Mitchell Repair Information Company LLC ...

Page 218: ... from the right rocker arm cover and intake manifold Fig 112 Spark Plug Wire Courtesy of GENERAL MOTORS CORP 13 Disconnect the spark plug wires from the ignition coils z Twist the spark plug wire boot 1 2 turn 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 118 2005 Mitchell Repair Information Co...

Page 219: ...ectrical connector Fig 113 Ignition Coil Bracket Studs Courtesy of GENERAL MOTORS CORP 15 Remove the ignition coil bracket studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 119 2005 Mitchell Repair Information Company LLC ...

Page 220: ... GENERAL MOTORS CORP 17 Loosen the valve rocker arm cover bolts 18 Remove the valve rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 120 2005 Mitchell Repair Information Company LLC ...

Page 221: ...9 Remove the gasket 1 from the rocker cover Discard the OLD gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 121 2005 Mitchell Repair Information Company LLC ...

Page 222: ...from the oil fill tube 21 Remove the oil fill tube if required 22 Discard the oil fill tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 122 2005 Mitchell Repair Information Company LLC ...

Page 223: ...sembly z DO NOT reuse the valve rocker arm cover gasket z The valve rocker arm cover bolt grommets may be reused z If the oil fill tube has been removed from the rocker arm cover install a NEW fill tube during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 123 2005 Mitchell Repair Infor...

Page 224: ...ngine oil 2 Insert the NEW oil fill tube into the rocker arm cover Rotate the tube clockwise until locked in the proper position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 124 2005 Mitchell Repair Information Company LLC ...

Page 225: ...Rocker Arm Cover Gasket Courtesy of GENERAL MOTORS CORP 4 Install a NEW gasket 1 into the valve rocker cover lip 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 125 2005 Mitchell Repair Information Company LLC ...

Page 226: ...en the rocker arm cover bolts Tighten Tighten the valve rocker arm cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 126 2005 Mitchell Repair Information Company LLC ...

Page 227: ... P N 12345382 Canadian P N 10953489 or equivalent to the threads of the bracket studs 9 Install the ignition coil bracket studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 127 2005 Mitchell Repair Information Company LLC ...

Page 228: ...P 10 Connect the ignition coil wire harness main electrical connector 11 Install the spark plug wires to the ignition coils 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 128 2005 Mitchell Repair Information Company LLC ...

Page 229: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 129 2005 Mitchell Repair Information Company LLC ...

Page 230: ...en Tighten the PCV valve strap nut to 12 N m 106 lb in Fig 123 PCV Tube Rocker Arm Cover Courtesy 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 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 130 2005...

Page 231: ... AIR pipe into place 17 Slide the AIR pipe behind the bolt on the rear of the left cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 131 2005 Mitchell Repair Information Company LLC ...

Page 232: ...t 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 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 132 2005 Mitchell Repair Information Company LLC ...

Page 233: ...Connect the AIR hose 1 to the check valve 23 Install the AIR hose clamp 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 37 AM Page 133 2005 Mitchell Repair Information Company LLC ...

Page 234: ...ight fuel injection rail cover VALVE ROCKER ARM AND PUSH ROD REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 134 2005 Mitchell Repair Information Company LLC ...

Page 235: ... valve rocker arm bolts 3 Remove the valve rocker arms IMPORTANT Place the valve rocker arms valve pushrods and pivot support in a rack so that they can be installed in the same location from which they were removed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 135 2005 Mitchell Repair Informat...

Page 236: ...ENERAL MOTORS CORP 4 Remove the valve rocker arm pivot support 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 136 2005 Mitchell Repair Information Company LLC ...

Page 237: ...n Installation Procedure Valve lash is net build no valve adjustment is required IMPORTANT When reusing the valvetrain components always install the components to the original location and position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 137 2005 Mitchell Repair Information Company LLC ...

Page 238: ...valve rocker arm bolts with clean engine oil Lubricate the flange or washer surface of the bolt that will contact the valve rocker arm 3 Install the valve rocker arm pivot support 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 138 2005 Mitchell Repair Information Company LLC ...

Page 239: ... IMPORTANT Make sure that the pushrods seat properly to the valve lifter sockets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 139 2005 Mitchell Repair Information Company LLC ...

Page 240: ...ten the rocker arm bolts at this time IMPORTANT Make sure that the pushrods seat properly to the ends of the rocker arms 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 140 2005 Mitchell Repair Information Company LLC ...

Page 241: ...ORP NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 141 2005 Mitchell Repair Information Company LLC ...

Page 242: ...to 30 N m 22 lb ft 8 Rotate the crankshaft 360 degrees 9 Tighten the following valve rocker arm bolts Tighten z Tighten the exhaust valve rocker arm bolts 3 4 5 and 6 to 30 N m 22 lb ft z Tighten the intake valve rocker arm bolts 2 6 7 and 8 to 30 N m 22 lb ft 10 Install the valve rocker arm covers Refer to Valve Rocker Arm Cover Replacement Left or Valve Rocker Arm Cover Replacement Right VALVE S...

Page 243: ...g wire from the spark plug for the cylinder to be serviced z Twist the plug wire 1 2 turn z Pull only on the boot in order to remove the wire from the spark plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 143 2005 Mitchell Repair Information Company LLC ...

Page 244: ...or debris around the spark plug 5 Remove the spark plug IMPORTANT Remove the spark plugs from the cylinder head with the engine at room temperature 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 144 2005 Mitchell Repair Information Company LLC ...

Page 245: ... an air hose to J 22794 8 Tap the end of the valve stem with a plastic face hammer in order to loosen any varnish on the valve stem keys 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 145 2005 Mitchell Repair Information Company LLC ...

Page 246: ...RS CORP 9 Use the J 38606 in order to compress the valve spring 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 146 2005 Mitchell Repair Information Company LLC ...

Page 247: ...rtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 147 2005 Mitchell Repair Information Company LLC ...

Page 248: ...d design Installation Procedure IMPORTANT A second design valve stem oil seal and shim may be used on later engines A separate spring shim is not required with the second design seal and shim IMPORTANT The LS6 engine uses a copper plated spring shim A shim of the same design must be installed during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of...

Page 249: ...rtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 149 2005 Mitchell Repair Information Company LLC ...

Page 250: ...valve stem oil seal and shim 2 second design The J 42078 is not required for installation of the second design seal and shim 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 150 2005 Mitchell Repair Information Company LLC ...

Page 251: ... 3 Use the J 42078 in order to install the oil seal Push or lightly tap the tool until the tool bottoms against the valve spring shim IMPORTANT The valve stem oil seal alignment and position on the valve guide is critical An improperly installed valve stem oil seal may lead to excessive oil consumption and increased vehicle emissions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanica...

Page 252: ...the oil seal body and the valve spring shim surface Fig 143 J 38606 J 5892 D Valve Spring Courtesy of GENERAL MOTORS CORP 6 Install the valve spring to the J 38606 7 Compress the valve spring using the J 38606 8 Install the valve spring to the cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38...

Page 253: ...rtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 38 AM Page 153 2005 Mitchell Repair Information Company LLC ...

Page 254: ...ove the J 38606 z Tap the end to the valve stem with a plastic faced hammer to seat the keys if necessary Fig 145 Install Remove J 22794 Spark Plug Hole Courtesy of GENERAL MOTORS CORP 11 Disconnect and remove the air supply from the J 22794 12 Remove the J 22794 from the spark plug hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Help...

Page 255: ... 82 in install a valve spring shim of approximately 0 5 mm 0 02 in thick z Do not shim the valve spring to obtain less than the specified height Do not assemble the components without a spring shim on the cylinder head 14 Remove the air hose from the J 22794 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 3...

Page 256: ...e spark plug Tighten Tighten the spark plugs to 15 N m 11 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 156 2005 Mitchell Repair Information Company LLC ...

Page 257: ...ve rocker arms Refer to Valve Rocker Arm and Push Rod Replacement OIL LEVEL INDICATOR AND TUBE REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 157 2005 Mitchell Repair Information Company LLC ...

Page 258: ...AL MOTORS CORP 1 Remove the oil level indicator 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 158 2005 Mitchell Repair Information Company LLC ...

Page 259: ...emove the oil level indicator tube IMPORTANT Inspect the O ring seal for cuts or damage The O ring seal may be reused 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 159 2005 Mitchell Repair Information Company LLC ...

Page 260: ...Fig 151 Oil Level Indicator Tube Bolt Courtesy of GENERAL MOTORS CORP if not cut or damaged 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 160 2005 Mitchell Repair Information Company LLC ...

Page 261: ...nto the engine block until the collar is flush with the block 5 Lower the vehicle 6 Install the oil level indicator tube bolt Tighten Tighten the oil level indicator tube bolt to 25 N m 18 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page ...

Page 262: ...tor 8 Check the oil level and add if necessary CYLINDER HEAD REPLACEMENT LEFT Tools Required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 162 2005 Mitchell Repair Information Company LLC ...

Page 263: ...the valve rocker arms and pushrods Refer to Valve Rocker Arm and Push Rod Replacement 2 Remove the engine coolant air bleed pipe and covers Refer to Coolant Air Bleed Pipe Assembly Replacement in Engine Cooling 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 163 2005 Mitchell Repair Information C...

Page 264: ...engine wire harness ground strap 6 away from the cylinder head Fig 154 View Of Cylinder Head Bolts Left Courtesy of GENERAL MOTORS CORP IMPORTANT The cylinder head bolts are NOT reusable NOTE After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette He...

Page 265: ...10 Discard the gasket 11 Discard the M11 cylinder head bolts 12 Clean and inspect the cylinder head Refer to Cylinder Head Cleaning and Inspection Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 165 2005 Mitchell Repair Information Company LLC ...

Page 266: ...lure to remove all foreign material may result in damaged threads improperly tightened fasteners or damage to components IMPORTANT z Do not use the cylinder head bolts again Install NEW cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 166 2005 Mitchell Repair Information Company LLC ...

Page 267: ... the hole 3 Clean the cylinder head bolt holes with compressed air bolts during assembly z Do not use any type sealant on the cylinder head gasket unless specified z The cylinder head gaskets must be installed in the proper direction and position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 16...

Page 268: ...esign engine blocks have different drill and tap depths using both medium length 100 mm 3 94 in and long 155 mm 6 1 in M11 cylinder head bolts Second design engine blocks use only the medium length 100 mm 3 94 in bolt with a common drill and tap depth 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Pa...

Page 269: ...MOTORS CORP 6 Inspect the displacement markings 1 on the gasket for proper usage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 169 2005 Mitchell Repair Information Company LLC ...

Page 270: ...ORTANT When properly installed the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 170 2005 Mitchell Repair Information Company LLC ...

Page 271: ...inder head onto the locating pins and the gasket 9 Install the NEW cylinder head bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 171 2005 Mitchell Repair Information Company LLC ...

Page 272: ...g side to side work outward tightening all of the bolts 11 Tighten the second design cylinder head bolts Tighten 1 Tighten the second design M11 cylinder head bolts 1 10 a first pass in sequence to 30 N m 22 lb ft 2 Tighten the second design M11 cylinder head bolts 1 10 a second pass in sequence to 90 degrees using the J 45059 3 Tighten the second design M11 cylinder head bolts 1 10 a final pass i...

Page 273: ... Install the engine wiring harness ground bolt 5 to the rear of the left cylinder head Tighten Tighten the engine wire harness ground bolt to 32 N m 24 lb ft 15 Install the exhaust manifold Refer to Exhaust Manifold Replacement Left in Engine Exhaust 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Pag...

Page 274: ...ve rocker arms and pushrods Refer to Valve Rocker Arm and Push Rod Replacement CYLINDER HEAD REPLACEMENT RIGHT Tools Required z J 42385 100 Thread Repair Kit Cylinder Head Main Bearing Bolt z J 45059 Angle Meter Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 174 2005 Mitchell R...

Page 275: ...nt air bleed pipe and covers Refer to Coolant Air Bleed Pipe Assembly Replacement in Engine Cooling 3 Remove the exhaust manifold Refer to Exhaust Manifold Replacement Right in Engine Exhaust 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 175 2005 Mitchell Repair Information Company LLC ...

Page 276: ... Head Bolts Courtesy of GENERAL MOTORS CORP IMPORTANT The cylinder head bolts are NOT reusable NOTE After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 39 AM Page 176 2005 Mitchell Repair Information Company LLC ...

Page 277: ...et 10 Discard the gasket 11 Discard the cylinder head bolts 12 Clean and inspect the cylinder head Refer to Cylinder Head Cleaning and Inspection Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 177 2005 Mitchell Repair Information Company LLC ...

Page 278: ...lure to remove all foreign material may result in damaged threads improperly tightened fasteners or damage to components IMPORTANT z Do not use the cylinder head bolts again Install NEW cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 178 2005 Mitchell Repair Information Company LLC ...

Page 279: ... the hole 3 Clean the cylinder head bolt holes with compressed air bolts during assembly z Do not use any type sealant on the cylinder head gasket unless specified z The cylinder head gaskets must be installed in the proper direction and position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 17...

Page 280: ...esign engine blocks have different drill and tap depths using both medium length 100 mm 3 94 in and long 155 mm 6 1 in M11 cylinder head bolts Second design engine blocks use only the medium length 100 mm 3 94 in bolt with a common drill and tap depth 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Pa...

Page 281: ...MOTORS CORP 6 Inspect the displacement markings 1 on the gasket for proper usage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 181 2005 Mitchell Repair Information Company LLC ...

Page 282: ...ORTANT When properly installed the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 182 2005 Mitchell Repair Information Company LLC ...

Page 283: ...inder head onto the locating pins and the gasket 9 Install the NEW cylinder head bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 183 2005 Mitchell Repair Information Company LLC ...

Page 284: ...g side to side work outward tightening all of the bolts 11 Tighten the second design cylinder head bolts Tighten 1 Tighten the second design M11 cylinder head bolts 1 10 a first pass in sequence to 30 N m 22 lb ft 2 Tighten the second design M11 cylinder head bolts 1 10 a second pass in sequence to 90 degrees using the J 45059 3 Tighten the second design M11 cylinder head bolts 1 10 a final pass i...

Page 285: ...y of GENERAL MOTORS CORP 13 Position the oil level indicator tube into place 14 Install the oil level indicator tube bolt 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 185 2005 Mitchell Repair Information Company LLC ...

Page 286: ...eed Pipe Assembly Replacement in Engine Cooling 17 Install the valve rocker arms and pushrods Refer to Valve Rocker Arm and Push Rod Replacement VALVE LIFTER REPLACEMENT Tools Required J 3049 A Valve Lifter Remover Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 186 2005 Mitchel...

Page 287: ...ement Left or Cylinder Head Replacement Right 2 Remove the valve lifter guide bolts 1 3 Remove the valve lifters and guide 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 187 2005 Mitchell Repair Information Company LLC ...

Page 288: ...o remove the valve lifters if required IMPORTANT Some valve lifters may be stuck in their bores because of gum or varnish deposits 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 188 2005 Mitchell Repair Information Company LLC ...

Page 289: ...moved 7 Clean and inspect the valve lifters and guides Refer to Valve Lifters and Guides Cleaning and Inspection Installation Procedure IMPORTANT When reusing valve lifters install the lifters to their original locations 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 189 2005 Mitchell Repair Inf...

Page 290: ...he valve lifters into the lifter guides Align the flat area on the top of the lifter with the flat area in the guide bore Push the lifter completely into the guide bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 190 2005 Mitchell Repair Information Company LLC ...

Page 291: ...fter guide bolt to 12 N m 106 lb in 5 Install the cylinder head Refer to Cylinder Head Replacement Left or Cylinder Head Replacement Right NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 191 2005 Mitchell Repair Information Company LLC ...

Page 292: ...386 A Flywheel Holding Tool z J 41665 Crankshaft Balancer and Sprocket Installer z J 36660 A Torque Angle Meter Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 192 2005 Mitchell Repair Information Company LLC ...

Page 293: ...r Refer to Power Steering Gear Replacement in Power Steering System 3 Remove the starter motor Refer to Starter Motor Replacement in Engine Electrical 4 Remove the right transmission cover and bolt 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 193 2005 Mitchell Repair Information Company LLC ...

Page 294: ...42386 A bolts to 50 N m 37 lb ft NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT Make sure that the teeth of the flywheel holding tool mesh with the teeth of the engine flywheel 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 194 2005 Mitchell Repair Information Company LLC ...

Page 295: ...o not discard the crankshaft balancer bolt The balancer bolt will be used during the balancer installation procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 40 AM Page 195 2005 Mitchell Repair Information Company LLC ...

Page 296: ...t and the balancer before removal If replacing the crankshaft balancer note the location of any existing balance weights if applicable Install new balance weights into the new crankshaft balancer if applicable in the same location as the old balancer A properly installed balance weight will be either flush or below flush with the face of the balancer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE...

Page 297: ... CORP 8 Use the J 38416 B and the J 41816 2 in order to remove the crankshaft balancer 9 Remove the J 38416 B and the J 41816 2 from the crankshaft balancer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 197 2005 Mitchell Repair Information Company LLC ...

Page 298: ...n Procedure IMPORTANT z The used crankshaft balancer bolt will be used only during the first pass on the balancer installation procedure Install a NEW crankshaft balancer bolt and tighten as described in the second third and fourth passes of the balancer bolt tightening procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn ...

Page 299: ...ed z The crankshaft balancer installation and bolt tightening involves a four stage tightening process The first pass ensures that the balancer is installed completely onto the crankshaft The third and fourth passes tighten the new bolt to the proper torque 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41...

Page 300: ... Align the scribe mark on the balancer with the scribe mark on the crankshaft The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 200 2005 Mitchell Repair Information Company LLC ...

Page 301: ...f the balancer 2 Use a wrench and hold the hex end of the threaded rod 3 Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft 4 Remove the tool and reverse the installation tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 201 200...

Page 302: ... wrench and rotate the installation tool nut clockwise until the balancer is installer onto the crankshaft 7 Remove the balancer installation tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 202 2005 Mitchell Repair Information Company LLC ...

Page 303: ... used crankshaft balancer bolt Tighten Tighten the used crankshaft balancer bolt to 330 N m 240 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 203 2005 Mitchell Repair Information Company LLC ...

Page 304: ...ifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP 8 Install the NEW crankshaft balancer bolt Tighten IMPORTANT The nose of the crankshaft should be recessed 2 40 4 48 mm 0 094 0 176 in into the balancer bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 204 2005 Mitchell Repair Info...

Page 305: ...40 degrees using the J 36660 A Fig 189 J 42386 A Crankshaft Balancer Bolt Courtesy of GENERAL MOTORS CORP 9 Remove the J 42386 A and bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 205 2005 Mitchell Repair Information Company LLC ...

Page 306: ...l 12 Install the power steering gear Refer to Power Steering Gear Replacement in Power Steering System 13 Install the A C drive belt Refer to Drive Belt Replacement Air Conditioning 14 Perform the crankshaft position CKP system variation learn procedure Refer to CKP System 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn Decembe...

Page 307: ...nkshaft Front Oil Seal Installer Removal Procedure Fig 191 Front Cover Oil Seal Bore Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 207 2005 Mitchell Repair Information Company LLC ...

Page 308: ...g 192 Front Cover Oil Seal Bore Courtesy of GENERAL MOTORS CORP IMPORTANT z Do not lubricate the oil seal sealing surface z Do not reuse the crankshaft oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 208 2005 Mitchell Repair Information Company LLC ...

Page 309: ...d rod with nut washer guide and oil seal into the end of the crankshaft 5 Use the J 41478 in order to install the oil seal into the cover bore 1 Use a wrench and hold the hex on the installer tool 2 Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Cor...

Page 310: ...ONT COVER REPLACEMENT Tools Required z J 41476 Front and Rear Cover Alignment Crankshaft Oil Seal Area z J 41478 Crankshaft Front Oil Seal Installer Removal Procedure Fig 194 Oil Pan To Front Cover Bolts Oil Pan To Rear Cover Bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 210 2005 Mitchell...

Page 311: ...olts Courtesy of GENERAL MOTORS CORP 4 Remove the front cover bolts 5 Remove the front cover and gasket 6 Discard the front cover gasket 7 Clean and inspect the engine front cover Refer to Engine Front Cover Cleaning and Inspection Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM...

Page 312: ...t front oil seal z All gasket surfaces should be free of oil or other foreign material during assembly z The crankshaft front oil seal MUST be centered in relation to the crankshaft z An improperly aligned front cover may cause premature front oil seal wear and or engine oil leaks 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn...

Page 313: ...s until snug Do not overtighten Fig 197 Oil Pan To Front Cover Bolts Oil Pan To Rear Cover Bolts Courtesy of GENERAL MOTORS CORP 4 Install the oil pan to front cover bolts 2 until snug Do not overtighten 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 213 2005 Mitchell Repair Information Company ...

Page 314: ...s of the J 41476 with the machined alignment surfaces on the front cover NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 214 2005 Mitchell Repair Information Company LLC ...

Page 315: ...Tighten the engine front cover bolts to 25 N m 18 lb ft 8 Remove the J 41476 Fig 199 Front Cover Oil Seal Bore Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 41 AM Page 215 2005 Mitchell Repair Information Company LLC ...

Page 316: ...ront oil seal into the J 41478 guide 12 Install the J 41478 threaded rod with nut washer guide and oil seal into the end of the crankshaft IMPORTANT z Do not lubricate the oil seal sealing surface z Do not reuse the crankshaft oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 216 2005 Mitc...

Page 317: ...stalled evenly and completely into the front cover bore 14 Install the water pump Refer to Water Pump Replacement in Engine Cooling 15 Install the crankshaft balancer Refer to Crankshaft Balancer Replacement CRANKSHAFT REAR OIL SEAL REPLACEMENT Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instru...

Page 318: ...eal 1 from the rear cover Installation Procedure IMPORTANT z Do not lubricate the oil seal inside diameter ID of the crankshaft surface z Do not reuse the crankshaft rear oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 218 2005 Mitchell Repair Information Company LLC ...

Page 319: ...r lubricants to contact the seal surface 2 Lubricate the rear cover oil seal bore with clean engine oil DO NOT allow oil or other lubricants to contact the crankshaft surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 219 2005 Mitchell Repair Information Company LLC ...

Page 320: ...the tapered cone until the tool 1 contacts the oil seal 7 Align the oil seal onto the tool 1 8 Rotate the handle of the tool 1 clockwise until the seal enters the rear cover and bottoms into the cover bore 9 Remove the J 41479 10 Install the engine flywheel Refer to Engine Flywheel Replacement ENGINE REAR COVER REPLACEMENT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair In...

Page 321: ... Bolts Oil Pan To Rear Cover Bolts Courtesy of GENERAL MOTORS CORP 1 Remove the engine flywheel Refer to Engine Flywheel Replacement 2 Remove the oil pan to rear cover bolts 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 221 2005 Mitchell Repair Information Company LLC ...

Page 322: ...rear cover gasket z Do not apply any type of sealant to the rear cover gasket unless specified z The special tool in this procedure is used to center the crankshaft rear oil seal z All gasket surfaces should be free of oil or other foreign material during assembly z The crankshaft rear oil seal MUST be centered in relation to the 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Re...

Page 323: ...ankshaft rear oil seal will be installed after the rear cover has been installed z An improperly aligned rear cover may cause premature rear oil seal wear and or engine assembly oil leaks 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 223 2005 Mitchell Repair Information Company LLC ...

Page 324: ... MOTORS CORP 3 Install the oil pan to rear cover bolts 1 until snug Do not overtighten 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 224 2005 Mitchell Repair Information Company LLC ...

Page 325: ...aft 6 Tighten the J 41476 bolts until snug Do not overtighten Tighten IMPORTANT The tapered legs of the alignment tool must enter the rear cover oil seal bore NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 225 2005 Mitchell Repair Information...

Page 326: ... Oil Seal Courtesy of GENERAL MOTORS CORP IMPORTANT z Do not lubricate the oil seal inside diameter ID or the crankshaft surface z Do not reuse the crankshaft rear oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 226 2005 Mitchell Repair Information Company LLC ...

Page 327: ... 210 J 41479 Rear Crankshaft Cone Courtesy of GENERAL MOTORS CORP 10 Install the J 41479 cone 2 and bolts onto the rear of the crankshaft 11 Tighten the bolts until snug Do not overtighten 12 Install the rear oil seal onto the tapered cone 2 until the tool 1 contacts the oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn ...

Page 328: ...al enters the rear cover and bottoms into the cover bore 16 Remove the J 41479 17 Install the engine flywheel Refer to Engine Flywheel Replacement OIL FILTER ADAPTER REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 228 2005 Mitchell Repair Information Company LLC ...

Page 329: ...RP 1 Drain the engine oil 2 Remove the oil filter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 229 2005 Mitchell Repair Information Company LLC ...

Page 330: ...L MOTORS CORP 3 Remove the oil filter adapter 1 Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 230 2005 Mitchell Repair Information Company LLC ...

Page 331: ...r 1 Tighten Tighten the oil filter adapter to 55 N m 40 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 231 2005 Mitchell Repair Information Company LLC ...

Page 332: ...he oil filter Tighten Tighten the oil filter to 30 N m 22 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 232 2005 Mitchell Repair Information Company LLC ...

Page 333: ...ASS VALVE REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 233 2005 Mitchell Repair Information Company LLC ...

Page 334: ...il Filter Bypass Valve Courtesy of GENERAL MOTORS CORP 3 Remove the oil filter adapter 1 4 Remove the oil filter bypass valve 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 42 AM Page 234 2005 Mitchell Repair Information Company LLC ...

Page 335: ... 2 Install the oil filter adapter 1 Tighten Tighten the oil filter adapter to 55 N m 40 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 235 2005 Mitchell Repair Information Company LLC ...

Page 336: ...he oil filter Tighten Tighten the oil filter to 30 N m 22 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 236 2005 Mitchell Repair Information Company LLC ...

Page 337: ...OVER REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 237 2005 Mitchell Repair Information Company LLC ...

Page 338: ... Gasket Courtesy of GENERAL MOTORS CORP 3 Remove the oil pan cover bolts cover and gasket 4 Discard the gasket Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 238 2005 Mitchell Repair Information Company LLC ...

Page 339: ...s Tighten Tighten the oil pan cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 239 2005 Mitchell Repair Information Company LLC ...

Page 340: ...he oil filter Tighten Tighten the oil filter to 30 N m 22 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 240 2005 Mitchell Repair Information Company LLC ...

Page 341: ...in plug and allow the oil to drain 3 Re install the engine oil drain plug until snug 4 If oil pan and or gasket removal or replacement is NOT required proceed to step 10 IMPORTANT It is not necessary to remove the oil pan lower in order to remove the oil pan 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 4...

Page 342: ...AL MOTORS CORP 5 If replacement of the oil pan lower gasket is needed perform the following 6 Remove the oil pan lower bolt 1 15 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 242 2005 Mitchell Repair Information Company LLC ...

Page 343: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 243 2005 Mitchell Repair Information Company LLC ...

Page 344: ... pan lower gasket 2 9 Clean the oil pan lower gasket surface For the oil pan lower installation refer to step 13 in the installation procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 244 2005 Mitchell Repair Information Company LLC ...

Page 345: ... to Starter Motor Replacement in Engine Electrical 11 Remove the left transmission cover bolt and cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 245 2005 Mitchell Repair Information Company LLC ...

Page 346: ...l filter and allow the oil to drain 13 Re install the engine oil filter until snug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 246 2005 Mitchell Repair Information Company LLC ...

Page 347: ...e the automatic transmission fluid cooler line clamp bolt at the right transmission cover if equipped 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 247 2005 Mitchell Repair Information Company LLC ...

Page 348: ...5 Remove the automatic transmission fluid cooler line clamp bolt at the oil pan if equipped 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 248 2005 Mitchell Repair Information Company LLC ...

Page 349: ...ORS CORP 16 Remove the right transmission cover bolt and cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 249 2005 Mitchell Repair Information Company LLC ...

Page 350: ... MOTORS CORP 17 Remove the bottom 2 flywheel housing to oil pan bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 250 2005 Mitchell Repair Information Company LLC ...

Page 351: ...esy of GENERAL MOTORS CORP 18 Disconnect the engine oil level sensor electrical connector 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 251 2005 Mitchell Repair Information Company LLC ...

Page 352: ...NERAL MOTORS CORP 19 Disconnect the engine oil temperature sensor 3 electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 252 2005 Mitchell Repair Information Company LLC ...

Page 353: ...ket rivets DO NOT reuse the oil pan gasket When installing the oil pan install a NEW oil pan gasket Removal of the oil pan lower will not provide access to the crankshaft oil deflector crankshaft or other internal engine components 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 43 AM Page 253 2005 Mitchell...

Page 354: ...bolt hole locations of the oil pan provide mounting points for the flywheel housing cover To ensure the rigidity of the powertrain and correct transmission alignment it is important that the rear of the block and the rear of the oil pan are flush or even The rear of the oil pan must NEVER protrude beyond the engine block Do NOT reuse the oil pan gasket It is not necessary to rivet the NEW gasket t...

Page 355: ...0 or equivalent 20 mm 0 80 in long to the engine block Apply the sealant directly onto the tabs of the front cover gasket that protrude into the oil pan surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 255 2005 Mitchell Repair Information Company LLC ...

Page 356: ...0 or equivalent 20 mm 0 80 in long to the engine block Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 256 2005 Mitchell Repair Information Company LLC ...

Page 357: ... oil pan bolts to the pan and through the gasket IMPORTANT Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 257 2005 Mitchell Repair Information Company LLC ...

Page 358: ... 5 Tighten the 2 bottom flywheel housing bolts until snug Do not overtighten Tighten 1 Tighten the oil pan bolt and oil pan to front cover bolts to 25 N m 18 lb ft 2 Tighten the oil pan to rear cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn D...

Page 359: ...r Ground Straps Courtesy of GENERAL MOTORS CORP 6 Connect the engine oil temperature sensor 3 electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 259 2005 Mitchell Repair Information Company LLC ...

Page 360: ...rtesy of GENERAL MOTORS CORP 7 Connect the engine oil level sensor electrical connector 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 260 2005 Mitchell Repair Information Company LLC ...

Page 361: ...nsmission cover and bolt Tighten Tighten the right transmission cover bolt to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 261 2005 Mitchell Repair Information Company LLC ...

Page 362: ... clamp bolt at the oil pan if equipped Tighten Tighten the automatic transmission fluid cooler line clamp bolt at the oil pan to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 262 2005 Mitchell Repair Information Company LLC ...

Page 363: ...olt at right transmission cover if equipped Tighten Tighten the automatic transmission fluid cooler line bolt at right transmission cover to 2 5 N m 22 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 263 2005 Mitchell Repair Information Company LLC ...

Page 364: ...he left transmission cover bolt to 12 N m 106 lb in 12 Install the starter motor Refer to Starter Motor Replacement in Engine Electrical 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 264 2005 Mitchell Repair Information Company LLC ...

Page 365: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 265 2005 Mitchell Repair Information Company LLC ...

Page 366: ...olt 1 15 Courtesy of GENERAL MOTORS CORP 15 Tighten the oil pan lower bolts 1 15 in a crossing pattern alternating from side to side Tighten Tighten the oil pan lower bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 266 2005 Mitchell Repair Information Company LLC ...

Page 367: ... engine oil filter Tighten Tighten the engine oil filter to 30 N m 22 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 267 2005 Mitchell Repair Information Company LLC ...

Page 368: ... the proper quantity and grade of engine oil Refer to Capacities Approximate Fluid and Fluid and Lubricant Recommendations in Maintenance and Lubrication 20 Check the transmission fluid add if necessary 21 Run the engine and check for leaks ENGINE OIL PRESSURE SENSOR AND OR SWITCH REPLACEMENT Tools Required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of ...

Page 369: ...ntake Manifold Replacement 2 Disconnect the oil pressure sensor electrical connector 2 IMPORTANT Clean the area around the sensor before removal This avoids debris from entering the engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 269 2005 Mitchell Repair Information Company LLC ...

Page 370: ...12 to remove the oil pressure sensor from the engine block Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 44 AM Page 270 2005 Mitchell Repair Information Company LLC ...

Page 371: ... 41712 to install the oil pressure sensor to the engine block Tighten Tighten the engine oil pressure sensor to 20 N m 15 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 271 2005 Mitchell Repair Information Company LLC ...

Page 372: ...nnector 2 4 Install the intake manifold Refer to Intake Manifold Replacement ENGINE OIL LEVEL SENSOR AND OR SWITCH REPLACEMENT Removal Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 272 2005 Mitchell Repair Information Company LLC ...

Page 373: ...n 2 Remove the oil pan drain plug 3 Completely drain the engine oil 4 Disconnect the engine oil level sensor electrical connector 5 Remove the engine oil level sensor Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 273 2005 Mitchell Repair Information Company LLC ...

Page 374: ... level sensor to 13 N m 115 lb in 3 Connector the engine oil level sensor electrical connector 4 Lower the vehicle 5 Refill the engine with oil ENGINE OIL TEMPERATURE GAGE SENSOR REPLACEMENT NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 274 ...

Page 375: ...e Refer to Lifting and Jacking the Vehicle in General Information 2 Remove the engine oil temperature gage sensor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 275 2005 Mitchell Repair Information Company LLC ...

Page 376: ... Install the engine oil temperature gage sensor NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 276 2005 Mitchell Repair Information Company LLC ...

Page 377: ...ORS CORP 1 Remove the engine front cover Refer to Engine Front Cover Replacement 2 Remove the engine oil pan Refer to Oil Pan Replacement 3 Remove the oil pump screen bolt and nut 4 Remove the oil pump screen and O ring seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 277 2005 Mitchell Repair...

Page 378: ...esy of GENERAL MOTORS CORP 7 Remove the remaining crankshaft oil deflector nuts 8 Remove the crankshaft oil deflector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 278 2005 Mitchell Repair Information Company LLC ...

Page 379: ...ure IMPORTANT Do not allow dirt or debris to enter the oil pump cap the ends as necessary IMPORTANT Inspect the engine block oil gallery passages These surfaces must be clear and free of debris or restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 279 2005 Mitchell Repair Information Co...

Page 380: ...haft sprocket until the pump housing contacts the face of the engine block 3 Install the oil pump bolts Tighten Tighten the oil pump bolts to 25 N m 18 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 280 2005 Mitchell Repair Information ...

Page 381: ... Install the crankshaft oil deflector nuts Tighten Tighten the crankshaft oil deflector nuts to 25 N m 18 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 281 2005 Mitchell Repair Information Company LLC ...

Page 382: ...en bolt and nut Tighten IMPORTANT Push the oil pump screen tube completely into the oil pump prior to tightening the bolt Do not allow the bolt to pull the tube into the pump Align the oil pump screen brackets with the correct crankshaft bearing cap studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 A...

Page 383: ...Pulley Puller z J 41558 Crankshaft Sprocket Remover z J 41816 2 Crankshaft End Protector z J 41665 Crankshaft Balancer and Sprocket Installer Removal Procedure NOTE Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 ...

Page 384: ...p Pump Screen and Deflector Replacement 2 Remove the camshaft sprocket bolts 3 Remove the camshaft sprocket and timing chain 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 284 2005 Mitchell Repair Information Company LLC ...

Page 385: ...Use the J 8433 J 41816 2 and J 41558 in order to remove the crankshaft sprocket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 285 2005 Mitchell Repair Information Company LLC ...

Page 386: ...ENERAL MOTORS CORP 5 Remove the crankshaft sprocket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 286 2005 Mitchell Repair Information Company LLC ...

Page 387: ...an and inspect the timing chain and sprockets Refer to Timing Chain and Sprockets Cleaning and Inspection Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 45 AM Page 287 2005 Mitchell Repair Information Company LLC ...

Page 388: ...ORP 1 Install the key into the crankshaft keyway if previously removed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 288 2005 Mitchell Repair Information Company LLC ...

Page 389: ...CORP 2 Tap the key 1 into the keyway until both ends of the key bottom onto the crankshaft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 289 2005 Mitchell Repair Information Company LLC ...

Page 390: ...cket onto the front of the crankshaft Align the crankshaft key with the crankshaft sprocket keyway 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 290 2005 Mitchell Repair Information Company LLC ...

Page 391: ...rocket onto the crankshaft until fully seated against the crankshaft flange 5 Rotate the crankshaft sprocket until the alignment mark is in the 12 o clock position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 291 2005 Mitchell Repair Information Company LLC ...

Page 392: ... The sprocket teeth and timing chain must mesh z The camshaft and the crankshaft sprocket alignment marks MUST be aligned correctly Locate the camshaft sprocket alignment mark in the 6 o clock 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 292 2005 Mitchell Repair Information Company LLC ...

Page 393: ...rankshaft Sprocket Courtesy of GENERAL MOTORS CORP position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 293 2005 Mitchell Repair Information Company LLC ...

Page 394: ... pump Refer to Oil Pump Pump Screen and Deflector Replacement CAMSHAFT REPLACEMENT Tools Required J 41476 Front and Rear Cover Alignment Tool Removal Procedure NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 294 2005 Mitchell Repair Informatio...

Page 395: ...ight 5 Remove the water pump Refer to Water Pump Removal 6 Remove the intake manifold Refer to Intake Manifold Removal 7 Remove the coolant air bleed pipe Refer to Coolant Air Bleed Pipe Removal 8 Remove the left and right valve rocker arm covers Refer to Valve Rocker Arm Cover Removal Left and Valve Rocker Arm Cover Removal Right 9 Remove the valve rocker arms and push rods Refer to Valve Rocker ...

Page 396: ...il pan to front cover bolts 2 Fig 274 Front Cover Gasket Bolts Courtesy of GENERAL MOTORS CORP 13 Remove the front cover bolts 14 Remove the front cover and gasket Discard the old gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 296 2005 Mitchell Repair Information Company LLC ...

Page 397: ...RP 15 Rotate the engine in order to align the timing marks 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 297 2005 Mitchell Repair Information Company LLC ...

Page 398: ...ing chain to rest on the crankshaft sprocket 18 Remove the camshaft Refer to Camshaft Removal 19 Clean and inspect the camshaft and bearings Refer to Camshaft and Bearings Cleaning and Inspection 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 298 2005 Mitchell Repair Information Company LLC ...

Page 399: ...placed remove the oil pan to rear cover bolts 1 IMPORTANT Rear cover removal is not required if the camshaft bearings are not being replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 299 2005 Mitchell Repair Information Company LLC ...

Page 400: ...and gasket Discard the gasket 23 Remove the camshaft bearings if required Refer to Camshaft Bearing Removal Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 300 2005 Mitchell Repair Information Company LLC ...

Page 401: ... Bearing Installation 2 Apply a 5 mm bead of sealant GM P N 12378190 or equivalent 20 mm 0 8 in long to the oil pan to engine block junction if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 301 2005 Mitchell Repair Information Company LLC ...

Page 402: ...r cover and a new gasket if required 4 Install the rear cover bolts until snug if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 302 2005 Mitchell Repair Information Company LLC ...

Page 403: ...RAL MOTORS CORP 5 Install the oil pan to rear cover bolts 1 until snug if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 303 2005 Mitchell Repair Information Company LLC ...

Page 404: ... bolts until snug Do not overtighten if required Tighten NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT The tapered legs of the alignment tool must enter the rear cover oil seal bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 46 AM Page 304 2005 Mitchell Repair Information Company LLC ...

Page 405: ...8 Remove the J 41476 9 Install a NEW crankshaft rear oil seal if required Refer to Crankshaft Rear Oil Seal Installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 305 2005 Mitchell Repair Information Company LLC ...

Page 406: ...osition Fig 284 View Of Camshaft Sprocket Bolt Timing Chain Courtesy of GENERAL MOTORS CORP 12 Install the camshaft sprocket and timing chain 13 Install the camshaft sprocket bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 306 2005 Mitchell Repair Information Company LLC ...

Page 407: ...f GENERAL MOTORS CORP 14 Apply a 5 mm 0 2 in bead of sealant GM P N 12378190 or equivalent 20 mm 0 8 in long to the oil pan to engine block junction 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 307 2005 Mitchell Repair Information Company LLC ...

Page 408: ... the front cover and a new gasket 16 Install the front cover bolts until snug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 308 2005 Mitchell Repair Information Company LLC ...

Page 409: ... GENERAL MOTORS CORP 17 Install the oil pan to front cover bolts 1 until snug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 309 2005 Mitchell Repair Information Company LLC ...

Page 410: ...legs of the J 41476 with the machined alignment surfaces on the front cover 20 Install the crankshaft balancer bolt until snug Do not overtighten Tighten 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 310 2005 Mitchell Repair Information Company LLC ...

Page 411: ...ancer Installation 33 Install the engine assembly Refer to Engine Replacement ENGINE FLYWHEEL REPLACEMENT Removal Procedure NOTE Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing NOTE When tilting down the rear of the driveline observe the clearance between the rear of the engine and the composite dash panel Do not allow t...

Page 412: ... prop shaft hub and flex plate are balanced as an assembly If service is required the entire flywheel assembly should be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 312 2005 Mitchell Repair Information Company LLC ...

Page 413: ... Transmission or Driveline Support Assembly Replacement Manual Transmission in Propeller Shaft 3 Remove the clutch assembly if equipped with a manual transmission Refer to Clutch Assembly Replacement in Clutch 4 Mark or scribe the end of the crankshaft and the manual transmission flywheel Refer to Engine Balancing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instruction...

Page 414: ...NERAL MOTORS CORP 6 If equipped with a manual transmission remove the engine flywheel bolts 7 Remove the engine flywheel Installation Procedure IMPORTANT For manual transmission applications note the position and direction of the 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 314 2005 Mitchell R...

Page 415: ...t the crankshaft flange but will be pulled onto the crankshaft by the engine flywheel bolts This procedure requires a 3 stage tightening process DO NOT remove the prop shaft hub or flex plate from the automatic transmission engine flywheel The flywheel prop shaft hub and flex plate are balanced as an assembly If service is required the entire flywheel assembly should be replaced 2004 Chevrolet Cor...

Page 416: ...er to Engine Balancing Fig 293 Automatic Transmission Engine Flywheel Bolts Courtesy of GENERAL MOTORS CORP 2 Install the engine flywheel 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 316 2005 Mitchell Repair Information Company LLC ...

Page 417: ...Install the engine flywheel bolts until snug Tighten 1 Tighten the engine flywheel bolts a first pass in sequence to 20 N m 15 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 317 2005 Mitchell Repair Information Company LLC ...

Page 418: ... Converter Replacement in Engine Exhaust ENGINE REPLACEMENT Tools Required z J 25034 C Power Steering Pump Pulley Remover z J 42188 Ball Joint Separator z J 39580 Engine Support Table z J 39580 500 Engine Support Table Top z J 41798 Engine Lifting Brackets z J 42203 Driveline Support z J 36221 Hydraulic Clutch Line Separator z J 25033 C Power Steering Pump Pulley Installer z J 36660 A Torque Angle...

Page 419: ...4 Reposition the brake pipes 5 Remove the accessory drive belt Refer to Drive Belt Replacement Accessory 6 Remove the right fuel injection rail cover 7 Relieve the fuel system pressure Refer to Fuel Pressure Relief Procedure in Engine Controls 5 7 L 8 Disconnect the EVAP emission canister purge hose at the fuel line 9 Remove the fuel feed hose Refer to Fuel Hose Pipes Replacement Engine Compartmen...

Page 420: ...oses and inlets when separating the cooling system components this prevents dirt and other contaminants from entering the cooling system 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 47 AM Page 320 2005 Mitchell Repair Information Company LLC ...

Page 421: ...TORS CORP 11 Remove the heater hoses from the water pump 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 321 2005 Mitchell Repair Information Company LLC ...

Page 422: ... connectors z The evaporative emission EVAP solenoid 2 z The electric throttle motor 3 z The throttle position TP sensor z The engine coolant temperature ECT sensor z The A C compressor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 322 2005 Mitchell Repair Information Company LLC ...

Page 423: ... Booster Hose Courtesy of GENERAL MOTORS CORP 14 Remove the power brake booster vacuum hose 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 323 2005 Mitchell Repair Information Company LLC ...

Page 424: ...teering gear 16 Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 324 2005 Mitchell Repair Information Company LLC ...

Page 425: ...wheels Refer to Tire and Wheel Removal and Installation in Tires and Wheels 19 Remove the catalytic converter Refer to Catalytic Converter Replacement in Engine Exhaust 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 325 2005 Mitchell Repair Information Company LLC ...

Page 426: ...s 21 Remove the driveline tunnel close out panel 22 Remove the starter motor Refer to Starter Motor Replacement in Engine Electrical 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 326 2005 Mitchell Repair Information Company LLC ...

Page 427: ... sensor electrical connector 1 24 Disconnect the oil level sensor electrical connector 2 25 Disconnect the right heated oxygen sensor HO2S electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 327 2005 Mitchell Repair Information Company LLC ...

Page 428: ... condenser hose bolt at compressor 27 Separate the A C compressor and condenser hose from the A C compressor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 328 2005 Mitchell Repair Information Company LLC ...

Page 429: ...electrical connector 29 Disconnect the left HO2S electrical connector 30 Remove the ground strap bolt Remove the ground straps 1 and 2 from the engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 329 2005 Mitchell Repair Information Company LLC ...

Page 430: ...ical connectors z Shock absorber damper z Position sensor pigtail 33 Unclip the transmission wire harness from the crossmember 34 Disconnect the electronic variable orifice EVO control connector clips from the crossmember 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 330 2005 Mitchell Repair In...

Page 431: ...6 Unclip the transmission wire harness from the engine wire harness 37 Remove the stabilizer shaft Refer to Stabilizer Shaft Replacement in Front Suspension 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 331 2005 Mitchell Repair Information Company LLC ...

Page 432: ...e J 42188 until the steering knuckle and the lower control arm ball stud separate 41 Disconnect the antilock brake system ABS electrical connector clips from the crossmember if equipped 42 Remove the front transverse leaf spring Refer to Front Transverse Spring Replacement in Front Suspension 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette...

Page 433: ...ct the automatic transmission fluid cooler pipe clip from the front of the engine oil pan if equipped 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 333 2005 Mitchell Repair Information Company LLC ...

Page 434: ...fluid cooler pipes from the rear pipes 45 Disconnect the automatic transmission cooler pipe clip at the right transmission cover if equipped 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 334 2005 Mitchell Repair Information Company LLC ...

Page 435: ...r longer in each plug location NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 48 AM Page 335 2005 Mitchell Repair Info...

Page 436: ...sy of GENERAL MOTORS CORP 47 If equipped with a automatic transmission remove the flywheel housing plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 336 2005 Mitchell Repair Information Company LLC ...

Page 437: ...entate the prop shaft hub clamp for access to the bolt 1 2 Position the clamp bolt 1 facing downward 3 Loosen the prop shaft hub clamp bolt 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 337 2005 Mitchell Repair Information Company LLC ...

Page 438: ... 50 Remove the transmission wire harness from its mounting location rearward toward the driveline support 51 Lay the harness on the driveline support Secure if necessary 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 338 2005 Mitchell Repair Information Company LLC ...

Page 439: ... the close out panel flange IMPORTANT The weight of the engine should never be supported by the J 42203 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 339 2005 Mitchell Repair Information Company LLC ...

Page 440: ... actuator hose clip 2 Using the J 36221 depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect 3 Protect both ends from dirt and damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 340 2005 Mitchell Repair Informat...

Page 441: ...580 and the J 39580 500 56 Support the engine and crossmember on the J 39580 and the J 39580 500 IMPORTANT The weight of the engine should never be supported by the J 42203 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 341 2005 Mitchell Repair Information Company LLC ...

Page 442: ...TOOLS ONLY remove the front and rear crossmember nuts 58 Partially raise the vehicle 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 342 2005 Mitchell Repair Information Company LLC ...

Page 443: ... Remove the AIR pipe bolts from the right exhaust manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 343 2005 Mitchell Repair Information Company LLC ...

Page 444: ...ipe bracket bolt at the rear of the cylinder head 61 Remove the AIR pipe with check valve and gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 344 2005 Mitchell Repair Information Company LLC ...

Page 445: ...following electrical connectors from the back of the engine z The knock sensor wire harness 1 z The engine oil pressure sensor 2 z The manifold absolute pressure MAP sensor 3 z The camshaft position CMP sensor 4 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 345 2005 Mitchell Repair Information ...

Page 446: ... Bolts Courtesy of GENERAL MOTORS CORP 66 Remove the driveline support bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 346 2005 Mitchell Repair Information Company LLC ...

Page 447: ...ine away from the propeller shaft 69 As soon as the propeller input shaft clears the flywheel housing slowly raise the vehicle 70 Slide the engine and crossmember forward in order to clear the propeller shaft spline IMPORTANT Visually inspect the transmission wiring harness to ensure detachment from the engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 ...

Page 448: ...ulley hub cap if necessary 73 Using the J 25034 C remove the power steering pump pulley IMPORTANT Visually inspect the wiring harness clearances while raising the vehicle 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 49 AM Page 348 2005 Mitchell Repair Information Company LLC ...

Page 449: ... to the crossmember 77 Remove the A C compressor bracket Refer to Compressor Mounting Bracket Replacement in Heating Ventilation and Air Conditioning IMPORTANT It is not necessary to open the power steering system during the engine removal procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page...

Page 450: ...rator bracket bolts 79 Remove the generator bracket and power steering pump bracket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 350 2005 Mitchell Repair Information Company LLC ...

Page 451: ...ve the AIR pipe and gasket 82 Install the J 41798 to the engine 83 Remove the spark plugs Refer to Spark Plug Replacement in Engine Controls 5 7 L 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 351 2005 Mitchell Repair Information Company LLC ...

Page 452: ...g a engine hoist and the J 41798 slowly raise the engine 86 Remove the engine from the crossmember 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 352 2005 Mitchell Repair Information Company LLC ...

Page 453: ...isassembly Refer to Engine Balancing 90 Remove the engine hoist 91 Remove the J 41798 from the engine 92 Remove the engine mount bracket bolts 93 Remove the engine mount brackets from the engine block Installation Procedure Important 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 353 2005 Mitche...

Page 454: ...s Courtesy of GENERAL MOTORS CORP 2 Install the engine mount brackets to the engine block 3 Install the engine mount bracket bolts Tighten Tighten the engine mount bracket bolts to 50 N m 37 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Pag...

Page 455: ...nstall the flywheel housing bolts Tighten Tighten the flywheel housing bolts to 50 N m 37 lb ft 9 Using a engine hoist and the J 41798 lower the engine onto the crossmember Fig 331 Engine Mount Nuts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 355 2005 Mitchell Repair Information Company LLC ...

Page 456: ...m the engine Fig 332 AIR Pipe Bolts Exhaust Manifold Bolts Courtesy of GENERAL MOTORS CORP 13 Clean the exhaust manifold AIR pipe gasket flange if necessary 14 Install a NEW AIR pipe gasket and the pipe 15 Install the AIR pipe bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 356 2005 Mitchel...

Page 457: ...the generator bracket bolts until snug 19 Tighten the generator bracket bolts in the following order 1 Inner power steering pump reservoir bracket bolt 2 Upper generator bracket bolt 3 Outer power steering pump reservoir bracket bolt 4 Lower generator bracket bolt Tighten Tighten the generator bracket bolts to 50 N m 37 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair...

Page 458: ...racket 21 Install the power steering pump brace 22 Install the power steering pump bolts Tighten Tighten the power steering pump bolts to 25 N m 18 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 358 2005 Mitchell Repair Information Company LLC ...

Page 459: ...steering pump pulley hub cap if necessary 25 Roll the engine and crossmember underneath the vehicle 26 Partially lower the vehicle onto the engine and crossmember 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 359 2005 Mitchell Repair Information Company LLC ...

Page 460: ... bolt 5 to 32 N m 24 lb ft 28 Route the electrical harness and connect the following electrical connectors at the rear of the engine z The knock sensor wire harness 1 z The engine oil pressure sensor 2 z The MAP sensor 3 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 360 2005 Mitchell Repair Inf...

Page 461: ...ket flange if necessary 31 Install a NEW AIR pipe gasket and the pipe with check valve to the right exhaust manifold 32 Install the AIR pipe bolts until snug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 361 2005 Mitchell Repair Information Company LLC ...

Page 462: ...pe bracket bolt at the rear of the cylinder head Tighten Tighten the AIR pipe bolts to 20 N m 15 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 50 AM Page 362 2005 Mitchell Repair Information Company LLC ...

Page 463: ...per height and angle in order to install the propeller input shaft 36 Insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle Do Not Force Rotate the shaft slightly to bring the 2 splines into alignment if necessary 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58...

Page 464: ... Tighten Tighten the driveline support bolts to 50 N m 37 lb ft 39 Clip the clutch actuator hose to the clutch actuator hose clip 40 Connect the master cylinder hose to the clutch actuator hose 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 364 2005 Mitchell Repair Information Company LLC ...

Page 465: ...ller input shaft 43 Install the driveline support bolts Tighten Tighten the driveline support bolts to 50 N m 37 lb ft 44 Hand tighten the flywheel hub collar bolt 45 Lower the vehicle onto the crossmember and align the dowels IMPORTANT Do not tighten the flywheel hub collar bolt at this time 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette...

Page 466: ...nd suitably support the vehicle 48 Remove the J 39580 and the J 39580 500 49 Remove the J 42203 from the vehicle IMPORTANT Use only hand tools when tightening or torquing crossmember nuts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 366 2005 Mitchell Repair Information Company LLC ...

Page 467: ...1 Install the transmission wire harness bracket bolts Tighten Tighten the transmission wire harness bracket bolts to 50 N m 37 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 367 2005 Mitchell Repair Information Company LLC ...

Page 468: ... x 55 mm bolts from the front of the driveline support 53 Install 2 plugs in the driveline support Tighten Tighten the driveline support plugs to 50 N m 37 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 368 2005 Mitchell Repair Information Company LLC ...

Page 469: ... pipes to 25 N m 18 lb ft 55 Install the automatic transmission cooler pipe clamp bolt at the transmission cover if equipped Tighten Tighten the automatic transmission fluid cooler pipe clamp bolt at the transmission cover to 2 2 N m 22 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 369 20...

Page 470: ... the automatic transmission fluid cooler pipe clamp bolt at the oil pan to 12 N m 106 lb in 57 Install the front transverse leaf spring Refer to Front Transverse Spring Replacement in Front Suspension 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 370 2005 Mitchell Repair Information Company LLC...

Page 471: ...knuckle nut an additional 210 degrees using J 36660 A 3 Check the steering knuckle nut for a final torque of 55 N m 41 lb ft 60 Connect the ABS electrical connector clips to the crossmember if equipped 61 Install the front stabilizer shaft Refer to Stabilizer Shaft Replacement in Front Suspension 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corv...

Page 472: ...n 1 Tighten the transmission wire harness clip bolt near the harness ground to 32 N m 23 lb ft 2 Tighten the transmission wire harness clip bolt near the oil pan to 25 N m 18 lb ft 64 Install the EVO electrical connector clips to the crossmember 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 372...

Page 473: ...he crossmember 66 If equipped with RTD connect the following electrical connectors z Position sensor pigtail z Shock absorber damper 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 373 2005 Mitchell Repair Information Company LLC ...

Page 474: ...trap bolt Tighten Tighten the engine wire harness ground bolt to 32 N m 23 lb ft 69 Connect the left HO2S electrical connector 70 Connect the engine oil temperature sensor 3 electrical connector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 374 2005 Mitchell Repair Information Company LLC ...

Page 475: ...tall the A C compressor and condenser hose bolt at compressor Tighten Tighten the A C compressor and condenser hose bolt at compressor to 27 N m 20 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 51 AM Page 375 2005 Mitchell Repair Information Company LLC ...

Page 476: ...nnect the oil level sensor 2 electrical connector 75 Connect the CKP sensor 1 electrical connector 76 Install the starter motor Refer to Starter Motor Replacement in Engine Electrical 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 376 2005 Mitchell Repair Information Company LLC ...

Page 477: ...106 lb in 79 Install the catalytic converter Refer to Catalytic Converter Replacement in Engine Exhaust 80 Install the front tires and wheels Refer to Tire and Wheel Removal and Installation in Tires and Wheels 81 Lower the vehicle 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 377 2005 Mitchell...

Page 478: ...TORS CORP 82 Connect the AIR pump hose to the AIR pipe 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 378 2005 Mitchell Repair Information Company LLC ...

Page 479: ...ring gear 84 Install the intermediate steering shaft bolt Tighten Tighten the intermediate steering shaft bolt to 48 N m 35 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 379 2005 Mitchell Repair Information Company LLC ...

Page 480: ...ter vacuum hose 86 Install the generator Refer to Generator Replacement in Engine Electrical 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 380 2005 Mitchell Repair Information Company LLC ...

Page 481: ...The ignition coil main harness connectors z The EVAP solenoid 2 z The electric throttle motor 3 z The TP sensor z The ECT sensor z The A C compressor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 381 2005 Mitchell Repair Information Company LLC ...

Page 482: ...TORS CORP 88 Install the heater hoses to the water pump 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 382 2005 Mitchell Repair Information Company LLC ...

Page 483: ...Refer to Fuel Hose Pipes Replacement Engine Compartment in Engine Controls 5 7 L 91 Connect the EVAP emission canister purge hose at the fuel line 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 383 2005 Mitchell Repair Information Company LLC ...

Page 484: ...charging in Heating Ventilation and Air Conditioning 97 Program the transmitters Refer to Transmitter Programming in Keyless Entry 98 Bleed the clutch hydraulic system if equipped Refer to Hydraulic Clutch Bleeding in Clutch 99 Perform the CKP system variation learn procedure Refer to CKP System Variation Learn Procedure in Engine Controls 5 7 L 100 Fill the crankcase with the proper quantity and ...

Page 485: ...e engine has acceptable oil pressure If necessary install an oil pressure gauge and measure the engine oil pressure 106 Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature 107 Listen for sticking lifters and other unusual noises 108 Inspect for fuel oil and or other coolant leaks while the engine is running 2004 Chevrolet Corvette 2004 ENGINE PERFORMANC...

Page 486: ...Tighten Tighten the propeller shaft hub collar bolt to 125 N m 92 lb ft Fig 362 Flywheel Housing Plug Courtesy of GENERAL MOTORS CORP 110 Install the engine flywheel housing inspection plug 111 Perform a final inspection for the proper engine oil and coolant levels 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 ...

Page 487: ...cle Refer to Lifting and Jacking the Vehicle in General Information 4 Remove the oil pan drain plug 5 Drain the engine oil into an appropriate container Allow sufficient time for the oil to drain 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 387 2005 Mitchell Repair Information Company LLC ...

Page 488: ... old oil filter to ensure that the filter seal is not left on the engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 388 2005 Mitchell Repair Information Company LLC ...

Page 489: ...or the oil to drain from the oil filter opening 9 Wipe the excess oil from the oil filter mounting Installation Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 389 2005 Mitchell Repair Information Company LLC ...

Page 490: ...from the oil filter mounting NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 52 AM Page 390 2005 Mitchell Repair Information Company LLC ...

Page 491: ...il pan drain plug Tighten Tighten the oil pan drain plug to 25 N m 18 lb ft 5 Lower the vehicle IMPORTANT Lightly oil the engine oil filter gasket using CLEAN oil IMPORTANT DO NOT use any engine oil additives in Corvette engines 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 391 2005 Mitchell Re...

Page 492: ...the vehicle 12 Check the engine oil level 13 Top off the engine oil to the full mark on the oil level indicator dipstick if necessary 14 Install the oil fill cap 15 Close the hood 16 Reset the engine oil life monitor Refer to GM Oil Life System Resetting in Maintenance and Lubrication DRAINING FLUIDS AND OIL FILTER REMOVAL Tools Required J 41712 Oil Pressure Switch Socket 2004 Chevrolet Corvette 2...

Page 493: ...er to completely drain the oil from the oil pan internal baffling the bottom of the oil pan must be level during the oil drain procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 393 2005 Mitchell Repair Information Company LLC ...

Page 494: ...AL MOTORS CORP 2 Remove the engine oil filter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 394 2005 Mitchell Repair Information Company LLC ...

Page 495: ... Remove the right rear engine block coolant drain plug and allow the coolant to drain 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 395 2005 Mitchell Repair Information Company LLC ...

Page 496: ...Remove the left front engine block coolant drain plug if applicable and allow the coolant to drain 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 396 2005 Mitchell Repair Information Company LLC ...

Page 497: ... the engine block coolant heater if applicable and allow the coolant to drain 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 397 2005 Mitchell Repair Information Company LLC ...

Page 498: ...NKSHAFT BALANCER REMOVAL Tools Required z J 41816 Crankshaft Balancer Remover z J 41816 2 Crankshaft End Protector z J 42386 A Flywheel Holding Tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 398 2005 Mitchell Repair Information Company LLC ...

Page 499: ...ning Mark or scribe the end of the crankshaft and the balancer before component removal The crankshaft balancer must be installed to the original position If replacing the crankshaft balancer note the location of any existing balance weights if applicable Install new balance weights into the 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette ...

Page 500: ...ancer A properly installed balance weight will be either flush or below flush with the face of the balancer z Do not use the crankshaft balancer bolt again Install a NEW crankshaft balancer bolt during final assembly z Ensure that the teeth of the flywheel holding tool mesh with the teeth of the engine flywheel 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1...

Page 501: ...ing the balancer installation procedure Fig 375 Mark Crankshaft Balancer End Of Crankshaft Courtesy of GENERAL MOTORS CORP 3 Mark or scribe the crankshaft balancer and the end of the crankshaft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 401 2005 Mitchell Repair Information Company LLC ...

Page 502: ...y of GENERAL MOTORS CORP 4 Use the J 41816 and the J 41816 2 in order to remove the crankshaft balancer 5 Remove the J 42386 A and bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 402 2005 Mitchell Repair Information Company LLC ...

Page 503: ...lancer weights if applicable Refer to Crankshaft Balancer Cleaning and Inspection ENGINE FLYWHEEL REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 403 2005 Mitchell Repair Information Company LLC ...

Page 504: ...l transmission applications note the position and direction of the engine flywheel before removal The flywheel does 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 53 AM Page 404 2005 Mitchell Repair Information Company LLC ...

Page 505: ...ywheel will not initially seat against the crankshaft flange but will be pulled onto the crankshaft by the engine flywheel bolts This procedure requires a 3 stage tightening process z DO NOT remove the propeller shaft hub or flexplate from the automatic transmission engine flywheel The flywheel propeller shaft hub and flexplate are balanced as an assembly If service is required the entire flywheel...

Page 506: ...P 3 Remove the automatic transmission engine flywheel and bolts CLUTCH PILOT BEARING REMOVAL Tools Required J 43276 Clutch Pilot Bearing Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 406 2005 Mitchell Repair Information Company LLC ...

Page 507: ...kshaft 5 Rotate the J 43276 2 counterclockwise to remove the J 43276 2 from the J 43276 1 6 Remove the J 43276 1 from the tool body NOTE When using the J 43276 Clutch Pilot Bearing Remover always secure the J 43276 1 Clutch Pilot Bearing Remover tool body using a wrench Do not allow the J 43276 1 tool body to rotate Failing to do so causes damage to the J 43276 1 tool body 2004 Chevrolet Corvette ...

Page 508: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 408 2005 Mitchell Repair Information Company LLC ...

Page 509: ...e Courtesy of GENERAL MOTORS CORP 1 Remove the oil level indicator from the tube 2 Remove the oil level indicator tube bolt from the right cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 409 2005 Mitchell Repair Information Company LLC ...

Page 510: ...TORS CORP IMPORTANT Inspect the O ring seal for cuts or damage The O ring seal may be used again if it is not cut or damaged IMPORTANT z Do not remove the check valve from the air injection reaction AIR pipe unless service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 410 2005 Mitch...

Page 511: ...s Do not remove the spark plug wires from the ignition coils unless required 3 Remove the oxygen sensor from the manifold z Do not remove the oxygen sensor from the exhaust manifold unless service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 411 2005 Mitchell Repair Information Com...

Page 512: ...nd gasket 5 Discard the gasket 6 Remove the heat shield and bolts if required EXHAUST MANIFOLD REMOVAL RIGHT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 412 2005 Mitchell Repair Information Company LLC ...

Page 513: ...the check valve from the air injection reaction AIR pipe unless service is required z Do not remove the oxygen sensor from the exhaust manifold unless service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 413 2005 Mitchell Repair Information Company LLC ...

Page 514: ...2 Remove the AIR pipe with check valve bolts and gasket from the right exhaust manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 414 2005 Mitchell Repair Information Company LLC ...

Page 515: ...ls unless required 4 Remove the oxygen sensor from the manifold 5 Remove the exhaust manifold bolts and gasket 6 Discard the gasket 7 Remove the heat shield and bolts if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 415 2005 Mitchell Repair Information Company LLC ...

Page 516: ...ve the water pump bolts 2 Remove the water pump and gaskets 3 Discard the water pump gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 1 Of 3 5 7L Corvette Helpmelearn December 24 07 10 58 54 AM Page 416 2005 Mitchell Repair Information Company LLC ...

Page 517: ... fuel injection rail and fuel injectors may be removed as an assembly If not servicing the individual components remove the manifold as a complete assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 ...

Page 518: ... the electronic throttle control components Do not roughly handle the electronic throttle control components Do not immerse the electronic throttle control components in cleaning solvents of any type IMPORTANT DO NOT use the throttle body gasket again Install a NEW gasket during 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn D...

Page 519: ...L AND INJECTORS REMOVAL assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 09 AM Page 3 2005 Mitchell Repair Information Company LLC ...

Page 520: ... The intake manifold throttle body fuel injection rail and fuel injectors 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 09 AM Page 4 2005 Mitchell Repair Information Company LLC ...

Page 521: ...olts Courtesy of GENERAL MOTORS CORP may be removed as an assembly If not servicing the individual components remove the intake manifold as a complete assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 09 AM Page 5 2005 Mitchell Repair Information Company LLC ...

Page 522: ...IMPORTANT z Do not separate the fuel injectors from the fuel rail unless component service is required z Use cleanliness and care when handling the fuel system components z Do not allow dirt or debris to enter the fuel injectors or fuel rail components cap ends as necessary 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn Decemb...

Page 523: ... injectors may be removed as an assembly If not servicing the individual components remove the manifold as a complete assembly z DO NOT use the intake manifold to cylinder head gaskets again 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 7 2005 Mitchell Repair Information Company LLC ...

Page 524: ...CORP 2 Disconnect the knock sensor wire harness connector 1 from the fuel rail stop bracket 712 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 8 2005 Mitchell Repair Information Company LLC ...

Page 525: ...the positive crankcase ventilation PCV pipe dirty air 716 from the valley cover and intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 9 2005 Mitchell Repair Information Company LLC ...

Page 526: ... CAUTION Refer to Fuel Rail Stop Bracket Installation Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 10 2005 Mitchell Repair Information Company LLC ...

Page 527: ...t 712 Fig 9 Fuel Rail Ground Strap Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 11 2005 Mitchell Repair Information Company LLC ...

Page 528: ...ir Bleed Pipe Hose Throttle Body Courtesy of GENERAL MOTORS CORP 6 Remove the engine coolant air bleed pipe hose from the throttle body 7 Remove the intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 12 2005 Mitchell Repair Information Company LLC ...

Page 529: ...head gaskets 514 from the intake manifold 9 Discard the intake manifold gaskets COOLANT AIR BLEED PIPE REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 13 2005 Mitchell Repair Information Company LLC ...

Page 530: ...1 Remove the engine coolant air bleed pipe studs 309 2 Remove the pipe 307 and gaskets 308 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 14 2005 Mitchell Repair Information Company LLC ...

Page 531: ...ORS CORP 3 Remove the engine coolant air bleed cover bolts 312 and covers 313 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 15 2005 Mitchell Repair Information Company LLC ...

Page 532: ...4 Remove the gaskets from the pipe and covers 5 Discard the gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 16 2005 Mitchell Repair Information Company LLC ...

Page 533: ... hose 311 and clamps 310 from the pipe 307 ENGINE VALLEY COVER REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 17 2005 Mitchell Repair Information Company LLC ...

Page 534: ...ENERAL MOTORS CORP 1 Remove the knock sensor wire harness 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 18 2005 Mitchell Repair Information Company LLC ...

Page 535: ...ENERAL MOTORS CORP 2 Remove the knock sensors 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 19 2005 Mitchell Repair Information Company LLC ...

Page 536: ...ey cover bolts 4 Remove the valley cover and gasket 5 Discard the valley cover gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 20 2005 Mitchell Repair Information Company LLC ...

Page 537: ... knock sensor oil seals 520 from the cover 555 VALVE ROCKER ARM COVER REMOVAL LEFT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 21 2005 Mitchell Repair Information Company LLC ...

Page 538: ...PCV valve grommet from the cover unless service is required z If the grommet has been removed from the cover a NEW grommet must be installed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 22 2005 Mitchell Repair Information Company LLC ...

Page 539: ...tesy of GENERAL MOTORS CORP 2 Remove the valve rocker arm cover bolts 3 Remove the valve rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 23 2005 Mitchell Repair Information Company LLC ...

Page 540: ...sket 504 from the cover 5 Discard the gasket The bolt grommets may be used again if not damaged 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 24 2005 Mitchell Repair Information Company LLC ...

Page 541: ...n coils wire harness and bolts from the bracket if required VALVE ROCKER ARM COVER REMOVAL RIGHT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 25 2005 Mitchell Repair Information Company LLC ...

Page 542: ...the cover unless service is required z If the oil fill tube has been removed from the cover install a NEW tube during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 26 2005 Mitchell Repair Information Company LLC ...

Page 543: ... Courtesy of GENERAL MOTORS CORP 2 Remove the valve rocker arm cover bolts 3 Remove the valve rocker arm cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 27 2005 Mitchell Repair Information Company LLC ...

Page 544: ...from the oil fill tube 5 Remove the oil fill tube if required 6 Discard the oil fill tube 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 28 2005 Mitchell Repair Information Company LLC ...

Page 545: ...sket 504 from the cover 8 Discard the gasket The bolt grommets may be used again if not damaged 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 29 2005 Mitchell Repair Information Company LLC ...

Page 546: ...D PUSH ROD REMOVAL IMPORTANT Place valve rocker arms valve pushrods and pivot support in a rack so that they can be installed in the same location from which they were removed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 30 2005 Mitchell Repair Information Company LLC ...

Page 547: ... 1 Remove the valve rocker arm bolts 2 Remove the valve rocker arms 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 31 2005 Mitchell Repair Information Company LLC ...

Page 548: ...ENERAL MOTORS CORP 3 Remove the valve rocker arm pivot support 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 32 2005 Mitchell Repair Information Company LLC ...

Page 549: ...CORP 4 Remove the pushrods CYLINDER HEAD REMOVAL LEFT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 33 2005 Mitchell Repair Information Company LLC ...

Page 550: ...d bolts can NOT be used again Install NEW cylinder head bolts during assembly NOTE After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 10 AM Page 34 2005 Mitchell Repair Information Company LLC ...

Page 551: ...4 Remove the gasket 5 Discard the gasket 6 Discard the cylinder head bolts CYLINDER HEAD REMOVAL RIGHT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 35 2005 Mitchell Repair Information Company LLC ...

Page 552: ...bolts can NOT be used again Install NEW cylinder head bolts during assembly NOTE After removal place the cylinder head on two wood blocks to prevent damage to the sealing surfaces 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 36 2005 Mitchell Repair Information Company LLC ...

Page 553: ...t 5 Discard the gasket 6 Discard the cylinder head bolts VALVE LIFTER REMOVAL Tools Required J 3049 A Valve Lifter Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 37 2005 Mitchell Repair Information Company LLC ...

Page 554: ...Remove the valve lifter guide bolts 211 2 Remove the valve lifters and guide 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 38 2005 Mitchell Repair Information Company LLC ...

Page 555: ... to remove the valve lifters if required IMPORTANT Some valve lifters may be stuck in their bores because of gum or varnish deposits 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 39 2005 Mitchell Repair Information Company LLC ...

Page 556: ...nents so that they can be installed in the same location from which they were removed Refer to Separating Parts OIL FILTER ADAPTER AND PAN COVER REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 40 2005 Mitchell Repair Information Company LLC ...

Page 557: ...AL MOTORS CORP 1 Remove the oil filter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 41 2005 Mitchell Repair Information Company LLC ...

Page 558: ...il temperature sensor from the oil pan cover 3 Remove the oil pan cover bolts and gasket 4 Discard the gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 42 2005 Mitchell Repair Information Company LLC ...

Page 559: ... Remove the oil filter fitting 438 and valve 436 if required OIL PAN REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 43 2005 Mitchell Repair Information Company LLC ...

Page 560: ...l pan lower in order to remove the oil pan assembly z The original oil pan gasket is retained and aligned to the oil pan by 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 44 2005 Mitchell Repair Information Company LLC ...

Page 561: ...nstalling a new gasket it is not necessary to install new oil pan gasket rivets z DO NOT use the oil pan gaskets again When installing the oil pan install NEW oil pan gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 45 2005 Mitchell Repair Information Company LLC ...

Page 562: ...TANT It is not necessary to remove the oil level sensor prior to oil pan removal Remove the oil level sensor if service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 46 2005 Mitchell Repair Information Company LLC ...

Page 563: ...if required IMPORTANT It is not necessary to remove the oil pan lower to remove the oil pan assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 47 2005 Mitchell Repair Information Company LLC ...

Page 564: ... provide access to the crankshaft oil deflector crankshaft or other internal engine components 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 48 2005 Mitchell Repair Information Company LLC ...

Page 565: ...Separate the oil pan 400 upper gasket 453 oil pan 454 lower and bolts 455 if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 49 2005 Mitchell Repair Information Company LLC ...

Page 566: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 50 2005 Mitchell Repair Information Company LLC ...

Page 567: ...s Courtesy of GENERAL MOTORS CORP IMPORTANT z DO NOT allow foreign material to enter the oil passages of the oil pan Cap or cover the openings as required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 51 2005 Mitchell Repair Information Company LLC ...

Page 568: ...et Courtesy of GENERAL MOTORS CORP 1 Remove the front cover bolts 2 Remove the front cover and gasket 3 Discard the front cover gasket z Use care not to gouge score or damage the oil pan sealing surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 52 2005 Mitchell Repair Information Company LL...

Page 569: ...move the crankshaft front oil seal 140 from the cover ENGINE REAR COVER REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 53 2005 Mitchell Repair Information Company LLC ...

Page 570: ...e rear cover bolts 2 Remove the rear cover and gasket 3 Discard the rear cover gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 54 2005 Mitchell Repair Information Company LLC ...

Page 571: ... crankshaft rear oil seal 141 from the cover OIL PUMP PUMP SCREEN AND DEFLECTOR REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 55 2005 Mitchell Repair Information Company LLC ...

Page 572: ... 2 Remove the oil pump screen with O ring seal 3 Remove the O ring seal from the pump screen 4 Discard the O ring seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 56 2005 Mitchell Repair Information Company LLC ...

Page 573: ... remaining crankshaft oil deflector nuts 6 Remove the crankshaft oil deflector 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 57 2005 Mitchell Repair Information Company LLC ...

Page 574: ...er Bar z J 41558 Crankshaft Sprocket Remover z J 41816 2 Crankshaft End Protector IMPORTANT Do not allow dirt or debris to enter the oil pump assembly Cap ends as necessary 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 11 AM Page 58 2005 Mitchell Repair Information Company LLC ...

Page 575: ...ng chain NOTE Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 59 2005 Mitchell Repair Information Company LLC ...

Page 576: ...ORS CORP 3 Remove the chain dampener 232 and bolts 231 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 60 2005 Mitchell Repair Information Company LLC ...

Page 577: ...he J 8433 1 the J 41816 2 and the J 41558 in order to remove the crankshaft sprocket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 61 2005 Mitchell Repair Information Company LLC ...

Page 578: ...ENERAL MOTORS CORP 5 Remove the crankshaft sprocket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 62 2005 Mitchell Repair Information Company LLC ...

Page 579: ...ORP 6 Remove the crankshaft sprocket key if required CAMSHAFT REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 63 2005 Mitchell Repair Information Company LLC ...

Page 580: ...CORP 1 Remove the camshaft position CMP sensor bolt and the sensor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 64 2005 Mitchell Repair Information Company LLC ...

Page 581: ...TORS CORP 2 Remove the camshaft retainer bolts and the retainer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 65 2005 Mitchell Repair Information Company LLC ...

Page 582: ...ngine block 3 Remove the bolts from the front of the camshaft PISTON CONNECTING ROD AND BEARING REMOVAL Tools Required NOTE All camshaft journals are the same diameter so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 ...

Page 583: ...p of the piston 3 Use the J 24270 or equivalent in order to remove cylinder ring ridge 4 Turn the crankshaft so the piston is at the top of the stroke 5 Remove the cloth 6 Remove the cutting debris from the cylinder and piston IMPORTANT The connecting rods and the bearing caps are NOT interchangeable 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L ...

Page 584: ...mbers on the connecting rods and the connecting rod caps The connecting rods and caps MUST be assembled to their original position and direction 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 68 2005 Mitchell Repair Information Company LLC ...

Page 585: ...ank journal may effect component geometry z Mark the top of the piston to the specific cylinder bore IMPORTANT Mark sort or organize the connecting rod bearings so they may be installed to their original position and location 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 69 2005 Mitchell Repair...

Page 586: ... 5 Use a hammer and tap lightly on the end of the J 41556 in order to remove the piston and connecting rod assembly from the cylinder bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 70 2005 Mitchell Repair Information Company LLC ...

Page 587: ...rod assembly assemble the connecting rod cap and bolts onto the matching connecting rod CRANKSHAFT AND BEARINGS REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 71 2005 Mitchell Repair Information Company LLC ...

Page 588: ...entify each crankshaft bearing cap location and direction before removal The crankshaft bearing caps MUST be installed to their original position and direction z Do not use the bearing cap M8 bolts again z Remove the bearing cap M8 bolts prior to cap removal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 1...

Page 589: ...rtesy of GENERAL MOTORS CORP 3 Remove the crankshaft bearing cap M8 bolts 4 Remove the bearing cap M10 bolts and studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 73 2005 Mitchell Repair Information Company LLC ...

Page 590: ...n 6 Install the J 6125 1B to the J 41818 in order to remove the crankshaft bearing caps NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 74 2005 Mitchell Repair Information Company LLC ...

Page 591: ...ENERAL MOTORS CORP 7 Remove the bearing caps 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 75 2005 Mitchell Repair Information Company LLC ...

Page 592: ...ENERAL MOTORS CORP 8 Remove the crankshaft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 76 2005 Mitchell Repair Information Company LLC ...

Page 593: ...rankshaft Avoid damage to the crankshaft position sensor reluctor ring teeth Nicks burrs or other damage to the teeth may effect On Board Diagnostics OBD II system performance 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 77 2005 Mitchell Repair Information Company LLC ...

Page 594: ...Mark sort or organize the crankshaft bearings so they may be installed to their original position and location Refer to Separating Parts ENGINE BLOCK PLUG REMOVAL 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 78 2005 Mitchell Repair Information Company LLC ...

Page 595: ...ngine block front oil gallery plug unless service is required z If the front oil gallery plug is removed for service a NEW oil gallery plug must be installed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 79 2005 Mitchell Repair Information Company LLC ...

Page 596: ...g Location On Underside Of Block Courtesy of GENERAL MOTORS CORP 2 Remove the engine block right side coolant drain hole plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 80 2005 Mitchell Repair Information Company LLC ...

Page 597: ...MOTORS CORP 3 Remove the engine block coolant heater if applicable 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 12 AM Page 81 2005 Mitchell Repair Information Company LLC ...

Page 598: ...MOTORS CORP 4 Remove the engine block left side coolant drain hole plug if applicable 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 82 2005 Mitchell Repair Information Company LLC ...

Page 599: ...AL MOTORS CORP 5 Remove the engine block left front oil gallery plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 83 2005 Mitchell Repair Information Company LLC ...

Page 600: ...spect the block plug sealing washers If the block plug and coolant heater sealing washers are not damaged they may be used during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 84 2005 Mitchell Repair Information Company LLC ...

Page 601: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 85 2005 Mitchell Repair Information Company LLC ...

Page 602: ...ay be used during assembly Fig 84 Engine Block Front Oil Gallery Plug Courtesy of GENERAL MOTORS CORP IMPORTANT z Remove the front oil gallery plug only if service is required z If the front oil gallery plug is removed a NEW oil gallery plug must 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 86...

Page 603: ...tool J 42385 107 may be used to clean the threads of old threadlocking material 2 Inspect the following areas z The cylinder walls for excessive scratches gouging or ring ridge z The coolant jacket for cracks z The valve lifter bores for excessive scoring or wear z The crankshaft bearing webs for cracks be installed NOTE Do not use a caustic solution to clean the aluminum engine block IMPORTANT Wh...

Page 604: ...der bores for oversize Measuring the Cylinder for Oversize Fig 85 Measuring The Micrometer Bore Gauge Dial Using J 8087 Courtesy of GENERAL MOTORS CORP 1 Adjust the micrometer to 99 0 mm 3 897 in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 88 2005 Mitchell Repair Information Company LLC ...

Page 605: ... 3 Use a bore gage and measure the cylinder bore for oversize Slide the bore gage up and down throughout the length of the cylinder bore Check the bore both parallel 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 89 2005 Mitchell Repair Information Company LLC ...

Page 606: ...oversize service piston and piston ring set are available for the LS1 LS6 engine 2 It is recommended to hone the cylinder to achieve proper fit for the oversize piston Refer to the Cylinder Honing information for the proper honing procedure Honing Procedure IMPORTANT Do not bore the cylinder liners on the LS1 LS6 engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instr...

Page 607: ...ne grade stone honing the cylinder to the proper clearance 2 During the honing operation thoroughly clean the cylinder bore Repeatedly check the cylinder bore for fit with the selected piston All measurements of the piston or the cylinder bore should be made with the components at normal room temperature 3 When honing a cylinder for fit to an oversize piston first perform the preliminary honing wi...

Page 608: ...ing and before the piston is checked for fit clean the cylinder bores with hot water and detergent Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water Do not allow any abrasive material to remain in the cylinder bores This abrasive material may cause premature wear of the new piston rings and the cylinder bores Abrasive material will also contaminate the engine...

Page 609: ...zing procedure A 240 grit stone is preferred for final honing If a 240 grit stone is not available a 220 grit stone may be used as a substitute CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION Tools Required z J 6125 1B Slide Hammer z J 7872 Magnetic Base Dial Indicator Set z J 41818 Crankshaft Bearing Cap Remover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions...

Page 610: ...en handling the crankshaft Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring Damage to the teeth of the crankshaft position reluctor ring may effect On Board Diagnostics OBD II system performance CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L C...

Page 611: ...r damage IMPORTANT z The reluctor ring teeth should not have imperfections on the rising or falling edges z Imperfections of the reluctor ring teeth may effect OBD II system performance 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 95 2005 Mitchell Repair Information Company LLC ...

Page 612: ...spect the crankshaft journals for grooves or scoring 2 5 Inspect the crankshaft journals for scratches or wear 3 6 Inspect the crankshaft journals for pitting or imbedded bearing material 4 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 96 2005 Mitchell Repair Information Company LLC ...

Page 613: ...S CORP 7 Inspect the crankshaft key 122 keyway 1 and threaded hole 2 for damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 97 2005 Mitchell Repair Information Company LLC ...

Page 614: ...CORP 8 Measure the crankpins for the out of round 9 Measure the crankpins for taper 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 98 2005 Mitchell Repair Information Company LLC ...

Page 615: ...aft thrust wall width A crankshaft with a thrust wall width in excess of 26 2 mm 1 0315 in must be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 99 2005 Mitchell Repair Information Company LLC ...

Page 616: ...he J 7872 in order to measure the runout of the crankshaft rear flange 14 Use the J 7872 in order to measure the runout of the crankshaft position reluctor ring Reluctor ring runout should be measured 1 0 mm 0 04 in below the ring teeth If the reluctor ring has runout in excess of 0 7 mm 0 028 in replace the crankshaft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instru...

Page 617: ...IMPORTANT A loose or damaged crankshaft oil gallery plug must be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 101 2005 Mitchell Repair Information Company LLC ...

Page 618: ... GENERAL MOTORS CORP 16 Inspect crankshaft bearings for craters or pockets Flattened sections on the bearing halves also indicate fatigue 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 102 2005 Mitchell Repair Information Company LLC ...

Page 619: ...ft bearings for excessive scoring or discoloration 18 Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 13 AM Page 103 2005 Mitchell Repair Information Company LLC ...

Page 620: ...e bearing is worn or damaged both upper and lower halves should be replaced Generally if the lower half is suitable for use the upper half should also be suitable for use Measuring Main Bearing Clearance Gaging Plastic Method 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 104 2005 Mitchell Repai...

Page 621: ...pair or replacement may be required z Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface z The crankshaft bearing clearances are critical Excessive bearing clearance may effect crankshaft position sensor signals and may effect On Board Diagnostics OBD II system operation z Remove the bearing cap side bolts prior to cap removal 2004 Chevrolet...

Page 622: ...ORS CORP 2 Remove the bearing cap M10 bolts and studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 106 2005 Mitchell Repair Information Company LLC ...

Page 623: ... 11 N m 100 lb in 4 Install the J 6125 1B to the J 41818 in order to remove the bearing cap NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 107 2005 Mitchell Repair Information Company LLC ...

Page 624: ...GENERAL MOTORS CORP 5 Remove the bearing cap and lower bearing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 108 2005 Mitchell Repair Information Company LLC ...

Page 625: ...stic onto the crankshaft journal Install the gaging plastic the full width of crankshaft bearing journal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 109 2005 Mitchell Repair Information Company LLC ...

Page 626: ...e M10 studs 11 20 a first pass in sequence to 20 N m 15 lb ft 4 Tighten the M10 studs 11 20 a final pass in sequence to 53 degrees using the J 45059 5 Tighten the M8 bolts to 25 N m 18 lb ft Tighten the bolt on one side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of...

Page 627: ... bearing cap M8 bolts IMPORTANT Remove the bearing cap side bolts prior to cap removal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 111 2005 Mitchell Repair Information Company LLC ...

Page 628: ...ORS CORP 9 Remove the bearing cap M10 bolts and studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 112 2005 Mitchell Repair Information Company LLC ...

Page 629: ... Use the J 41818 and the J 6125 1B in order to remove the bearing cap 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 113 2005 Mitchell Repair Information Company LLC ...

Page 630: ...rnal with a micrometer z If the bearing clearance is greater than 0 065 mm 0 0025 in select and install an undersized bearing set and measure the clearance with gaging plastic z If clearance cannot be brought to specifications replace the crankshaft or grind the crankshaft for use with the next undersized bearing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions...

Page 631: ...g clearance is not within specifications z Inspect the thrust surfaces for nicks gouges or raised metal Minor imperfections may be removed with a fine stone z Replace the thrust bearings and measure the end play z If the correct measurements cannot be obtained repair the crankshaft thrust surfaces or replace the crankshaft Measuring Connecting Rod Bearing Clearance Gaging Plastic Method 2004 Chevr...

Page 632: ... a powdered metal design and cannot be shimmed or filed for bearing fit If clearances are found to be excessive a new bearing and or connecting rod are required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 116 2005 Mitchell Repair Information Company LLC ...

Page 633: ... bearing journal Install the gaging plastic the full width of the journal z Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 117 2005 Mitchell Repair Information Company LLC ...

Page 634: ...he bearing cap bearing and bolts NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 118 2005 Mitchell Repair Information Company LLC ...

Page 635: ...MOTORS CORP 5 Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit Refer to Engine Mechanical Specifications LS1 or Engine Mechanical Specifications LS6 Measuring Connecting Rod Bearing Clearance Using J 43690 J 43690 100 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 0...

Page 636: ... to the tool instruction sheets as supplied by the tool manufacturer Fig 115 View Of J 43690 Components Courtesy of GENERAL MOTORS CORP J 43690 z J 43690 20 Swivel Base 1 z J 43690 19 Dial Indicator 2 z J 43690 2 Base 3 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 120 2005 Mitchell Repair Info...

Page 637: ... 8 z 280319 Screw 9 z 280311 Screw 10 z J 43690 17 18 Adapter 11 z 280310 Pin 12 Fig 116 View Of J 43690 100 Components 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 121 2005 Mitchell Repair Information Company LLC ...

Page 638: ... 106 Retainer Plate 5 z J 43690 107 Cap 6 z J 43690 102 Foot 7 z J 43690 101 Pivot Arm Assembly 8 z J 43690 103 Adapter 9 z 505439 Adapter 10 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 122 2005 Mitchell Repair Information Company LLC ...

Page 639: ...ition 2 Remove a bearing cap and bolts 1 3 Remove the bearing half 2 IMPORTANT The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 123 2005 Mitchell Repair Information Company LLC ...

Page 640: ...g 118 View Of J 43690 2 J 43690 3 J 43690 101 280310 J 43690 5 Courtesy of GENERAL MOTORS CORP 6 Install the following 1 J 43690 2 5 2 J 43690 3 4 3 J 43690 101 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 124 2005 Mitchell Repair Information Company LLC ...

Page 641: ...he connecting rod bearing clearance A connecting rod with a clearance in excess of 0 076 mm 0 003 in is considered excessive Service components as required CRANKSHAFT BALANCER CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM Page 125 2005 Mitchell Repair Information Company LLC ...

Page 642: ...for the following z Loose or improperly installed balance weights manual transmission applications A properly installed balance weight should be installed until flush or below flush with the face of the balancer z Worn grooved or damaged hub seal surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 14 AM...

Page 643: ...hat may not allow the belt to track properly Minor imperfections may be removed with a fine file z Worn chunking or deteriorated rubber between the hub and pulley Replacing the Crankshaft Balancer and Balance Weights Corvette IMPORTANT In order for the belt to track properly the belt grooves should be free of all dirt or debris 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repa...

Page 644: ...The crankshaft balancer must be installed to the original position If replacing the crankshaft balancer note the location of any existing balance weights if applicable Crankshaft balancer weights must be installed into the new balancer in the same location as the old balancer A properly installed balance weight will be either flush or below flush with the face of the balancer 2004 Chevrolet Corvet...

Page 645: ...ance weight size for the new balancer z A balance weight hole depth that measures 13 0 mm 0 512 in has a short balance weight in the hole z A balance weight hole depth that measures 6 69 mm 0 263 in has a medium balance weight in the hole z A balance weight hole that depth measures 0 29 mm 0 011 in has a long balance weight in the hole A short balance weight will measure 12 7 mm 0 5 in in length A...

Page 646: ...oper component balance contact surface taper and heat transfer manual transmission flywheels are NOT to be machined 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 130 2005 Mitchell Repair Information Company LLC ...

Page 647: ...perly installed balance weight should be installed until flush or below flush with the face of the flywheel CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 131 2005 Mitchell Repair Information Company LLC ...

Page 648: ...t onto the flywheel and should be positioned completely against the flange of the flywheel z Missing bent or damaged pressure plate locating pins The 2 locating pins are installed into the flywheel and spaced 170 degrees apart to ensure proper orientation of the clutch pressure plate to the engine flywheel during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Ins...

Page 649: ...nes z Loose prop shaft drive hub z Welded areas that retain the ring gear onto the flywheel for cracking PISTON AND CONNECTING ROD DISASSEMBLE IMPORTANT Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate Install a new flywheel 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 ...

Page 650: ...y create scoring or damage to the piston pin and piston pin bore If the piston pin and connecting rod have been disassembled replace the components as an assembly z The disassembly procedure as shown is to be used for diagnostic 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 134 2005 Mitchell Re...

Page 651: ...of GENERAL MOTORS CORP 2 Using piston ring pliers remove the piston rings from the piston purposes only 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 135 2005 Mitchell Repair Information Company LLC ...

Page 652: ...MOTORS CORP 3 Install fork insert J 24086 920A into J 24086 10 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 136 2005 Mitchell Repair Information Company LLC ...

Page 653: ...o J 24086 10 5 Install J 24086 107 to the piston pin 6 Install J 24086 88A through the fixture and to the J 24086 107 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 137 2005 Mitchell Repair Information Company LLC ...

Page 654: ...ler hub bottoms on the support assembly do not exceed 35 000 kPa 5 000 psi pressure this could cause damage to the tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 138 2005 Mitchell Repair Information Company LLC ...

Page 655: ...nnecting Rod Components Courtesy of GENERAL MOTORS CORP 1 Remove the connecting rod bearings 3 from the rod 2 and cap 4 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 139 2005 Mitchell Repair Information Company LLC ...

Page 656: ...Using piston ring pliers remove the piston rings from the piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 140 2005 Mitchell Repair Information Company LLC ...

Page 657: ...retaining clips until the ring end gap is positioned in the cutout area 1 of the pin bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 141 2005 Mitchell Repair Information Company LLC ...

Page 658: ...ORS CORP 4 Remove the clips starting in the cutout area of the pin bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 142 2005 Mitchell Repair Information Company LLC ...

Page 659: ...o be serviced separately Mark sort or organize the piston and the matching piston pin PISTON CONNECTING ROD AND BEARINGS CLEANING AND INSPECTION Piston Pin and Piston Rings 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 143 2005 Mitchell Repair Information Company LLC ...

Page 660: ...s fit piston pin and connecting rod are to be serviced as an assembly z Do not wire brush any part of the piston z Measurement of the components should be taken with the components at normal room temperature 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 144 2005 Mitchell Repair Information Comp...

Page 661: ...mponents with compressed air CAUTION Wear safety glasses in order to avoid eye damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 145 2005 Mitchell Repair Information Company LLC ...

Page 662: ... Clean the piston ring grooves with a suitable ring groove cleaning tool 4 Clean the oil lubrication holes and slots 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 146 2005 Mitchell Repair Information Company LLC ...

Page 663: ... for nicks burrs or warpage which may cause the piston ring to bind MINOR imperfections may be removed from the piston with a fine file z Scuffed or damaged skirts 2 z Eroded areas at the top of the piston 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 15 AM Page 147 2005 Mitchell Repair Information Comp...

Page 664: ...fied by a paint mark 3 located 180 degrees from the end gap The lower compression ring can be identified by a paint mark 3 located 90 degrees from the end gap Both rings should be installed with the orientation marks 1 2 facing the top of the piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page...

Page 665: ...und the piston If binding is caused by distorted ring groove MINOR imperfections may be removed with a fine file If binding is caused by a distorted piston ring replace the rings as required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 149 2005 Mitchell Repair Information Company LLC ...

Page 666: ...on ring If the proper ring to groove clearance cannot be obtained replace the first design press fit piston pin and connecting rod assembly Refer to Engine Mechanical Specifications LS1 or Engine Mechanical Specifications LS6 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 150 2005 Mitchell Repai...

Page 667: ...iston pin to bore clearance use a micrometer and measure the piston pin outside diameter OD 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 151 2005 Mitchell Repair Information Company LLC ...

Page 668: ...ston pin OD measurement from the piston pin bore ID measurement to determine pin to bore clearance Refer to Engine Mechanical Specifications LS1 or Engine Mechanical Specifications LS6 Measuring Piston Ring End Gap 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 152 2005 Mitchell Repair Informati...

Page 669: ... 3 located 90 degrees from the end gap Both rings should be installed with the orientation marks 1 2 facing the top of the piston IMPORTANT z Do not attempt to file the end of the piston ring to achieve the proper end gap clearance z Measure the piston ring in the cylinder in which it will be used 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Cor...

Page 670: ... the ring travel area 3 Insert a feeler gage and measure the piston ring end gap Refer to Engine Mechanical Specifications LS1 or Engine Mechanical Specifications LS6 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 154 2005 Mitchell Repair Information Company LLC ...

Page 671: ...repair or modifications to either mating surface Do not attempt to repair the rod or cap If service is required replace the first design press fit piston pin and connecting rod as an assembly z Do not attempt to repair the bolt hole threads of the connecting rod 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 ...

Page 672: ...th compressed air CAUTION Wear safety glasses in order to avoid eye damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 156 2005 Mitchell Repair Information Company LLC ...

Page 673: ... rod for the following conditions z Twisting 1 z Proper fit of the connecting rod and cap mating surfaces 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 157 2005 Mitchell Repair Information Company LLC ...

Page 674: ...ring The Connecting Rod Bearing Bore For Out Of Round Condition Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 158 2005 Mitchell Repair Information Company LLC ...

Page 675: ... The Piston Pin Diameter Courtesy of GENERAL MOTORS CORP 5 To determine piston pin to connecting rod bore clearance use a micrometer and measure the piston pin outside diameter OD 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 159 2005 Mitchell Repair Information Company LLC ...

Page 676: ...eter and measure the connecting rod pin bore 1 inside diameter ID 7 Subtract the piston pin OD measurement from the connecting rod pin bore ID measurement to determine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 160 2005 Mitchell Repair Information Company LLC ...

Page 677: ...ourtesy of GENERAL MOTORS CORP 8 Inspect the connecting rod bearings for craters or pockets Flattened sections on the bearing halves indicate fatigue 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 161 2005 Mitchell Repair Information Company LLC ...

Page 678: ... bearings for excessive scoring or discoloration 10 Inspect the connecting rod bearings for dirt or debris imbedded into the bearing material 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 162 2005 Mitchell Repair Information Company LLC ...

Page 679: ...ated by bright polished sections of the bearing surface PISTON AND CONNECTING ROD ASSEMBLE Tools Required J 24086 C Piston Pin Remover Installer Set 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 163 2005 Mitchell Repair Information Company LLC ...

Page 680: ...he piston pin and connecting rod have been disassembled replace the components as an assembly z If reusing the piston and connecting rod assembly install the assembly to the original cylinder and corresponding crankshaft journal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 164 2005 Mitchell Re...

Page 681: ...ntact with HOT components Wear safety glasses and protective gloves to avoid personal injury NOTE Applying excessive heat to the connecting rod may damage or distort the rod Rod temperature SHOULD NOT exceed 315 C 600 F At this 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 16 AM Page 165 2005 Mitchell Rep...

Page 682: ...on the top of the piston should both be facing the front of the engine Fig 155 View Of Piston Connecting Rod J 24086 16A Courtesy of GENERAL MOTORS CORP 4 Assemble the piston the connecting rod and the J 24086 16A temperature the end of the connecting rod will turn a straw color upon visual inspection 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L...

Page 683: ...OTORS CORP 5 Adjust the J 24086 9 to I 8 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 167 2005 Mitchell Repair Information Company LLC ...

Page 684: ...piston connecting rod piston pin and J 24086 16A to the J 24086 10 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 168 2005 Mitchell Repair Information Company LLC ...

Page 685: ...ting rod 2 for proper assembly When properly installed the piston pin 3 should be centered in the connecting rod 2 NOTE After the installer hub bottoms on the support assembly do not exceed 35 000 kPa 5 000 psi pressure this could cause damage to the tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 A...

Page 686: ...cated 180 degrees from the end gap The lower compression ring can be identified by a paint mark 3 located 90 degrees from the end gap Both rings should be installed with the orientation marks 1 2 facing the top of the piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 170 2005 Mitchell Repair...

Page 687: ...degrees opposite each other IMPORTANT When installing piston rings use a ring expander plier type tool Do not roll the rings into the grooves of the piston Use caution and care to expand the rings only slightly larger than the outside diameter OD of the piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03...

Page 688: ...Install the connecting rod bearings 3 to the rod 2 and cap 4 Full Floating Piston Pin 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 172 2005 Mitchell Repair Information Company LLC ...

Page 689: ...RP 1 Install the retaining clip The clip should be seated in the groove of the pin bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 173 2005 Mitchell Repair Information Company LLC ...

Page 690: ...n and connecting rod 3 Install the retaining clip The clip should be seated in the groove of the pin bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 174 2005 Mitchell Repair Information Company LLC ...

Page 691: ...from the end gap Both rings should be installed with the orientation marks 1 2 facing the top of the piston IMPORTANT When installing piston rings use a ring expander plier type tool Do not roll the rings into the grooves of the piston Use caution and care to expand the rings only slightly larger than the outside diameter OD of the piston 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mech...

Page 692: ...e oil control ring end gaps a minimum of 25 mm 1 0 in from each other 7 Position the compression ring end gaps 180 degrees opposite each other 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 176 2005 Mitchell Repair Information Company LLC ...

Page 693: ... bearings 3 to the rod 2 and cap 4 CAMSHAFT BEARING REMOVAL Tools Required J 33049 Camshaft Bearing Service Set 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 177 2005 Mitchell Repair Information Company LLC ...

Page 694: ... Bearings Cleaning and Inspection 2 Repair or replace the components as required IMPORTANT A loose camshaft bearing may be caused by an enlarged out of round or damaged engine block bearing bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 178 2005 Mitchell Repair Information Company LLC ...

Page 695: ...or 3 from the tool usage information 4 Assemble the J 33049 5 Insert the tool through the front of the engine block and into the bearing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 179 2005 Mitchell Repair Information Company LLC ...

Page 696: ...epeat the above procedures to remove the remaining bearings Tool Usage Information IMPORTANT To remove the front camshaft bearing operate the tool from the rear of the block using the guide cone in the rear camshaft bearing bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 180 2005 Mitchell Re...

Page 697: ... 3 expander bearing drivers 4 8 driver bars 9 or 10 expander jaws 11 expander sleeve 12 expander cone 13 expander shaft 14 and expander assembly 15 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 181 2005 Mitchell Repair Information Company LLC ...

Page 698: ...and the large washer Tool Assembly and Operation 1 Select the proper expanding driver and washer from the expanding driver and washer information 2 Place the expanding driver onto the expander assembly 3 Check to ensure that the separation lines between the segments of the expanding driver align with the separation lines of the expander assembly 4 Place the guide cone over the driving bar with the...

Page 699: ...ble except from either end In this case you must use a socket and extension to enlarge and reduce the expander assembly 8 Slide the nylon cone into the front or rear camshaft bearing This will properly align the tool 9 Drive the bearing out of or into the engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 ...

Page 700: ...nsion 12 Drive the bearings out of or into the engine block CAMSHAFT AND BEARINGS CLEANING AND INSPECTION Tools Required z J 7872 Magnetic Base Dial Indicator Set z J 8520 Camshaft Lobe Lift Indicator 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 17 AM Page 184 2005 Mitchell Repair Information Company LLC...

Page 701: ...t valve lifter lobes 2 for scoring or excessive wear 5 Inspect the threaded bolt holes 3 in the front of the camshaft for damaged threads or debris 6 Inspect the camshaft sprocket pin 204 for damage 7 Inspect the camshaft position CMP reluctor ring for nicks or damage CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical R...

Page 702: ...r or a damaged sealing gasket If the camshaft retainer plate sealing gasket is not cut or damaged it may be used again 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 186 2005 Mitchell Repair Information Company LLC ...

Page 703: ...gine block and should not be loose in their engine block bearing bores 10 Inspect the camshaft bearings for excessive wear or scoring Bearings with excessive scoring or wear must be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 187 2005 Mitchell Repair Information Company LLC ...

Page 704: ... bearing journals that measure more than 0 025 mm 0 001 in out of round must be replaced z A camshaft with bearing journal diameters that measure less that 54 99 mm 2 164 in must be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 188 2005 Mitchell Repair Information Company LLC ...

Page 705: ...xhaust lobe that measures 46 31 mm 1 823 in or less must be replaced z An LS6 camshaft with an intake lobe that measures 46 24 mm 1 82 in or less must be replaced z An LS6 camshaft with an exhaust lobe that measures 46 19 mm 1 818 in or less must be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 1...

Page 706: ...e runout of the intermediate camshaft bearing journals using the J 7872 3 If camshaft runout exceeds 0 05 mm 0 002 in the camshaft is bent and should be replaced Measuring Camshaft Lobe Lift 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 190 2005 Mitchell Repair Information Company LLC ...

Page 707: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 191 2005 Mitchell Repair Information Company LLC ...

Page 708: ... for the LS1 exhaust lobes is 7 13 mm 0 281 in z The proper lobe lift for the LS6 intake lobes is 8 24 mm 0 324 in z The proper lobe lift for the LS6 exhaust lobes is 8 19 mm 0 322 in 8 Remove the tool 2 Compare measurements to specifications If the readings are not within specifications remove the camshaft Inspect and or replace components as required CAMSHAFT BEARING INSTALLATION Tools Required ...

Page 709: ...s IMPORTANT The engine block camshaft bearing bores are machined for 3 different OD size bearings Positions 1 and 5 are the largest diameter bores Position 3 is the smallest diameter bore Positions 2 and 4 are the intermediate size bores The ID for all camshaft bearings is the same size 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpm...

Page 710: ...2 Select the expanding driver 4 8 and washer 2 or 3 from the J 33049 Refer to Camshaft Bearing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 194 2005 Mitchell Repair Information Company LLC ...

Page 711: ...the guide cone into the front camshaft bearing to align the tool 7 Drive the bearing into the block bore 8 Repeat the above procedures to install the remaining bearings TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 195 2005 Mitchell Repair Info...

Page 712: ...pressed air CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 196 2005 Mitchell Repair Information Company LLC ...

Page 713: ... GENERAL MOTORS CORP 3 Inspect the timing chain for binding or wear 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 197 2005 Mitchell Repair Information Company LLC ...

Page 714: ...d crankshaft sprockets for z Worn teeth 1 z Damaged teeth 2 z Chipped teeth 3 z Worn valleys between the sprocket teeth 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 198 2005 Mitchell Repair Information Company LLC ...

Page 715: ...t sprocket keyway for wear 6 Inspect the crankshaft sprocket oil pump drive splines for wear 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 199 2005 Mitchell Repair Information Company LLC ...

Page 716: ...n contact area z Excessive grooves 3 in the chain contact area Grooves 1 mm 0 040 in or less in depth are to be considered normal wear VALVE ROCKER ARM AND PUSH RODS CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 200 2005 Mitchell Repair Information Company LLC ...

Page 717: ... Clean the components with cleaning solvent IMPORTANT Parts that are to be used again must be marked sorted or organized for assembly CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 18 AM Page 201 2005 Mitchell Repair Information Company LLC ...

Page 718: ... of GENERAL MOTORS CORP 6 Inspect the pushrods for worn or scored ends These surfaces should be smooth with no scoring or exceptional wear 7 Inspect the pushrods for bends Roll the pushrod on a flat surface to determine if the pushrod is bent 8 Inspect the pushrod oil passages for restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvett...

Page 719: ...pivot supports for cracks wear or other damage VALVE LIFTERS AND GUIDES CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 203 2005 Mitchell Repair Information Company LLC ...

Page 720: ...s in cleaning solvent IMPORTANT Components that are to be used again must be marked sorted or organized for assembly CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 204 2005 Mitchell Repair Information Company LLC ...

Page 721: ...roller 4 z Loose or damaged pin 5 z Plugged oil hole 6 z Worn or damaged roller bearing The roller should rotate freely with no binding or roughness Fig 191 View Of Valve Lifters Removed From Guide Courtesy of GENERAL MOTORS CORP 5 Inspect the valve lifter guides for the following 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn...

Page 722: ...CYLINDER HEAD DISASSEMBLE Tools Required J 8062 Valve Spring Compressor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 206 2005 Mitchell Repair Information Company LLC ...

Page 723: ...nents Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 207 2005 Mitchell Repair Information Company LLC ...

Page 724: ...inder head components for assembly Return the components to their original location during assembly z Do not remove the cylinder head expansion plugs 226 unless service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 208 2005 Mitchell Repair Information Company LLC ...

Page 725: ...AL MOTORS CORP 2 Use the J 8062 in order to compress the valve spring 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 209 2005 Mitchell Repair Information Company LLC ...

Page 726: ...nents Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 210 2005 Mitchell Repair Information Company LLC ...

Page 727: ...22 Refer to Separating Parts Fig 195 View Of Cylinder Head Expansion Plugs Courtesy of GENERAL MOTORS CORP 8 Remove the cylinder head expansion plugs 226 if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 211 2005 Mitchell Repair Information Company LLC ...

Page 728: ...GENERAL MOTORS CORP 9 Remove the coolant sensor from the left cylinder head 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 212 2005 Mitchell Repair Information Company LLC ...

Page 729: ...ylinder head CYLINDER HEAD CLEANING AND INSPECTION Tools Required z J 8089 Carbon Removing Brush z J 9666 Valve Spring Tester 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 213 2005 Mitchell Repair Information Company LLC ...

Page 730: ...aution in Cautions and Notices IMPORTANT When cleaning a cylinder head in a thermal type oven do not exceed 204 C 400 F IMPORTANT Be careful not to scuff the chamber 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 214 2005 Mitchell Repair Information Company LLC ...

Page 731: ... Valve stems and heads on a buffing wheel z Bolt hole threads Remove all dirt debris or threadlocking material from the bolt holes 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 215 2005 Mitchell Repair Information Company LLC ...

Page 732: ...nents Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 216 2005 Mitchell Repair Information Company LLC ...

Page 733: ...lacing Engine Gaskets 4 The bolt hole threads for debris or damaged threads Refer to Thread Repair or Thread Repair Specifications Fig 200 Inspecting The Cylinder Head For Warpage Courtesy of GENERAL MOTORS CORP 3 Inspect the cylinder head for warpage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Pa...

Page 734: ...ENERAL MOTORS CORP 4 Inspect the valve springs for squareness 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 218 2005 Mitchell Repair Information Company LLC ...

Page 735: ...ss than 310 N 70 lb at 45 75 mm 1 80 in z Replace the LS6 spring if the spring tension is less than 400 N 90 lb at 45 75 mm 1 80 in VALVE GUIDE REAMING VALVE AND SEAT GRINDING Valve Guide Reaming 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 19 AM Page 219 2005 Mitchell Repair Information Company LLC ...

Page 736: ...tem To Guide Clearance Using Dial Indicator Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 220 2005 Mitchell Repair Information Company LLC ...

Page 737: ...y cause a noisy valve train premature valve stem oil seal wear component damage and or excessive engine oil consumption z Insufficient valve stem to guide clearance will result in noisy or sticking valves Valves that are too tight may disturb engine smoothness or lead to component damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Help...

Page 738: ...ith clearance in excess of 0 093 mm 0 0037 in must be repaired or the components replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 222 2005 Mitchell Repair Information Company LLC ...

Page 739: ...ve stem to guide clearance should be reamed and valves with oversize stems installed 4 Measure the valve stem diameter A valve stem with a diameter less than 7 95 mm 0 313 in must be replaced Position the tip of the dial indicator at the top of the valve guide 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03...

Page 740: ... Fig 206 Reaming The Valve Guide Using J 37378 1 Courtesy of GENERAL MOTORS CORP 5 Ream the valve guide using the J 37378 1 6 Clean the guide bore of all metal shavings and debris 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 224 2005 Mitchell Repair Information Company LLC ...

Page 741: ...27 and 228 with oversize stem into the cylinder head 218 8 Inspect the valve for proper fit 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 225 2005 Mitchell Repair Information Company LLC ...

Page 742: ... of GENERAL MOTORS CORP IMPORTANT z Reconditioning the valve seats is very important The seating of the valves must be perfect for the engine to deliver optimum power and 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 226 2005 Mitchell Repair Information Company LLC ...

Page 743: ...ced to the proper angle Valve stems that show excessive wear or valves that are warped excessively must be replaced When a valve head that is warped excessively is refaced a knife edge may be ground on part or all of the valve head due to the amount of metal that must be removed Knife edges lead to breakage burning or pre ignition due to heat localizing on this knife edge If the edge of the valve ...

Page 744: ...or the following conditions z Worn or no margin 1 or 4 z Pitted surfaces 2 z Burnt or eroded areas 3 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 228 2005 Mitchell Repair Information Company LLC ...

Page 745: ...e exhaust valve may be refaced if the margin is greater than 1 25 mm 0 05 in thick before grinding 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 229 2005 Mitchell Repair Information Company LLC ...

Page 746: ...If the valve face has been ground it may be necessary to shim the valve spring to obtain the proper spring installed height Refer to Cylinder Head Assemble 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 230 2005 Mitchell Repair Information Company LLC ...

Page 747: ...nents Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 231 2005 Mitchell Repair Information Company LLC ...

Page 748: ...sed it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the tool pilot in the guide 10 Inspect the valve seats z The valve seats should be concentric to within 0 05 mm 0 0021 in total indicator reading z If the valve seat has been ground it may be necessary to shim the valve spring to attain the proper spring installed height Refer to Cylinder Head Asse...

Page 749: ...nents Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 233 2005 Mitchell Repair Information Company LLC ...

Page 750: ...mponents again install the parts to their original location IMPORTANT z The valve stem oil seal alignment and position on the valve guide is critical z An improperly installed valve stem oil seal may lead to excessive oil consumption increased vehicle emissions or component damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn...

Page 751: ... valve stem keys 1 Use grease to hold the keys in place and remove the J 8062 2 Ensure the keys seat properly in the groove of the valve stem 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 20 AM Page 235 2005 Mitchell Repair Information Company LLC ...

Page 752: ...f the valve spring to the top of the valve spring Specification z If the installed height exceeds 46 25 mm 1 82 in install a valve spring shim of approximately 0 5 mm 0 02 in thick z Do not shim the valve spring to obtain less than the specified height 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM P...

Page 753: ...P N 12346004 Canadian P N 10953480 or equivalent to the threads of the coolant sensor 11 Install the coolant sensor into the left cylinder head Tighten Tighten the coolant sensor to 20 N m 15 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Pa...

Page 754: ...he coolant plug to the right cylinder head Tighten Tighten the coolant plug to 20 N m 15 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 238 2005 Mitchell Repair Information Company LLC ...

Page 755: ...expansion plugs 226 14 Install the expansion plugs into the cylinder head A properly installed plug should be installed 2 5 mm 0 1 in below the end face of the head OIL PUMP DISASSEMBLE 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 239 2005 Mitchell Repair Information Company LLC ...

Page 756: ...pump assembly are not serviced separately excluding the spring If the oil pump components are worn or damaged replace the oil pump as an assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 240 2005 Mitchell Repair Information Company LLC ...

Page 757: ...ENERAL MOTORS CORP 2 Remove the oil pump cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 241 2005 Mitchell Repair Information Company LLC ...

Page 758: ...e drive gear IMPORTANT Mark or identify the gears for assembly Refer to Separating Parts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 242 2005 Mitchell Repair Information Company LLC ...

Page 759: ...of GENERAL MOTORS CORP 4 Remove the driven gear 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 243 2005 Mitchell Repair Information Company LLC ...

Page 760: ...of GENERAL MOTORS CORP 5 Remove the pressure relief valve plug 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 244 2005 Mitchell Repair Information Company LLC ...

Page 761: ...of GENERAL MOTORS CORP 6 Remove the pressure relief valve spring 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 245 2005 Mitchell Repair Information Company LLC ...

Page 762: ...ING AND INSPECTION IMPORTANT z The internal parts of the oil pump assembly are not serviced separately excluding the spring If the oil pump components are worn or damaged replace the oil pump as an assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 246 2005 Mitchell Repair Information Compa...

Page 763: ...urface for scratches or gouging 5 Inspect the oil pump housing for damaged bolt hole threads z The oil pump pipe and screen are to be serviced as an assembly Do not attempt to repair the wire mesh portion of the pump and screen assembly CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L C...

Page 764: ...valve plug and plug bore for damaged threads 7 Inspect the oil pump internal oil passages for restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 248 2005 Mitchell Repair Information Company LLC ...

Page 765: ...r for chipping galling or wear Minor burrs or imperfections on the gears may be removed with a fine oil stone 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 249 2005 Mitchell Repair Information Company LLC ...

Page 766: ... MOTORS CORP 9 Inspect the drive gear splines for excessive wear 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 250 2005 Mitchell Repair Information Company LLC ...

Page 767: ...e relief valve and bore for scoring or wear The valve must move freely in the bore with no restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 251 2005 Mitchell Repair Information Company LLC ...

Page 768: ... for debris or restrictions 12 Inspect the oil pump screen for broken or loose wire mesh OIL PUMP ASSEMBLE 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 21 AM Page 252 2005 Mitchell Repair Information Company LLC ...

Page 769: ...th the orientation mark facing the pump cover IMPORTANT Prior to assembling the oil pump coat all wear or internal surfaces with clean engine oil 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 253 2005 Mitchell Repair Information Company LLC ...

Page 770: ...RAL MOTORS CORP 2 Install the drive gear into the pump housing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 254 2005 Mitchell Repair Information Company LLC ...

Page 771: ...NERAL MOTORS CORP 3 Install the oil pump cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 255 2005 Mitchell Repair Information Company LLC ...

Page 772: ...n Tighten the oil pump cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 256 2005 Mitchell Repair Information Company LLC ...

Page 773: ...sy of GENERAL MOTORS CORP 5 Install the regulator valve 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 257 2005 Mitchell Repair Information Company LLC ...

Page 774: ...y of GENERAL MOTORS CORP 6 Install a NEW regulator valve spring 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 258 2005 Mitchell Repair Information Company LLC ...

Page 775: ...e relief valve plug to 12 N m 106 lb in 8 Inspect the oil pump for smooth operation by rotating the drive gear ENGINE FRONT COVER CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 259 2005 Mitchell Repair Information Company LLC ...

Page 776: ...again Install a NEW crankshaft oil seal during assembly z Do not use the front cover to engine block gasket again Install a 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 260 2005 Mitchell Repair Information Company LLC ...

Page 777: ...ging 5 Inspect the cover to oil pan threaded bolt holes for damaged threads or debris 6 Inspect the crankshaft oil seal mounting bore for damage ENGINE REAR COVER CLEANING AND INSPECTION NEW gasket during assembly CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn Dec...

Page 778: ...eplacing Engine Gaskets IMPORTANT z Do not use the crankshaft oil seal again Install a NEW crankshaft oil seal during assembly z Do not use the rear cover to engine block gasket again Install a NEW gasket during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 262 2005 Mitchell Repair Inf...

Page 779: ...OVER CLEANING AND INSPECTION Fig 240 Knock Sensor Oil Seals Cover Courtesy of GENERAL MOTORS CORP CAUTION Refer to Safety Glasses Caution in Cautions and Notices IMPORTANT Do not use the valley cover knock sensor oil seals again Install NEW oil seals during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07...

Page 780: ...baffle 3 from the valley cover 555 3 Clean the valley cover components in solvent 4 Dry the components with compressed air CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 264 2005 Mitchell Repair Information Company LLC ...

Page 781: ...baffle 3 baffle cover 2 and bolts 1 to the valley cover 555 Tighten Tighten the baffle cover bolts to 5 N m 44 lb in VALVE ROCKER ARM COVER CLEANING AND INSPECTION NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 265 2005 Mitchell Repair Inform...

Page 782: ...W gasket during assembly z Remove the ignition coils from the bracket before cleaning the bracket in solvent Do not submerge the ignition coils in solvent 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 266 2005 Mitchell Repair Information Company LLC ...

Page 783: ... not remove the oil fill tube from the cover unless service is required z If the oil fill tube has been removed from the rocker arm cover install a NEW tube during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 267 2005 Mitchell Repair Information Company LLC ...

Page 784: ... Fill Tube Courtesy of GENERAL MOTORS CORP 3 Inspect the tube for a loose fit or damage 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 22 AM Page 268 2005 Mitchell Repair Information Company LLC ...

Page 785: ...s 6 Remove the cover mounting bolts with grommets Cover mounting bolts and grommets that are not damaged may be used again during assembly 7 Clean the covers and coil brackets in solvent 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 269 2005 Mitchell Repair Information Company LLC ...

Page 786: ...Inspect the gasket grooves for damage 11 Inspect the coil bracket threaded bolt holes for damaged threads or debris CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 270 2005 Mitchell Repair Information Company LLC ...

Page 787: ...le threads or other damage 13 Inspect the ignition coils for exterior damage and bent or broken connector pins OIL PAN CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 271 2005 Mitchell Repair Information Company LLC ...

Page 788: ...n Install NEW gaskets during assembly z When installing a NEW oil pan gasket it is not necessary to install the rivets that retain the NEW gasket to the pan 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 272 2005 Mitchell Repair Information Company LLC ...

Page 789: ...AL MOTORS CORP 2 Remove the oil temperature sensor oil pan cover gasket and bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 273 2005 Mitchell Repair Information Company LLC ...

Page 790: ... MOTORS CORP 3 Remove the oil pan drain plug and O ring seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 274 2005 Mitchell Repair Information Company LLC ...

Page 791: ...he oil pan gasket retaining rivets 1 if required 5 Remove the oil pan gasket 426 6 Discard the gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 275 2005 Mitchell Repair Information Company LLC ...

Page 792: ...MOTORS CORP 7 Remove the oil pan lower bolts 1 15 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 276 2005 Mitchell Repair Information Company LLC ...

Page 793: ...ORP 8 Separate the oil pan 400 upper gasket 453 oil pan 454 lower and bolts 455 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 277 2005 Mitchell Repair Information Company LLC ...

Page 794: ...pan halves in solvent Be sure to thoroughly clean all of the oil passages and recesses of dirt and debris 11 Clean the oil pan gasket surfaces Refer to Replacing Engine Gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 278 2005 Mitchell Repair Information Company LLC ...

Page 795: ...S CORP 14 Inspect the oil pan oil level sensor seal surface damage The O ring seal of the sensor may be used again if it is not cut or damaged CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 279 2005 Mitchell Repair Information Compa...

Page 796: ...hreaded drain hole for damaged threads The drain plug O ring seal may be used again if it is not cut or damaged 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 280 2005 Mitchell Repair Information Company LLC ...

Page 797: ...oil filter and pan cover sealing surface for scratches or gouging 17 Inspect the oil passages for restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 281 2005 Mitchell Repair Information Company LLC ...

Page 798: ...36 for proper operation Lightly push the bypass valve into the bore The valve spring should seat the valve to the proper position INTAKE MANIFOLD CLEANING AND INSPECTION Cleaning Procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 282 2005 Mitchell Repair Information Company LLC ...

Page 799: ... be installed upon completion of the cleaning and inspection procedures 2 Inspect the sealing grommet on the MAP sensor The grommet should not be torn or damaged 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 283 2005 Mitchell Repair Information Company LLC ...

Page 800: ...NERAL MOTORS CORP 3 Remove the throttle body 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 23 AM Page 284 2005 Mitchell Repair Information Company LLC ...

Page 801: ...P 4 Remove the throttle body gasket 509 5 Discard the gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 285 2005 Mitchell Repair Information Company LLC ...

Page 802: ...TORS CORP 6 Remove the fuel rail with injectors 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 286 2005 Mitchell Repair Information Company LLC ...

Page 803: ...uum passages at the rear of the intake 9 Dry the intake manifold with compressed air 10 Upon installation of the intake manifold install NEW manifold to cylinder head gaskets Inspection Procedure CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 ...

Page 804: ...ect the throttle body bolt inserts for looseness or damaged threads 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 288 2005 Mitchell Repair Information Company LLC ...

Page 805: ...ooseness or damaged threads 3 Inspect the intake manifold vacuum passages for debris or restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 289 2005 Mitchell Repair Information Company LLC ...

Page 806: ...the intake manifold Repair or replace the components as necessary IMPORTANT z The manifold absolute pressure MAP sensor housing is retained to the intake manifold by push in place snap lock design z The MAP sensor housing is sealed at the intake manifold by an O ring seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December...

Page 807: ...t all the gasket sealing surfaces and grooves for cracking or damage Fig 267 Fuel Rail Bolts Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 291 2005 Mitchell Repair Information Company LLC ...

Page 808: ...ween the intake manifold and the straight edge A intake manifold with warpage in excess of 0 5 mm 0 02 in must be replaced 9 Upon completion of inspection install the MAP sensor to the manifold EXHAUST MANIFOLD CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 292 2005 Mitch...

Page 809: ...excessive scratches or gouging 8 Inspect for a loose or damaged heat shield IMPORTANT z Do not use the exhaust manifold to cylinder head gaskets again Upon installation of the exhaust manifold install a NEW gasket An improperly installed gasket or leaking exhaust system may effect On Board Diagnostics OBD II system performance z Remove the oxygen sensor prior to cleaning the manifold do not submer...

Page 810: ...f GENERAL MOTORS CORP 9 Inspect the take down studs for damaged threads 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 294 2005 Mitchell Repair Information Company LLC ...

Page 811: ...deck with warpage in excess of 0 25 mm 0 01 in may cause an exhaust leak and may effect OBD II system performance Exhaust manifolds not within specifications must be replaced COOLANT AIR BLEED PIPE CLEANING AND INSPECTION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 295 2005 Mitchell Repair In...

Page 812: ... covers IMPORTANT Do not use the engine coolant air bleed pipe and cover gaskets again Upon installation of the pipe and covers install NEW gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 296 2005 Mitchell Repair Information Company LLC ...

Page 813: ...ect the gasket and hose sealing surfaces for damage 7 Inspect the hose 311 for restrictions cracking or wear The hose may be used again if it is not damaged CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 2 Of 3 5 7L Corvette Helpmelearn December 24 07 11 03 24 AM Page 297 2005 Mitchell Repair Inf...

Page 814: ...ump for the following z Gasket sealing surfaces for excessive scratches or gouging z Hose sealing surfaces for scratches or gouging z Restrictions within the internal coolant passages 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette He...

Page 815: ...If leakage occurs such as dripping with the engine running and the cooling system pressurized replace the water pump THREAD REPAIR Tools Required z J 42385 100 Head Main Bolt Thread Repair Kit z J 42385 200 General Threads Kit z J 42385 300 Fixtures Hardware Kit General Thread Repair 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmele...

Page 816: ...nds the bottom external threads of the insert into the base material 2 This action mechanically locks the insert in place Also when installed to the proper depth the flange of the insert will be seated against the counterbore of the repaired hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 34 AM Page 3 ...

Page 817: ...52864 Canadian P N 992881 WD 40 R or equivalent is recommended when performing the drilling counterboring and tapping procedures z Driver oil MUST be used on the installer driver tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 34 AM Page 4 2005 Mitchell Repair Information Company LLC ...

Page 818: ...ts require a minimum drill depth of 23 5 mm 0 93 in 2 Using compressed air clean out any chips z The tool kits are designed for use with either a suitable tap wrench or drill motor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 34 AM Page 5 2005 Mitchell Repair Information Company LLC ...

Page 819: ...le to the full depth permitted by the tool 1 4 Using compressed air clean out any chips 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 34 AM Page 6 2005 Mitchell Repair Information Company LLC ...

Page 820: ...nimum tap depth of 23 5 mm 0 93 in 6 Using compressed air clean out any chips 7 Spray cleaner GM P N 12346139 Canadian P N 10953463 GM P N 12377981 Canadian P N 10953463 or equivalent into the hole 8 Using compressed air clean any cutting oil and chips out of the hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 ...

Page 821: ...ol 2 with the driver oil 1 IMPORTANT Do not allow oil or other foreign material to contact the outside diameter OD of the insert 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 34 AM Page 8 2005 Mitchell Repair Information Company LLC ...

Page 822: ...MOTORS CORP 10 Install the insert 2 onto the driver tool 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 9 2005 Mitchell Repair Information Company LLC ...

Page 823: ...ORP 11 Apply threadlock LOCTITE tm 277 J 42385 109 1 or equivalent to the insert OD threads 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 10 2005 Mitchell Repair Information Company LLC ...

Page 824: ...ll the insert until the flange of the insert contacts the counterbored surface Continue to rotate the installer tool 1 through the insert 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 11 2005 Mitchell Repair Information Company LLC ...

Page 825: ...e Material Courtesy of GENERAL MOTORS CORP 13 Inspect the insert for proper installation into the hole A properly installed insert 1 will be either flush or slightly below flush with the surface of the base material 2 Cylinder Head Bolt Hole Thread Repair 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 A...

Page 826: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 13 2005 Mitchell Repair Information Company LLC ...

Page 827: ...the depth of the cylinder head bolt holes 1 10 to determine the proper drill and tap depths Refer to Thread Repair Specifications IMPORTANT First design engine blocks have different drill and tap depths using both medium length 100 mm 3 94 in and long 155 mm 6 1 in M11 cylinder head bolts Second design engine blocks use only the medium length 100 mm 3 94 in bolt with a common drill and tap depth 2...

Page 828: ...81 WD 40 R or equivalent is recommended when performing the drilling and tapping procedures z Driver oil MUST be used on the installer driver tool z The tool kits are designed for use with either a suitable tap wrench or drill motor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 15 2005 Mitchell...

Page 829: ...sy of GENERAL MOTORS CORP 4 Position the alignment pin 1 through the bushing and into the hole 5 With the alignment pin in the desired hole tighten the fixture retaining bolts 2 6 Remove the alignment pin from the hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 16 2005 Mitchell Repair Inform...

Page 830: ...TORS CORP 7 Install the sleeve 2 onto the drill 1 if required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 17 2005 Mitchell Repair Information Company LLC ...

Page 831: ...ve contacts the bushing 9 Using compressed air clean out any chips IMPORTANT During the reaming process it is necessary to repeatedly remove the drill and clean the chips from the hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 18 2005 Mitchell Repair Information Company LLC ...

Page 832: ...NERAL MOTORS CORP 10 Using a tap wrench tap the threads of the drilled hole 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 19 2005 Mitchell Repair Information Company LLC ...

Page 833: ...bushing 3 For the deeper cylinder head bolt holes rotate the tap until the upper mark on the tap 4 aligns with the top of the drill bushing For the shallower cylinder head bolt holes rotate the tap until the lower mark on the tap 1 aligns with 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 20 20...

Page 834: ...ing compressed air clean any cutting oil and chips out of the hole Fig 19 Lubricating Installer Tool Using Driver Oil Courtesy of GENERAL MOTORS CORP IMPORTANT Do not allow oil or other foreign material to contact the outside diameter OD of the insert 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Pa...

Page 835: ...ng Type Insert Courtesy of GENERAL MOTORS CORP 17 Install the insert 2 onto the driver tool 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 22 2005 Mitchell Repair Information Company LLC ...

Page 836: ...CORP 18 Apply threadlock LOCTITE tm 277 J 42385 109 1 or equivalent to the insert OD threads 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 23 2005 Mitchell Repair Information Company LLC ...

Page 837: ...installer tool will tighten up before screwing completely through the insert This is acceptable You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads Main Cap Bolt Hole Thread Repair 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 24 200...

Page 838: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 25 2005 Mitchell Repair Information Company LLC ...

Page 839: ...llowing items z The drill 1 z The tap 2 z The installer 3 z The fixture plate 4 z The long bolts 5 z The short bolts 6 z The alignment pin 7 z The bushing 8 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 26 2005 Mitchell Repair Information Company LLC ...

Page 840: ...he fixture plate and bushing over the hole that is to be repaired 3 Position the alignment pin in the desired hole and tighten the fixture retaining bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 27 2005 Mitchell Repair Information Company LLC ...

Page 841: ...terbores Use sleeve J 42385 316 with the drill Drill until the stop collar of the drill bit or the sleeve contacts the bushing 5 Using compressed air clean out any chips 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 28 2005 Mitchell Repair Information Company LLC ...

Page 842: ...te the tap into the hole until the mark on the tap aligns with the top of the bushing For the deeper main cap holes 1 10 rotate the tap until the upper mark 4 on the tap aligns with the top of the bushing 3 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 29 2005 Mitchell Repair Information Compan...

Page 843: ...sing compressed air clean any cutting oil and chips out of the hole Fig 27 Lubricating Installer Tool Using Driver Oil Courtesy of GENERAL MOTORS CORP IMPORTANT Do not allow oil or other foreign material to contact the outside diameter OD of the insert 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM P...

Page 844: ...ng Type Insert Courtesy of GENERAL MOTORS CORP 11 Install the insert 2 onto the driver tool 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 31 2005 Mitchell Repair Information Company LLC ...

Page 845: ...CORP 12 Apply threadlock LOCTITE tm 277 J 42385 109 1 or equivalent to the insert OD threads 2 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 32 2005 Mitchell Repair Information Company LLC ...

Page 846: ...tool until the mark on the tool 3 aligns with the top of the bushing 2 IMPORTANT The fixture plate and bushing remains installed onto the engine block during the insert installation procedure 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 33 2005 Mitchell Repair Information Company LLC ...

Page 847: ... Components that are not within the manufacturers specifications must be repaired or replaced z When the components are installed into an engine return the components to their original location position and direction Refer to Separating Parts z During assembly lubricate all the moving parts with clean engine oil This will provide initial lubrication when the engine is first started ENGINE PRELUBIN...

Page 848: ... and continuous flow of clean engine oil is required in order to properly prime the engine Be sure to use an approved engine oil as specified in the owners manual NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 35 2005 Mitchell Repair Informat...

Page 849: ...ter P N 509375 Fig 32 Flexible Hose Adapter Gallery Plugs Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 35 AM Page 36 2005 Mitchell Repair Information Company LLC ...

Page 850: ...move the flexible hose and adapter from the engine 8 Install the gallery plug to the engine Tighten Tighten the oil gallery plug to 60 N m 44 lb ft 9 Top off the engine oil to the proper level ENGINE BLOCK PLUG INSTALLATION Tools Required J 41712 Oil Pressure Switch Socket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn Decembe...

Page 851: ...oil gallery and coolant and coolant heater sealing washers may be used again if not bent scored or otherwise damaged z Apply the proper amount and type of sealant to the sealing washer as recommended in the service procedure NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn De...

Page 852: ... N 12346004 Canadian P N 10953480 or equivalent to the engine block left side coolant drain hole plug sealing washer if applicable 4 Install the engine block left side coolant drain hole plug if applicable Tighten Tighten the block left front coolant drain plug to 60 N m 44 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn ...

Page 853: ... block right side coolant drain hole plug sealing washer 6 Install the engine block right side coolant drain hole plug Tighten Tighten the block right side coolant drain hole plug to 60 N m 44 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 40 2005 Mitchell Repair Information Company LLC ...

Page 854: ... the engine block left front oil gallery plug sealing washer 8 Install the engine block left front oil gallery plug Tighten Tighten the block left front oil gallery plug to 60 N m 44 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 41 2005 Mitchell Repair Information Company LLC ...

Page 855: ...the engine block left rear oil gallery plug sealing washer 10 Install the engine block left rear oil gallery plug Tighten Tighten the block left rear oil gallery plug to 60 N m 44 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 42 2005 Mitchell Repair Information Company LLC ...

Page 856: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 43 2005 Mitchell Repair Information Company LLC ...

Page 857: ... gallery plug into the oil gallery bore A properly installed block plug will protrude 0 8 1 4 mm 0 0315 0 055 in beyond the rear face of the block Fig 39 View Of Engine Block Front Oil Gallery Plug Courtesy of GENERAL MOTORS CORP IMPORTANT The engine block front oil gallery plug should not be removed unless service is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repai...

Page 858: ...0 011 in below flush Do not install the plug more than the recommended depth Fig 40 Install J 41712 Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP 16 Apply sealant GM P N 12346004 Canadian P N 10953480 or equivalent to the threads of the oil pressure sensor 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 ...

Page 859: ... oil pressure sensor to 20 N m 15 lb ft CRANKSHAFT AND BEARINGS INSTALLATION Tools Required J 45059 Angle Meter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 46 2005 Mitchell Repair Information Company LLC ...

Page 860: ...z Crankshaft bearing caps must be installed to the proper location and direction z When installing the crankshaft bearings align the locating tabs on the bearings with the locating notches in the engine block journal bore and the bearing cap z Always install crankshaft bearings with their machined partner Do not file bearings or mix bearing halves z To prevent engine block oil leakage install NEW ...

Page 861: ...oper crankshaft end play use extreme care during crankshaft installation Avoid scoring or damaging the thrust bearing 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 48 2005 Mitchell Repair Information Company LLC ...

Page 862: ...ts and studs 7 Tap the bearing caps into place with a plastic face hammer IMPORTANT The bearing caps must be installed in the proper location and direction 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 49 2005 Mitchell Repair Information Company LLC ...

Page 863: ...AL MOTORS CORP 8 Install the NEW M8 bearing cap side bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 50 2005 Mitchell Repair Information Company LLC ...

Page 864: ... J 45059 2 Tighten the M10 studs 11 20 a first pass in sequence to 20 N m 15 lb ft 3 Tighten the M10 studs 11 20 a final pass in sequence 51 degrees using the J 45059 4 Tighten the M8 bolts to 25 N m 18 lb ft NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT To properly align the crankshaft thrust bearings the final thrust of the crankshaft MUST be in the forward direction 2004 Chevr...

Page 865: ...l is not cut or damaged it may be used 2 Coat the O ring seal with clean engine oil 3 Install the sensor Align the notch in the sensor retaining bracket with the bolt hole in the block 4 Install the sensor bolt Tighten Tighten the CKP sensor bolt to 25 N m 18 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 ...

Page 866: ...0078 in 3 If the bearing clearance is not within specifications inspect the thrust surfaces for nicks gouges or raised metal Minor imperfections may be removed with a fine stone PISTON CONNECTING ROD AND BEARING INSTALLATION Tools Required z J 8037 Piston Ring Compressor z J 8087 Cylinder Bore Gage z J 41556 Connecting Rod Guide z J 45059 Angle Meter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE...

Page 867: ...piston OD IMPORTANT Measurements of all components should be taken with the components at normal room temperature For proper piston fit the engine block cylinder bores must not have excessive wear or taper A used piston pin and connecting rod assembly may be installed if after inspection is within specifications 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions ...

Page 868: ...r to the recorded piston OD 4 Insert the J 8087 into the micrometer and zero the gage dial 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 55 2005 Mitchell Repair Information Company LLC ...

Page 869: ...int 64 mm 2 5 in from the top of the cylinder 6 Record the cylinder bore ID 7 Subtract the piston OD from the cylinder bore ID to determine the piston to bore clearance Refer to 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 56 2005 Mitchell Repair Information Company LLC ...

Page 870: ...linder bore may require honing for an oversize piston Piston Pin and Connecting Rod Installation Fig 51 View Of Piston Connecting Rod Components Courtesy of GENERAL MOTORS CORP 1 Lightly lubricate the following components with clean engine oil z Piston 1 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM...

Page 871: ...pression ring end gaps 180 degrees opposite each other Fig 52 View Of J 41556 Connecting Rod Courtesy of GENERAL MOTORS CORP 4 Install the J 41556 to the connecting rod 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 58 2005 Mitchell Repair Information Company LLC ...

Page 872: ...ompressor firmly against the engine block Using a wooden hammer handle lightly tap the top of the piston until all the piston rings have entered the cylinder bore IMPORTANT The piston alignment mark MUST face the front of the engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 59 2005 Mi...

Page 873: ... connecting rod onto the crankshaft journal 8 Remove the J 41556 from the connecting rod 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 60 2005 Mitchell Repair Information Company LLC ...

Page 874: ...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 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 36 AM Page 61 2005 Mitchell Repair Information Company LLC ...

Page 875: ...pecified 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 IMPORTANT The connecting rod and cap must be assembled with the mating surfaces properly aligned 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Ins...

Page 876: ...y of GENERAL MOTORS CORP 1 Lubricate the camshaft journals and the bearings with clean engine oil 2 Install 3 M8 1 25 x 100 mm M8 1 25 x 4 0 in bolts into the camshaft front bolt holes IMPORTANT If camshaft replacement is required the valve lifters must also be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 2...

Page 877: ...iameter so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT z Install the retainer plate with the sealing gasket facing the engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page...

Page 878: ... again 7 Lubricate the O ring seal with clean engine oil Fig 59 View Of Camshaft Sensor Bolt Courtesy of GENERAL MOTORS CORP z The gasket surface on the engine block should be clean and free of dirt or debris 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 65 2005 Mitchell Repair Information Comp...

Page 879: ...kshaft Balancer and Sprocket Installer Fig 60 View Of Crankshaft Sprocket Key Courtesy of GENERAL MOTORS CORP 1 Install the key into the crankshaft keyway if previously removed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 66 2005 Mitchell Repair Information Company LLC ...

Page 880: ...the key 122 into the keyway until both ends of the key bottom onto the crankshaft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 67 2005 Mitchell Repair Information Company LLC ...

Page 881: ...cket onto the front of the crankshaft Align the crankshaft key with the crankshaft sprocket keyway 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 68 2005 Mitchell Repair Information Company LLC ...

Page 882: ...rocket onto the crankshaft until fully seated against the crankshaft flange 5 Rotate the crankshaft sprocket until the alignment mark is in the 12 o clock position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 69 2005 Mitchell Repair Information Company LLC ...

Page 883: ...s 231 Tighten Tighten the bolts to 35 N m 26 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 70 2005 Mitchell Repair Information Company LLC ...

Page 884: ...rly installed the heads of the bolts 231 should install to flush or below the face of the dampener 232 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 71 2005 Mitchell Repair Information Company LLC ...

Page 885: ...t teeth and timing chain must mesh z The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly z Locate the camshaft sprocket alignment mark in the 6 o clock position 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 72 2005 Mitchell Repair Information Company LLC ...

Page 886: ...f GENERAL MOTORS CORP 9 If necessary rotate the camshaft or crankshaft sprockets in order to align the timing marks 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 73 2005 Mitchell Repair Information Company LLC ...

Page 887: ...he oil pump drive gear and install the oil pump 2 Install the oil pump onto the crankshaft sprocket until the pump housing contacts the face of the engine block IMPORTANT Inspect the oil pump and engine block oil gallery passages These surfaces must be clear and free of debris or restrictions 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette...

Page 888: ...ector 5 Lubricate a NEW oil pump screen O ring seal with clean engine oil 6 Install the NEW O ring seal onto the oil pump screen NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 75 2005 Mitchell Repair Information Company LLC ...

Page 889: ... completely into the oil pump prior to tightening the bolt Do not allow the bolt to pull the tube into the pump z Align the oil pump screen mounting brackets with the correct crankshaft bearing cap studs 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 76 2005 Mitchell Repair Information Company L...

Page 890: ...TION Tools Required z J 41480 Front and Rear Cover Alignment Oil Pan Surface z J 41476 Front and Rear Cover Alignment Tool Crankshaft Oil Seal Area 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 77 2005 Mitchell Repair Information Company LLC ...

Page 891: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 78 2005 Mitchell Repair Information Company LLC ...

Page 892: ...ar oil seal z The crankshaft rear oil seal will be installed after the rear cover has been installed and aligned Install the rear cover without the crankshaft oil seal The crankshaft rear oil seal MUST be centered in relation to the crankshaft The oil pan sealing surface at the rear cover and engine block MUST be aligned within specifications An improperly aligned rear cover may cause premature re...

Page 893: ...ear cover gasket rear cover and bolts 3 Tighten the bolts finger tight Do not overtighten 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 80 2005 Mitchell Repair Information Company LLC ...

Page 894: ...otice in Cautions and Notices IMPORTANT Start the J 41480 tool to rear cover bolts Do not tighten the bolts at this time 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 81 2005 Mitchell Repair Information Company LLC ...

Page 895: ...are parallel to the oil pan surface IMPORTANT To properly align the rear cover the J 41476 must be installed onto the rear of the crankshaft with the tool mounting bolts parallel to the oil pan surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 82 2005 Mitchell Repair Information Company LLC...

Page 896: ...2 Tighten the J 41480 tool to rear cover bolts evenly to 12 N m 106 lb in 3 Tighten the rear cover bolts to 25 N m 18 lb ft IMPORTANT The tapered legs of the alignment tool must enter the rear cover oil seal bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 83 2005 Mitchell Repair Information ...

Page 897: ...lock Oil Pan Surface For Flatness Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 84 2005 Mitchell Repair Information Company LLC ...

Page 898: ... 5 mm 0 02 in below flush 9 If the rear cover to engine block oil pan surface alignment is not within specifications repeat the cover alignment procedure 10 If the correct rear cover to engine block alignment at the oil pan surface cannot be obtained replace the rear cover CRANKSHAFT REAR OIL SEAL INSTALLATION Tools Required J 41479 Crankshaft Rear Oil Seal Installer 2004 Chevrolet Corvette 2004 E...

Page 899: ...l surface 2 Lubricate the rear cover oil seal bore with clean engine oil IMPORTANT z Do not lubricate the oil seal inside diameter ID or the crankshaft surface z Do not use the crankshaft rear oil seal again 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 37 AM Page 86 2005 Mitchell Repair Information Compa...

Page 900: ... to the rear cover bore 6 Thread the J 41479 threaded rod into the tapered cone until the tool 1 contacts the oil seal 7 Align the oil seal onto the tool 1 8 Rotate the handle of the tool 1 clockwise until the seal enters the rear cover and bottoms into the cover bore 9 Remove the tool ENGINE FRONT COVER INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instruct...

Page 901: ...e engine front cover gasket again z Do not apply any type sealant to the front cover gasket unless specified z The special tools in this procedure are used to properly align the engine front cover at the oil pan surface and to center the crankshaft front oil seal 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11...

Page 902: ...centered in relation to the crankshaft The oil pan sealing surface at the front cover and engine block MUST be aligned within specifications An improperly aligned front cover may cause premature front oil seal wear and or engine assembly oil leaks 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 8...

Page 903: ...otice in Cautions and Notices IMPORTANT Start the tool to front cover bolts Do not tighten the bolts at this time 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 90 2005 Mitchell Repair Information Company LLC ...

Page 904: ...the J 41476 5 Install the crankshaft balancer bolt IMPORTANT Align the tapered legs of the tool with the machined alignment surfaces on the front cover 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 91 2005 Mitchell Repair Information Company LLC ...

Page 905: ...hten the J 41480 3 Tighten the engine front cover bolts to 25 N m 18 lb ft 6 Remove the tools 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 92 2005 Mitchell Repair Information Company LLC ...

Page 906: ... GENERAL MOTORS CORP 7 Measure the oil pan surface flatness front cover to engine block 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 93 2005 Mitchell Repair Information Company LLC ...

Page 907: ...ow flush 8 If the front cover to engine block oil pan surface alignment is not within specifications repeat the cover alignment procedure 9 If the correct front cover to engine block alignment cannot be obtained replace the front cover CRANKSHAFT FRONT OIL SEAL INSTALLATION Tools Required J 41478 Crankshaft Front Oil Seal Installer 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical ...

Page 908: ...not lubricate the oil seal sealing surface z Do not use the crankshaft front oil seal again 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 95 2005 Mitchell Repair Information Company LLC ...

Page 909: ...th nut washer guide and oil seal into the end of the crankshaft 5 Use the J 41478 in order to install the oil seal into the cover bore 1 Use a wrench and hold the hex on the installer bolt 2 Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette He...

Page 910: ...t surfaces should be free of oil or other foreign material during assembly z The alignment of the structural oil pan is critical The rear bolt hole locations of the oil pan provide mounting points for the transmission housing To ensure the rigidity of the powertrain and correct 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn De...

Page 911: ...lock and the rear of the oil pan are flush or even The rear of the oil pan must NEVER protrude beyond the engine block and transmission housing plane z DO NOT use the oil pan gaskets again z It is not necessary to rivet the NEW gasket to the oil pan z It is not necessary to remove the oil level sensor prior to oil pan installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical R...

Page 912: ... the engine block Apply the sealant directly onto the tabs of the rear cover gasket that protrude into the oil pan surface 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 99 2005 Mitchell Repair Information Company LLC ...

Page 913: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 100 2005 Mitchell Repair Information Company LLC ...

Page 914: ...k 5 Tighten bolts finger tight Do not overtighten 6 Place a straight edge across the rear of the engine block and the rear of the oil pan at the transmission housing mounting surfaces IMPORTANT Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L C...

Page 915: ...g surfaces 2 Insert a feeler gage between the straight edge and the oil pan transmission housing mounting surface and check to make sure that there is no more than a 0 25 mm 0 01 in gap between the pan and straight edge 3 If the oil pan alignment is not within specifications remove the oil pan and repeat the above procedure NOTE Refer to Fastener Notice in Cautions and Notices IMPORTANT The rear o...

Page 916: ...RS CORP 9 Install the oil pan lower 454 and gasket 453 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 103 2005 Mitchell Repair Information Company LLC ...

Page 917: ...n the oil pan lower bolts to 12 N m 106 lb in Tighten the bolts in a crossing pattern alternating from side to side 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 104 2005 Mitchell Repair Information Company LLC ...

Page 918: ...oil level sensor Tighten Tighten the oil level sensor to 13 N m 115 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 105 2005 Mitchell Repair Information Company LLC ...

Page 919: ...left closeout cover and bolt Tighten Tighten the closeout cover bolt to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 106 2005 Mitchell Repair Information Company LLC ...

Page 920: ...and bolt Tighten Tighten the closeout cover bolt to 12 N m 106 lb in OIL FILTER ADAPTER PAN COVER INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 107 2005 Mitchell Repair Information Company LLC ...

Page 921: ... cover and the bolts Tighten Tighten the oil pan cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 108 2005 Mitchell Repair Information Company LLC ...

Page 922: ...TORS CORP 3 Install a new oil filter bypass valve 436 into the oil pan if required 4 Install the oil filter fitting 438 Tighten Tighten the oil filter to 55 N m 40 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 109 2005 Mitchell Repair Information Company LLC ...

Page 923: ...he oil filter Tighten Tighten the oil filter to 30 N m 22 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 110 2005 Mitchell Repair Information Company LLC ...

Page 924: ...plug Tighten Tighten the oil pan drain plug to 25 N m 18 lb ft VALVE LIFTER INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 38 AM Page 111 2005 Mitchell Repair Information Company LLC ...

Page 925: ... with the flat area in the lifter guide bore Push the lifter completely into the guide bore IMPORTANT z When using the valve lifters again install the lifters to their original locations z If camshaft replacement is required the valve lifters must also be replaced 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 1...

Page 926: ...fter guide bolt 211 Tighten Tighten the valve lifter guide bolt to 12 N m 106 lb in CYLINDER HEAD INSTALLATION LEFT NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 113 2005 Mitchell Repair Information Company LLC ...

Page 927: ...155 mm Bolts Courtesy of GENERAL MOTORS CORP CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 114 2005 Mitchell Repair Information Company LLC ...

Page 928: ...perly tightened fasteners or damage to components IMPORTANT z Do not use the cylinder head bolts again Install NEW cylinder head bolts during assembly z Do not use any type sealant on the cylinder head gasket unless specified z The cylinder head gaskets must be installed in the proper direction and position IMPORTANT First design engine blocks have different drill and tap depths using both medium ...

Page 929: ...NERAL MOTORS CORP 5 Check the cylinder head locating pins for proper installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 116 2005 Mitchell Repair Information Company LLC ...

Page 930: ...CORP 6 Install the NEW left cylinder head gasket onto the locating pins 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 117 2005 Mitchell Repair Information Company LLC ...

Page 931: ...the left cylinder head gasket is located left of center or closer to the front of the engine and the words This Side Up and the engine displacement is visible 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 118 2005 Mitchell Repair Information Company LLC ...

Page 932: ...cylinder head onto the locating pins and the gasket 9 Install the NEW cylinder head bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 119 2005 Mitchell Repair Information Company LLC ...

Page 933: ...k outward tightening all of the bolts 11 Tighten the second design engine block cylinder head bolts Tighten 1 Tighten the second design M11 cylinder head bolts 1 10 a first pass in sequence to 30 N m 22 lb ft 2 Tighten the second design M11 cylinder head bolts 1 10 a second pass in sequence to 90 degrees using the J 45059 3 Tighten the second design M11 cylinder head bolts 1 10 a final pass in seq...

Page 934: ...6 View Of 100 mm 155 mm Bolts Courtesy of GENERAL MOTORS CORP CAUTION Refer to Safety Glasses Caution in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 121 2005 Mitchell Repair Information Company LLC ...

Page 935: ...perly tightened fasteners or damage to components IMPORTANT z Do not use the cylinder head bolts again Install NEW cylinder head bolts during assembly z Do not use any type sealant on the cylinder head gasket unless specified z The cylinder head gaskets must be installed in the proper direction and position IMPORTANT First design engine blocks have different drill and tap depths using both medium ...

Page 936: ...NERAL MOTORS CORP 5 Check the cylinder head locating pins for proper installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 123 2005 Mitchell Repair Information Company LLC ...

Page 937: ...CORP 6 Install the NEW right cylinder head gasket onto the locating pins 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 124 2005 Mitchell Repair Information Company LLC ...

Page 938: ...he right cylinder head gasket is located right of center or closer to the front of the engine and the words This Side Up and the engine displacement is visible 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 125 2005 Mitchell Repair Information Company LLC ...

Page 939: ...inder head onto the locating pins and the gasket 9 Install the NEW cylinder head bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 126 2005 Mitchell Repair Information Company LLC ...

Page 940: ...work outward tightening all of the bolts 11 Tighten the second design engine block cylinder head bolts Tighten 1 Tighten the second design M11 cylinder head bolts 1 10 a first pass in sequence to 30 N m 22 lb ft 2 Tighten the second design M11 cylinder head bolts 1 10 a second pass in sequence to 90 degrees using the J 45059 3 Tighten the second design M11 cylinder head bolts 1 10 a final pass in ...

Page 941: ...bricate the flange or washer surface of the bolt that will contact the valve rocker arm IMPORTANT z When using the valve train components again always install the components to the original location and position z Valve lash is net build no valve adjustment is required 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24...

Page 942: ...P 4 Install the pushrods IMPORTANT Ensure that the pushrods seat properly to the valve lifter sockets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 129 2005 Mitchell Repair Information Company LLC ...

Page 943: ...sure that the pushrods seat properly to the ends of the rocker arms z DO NOT tighten the rocker arm bolts at this time 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 130 2005 Mitchell Repair Information Company LLC ...

Page 944: ...er of compression stroke In this position cylinder number one rocker arms will be off lobe lift and the crankshaft sprocket key 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 131 2005 Mitchell Repair Information Company LLC ...

Page 945: ... 8 to 30 N m 22 lb ft z Tighten intake valve rocker arm bolts 1 3 4 and 5 to 30 N m 22 lb ft 8 Rotate the crankshaft 360 degrees 9 Tighten the following valve rocker arm bolts Tighten z Tighten exhaust valve rocker arm bolts 3 4 5 and 6 to 30 N m 22 lb ft z Tighten intake valve rocker arm bolts 2 6 7 and 8 to 30 N m 22 lb ft VALVE ROCKER ARM COVER INSTALLATION LEFT NOTE Refer to Fastener Notice in...

Page 946: ...should be free of oil or other foreign material during assembly z DO NOT use the valve rocker arm cover gasket again z The valve rocker arm cover bolt grommets may be used again 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 133 2005 Mitchell Repair Information Company LLC ...

Page 947: ... cover bolts with grommets Tighten Tighten the valve rocker arm cover bolts to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 134 2005 Mitchell Repair Information Company LLC ...

Page 948: ...rness and bolts onto the mounting bracket Tighten Tighten the ignition coil bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 39 AM Page 135 2005 Mitchell Repair Information Company LLC ...

Page 949: ...f the bracket bolts 6 Install the ignition coils and bracket assembly and bolts onto the rocker cover Tighten Tighten the ignition coil bracket bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 136 2005 Mitchell Repair Information Company LLC ...

Page 950: ...ATION RIGHT Fig 120 View Of Oil Fill Tube Courtesy of GENERAL MOTORS CORP 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 137 2005 Mitchell Repair Information Company LLC ...

Page 951: ...l gasket surfaces should be free of oil or other foreign material during assembly z DO NOT use the valve rocker arm cover gasket again z The valve rocker arm cover bolt grommets may be used again z If the oil fill tube has been removed from the valve rocker arm cover install a NEW oil fill tube during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 ...

Page 952: ...Arm Cover Bolts Right Courtesy of GENERAL MOTORS CORP 5 Install the valve rocker arm cover onto the cylinder head NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 139 2005 Mitchell Repair Information Company LLC ...

Page 953: ...NERAL MOTORS CORP 7 Install the ignition coils wire harness and bolts onto the mounting bracket Tighten Tighten the ignition coil bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 140 2005 Mitchell Repair Information Company LLC ...

Page 954: ...of the bracket bolts 9 Install the ignition coils and bracket assembly and bolts to the rocker cover Tighten Tighten the ignition coil bracket bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 141 2005 Mitchell Repair Information Company LLC ...

Page 955: ...nsor oil seals 520 into the valley cover 555 Lubricate the seal surfaces with clean engine oil IMPORTANT All gasket surfaces should be free of oil or other foreign material during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 142 2005 Mitchell Repair Information Company LLC ...

Page 956: ... cover bolts Tighten Tighten the valley cover bolts to 25 N m 18 lb ft NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 143 2005 Mitchell Repair Information Company LLC ...

Page 957: ...l the knock sensors Tighten Tighten the knock sensors to 20 N m 15 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 144 2005 Mitchell Repair Information Company LLC ...

Page 958: ...5 Install the knock sensor wire harness COOLANT AIR BLEED PIPE INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 145 2005 Mitchell Repair Information Company LLC ...

Page 959: ...IMPORTANT z Install the pipe gaskets properly onto the pipe and covers z Position the gasket O ring seal onto the nipple portion of the pipe 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 146 2005 Mitchell Repair Information Company LLC ...

Page 960: ...9 Install the two pipe studs to the front of the engine Tighten Tighten the pipe studs to 12 N m 106 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 147 2005 Mitchell Repair Information Company LLC ...

Page 961: ...rs 313 gaskets 308 and bolts 312 onto the rear of the engine Tighten Tighten the cover bolts to 12 N m 106 lb in 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 148 2005 Mitchell Repair Information Company LLC ...

Page 962: ... hose 311 and clamps 310 onto the pipe 307 INTAKE MANIFOLD INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 149 2005 Mitchell Repair Information Company LLC ...

Page 963: ...may be removed as an assembly If not servicing the individual components install the intake manifold as a complete assembly z DO NOT use intake manifold gaskets again Install NEW intake manifold to cylinder head gaskets 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 150 2005 Mitchell Repair Info...

Page 964: ...OTORS CORP 2 Install the intake manifold to the engine 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 151 2005 Mitchell Repair Information Company LLC ...

Page 965: ...nt to the threads of the intake manifold bolts 713 Refer to Sealers Adhesives and Lubricants 4 Install the fuel rail stop bracket 712 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 152 2005 Mitchell Repair Information Company LLC ...

Page 966: ...ss in sequence to 5 N m 44 lb in 2 Tighten intake manifold bolts a final pass in sequence to 10 N m 89 lb in NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 153 2005 Mitchell Repair Information Company LLC ...

Page 967: ...S CORP 6 Install the knock sensor wire harness connector 1 onto the fuel rail stop bracket 712 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 154 2005 Mitchell Repair Information Company LLC ...

Page 968: ...P 7 Note the location of the fuel rail ground strap 550 on the intake manifold 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 155 2005 Mitchell Repair Information Company LLC ...

Page 969: ...r Courtesy of GENERAL MOTORS CORP 8 Install the manifold absolute pressure MAP sensor if previously removed 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 156 2005 Mitchell Repair Information Company LLC ...

Page 970: ...kcase ventilation PCV pipe dirty air 716 to the valley cover and intake manifold FUEL RAIL AND INJECTORS INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 40 AM Page 157 2005 Mitchell Repair Information Company LLC ...

Page 971: ...IMPORTANT DO NOT use fuel injector O ring seals again Install NEW fuel injector O 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 158 2005 Mitchell Repair Information Company LLC ...

Page 972: ...f the fuel rail ground strap 550 on the intake manifold The fuel rail ground strap must be installed during assembly ring seals during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 159 2005 Mitchell Repair Information Company LLC ...

Page 973: ...10953489 or equivalent to the threads of the fuel rail bolts 6 Install the fuel rail bolts Tighten Tighten the fuel rail bolts to 10 N m 89 lb in THROTTLE BODY INSTALLATION CAUTION Refer to Fuel Rail Stop Bracket Installation Caution in Cautions and Notices NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 ...

Page 974: ...c throttle control components Do not roughly handle the electronic throttle control components Do not immerse the electronic throttle control components in cleaning solvents of any type IMPORTANT DO NOT use the throttle body gasket again Install a NEW gasket during assembly 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn Decemb...

Page 975: ... N m 106 lb in 3 Install the engine coolant air bleed hose and clamp WATER PUMP INSTALLATION NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 162 2005 Mitchell Repair Information Company LLC ...

Page 976: ... passages of the cooling system or the engine components Restricted coolant flow may cause engine overheating and or damage to the cooling system or the engine components assembly IMPORTANT All gasket surfaces should be free of oil or other foreign material during assembly NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair...

Page 977: ...NT z Tighten the exhaust manifold bolts as specified in the service procedure Improperly installed and or leaking exhaust manifold gaskets may effect vehicle emissions and or On Board Diagnostics OBD II system performance z The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanica...

Page 978: ...lb ft Tighten the exhaust manifold bolts beginning with the center 2 bolts Alternate from side to side and work toward the outside bolts 4 Using a flat punch bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head 5 Install the exhaust manifold heat shield and bolts if required Tighten Tighten the heat shield bolts to 9 N m 80 lb in NOTE Refer to Fastener No...

Page 979: ...ipe with check valve NEW gasket and bolts Tighten Tighten the AIR pipe to exhaust manifold bolts to 20 N m 15 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 166 2005 Mitchell Repair Information Company LLC ...

Page 980: ...e intake manifold Tighten Tighten the oxygen sensor to 42 N m 30 lb ft EXHAUST MANIFOLD INSTALLATION RIGHT 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 167 2005 Mitchell Repair Information Company LLC ...

Page 981: ...mproperly installed and or leaking exhaust manifold gaskets may effect vehicle emissions and or On Board Diagnostics OBD II system performance z The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 ...

Page 982: ... Tighten the exhaust manifold bolts beginning with the center 2 bolts Alternate from side to side and work toward the outside bolts 4 Using a flat punch bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head 5 Install the exhaust manifold heat shield and bolts if required Tighten Tighten the heat shield bolts to 9 N m 80 lb in NOTE Refer to Fastener Notic...

Page 983: ...stall the air injection reaction AIR pipe with check valve NEW gasket and bolts 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 170 2005 Mitchell Repair Information Company LLC ...

Page 984: ... 2 Tighten the AIR pipe to left cylinder head bolt to 20 N m 15 lb ft 8 Install the oxygen sensor into the intake manifold Tighten Tighten the oxygen sensor to 42 N m 30 lb ft OIL LEVEL INDICATOR AND TUBE INSTALLATION 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 171 2005 Mitchell Repair Inform...

Page 985: ...ine oil 3 Install the O ring seal onto the oil level indicator tube 4 Install the oil level indicator tube into the engine block and rotate into proper position 5 Install the tube bolt to the right cylinder head NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 ...

Page 986: ...y of GENERAL MOTORS CORP 1 Install a 5 8 inch washer 1 onto the J 38836 or equivalent The washer serves as a stop against the crankshaft face and will assist in installing the bearing to the proper depth 2 Install the new pilot bearing 2 onto the tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Pa...

Page 987: ...nstall the new pilot bearing into the crankshaft using the J 38836 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 174 2005 Mitchell Repair Information Company LLC ...

Page 988: ...2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 175 2005 Mitchell Repair Information Company LLC ...

Page 989: ... GENERAL MOTORS CORP IMPORTANT z For manual transmission applications note the position and direction of the engine flywheel before removal The flywheel does not use a locating pin for alignment Mark or scribe the end of the crankshaft and the flywheel before component removal The existing manual transmission engine flywheel must be installed to the 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE ...

Page 990: ... but will be pulled onto the crankshaft by the engine flywheel bolts This procedure requires a three stage tightening process z DO NOT remove the propshaft hub or flexplate from the automatic transmission engine flywheel The flywheel prop shaft hub and flex plate are balanced as an assembly If service is required the entire flywheel assembly should be replaced 2004 Chevrolet Corvette 2004 ENGINE P...

Page 991: ...alent to the threads of the flywheel bolts 4 Install the engine flywheel bolts Tighten NOTE Refer to Fastener Notice in Cautions and Notices 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 41 AM Page 178 2005 Mitchell Repair Information Company LLC ...

Page 992: ...nal pass in sequence to 100 N m 74 lb ft CRANKSHAFT BALANCER INSTALLATION Tools Required z J 41665 Crankshaft Balancer and Sprocket Installer z J 42386 A Flywheel Holding Tool z J 45059 Angle Meter 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 179 2005 Mitchell Repair Information Company LLC ...

Page 993: ...aft balancer weights must be installed into the new balancer in the same location as the old balancer A properly installed balance weight will be either flush or below flush with the face of the balancer z The crankshaft balancer installation and bolt tightening involves a 4 stage tightening process The first pass ensures that the balancer is installed completely onto the crankshaft The second thi...

Page 994: ...ion if required Install balance weights into the NEW balancer if required Refer to Engine Balancing and Crankshaft Balancer Cleaning and Inspection 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 181 2005 Mitchell Repair Information Company LLC ...

Page 995: ...he balancer with the scribe mark on the crankshaft z The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 182 2005 Mitchell Repair Information Company LLC ...

Page 996: ...ncer 2 Use a wrench and hold the hex end of the threaded rod 3 Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto crankshaft 4 Remove the tool and reverse the installation tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 183 2005 Mitchell Rep...

Page 997: ... wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft 7 Remove the balancer installation tool 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 184 2005 Mitchell Repair Information Company LLC ...

Page 998: ...he used crankshaft balancer bolt Tighten Tighten the crankshaft balancer bolt to 330 N m 240 lb ft 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 185 2005 Mitchell Repair Information Company LLC ...

Page 999: ...ifying Harmonic Balancer Bolt Courtesy of GENERAL MOTORS CORP 8 Install the NEW crankshaft balancer bolt Tighten IMPORTANT The nose of the crankshaft should be recessed 2 40 4 48 mm 0 094 0 176 in into the balancer bore 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 186 2005 Mitchell Repair Info...

Page 1000: ...kshaft balancer bolt a second pass to 140 degrees using the J 45059 9 Remove the J 42386 A 2004 Chevrolet Corvette 2004 ENGINE PERFORMANCE Engine Mechanical Repair Instructions 3 Of 3 5 7L Corvette Helpmelearn December 24 07 11 06 42 AM Page 187 2005 Mitchell Repair Information Company LLC ...

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