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Chevrolet C-5 Corvette Header System Installation Instructions

January 2nd, 2011 · No Comments

Stock System Removal
Under the Hood: Place the vehicle up on jack stands or a hydraulic lift to provide access to the bottom of the vehicle. For safety and to protect you car’s electrical system, remove the ground cable from the negative battery terminal.
Carefully remove the fuel rail covers, from both the top left and right sides of the engine.
To remove the right side cover – remove the oil filler cap first. Reinstall the cap after the cover is removed
We’ll work on the right side (passenger side) of the engine first.
On the right side of the engine (passenger side) remove the bolt holding the oil dipstick tube to the exhaust manifold. On 2001 and newer C-5’s, remove the dipstick tube hold down bolt out of the head itself as opposed to the exhaust manifold. Pull the dipstick tube and dipstick out of the hole in the engine block and set aside for re-installation during a later step. Remove the sparkplug wires from both the coil packs and sparkplugs. Remove the sparkplugs from the right side engine bank (passenger side). Remove the bolts from the air tube flange and remove the air tube flange gasket. Disconnect the plug connecting the coil packs to the main wiring harness and two (2) press–on hoses. Loosen and remove the bolts holding the valve cover to the head. Lift the valve cover with the coil packs still attached off the right side engine bank (passenger side) and cover the exposed valve springs with several shop towels to prevent contamination.
* On 2001 and newer C-5’s, the entire coil pack must be removed as a unit to get to the valve cover hold down bolts
Now switch to left side (driver side) of the engine.
Remove the bolts from the air tube flange and remove the air tube flange gasket from the air tube on the left side engine bank (driver side). Remove the clamp holding the air tube/gulp valve assembly to the hose, remove the assembly and set it aside for reinstallation during a later step. Remove the sparkplug wires from both the coil packs and sparkplugs on plugs # 1 & # 3. Remove the sparkplug wires from the coil packs on #5 and # 7. Remove the two (2) rear coil packs from the valve cover and lay on top of the valley cover.
* On 2001 and newer C-5’s, the entire coil pack unit should be removed to give more hand and maneuvering clearance. Disconnect the plug wires on all left (driver side) bank cylinders from both the coil packs and the spark plugs. Remove the sparkplug wires from the balance of the sparkplugs. Remove the sparkplugs from the left side engine bank (driver side) Loosen the alternator drive belt at the belt tensioner and slip the belt off the alternator pulley. Remove the alternator mounting bolts and lay the alternator on the front of the engine. (This is necessary to provide clearance while removing the stock manifold.)

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