This may have been covered before but I haven't found it yet. I have a ZO6 air box cover I want to put on my 04 coup. I really don't want to start yanking and pulling without knowing what I'm doing. Is this a real hassle to do? Is it worth it? Getting the old one off may be not that difficult but how about getting the new one on? Those rubber bushings with torx screws in the middle look like trouble to get to, maybe you don't have to remove them? Is there somewhere that shows a detailed step by step procedure to do this with pictures? Probably dumb questions but I had to ask.
Larry

 

Is it worth it...yes! The oem Z06 cover will allow more air into the filter and you will benefit. Don't expect another 25hp, but there will be the benefit of extra air intake and there won't be any codes if you're careful in R&R. You don't remove the TORX screw studs, but you do need to wiggle the rubber bushings off the TORX screw studs. They're probably dry, so be patient.
You might get lucky and just be able to remove the flat metal straps and slide the oem cover off the air box assembly. Chances are in doing so, one or both of the clamps will come off their point of attachment on the lower part of the assembly.
I'd suggest since you're apparently new to your C5/Z06 that this is a good place to learn some basics...it's fun, take your time.
Loosen the band clamp that secures the bellows at the throttle body, it takes a 5/16" socket or wrench.
Loosen the air bridge from the radiator rubber bushings, be careful they don't get lost. Replacements cost about $3.00 at the dealer.
Remove any wiring connectors at the air bridge and/or MAF. Again, be careful you don't lose any plastic "locks" that are sometimes used to secure the connections. Most of the connections require a pinch to remove them.
Loosen the band clamp at the oem air box.
Now remove the loosened part of the assembly from the air box and be careful not to damage the sensitive wires inside the MAF.
Now is a good time to check inside your throttle body for signs of oil and inside the MAF for signs of contamination of the sensor wires. There are products to clean either.
Now loosen the two flat metal band straps that secure the top of the air box to the bottom of the air box. Remove the air filter and square plastic piece that secures it. Clean and/or change your filter if needed.
Now, look between the front bumper and open hood and get your hands down there where the rubber bushings on the metal cross member secure the air box assembly. Wiggle the corners a bit and the assembly should come off.
Install the Z06 cover in place of the oem cover, install the filter and plastic piece, attach the flat metal straps and re-attach the air box assembly as one unit to the TORX screw studs. I've found this easier than any other manner.
I'd suggest you lube the bushings with your favorite lubrication...some use water, I prefer a light application of white lithium grease. This will make installation easier this time and in the future.
Put the assembly back together in the reverse order. Confirm there are no points for an air leak at the band clamps or loose connections.
Do a search on the "relearn" procedure, but you probably won't need it. Double check everything and drive the car normally for a few miles until the computer adjusts for the increase in air flow.
That's it.

 

Yep, it's an easy mod., I did it. Also drilled 1 1/2" holes in the sides of my 02 ZO6 lid to allow more air into it. Agree on lubing the two rubber bushings, doing so makes installation easier.

 

Thanks alot! I did it! If I can do it anyone can.
Larry