check engine CHEVROLET CORVETTE 2004 5.G Service Manual

1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be able
to start your vehicle, and the bad grounding
could damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake firmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in NEUTRAL before setting the parking brakes.Notice:If you leave your radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered
by your warranty. Always turn off your radio and
other accessories when jump starting your vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or in the accessory power outlet. Turn off
the radio and all lamps that are not needed. This will
avoid sparks and help save both batteries. And it
could save your radio!
4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle. SeeEngine Compartment Overview
on page 5-12for more information on location.
{CAUTION:
An electric fan can start up even when the
engine is not running and can injure you. Keep
hands, clothing and tools away from any
underhood electric fan.
5-42

{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
ashlight if you need more light.
Be sure the battery has enough water. You do
not need to add water to the ACDelco
®battery
installed in your new vehicle. But if a battery
has ller caps, be sure the right amount of
uid is there. If it is low, add water to take care
of that rst. If you do not, explosive gas could
be present.
Battery uid contains acid that can burn you.
Do not get it on you. If you accidentally get it
in your eyes or on your skin, ush the place
with water and get medical help immediately.
{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5. Check that the jumper cables do not have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged, too.
Before you connect the cables, here are some
basic things you should know. Positive (+) will go to
positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a heavy,
unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts, too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.
5-43

Z06 models do not have Extended Mobility Tires. If a
Z06 model tire goes flat, avoid further tire and wheel
damage by driving slowly to a level place and stopping.
Then do this:
1. Turn on the hazard warning flashers.
2. Set the parking brake firmly.
3. Put the shift lever (manual transmission) in
REVERSE (R).
4. Turn off the engine.
5. Inspect the flat tire.
If the tire has been separated from the wheel or has
damaged sidewalls or large tears that allow rapid
air loss, call a tire repair facility. SeeRoadside
Assistance Program on page 7-6.
If the flat tire is due to a slow leak caused by a nail or
other similar road hazard, the tire inflator kit may
be used to repair the damaged tire temporarily. The kit
uses a liquid tire sealant to seal small punctures inthe tread area of the tire. The flat tire is then inflated to
at least 26 psi (179 kPa) and driven to evenly distribute
the tire sealant. The tire pressure is checked after
driving for a maximum of 10 minutes to see if the slow
leak has been stopped. If the tire pressure is 19 psi
(131 kPa) or more, inflate the tire up to the standard
operating pressure as shown on the Tire Pressure Label
found on the rear edge of the driver’s door. See
Ination - Tire Pressure on page 5-62.
You should have the damaged tire repaired as soon as
possible. The tire sealant is a temporary repair only.
For more information regarding the tire inflator kit
see “Tire Inflator Kit (Z06 Only)” following this section.
Notice:If the tire pressure has dropped below
19 psi (131 kPa), the vehicle should not be driven
further. Damage to the tire may be severe and
the sealant will not be effective. Contact Roadside
Assistance. See “Roadside Assistance” in the Index.
5-76

Capacities and Specications
The following approximate capacities are given in English and metric conversions.
Please refer toRecommended Fluids and Lubricants on page 6-11for more information.
Capacities and Specications
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.75 lbs 0.79 kg
Automatic Transmission
Drain and Refill 5.0 quarts 4.7 L
Overhaul 10.8 quarts 10.2 L
Cooling System 12.6 quarts 11.9 L
Engine Oil with Filter 6.5 quarts 6.1 L
Fuel Tank 18.0 gallons 68.0 L
Manual Transmission (Overhaul) 4.1 quarts 3.8 L
Wheel Nut Torque 100 lb ft 140Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling
5-99

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
Using Your Maintenance Schedule....................6-2
Scheduled Maintenance...................................6-4
Additional Required Services............................6-6
Maintenance Footnotes...................................6-7Owner Checks and Services............................6-8
At Each Fuel Fill............................................6-8
At Least Once a Month...................................6-9
At Least Once a Year.....................................6-9
Recommended Fluids and Lubricants...............6-11
Normal Maintenance Replacement Parts..........6-13
Engine Drive Belt Routing..............................6-14
Maintenance Record.....................................6-15
Section 6 Maintenance Schedule
6-1

Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Have you purchased the GM Protection Plan? The Plan
supplements your new vehicle warranties. See your
Warranty and Owner Assistance booklet or your dealer
for details.
Maintenance Requirements
Notice:Maintenance intervals, checks, inspections,
replacement parts and recommended uids and
lubricants as prescribed in this manual are
necessary to keep your vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance may not be covered by
warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance is
important. Improper vehicle maintenance can even
affect the quality of the air we breathe. Improper fluid
levels or the wrong tire inflation can increase the level of
emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good condition,
be sure to maintain your vehicle properly.
Using Your Maintenance Schedule
We at General Motors want to help you keep your
vehicle in good working condition. But we do not know
exactly how you will drive it. You may drive very
short distances only a few times a week. Or you may
drive long distances all the time in very hot, dusty
weather. You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in many
other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your GM Goodwrench dealer.
6-2

Scheduled Maintenance
When the CHANGE OIL SOON message comes on, it
means that service is required for your vehicle. Have your
vehicle serviced as soon as possible within the next 600
miles (1 000 km). It is possible that, if you are driving
under the best conditions, the engine oil life system may
not indicate that vehicle service is necessary for over a
year. However, your engine oil and filter must be changed
at least once a year and at this time the system must be
reset. Your GM Goodwrench dealer has GM-trained
service technicians who will perform this work using
genuine GM parts and reset the system.
If the engine oil life system is ever reset accidentally,
you must service your vehicle within 3,000 miles
(5 000 km) since your last service. Remember to reset
the oil life system whenever the oil is changed. See
Engine Oil on page 5-13for information on the Engine
Oil Life System and resetting the system.When the CHANGE OIL SOON message appears,
certain services, checks and inspections are required.
Required services are described in the following for
“MaintenanceI” and “MaintenanceII.” Generally,
it is recommended that your first service be
MaintenanceI, your second service be MaintenanceII
and that you alternate MaintenanceIand MaintenanceII
thereafter. However, in some cases, MaintenanceII
may be required more often.
MaintenanceI— Use MaintenanceIif the message
comes on within ten months since vehicle was
purchased or MaintenanceIIwas performed.
MaintenanceII— Use MaintenanceIIif the previous
service performed was MaintenanceI. Always use
MaintenanceIIwhenever the message comes on ten
months or more since the last service or if the message
has not come on at all for one year.
6-4

Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and filter. Reset oil life system. SeeEngine Oil on
page 5-13.An Emission Control Service.••
Visually check for any leaks or damage.See footnote (g).••
Inspect engine air cleaner filter. If necessary, replace filter. SeeEngine Air
Cleaner/Filter on page 5-18.An Emission Control Service. See footnote †.••
Check tire inflation pressures and tire wear. SeeTires on page 5-55.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer fluid levels and add fluid as
needed.••
Perform any needed additional services. See “Additional Required Services” in
this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
6-5

(h)Change automatic transmission uid and lter if the
vehicle is mainly driven under one or more of these
conditions:
-In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
-In hilly or mountainous terrain.
-Uses such as high performance operation.
(i)Drain, ush and rell cooling system. See Engine
Coolant on page 5-23for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and filler neck.
Pressure test the cooling system and pressure cap.
Owner Checks and Services
These owner checks and services should be performed
at the intervals specified to help ensure the safety,
dependability and emission control performance of your
vehicle. Your GM Goodwrench dealer can assist you
with these checks and services.
Be sure any necessary repairs are completed at once.
Whenever any fluids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-11.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
Engine Coolant Level Check
Check the engine coolant level and add
DEX-COOL®coolant mixture if necessary. SeeEngine
Coolant on page 5-23for further details.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer tank and add the proper fluid if necessary.
6-8

At Least Once a Month
Tire Inspection and Ination Check
Visually inspect your tires for wear and make sure tires
are inflated to the correct pressures. SeeTires on
page 5-55for further details.
Cassette Tape Player Service
Clean cassette tape player. Cleaning should be done
every 50 hours of tape play. SeeAudio System(s)
on page 3-69for further details.
Power Antenna Service
Clean power antenna mast. SeeAudio System(s) on
page 3-69for further details.
At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-31if
necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. On automatic transmission vehicles, try to start the
engine in each gear. The starter should work only
in PARK (P) or NEUTRAL (N). If the starter works in
any other position, contact your GM Goodwrench
dealer for service.
4. On manual transmission vehicles, put the shift lever
in NEUTRAL (N), push the clutch pedal down
halfway and try to start the engine. The starter
should work only when the clutch pedal is pushed
down all the way to the floor. If the starter works
when the clutch is not pushed all the way down,
contact your GM Goodwrench dealer for service.
6-9