cooling CHEVROLET CORVETTE 2002 5.G User Guide

5-15
If no coolant is visible in the surge tank, add coolant
as follows:
CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They are
under pressure, and if you turn the coolant surge
tank pressure cap
-- even a little -- they can come
out at high speed. Never turn the cap when the
cooling system, including the coolant surge tank
pressure cap, is hot. Wait for the cooling system
and coolant surge tank pressure cap to cool if you
ever have to turn the pressure cap.

5-16
CAUTION:
Adding only plain water to your cooling system
can be dangerous. Plain water, or some other
liquid such as alcohol, can boil before the proper
coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant
mixture. With plain water or the wrong mixture,
your engine could get too hot but you wouldn't
get the overheat warning. Your engine could
catch fire and you or others could be burned.
Use a 50/50 mixture of clean, drinkable water
and DEX
-COOL
coolant.
NOTICE:
In cold weather, water can freeze and crack the
engine, radiator, heater core and other parts.
So use the recommended coolant.
CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Don't spill coolant on a hot engine.

5-17
1. Park the vehicle on a level surface. You can remove
the coolant surge tank pressure cap when the cooling
system, including the coolant surge tank pressure cap
and upper radiator hose, is no longer hot. Turn the
pressure cap slowly counterclockwise (left) about
one
-quarter turn and then stop.
If you hear a hiss, wait for that to stop.
A hiss means there is still some pressure left.
2. Then keep turning the pressure cap slowly,
and remove it.
3. Then fill the coolant surge tank with the proper
mixture, to the FULL COLD mark on the coolant
surge tank.

5-18
4. With the coolant surge tank pressure cap off,
start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fan(s).
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower, add
more of the proper mixture to the coolant surge tank
until the level reaches the FULL COLD mark on the
coolant surge tank.5. Then replace the pressure cap. Be sure the pressure
cap is hand
-tight and fully seated.

6-23
If the level is below the bottom of the filler plug hole,
you'll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the filler plug hole.
What to Use
To add lubricant when the level is low, use SAE 75W-90
Synthetic Gear Lubricant (GM Part No. 12378261)
or equivalent meeting GM Specification 9986115.
To completely refill after draining, add 4 ounces
(118 ml) of Limited
-Slip Differential Lubricant Additive
(GM Part No. 1052358) or equivalent. Then fill to
the bottom of the filler plug hole with the Synthetic
Gear Lubricant.
Engine Coolant
The cooling system in your vehicle is filled with
DEX
-COOL engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add only
DEX
-COOL extended life coolant.
The following explains your cooling system and how
to add coolant when it is low. If you have a problem
with engine overheating, see ªEngine Overheatingº
in the Index.A 50/50 mixture of clean, drinkable water and
DEX
-COOL coolant will:

Give freezing protection down to
-34F (-37C).

Give boiling protection up to 265F (129C).

Protect against rust and corrosion.

Help keep the proper engine temperature.

Let the warning lights and gages work as
they should.
NOTICE:
When adding coolant, it is important that you
use only DEX
-COOL (silicate-free) coolant.
If coolant other than DEX-COOL is added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the
engine coolant will require change sooner
-- at
30,000 miles (50 000 km) or 24 months,
whichever occurs first. Damage caused by the
use of coolant other than DEX
-COOL is not
covered by your new vehicle warranty.

6-24 What to Use
Use a mixture of one-half clean, drinkable water and
one
-half DEX-COOL
coolant which won't damage
aluminum parts. If you use this coolant mixture, you
don't need to add anything else.
CAUTION:
Adding only plain water to your cooling system
can be dangerous. Plain water, or some other
liquid such as alcohol, can boil before the proper
coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant
mixture. With plain water or the wrong mixture,
your engine could get too hot but you wouldn't
get the overheat warning. Your engine could
catch fire and you or others could be burned.
Use a 50/50 mixture of clean, drinkable water
and DEX
-COOL
coolant.
NOTICE:
If you use an improper coolant mixture, your
engine could overheat and be badly damaged.
The repair cost wouldn't be covered by your
warranty. Too much water in the mixture can
freeze and crack the engine, radiator, heater core
and other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
NOTICE:
If you use the proper coolant, you don't have to
add extra inhibitors or additives which claim to
improve the system. These can be harmful.

6-50 Wheel Replacement
Replace any wheel that is bent, cracked, or badly rusted
or corroded. If wheel nuts keep coming loose, the wheel,
wheel bolts and wheel nuts should be replaced. If the
wheel leaks air, replace it (except some aluminum
wheels, which can sometimes be repaired). See your
dealer if any of these conditions exist.
Your dealer will know the kind of wheel you need.
Each new wheel should have the same load
-carrying
capacity, diameter, width, offset and be mounted the
same way as the one it replaces.
If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new GM original
equipment parts. This way, you will be sure to have the
right wheel, wheel bolts and wheel nuts for your vehicle.
CAUTION:
Using the wrong replacement wheels, wheel bolts
or wheel nuts on your vehicle can be dangerous.
It could affect the braking and handling of your
vehicle, make your tires lose air and make you
lose control. You could have a collision in which
you or others could be injured. Always use
the correct wheel, wheel bolts and wheel nuts
for replacement.
NOTICE:
The wrong wheel can also cause problems with
bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper
height, vehicle ground clearance and tire
clearance to the body and chassis.

6-74
Minifuse Usage
9 Headlamp High
-Beam Right
10 Headlamp Low
-Beam Left
11 Horn
12 Headlamp High
-Beam Left
13 Fuel Pump
14 Cooling Fan
- Ignition 3
15 Oxygen Sensor
16 Powertrain Control Module
17 Throttle Control
18 Injector 2
19 Engine Ignition
20 Blank
21 Blank
22 Injector 1
23 Powertrain Control Module
24 Air Conditioning
25 Blank
26 Blank
27 Spare Minifuse Usage
28 Spare
29 Spare
30 Spare
31 Spare
32 Spare
Micro Relay Usage
33 Air Pump
34 Air Conditioner and Clutch
35 Fuel Pump
36 Horn
37 Rear Fog Lamp
38 Back
-Up Lamps
39 Fog Lamp
40 Blank
41 Selective Real Time Damping
Mini Relay Usage
42 Ignition 1
43 Cooling Fan 2
44 Cooling Fan 3
45 Cooling Fan 1

6-75
Maxi-Fuse Usage
46 Cooling Fan 2
47 Blank
48 Blank
49 Cooling Fan 1
50 Air Pump
51 Blank
52 Anti
-Lock Brakes
53 Selective Real Time Damping
Electronics
54 Fuse Puller
Replacement Bulbs
High-Beam Headlamp 9005. . . . . . . . . . . . . . . . . . . .
Low
-Beam Headlamp 9006. . . . . . . . . . . . . . . . . . . .
Back
-Up 2057. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Stop/Tail and Turn Signal 3057. . . . . . . . . . . . .
For any bulb replacements or procedures not listed here,
please consult your dealer.
Capacities and Specifications
The following approximate capacities are given in
English and metric conversions.
Please refer to ªRecommended Fluids and Lubricantsº
in the Index for more information.
Automatic Transmission
Drain and Refill 5.0 quarts (4.7 L). . . . . . . . . . . . . .
Overhaul 10.8 quarts (10.2 L). . . . . . . . . . . . . . . . .
Cooling System12.6 quarts (11.9 L) . . . . . . . . . . . . . .
Engine Oil with Filter6.5 quarts (6.1 L) . . . . . . . . .
Fuel Tank18.5 U.S. gallons (70.0 L) . . . . . . . . . . . .
Manual Transmission
(Overhaul)4.1 quarts (3.8 L) . . . . . . . . . . . . . . . . .
Wheel Nut Torque100 lb
-ft (140 N´m) . . . . . . . . . .
All capacities are approximate. When adding, be sure
to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling.
Engine Specifications
Type5.7L V8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VIN Engine Code
LS1 G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LS6 S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scheduled Maintenance
7-12
100,000 Miles (166 000 km) (Continued)
Change automatic transmission fluid and filter 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.
Manual transmission fluid doesn't require change.
If you haven't used your vehicle under severe conditions listed previously and,
therefore, haven't changed your automatic transmission fluid, change both the
fluid and filter. Manual transmission fluid doesn't require change.
150,000 Miles (240 000 km)
Drain, flush and refill the cooling system (or every 60 months since last
service, whichever occurs first). See ªEngine Coolantº in the Index for
what to use.
An Emission Control Service. ACTUAL
SERVICED BY:MILEAGE
DATE