transmission CHEVROLET CORVETTE 2003 5.G Service Manual

Engine Speci®cations
Engine VIN Code Transmission Spark Plug Gap Firing Order
LS1 V8 G Automatic 0.060 inch
(1.524 mm)1±8±7±2±6±5±4±3
LS1 V8 G Manual 0.060 inch
(1.524 mm)1±8±7±2±6±5±4±3
LS6 V8 S Manual 0.060 inch
(1.524 mm)1±8±7±2±6±5±4±3
Engine Data
Engine Horsepower Torque Displacement Compression Ratio
LS1 Automatic
Transmission350 @ 5200 rpm 360 @ 4000 rpm 5.7 L 10.1:1
LS1 Manual
Transmission350 @ 5200 rpm 375 @ 4400 rpm 5.7 L 10.1:1
LS6 405 @ 6000 rpm 400 @ 4800 rpm 5.7 L 10.5:1
5-93

15,000 Miles (25 000 km)
qInspect engine air cleaner ®lter. If necessary, replace
the ®lter. If vehicle is driven in dusty/dirty conditions,
inspect ®lter at every engine oil change. See
Engine Air Cleaner/Filter on page 5-18for more
information.An Emission Control Service. (See
footnote ².)
30,000 Miles (50 000 km)
qReplace engine air cleaner ®lter. SeeEngine Air
Cleaner/Filter on page 5-18for more information.An Emission Control Service.
45,000 Miles (75 000 km)
qInspect engine air cleaner ®lter. If necessary, replace
the ®lter. If vehicle is driven in dusty/dirty conditions,
inspect ®lter at every engine oil change. See
Engine Air Cleaner/Filter on page 5-18for more
information.An Emission Control Service. (See
footnote ².)
50,000 Miles (83 000 km)
qChange automatic transmission ¯uid and ®lter if the
vehicle is mainly driven under one or more of these
conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC) or
higher.
þ In hilly or mountainous terrain.
þ Uses such as high performance operation.
If you do not use your vehicle under any of these
conditions, change the ¯uid and ®lter at
100,000 miles (166 000 km). Manual
transmission ¯uid doesn't require change.
60,000 Miles (100 000 km)
qReplace engine air cleaner ®lter. SeeEngine Air
Cleaner/Filter on page 5-18for more information.An Emission Control Service.
6-6

75,000 Miles (125 000 km)
qInspect engine air cleaner ®lter. If necessary, replace
the ®lter. If vehicle is driven in dusty/dirty conditions,
inspect ®lter at every engine oil change. See
Engine Air Cleaner/Filter on page 5-18for more
information.An Emission Control Service. (See
footnote ².)
90,000 Miles (150 000 km)
qReplace engine air cleaner ®lter. SeeEngine Air
Cleaner/Filter on page 5-18for more information.An Emission Control Service.
100,000 Miles (166 000 km)
qReplace spark plugs.An Emission Control Service.
qInspect spark plug wires.An Emission Control
Service.
qChange automatic transmission ¯uid and ®lter.
Manual transmission ¯uid doesn't required change.
150,000 Miles (240 000 km)
qDrain, ¯ush and re®ll the cooling system (or every
60 months since last service, whichever occurs
®rst). See
Engine Coolant on page 5-23for what to
use.An Emission Control Service.
qInspect engine accessory drive belt.An Emission
Control Service.
6-7

At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced.
Also look for any opened or broken air bag coverings,
and have them repaired or replaced. (The air bag
system does not need regular maintenance.)
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace
blade inserts that appear worn or damaged or that
streak or miss areas of the windshield. Also see
Cleaning the Outside of Your Vehicle on page 5-78.
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them last
longer, seal better, and not stick or squeak. Apply
silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
required. See
Part D: Recommended Fluids and
Lubricants on page 6-14.
Manual Transmission Check
Check the transmission ¯uid level; add if needed. SeeManual Transmission Fluid on page 5-20. Check
for leaks. A ¯uid leak is the only reason for ¯uid loss.
Have the system inspected and repaired if needed.
Automatic Transmission Check
It is not necessary to check the transmission ¯uid level.
A transmission ¯uid leak is the only reason for ¯uid
loss. Check for leaks. If a leak occurs, take the vehicle
to your dealer and have it repaired as soon as
possible.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
speci®ed in Part D.
Body Lubrication Service
Lubricate all body door hinges. Also lubricate all hinges
and latches, including those for the hood, rear
compartment, console door and any folding seat
hardware. Part D tells you what to use. More frequent
lubrication may be required when exposed to a corrosive
environment.
6-9

Starter Switch Check
{CAUTION:
When you are doing this check, the vehicle
could move suddenly. If it does, you or others
could be injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. See
Parking Brake on page 2-30if
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, your vehicle needs service.
On manual transmission vehicles, put the shift lever
in NEUTRAL (N), push the clutch down halfway
and try to start the engine. The starter should work
only when the clutch is pushed down all the way
to the ¯oor. If the starter works when the clutch isn't
pushed all the way down, your vehicle needs
service.
Automatic Transmission Shift Lock
Control System Check
{CAUTION:
When you are doing this check, the vehicle
could move suddenly. If it does, you or others
could be injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. See
Parking Brake
on page 2-30if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the key to the ON position,
but don't start the engine. Without applying the
regular brake, try to move the shift lever out
of PARK (P) with normal effort. If the shift lever
moves out of PARK (P), your vehicle needs service.
6-10

Ignition Automatic Transmission
Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to OFF in each shift lever position.
The key should turn to OFF only when the shift lever is
in PARK (P).
On all vehicles, the key should come out only in OFF.
Parking Brake and Automatic
Transmission Park (P)
Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
·To check the parking brake's holding ability:
With the engine running and transmission in
NEUTRAL (N), slowly remove foot pressure from
the regular brake pedal. Do this until the vehicle is
held by the parking brake only.
·To check the PARK (P) mechanism's holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Underbody Flushing Service
At least every spring, use plain water to ¯ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-11

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identi®ed below by name, part
number or speci®cation may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilThe engine requires a special
engine oil meeting GM Standard
GM4718M. Oils meeting this
standard may be identi®ed as
synthetic, and should also be
identi®ed with the American
Petroleum Institute Certi®ed for
Gasoline Engines starburst symbol.
However, not all synthetic API oils
with the starburst symbol will meet
this GM standard. You should look
for and use only an oil that meets
GM Standard GM4718M. For the
proper viscosity, see
Engine Oil on
page 5-13.
Usage Fluid/Lubricant
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
žCoolant. SeeEngine
Coolant on page 5-23.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake ¯uid.
Windshield
Washer SolventGM Optikleen
žWasher Solvent or
equivalent.
Hydraulic
Clutch SystemHydraulic Clutch Fluid (GM Part No.
U.S. 12345347, in Canada
10953517, or equivalent DOT-3
brake ¯uid).
Power Steering
SystemGM Power Steering Fluid (GM Part
No.U.S. 1052884, in Canada
993294, or equivalent).
Manual
TransmissionDEXRON
ž-III Automatic
Transmission Fluid.
Automatic
TransmissionDEXRON
ž-III Automatic
Transmission Fluid.
6-14

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you'll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-10

Audio System(s) (cont.)
Understanding Radio Reception.....................3-77
Automatic Transmission Check........................... 6-9
Automatic Transmission Shift Lock Control
System Check.............................................6-10
Automatic Transmission...................................2-21
Fluid..........................................................5-20
Operation...................................................2-24
B
Battery Replacement......................................... 2-8
Battery Run-Down Protection............................3-17
Battery..........................................................5-40
Before Leaving on a Long Trip.........................4-24
Body Lubrication Service................................... 6-9
Brake Fluid....................................................5-37
Brake Wear...................................................5-39
Brake............................................................2-30
Parking......................................................2-30
System Inspection.......................................6-13
System Warning Light..................................3-35
Brakes..........................................................5-37
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-6
Break-In, New Vehicle.....................................2-19
Bulb Replacement...........................................5-47
Back-Up Lamps...........................................5-51
Halogen Bulbs............................................5-47Bulb Replacement (cont.)
Headlamps.................................................5-47
Replacement Bulbs......................................5-51
Taillamps and Turn Signal Lamps..................5-49
Buying New Tires...........................................5-59
C
California Fuel.................................................. 5-5
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-7
Capacities and Speci®cations............................5-92
Carbon Monoxide...................4-27, 4-35, 2-11, 2-35
Care of.........................................................5-77
Safety Belts................................................5-77
Your Cassette Tape Player............................3-78
Your CD Player...........................................3-79
Your CDs ...................................................3-79
Cargo Cover..................................................2-42
Cassette Tape Messages.................................3-66
Cassette Tape Player Service............................. 6-8
CD Adapter Kits.............................................3-66
CD Changer, Trunk-Mounted............................3-71
Center Console Storage Area...........................2-39
Chains, Tires..................................................5-64
Check Engine Light.........................................3-38
Checking Coolant............................................5-25
Checking Engine Oil........................................5-13
2

Customer Assistance Information........................ 7-7
Courtesy Transportation.................................. 7-7
Customer Assistance for Text Telephone
(TTY) Users.............................................. 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors....7-10
Reporting Safety Defects to the Canadian
Government............................................7-10
Reporting Safety Defects to the United States
Government.............................................. 7-9
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-10
D
Daytime Running Lamps..................................3-13
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-27
Disabling the Theft-Deterrent Feature.................3-77
Disarming the System.....................................2-17
Doing Your Own Service Work........................... 5-3
Door............................................................... 2-9
Locks.......................................................... 2-9
Power Door Locks.......................................2-10
Downshifting (Manual Transmission)..................2-29Driver Information Center (DIC).........................3-44
DIC Controls and Displays............................3-45
DIC Warnings and Messages........................3-53
Other Messages..........................................3-61
Driver............................................................1-13
Position, Safety Belt.....................................1-13
Driving On Snow or Ice...................................4-28
Driving Through Deep Standing Water...............4-21
Driving Through Flowing Water.........................4-21
Driving..........................................................4-18
At Night.....................................................4-18
City...........................................................4-22
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-23
Hill and Mountain Roads..............................4-25
In Rain and on Wet Roads...........................4-19
Winter........................................................4-27
Dual Automatic Climate Control System.............3-22
E
Electrical System............................................5-84
Accessory Power Plug.................................5-84
Add-On Equipment......................................5-84
Fuses and Circuit Breakers...........................5-86
Headlamp Wiring.........................................5-85
4