service CHEVROLET CORVETTE 2003 5.G Workshop Manual

{CAUTION:
Getting under a vehicle when it is jacked up is
dangerous. If the vehicle slips off the jack, you
could be badly injured or killed. Never get
under a vehicle when it is supported only by
a jack.
{CAUTION:
Raising your vehicle with the jack improperly
positioned can damage the vehicle and even
make the vehicle fall. To help avoid personal
injury and vehicle damage, be sure to place
the jack in the proper location before raising
the vehicle.If you ever use a jack to lift your Corvette, such as to
display it at a show, follow the instructions that
came with the jack, and be sure to use the correct lifting
points to avoid damaging your vehicle.
Notice:Lifting your vehicle improperly can damage
your vehicle and result in costly repairs not
covered by your warranty. To lift your vehicle
properly, follow the advice in this part.
To help prevent vehicle damage:
·Be sure to place a block or pad between the
jack and the vehicle.
·Make sure the jack you're using spans at least
two crossmember ribs.
·Lift only in the areas shown in the following
pictures.
For additional information, see your dealer and the
Chevrolet Corvette service manual.
5-65

Lifting From the Rear
The rear lifting point can be accessed from the rear of
the vehicle, on either the driver's or passenger's side.
1. Locate the lifting point to jack your vehicle according
to the illustration shown.
2. Be sure to place a block or pad between the jack
and the vehicle.
3. Lift the vehicle with the jack, making sure the jack
spans at least two of the crossmember ribs.
For more information, see
Doing Your Own Service
Work on page 5-3.
5-67

If a Tire Goes Flat
Your Corvette has no spare tire, no tire changing
equipment and no place to store a tire.
It's unusual for a tire to ªblow outº while you're driving,
especially if you maintain your tires properly. See
Tires on page 5-54. If air goes out of a tire, it's much
more likely to leak out slowly.
If your vehicle has Extended Mobility Tires (EMT), you
won't need to stop on the side of the road to change
a ¯at tire. EMT tires can operate effectively with no air
pressure. If you drive on a de¯ated EMT for 50 miles
(80 km) or less and at speeds of 55 mph (90 km/h) or
less, there is a good chance that the tire can be
repaired. Contact the nearest authorized Chevrolet or
Goodyear EMT servicing facility, as soon as possible, to
have the ¯at tire inspected and repaired or replaced.
For more information, see
Extended Mobility Tires
(Except Z06) on page 5-54.
{CAUTION:
Special tools and procedures are required to
service an Extended Mobility Tire (EMT). If
these special tools and procedures aren't used
you or others could be injured and your
vehicle could be damaged. Always be sure the
proper tools and procedures, as described in
the service manual, are used.
To order a service manual, see
Service Publications
Ordering Information on page 7-10.
5-68

Finish Damage
Any stone chips, fractures or deep scratches in the
®nish should be repaired right away.
Minor chips and scratches can be repaired with touch-up
materials avaliable from your dealer or other service
outlets. Larger areas of ®nish damage can be corrected
in your dealer's body and paint shop.
Magnesium Wheel Finish
Notice:Improper paint repair or re®nishing can
cause corrosion damage to a magnesium wheel. See
your dealer if a magnesium wheel needs paint
repair or re®nishing.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are not
removed, accelerated corrosion (rust) can occur on
the underbody parts such as fuel lines, frame, ¯oor pan
and exhaust system even though they have corrosion
protection.
At least every spring, ¯ush these materials from the
underbody with plain water. Clean any areas where mud
and debris can collect. Dirt packed in close areas of
the frame should be loosened before being ¯ushed.
Your dealer or an underbody car washing system can
do this for you.
Titanium Exhaust System
(Z06 Only)
Time and high performance driving conditions can
cause a color change in titanium exhaust system parts.
This is normal for a titanium surface.
Fiberglass Springs
Notice:Don't use corrosive or acidic cleaning
agents, engine degreasers, aluminum cleaning
agents or other harsh solvents to clean ®berglass
springs; they'll damage the springs.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on your vehicle. This damage
can take two forms: blotchy, ring-shaped discolorations,
and small, irregular dark spots etched into the paint
surface.
Although no defect in the paint job causes this, GM will
repair, at no charge to the owner, the surfaces of
new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs ®rst.
5-81

Vehicle Identi®cation
Vehicle Identi®cation Number (VIN)
This is the legal identi®er for your vehicle. It appears on
a plate in the front corner of the instrument panel, on
the driver's side. You can see it if you look through the
windshield from outside your vehicle. The VIN also
appears on the Vehicle Certi®cation and Service Parts
labels and the certi®cates of title and registration.
Engine Identi®cation
The 8th character in your VIN is the engine code. This
code will help you identify your engine, speci®cations
and replacement parts.
Service Parts Identi®cation Label
You'll ®nd this label located inside the glovebox. It's
very helpful if you ever need to order parts. On this
label is:
·your VIN,
·the model designation,
·paint information and
·a list of all production options and special equipment
Be sure that this label is not removed from the
vehicle.
5-83

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Your Vehicle and the Environment....................6-2
Maintenance Requirements..............................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Scheduled Maintenance...................................6-4
Part B: Owner Checks and Services.................6-8
At Each Fuel Fill............................................6-8
At Least Once a Month...................................6-8
At Least Twice a Year....................................6-9At Least Once a Year.....................................6-9
Part C: Periodic MaintenanceInspections.........6-12
Steering and Suspension Inspection................6-12
Tire and Wheel Inspection.............................6-12
Exhaust System Inspection............................6-12
Fuel System Inspection..................................6-13
Engine Cooling System Inspection...................6-13
Rear Axle Service.........................................6-13
Brake System Inspection................................6-13
Part D: Recommended Fluids and
Lubricants................................................6-14
Part E: Maintenance Record...........................6-16
Section 6 Maintenance Schedule
6-1

How This Section is Organized
This maintenance schedule is divided into ®ve parts:
ªPart A: Scheduled Maintenance Servicesºexplains
what to have done and how often. Some of these
services can be complex, so unless you are technically
quali®ed and have the necessary equipment, you
should let your GM dealer's service department do
these jobs.
Your GM dealer has GM-trained and supported
service people that will perform the work using genuine
GM parts.
{CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you
can be seriously injured. Do your own
maintenance work only if you have the
required know-how and the proper tools and
equipment for the job. If you have any doubt,
have a quali®ed technician do the work.
If you want to get the service information, see
Service
Publications Ordering Information on page 7-10.ªPart B: Owner Checks and Servicesºtells you what
should be checked and when. It also explains what
you can easily do to help keep your vehicle in good
condition.
ªPart C: Periodic MaintenanceInspectionsºexplains
important inspections that your dealer's service
department can perform for you.
ªPart D: Recommended Fluids and Lubricantsºlists
some recommended products necessary to help
keep your vehicle properly maintained. These products,
or their equivalents, should be used whether you do
the work yourself or have it done.
ªPart E: Maintenance Recordºis a place for you to
record and keep track of the maintenance performed on
your vehicle. Keep your maintenance receipts. They
may be needed to qualify your vehicle for warranty
repairs.
6-3

Part A: Scheduled Maintenance
Services
This part contains engine oil scheduled maintenance
which explains the engine oil life system and how
it indicates when to change the engine oil and ®lter.
Also, listed are scheduled maintenance services which
are to be performed at the mileage intervals speci®ed.
Using Your Maintenance Schedule
We at General Motors want to keep your vehicle in good
working condition. But we don't know exactly how
you'll drive it. You may drive 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 the different ways people use their vehicles,
maintenance needs may vary. You may need more
frequent checks and replacements. So please read the
following and note how you drive. If you have
questions on how to keep your vehicle in good condition,
see your dealer.
This part tells you the maintenance services you should
have done and when to schedule them.When you go to your dealer for your service needs,
you'll know that GM-trained and supported service
people will perform the work using genuine GM parts.
The proper ¯uids and lubricants to use are listed in
Part D. Make sure whoever services your vehicle uses
these. All parts should be replaced and all necessary
repairs done before you or anyone else drives the
vehicle.
This schedule is for vehicles that:
·carry passengers and cargo within recommended
limits. You will ®nd these on your vehicle's
Tire-Loading Information label. See
Loading Your
Vehicle on page 4-33.
·are driven on reasonable road surfaces within legal
driving limits.
·use the recommended fuel. SeeGasoline Octane
on page 5-4
.
Scheduled Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown at 150,000 miles
(240 000 km) should be repeated at the same interval
after 150,000 miles (240 000 km) for the life of this
vehicle.
6-4

SeePart B: Owner Checks and Services on page 6-8,Part C: Periodic MaintenanceInspections on page 6-12andPart D: Recommended Fluids and Lubricants on
page 6-14.
Footnotes
²The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emissions warranty or limit recall liability prior to the
completion of the vehicle's useful life. We, however,
urge that all recommended maintenance services
be performed at the indicated intervals and the
maintenance be recorded.
Engine Oil Scheduled Maintenance
Change engine oil and ®lter as indicated by the
Engine Oil Life System (or every 12 months,
whichever occurs ®rst). Reset the system.
Your vehicle has a computer system that lets you know
when to change the engine oil and ®lter. This is
based on engine revolutions and engine temperature,
and not on mileage. Based on driving conditions,
the mileage at which an oil change will be indicated can
vary considerably. For the oil life system to work
properly, you must reset the system every time the oil is
changed.When the system has calculated that oil life has been
diminished, it will indicate that an oil change is
necessary. A CHANGE OIL SOON message will come
on. Change your oil as soon as possible within the
next two times you stop for fuel. It is possible that, if you
are driving under the best conditions, the oil life
system may not indicate that an oil change is necessary
for over a year. However, your engine oil and ®lter
must be changed at least once a year and at this time
the system must be reset. Your dealer has GM-trained
service people who will perform this work using
genuine GM parts and reset the system.
It is also important to check your oil regularly and keep
it at the proper level.
If the system is ever reset accidentally, you must
change your oil at 3,000 miles (5 000 km) since your
last oil change. Remember to reset the oil life system
whenever the oil is changed. SeeEngine Oil on
page 5-13for information on resetting the system.
Use engine oil meeting the GM Standard GM4718M.
An Emission Control Service.
See the mileage intervals following for additional
services that may be performed with an engine oil
change. After the services are performed, record the
date, odometer reading and who performed the service
on the maintenance record pages in Part E of this
schedule.
6-5

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