steering CHEVROLET CORVETTE 2004 5.G Owner's Guide

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-18
Automatic Transmission Fluid.........................5-20
Manual Transmission Fluid.............................5-21
Hydraulic Clutch...........................................5-22
Engine Coolant.............................................5-23
Coolant Surge Tank Pressure Cap..................5-26
Engine Overheating.......................................5-26
Cooling System............................................5-29
Power Steering Fluid.....................................5-35
Windshield Washer Fluid................................5-36Brakes........................................................5-37
Battery........................................................5-40
Jump Starting...............................................5-41
Rear Axle.......................................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps..................................................5-48
Taillamps and Turn Signal Lamps...................5-50
Back-Up Lamps............................................5-52
Windshield Wiper Blade Replacement..............5-52
Tires..............................................................5-55
Extended Mobility Tires (Except Z06)...............5-61
Inflation - Tire Pressure.................................5-62
Tire Pressure Monitor Operation
(Except Z06).............................................5-64
Tire Rotation................................................5-65
When It Is Time for New Tires.......................5-65
Buying New Tires.........................................5-66
Uniform Tire Quality Grading..........................5-67
Wheel Alignment and Tire Balance..................5-68
Wheel Replacement......................................5-68
Tire Chains..................................................5-71
Lifting Your Vehicle.......................................5-71
If a Tire Goes Flat........................................5-75
Tire Inflator Kit (Z06 Only).............................5-77
Section 5 Service and Appearance Care
5-1

A. Coolant Surge Tank and Pressure Cap. SeeEngine
Coolant on page 5-23.
B. Battery. SeeBattery on page 5-40.
C. Engine Oil Dipstick. SeeEngine Oil on page 5-13.
D. Engine Oil Fill Cap. SeeEngine Oil on page 5-13.
E. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-18.
F. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-35.
G. Brake Fluid Reservoir. SeeBrakes on page 5-37.
H. Clutch Master Cylinder Reservoir. SeeHydraulic
Clutch on page 5-22.
I. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-36.Engine Oil
If the LOW OIL LEVEL message on the Driver
Information Center comes on, it means you need to
check your engine oil level right away. For more
information, seeDriver Information Center (DIC) on
page 3-48.
You should check your engine oil level regularly; this is
an added reminder.
Checking Engine Oil
It is a good idea to check your engine oil level every
time you get fuel. In order to get an accurate reading,
the oil must be warm and the vehicle must be on
level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil a few minutes to
drain back into the oil pan. If you don’t, the oil dipstick
might not show the actual level.
Pull out the dipstick and clean it with a paper towel or a
cloth, then push it back in all the way. Remove it
again, keeping the tip down.
5-13

Power Steering Fluid
When to Check Power Steering Fluid
It is not necessary to regularly check power steering fluid
unless you suspect there is a leak in the system or
you hear an unusual noise. A fluid loss in this system
could indicate a problem. Have the system inspected
and repaired. SeeEngine Compartment Overview
on page 5-12for reservoir location.
How to Check Power Steering Fluid
Turn the key off, let the engine compartment cool down,
wipe the cap and the top of the reservoir clean, then
unscrew the cap and wipe the dipstick with a clean rag.
Replace the cap and completely tighten it. Then remove
the cap again and look at the fluid level on the dipstick.
There are markings on both sides of the dipstick.
The level should be at the FULL COLD mark.
If necessary, add only enough fluid to bring the
level up to the mark.
•When the engine
compartment is hot, the
level should be at
the HOT mark.
•When the engine
compartment is cool, the
level should be at the
FULL COLD mark.
What to Use
To determine what kind of fluid to use, see
Recommended Fluids and Lubricants on page 6-11.
Always use the proper fluid. Failure to use the proper
fluid can cause leaks and damage hoses and seals.
5-35

(C) Aspect Ratio:A two-digit number that indicates the
tire height-to-width measurements. For example, if
the tire size aspect ratio is “70,” as shown in item “C” of
the illustration, it would mean that the tire’s sidewall
is 70% as high as it is wide.
(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire. The letter
“R” means radial ply construction; the letter “D” means
diagonal or bias ply construction; and the letter “B”
means belted-bias ply construction.
(E) Rim Diameter:Diameter of the wheel in inches.
(F) Service Description:These characters represent
the load range and the speed rating of a tire. The
load range represents the load carrying capacity a tire is
certified to carry. The load index can range from 1 to
279. The speed rating is the maximum speed a tire
is certified to carry a load. Speed ratings range
from “A” to “Z”.Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to its
width.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi)
before a tire has built up heat from driving.
SeeInation - Tire Pressure on page 5-62.
5-58

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

Maintenance Footnotes
†The 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 emission 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.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chang, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear. Inspect power steering lines and
hoses for proper hook-up, binding, leaks, cracks,
chang, etc.
(c)Visually inspect hoses and have them replaced if
they are cracked, swollen or deteriorated. Inspect all
pipes, ttings and clamps; replace with genuine GM parts
as needed. To help ensure proper operation, a pressure
test of the cooling system and pressure cap and cleaning
the outside of the radiator and air conditioning condenser
is recommended at least once a year.(d)Visually inspect wiper blades for wear or cracking.
Replace blade inserts that appear worn or damaged
or that streak or miss areas of the windshield.
(e)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.)
(f)Lubricate all key lock cylinders and body door
hinges.Lubricate all hinges and latches, including those
for the hood, rear compartment, console door and
any folding seat hardware. More frequent lubrication
may be required when exposed to a corrosive
environment. Applying silicone grease on weatherstrips
with a clean cloth will make them last longer, seal
better and not stick or squeak.
(g)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired
and the uid level checked. Add uid if needed.
6-7

Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Hydraulic
Clutch SystemHydraulic Clutch Fluid (GM Part No.
U.S. 12345347, in Canada
10953517) or equivalent DOT-3
brake fluid.
Power Steering
SystemGM Power Steering Fluid (GM Part
No. U.S. 89021184, in Canada
89021186).
Manual
TransmissionDEXRON
®-III Automatic
Transmission Fluid.
Automatic
TransmissionDEXRON
®-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Usage Fluid/Lubricant
Rear Axle
(Limited-Slip
Differential)SAE 75W-90 Synthetic Axle
Lubricant (GM Part No. U.S.
12378261, in Canada 10953455)
meeting GM Specification 9986115.
With a complete drain and refill add
4 ounces (118 ml) of Limited-Slip
Axle Lubricant Additive (GM
Part No. U.S. 1052358, in
Canada 992694) where required.
SeeRear Axle on page 5-47.
Hood Latch
Assembly,
Secondary
Latch, Pivots,
Spring Anchor
and Release
PawlLubriplate Lubricant Aerosol
(GM Part No. U.S. 12346293, in
Canada 992723) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Hood and Door
HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Weatherstrip
ConditioningDielectric Silicone Grease
(GM Part No. U.S. 12345579, in
Canada 992887).
6-12

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 48232-5170
In 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
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
7-11

Electrical System (cont.)
Windshield Wiper Fuses...............................5-92
Emergency Trunk Release Handle
(Convertible Only)........................................2-13
Emissions Inspection and
Maintenance Programs.................................3-44
Engine
Air Cleaner/Filter.........................................5-18
Battery.......................................................5-40
Check and Service Engine Soon Light............3-41
Coolant......................................................5-23
Coolant Heater............................................2-23
Coolant Temperature Gage...........................3-41
Drive Belt Routing.......................................6-14
Engine Compartment Overview......................5-12
Exhaust.....................................................2-36
Oil .............................................................5-13
Oil Pressure Gage.......................................3-44
Overheating................................................5-26
Starting......................................................2-21
Engine Compartment Fuse Block......................5-96
Engine Oil Additives........................................5-16
Event Data Recorders (EDR)............................. 7-9
Exit/Entry Lighting...........................................3-17
Express-Down Window....................................2-15
Extended Mobility Tires....................................5-61
Extender, Safety Belt.......................................1-19
Exterior Lamps...............................................3-13F
Filter
Engine Air Cleaner......................................5-18
Finding a Station....................................3-71, 3-77
Finish Care....................................................5-86
Finish Damage...............................................5-89
Fixed Mast Antenna........................................3-89
Flash-to-Pass................................................... 3-8
Flat Tire........................................................5-75
Floor Mats.....................................................2-41
Fluid
Automatic Transmission................................5-20
Manual Transmission....................................5-21
Power Steering...........................................5-35
Windshield Washer......................................5-36
FM ...............................................................3-88
Fog Lamps....................................................3-15
Front Air Dam................................................2-19
Fuel............................................................... 5-4
Additives...................................................... 5-6
California Fuel.............................................. 5-5
Filling a Portable Fuel Container....................5-10
Filling Your Tank........................................... 5-7
Fuels in Foreign Countries.............................. 5-6
Gage.........................................................3-46
Gasoline Octane........................................... 5-5
Gasoline Specifications.................................. 5-5
5

Fuses
Fuses and Circuit Breakers...........................5-93
Windshield Wiper.........................................5-92
G
Gage
Check Gages Warning Light..........................3-46
Engine Coolant Temperature.........................3-41
Engine Oil Pressure.....................................3-44
Fuel..........................................................3-46
Speedometer..............................................3-34
Tachometer.................................................3-34
Voltmeter Gage...........................................3-37
Gasoline
Octane........................................................ 5-5
Specifications............................................... 5-5
Glove Box.....................................................2-40
GM Mobility Program for Persons with
Disabilities.................................................... 7-5
H
Hatch/Trunk...................................................2-11
Hatch/Trunk Lid Release..................................2-12
Hazard Warning Flashers................................... 3-4Headlamp High/Low-Beam Changer.................... 3-8
Headlamp Wiring............................................5-92
Headlamps....................................................5-48
Bulb Replacement.......................................5-48
Halogen Bulbs............................................5-48
Headlamps Doors...........................................3-14
Headlamps on Reminder................................... 3-8
Head-Up Display (HUD)...................................3-18
Highway Hypnosis...........................................4-26
Hill and Mountain Roads..................................4-26
Hood
Checking Things Under................................5-10
Release.....................................................5-11
Hood, Carbon Fiber........................................5-89
Horn............................................................... 3-5
How to Add Coolant to the Coolant
Surge Tank.................................................5-31
How to Add Fluid............................................5-22
How to Check and Add Fluid............................5-23
How to Check Lubricant...................................5-47
How to Check Power Steering Fluid..................5-35
How to Remove and Replace the Floor Mats......2-41
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-11
Hydraulic Clutch.............................................5-22
Hydroplaning..................................................4-22
6