engine CHEVROLET CORVETTE 2004 5.G Repair Manual

If You Are Stuck: In Sand, Mud,
Ice or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you do not want to
spin your wheels too fast. The method known as
“rocking” can help you get out when you are stuck, but
you must use caution.
{CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured.
And, the transmission or other parts of the
vehicle can overheat. That could cause an
engine compartment re or other damage.
When you are stuck, spin the wheels as little as
possible. Do not spin the wheels above 35 mph
(55 km/h) as shown on the speedometer.
Notice:Spinning your wheels can destroy parts of
your vehicle as well as the tires. If you spin the
wheels too fast while shifting your transmission
back and forth, you can destroy your transmission.
For information about using tire chains on your
vehicle, seeTire Chains on page 5-71.
Rocking Your Vehicle To Get It Out
First, turn your steering wheel left and right. That will
clear the area around your front wheels. You should turn
your TCS System off. SeeTraction Control System
(TCS) on page 4-9. Then shift back and forth between
REVERSE (R) and a forward gear, spinning the
wheels as little as possible. For a manual transmission,
shift slowly between either FIRST (1) or SECOND (2)
and REVERSE (R), allowing the wheels to stop
before shifting into gear. Release the accelerator pedal
while you shift, and press lightly on the accelerator
pedal when the transmission is in gear. By slowly
spinning your wheels in the forward and reverse
directions, you will cause a rocking motion that may free
your vehicle. If that does not get you out after a few
tries, you may need to be towed out. If you do need to
be towed out, seeTowing Your Vehicle on page 4-33.
4-32

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

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many fluids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Gasoline Octane
Use premium unleaded gasoline with a posted octane of
91 or higher for best performance. You may also use
middle grade or regular unleaded gasoline rated at
87 octane or higher, but your vehicle’s acceleration may
be slightly reduced. If the octane is less than 87, you
may get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher
as soon as possible. Otherwise, you might damage
your engine.
Gasoline Specications
It is recommended that gasoline meet specifications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of
Automobile Manufacturers at
www.autoalliance.org/fuel_charter.htm. Gasoline
meeting these specifications could provide improved
driveability and emission control system performance
compared to other gasoline.In Canada, look for the
“Auto Makers’ Choice”
label on the pump.California Fuel
If your vehicle is certified to meet California Emission
Standards (see the underhood emission control label), it
is designed to operate on fuels that meet California
specifications. If this fuel is not available in states
adopting California emissions standards, your vehicle will
operate satisfactorily on fuels meeting federal
specifications, but emission control system performance
may be affected. The malfunction indicator lamp may turn
on (seeMalfunction Indicator Lamp on page 3-41) and
your vehicle may fail a smog-check test. If this occurs,
return to your authorized GM dealer for diagnosis. If it is
determined that the condition is caused by the type of fuel
used, repairs may not be covered by your warranty.Canada Only
5-5

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. You should not have to add anything to your
fuel. However, some gasolines contain only the
minimum amount of additive required to meet U.S.
Environmental Protection Agency regulations. General
Motors recommends that you buy gasolines that
are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems due
to dirty injectors or valves, try a different brand of
gasoline.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specifications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.Some gasolines that are not reformulated for
low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General
Motors does not recommend the use of such gasolines.
Fuels containing MMT can reduce the life of spark
plugs and the performance of the emission control
system may be affected. The malfunction indicator lamp
may turn on. If this occurs, return to your authorized
GM dealer for service.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to find. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-6

Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The fuel filler door is located on the driver’s side of the
vehicle. The fuel cap is attached by a tether for your
convenience.
The fuel filler door release
button is located inside of
the center console
storage compartment.
5-7

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
5-10

Engine Compartment Overview
When you open the hood, you will see the following:
5-12

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

When to Add Engine Oil
If the oil is below the cross-hatched area at the tip of
the dipstick, you will need to add at least one quart of oil.
But you must use the right kind. This section explains
what kind of oil to use. For engine oil crankcase
capacity, seeCapacities and Specications on
page 5-99.
See “Racing or Other Competitive Driving” under
Starting Your Engine on page 2-21for additional
information on engine oil.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the
cross-hatched area that shows the proper operating
range, your engine could be damaged.SeeEngine Compartment
Overview on page 5-12for
the location of the
engine oil fill cap.
Be sure to add enough oil to put the level somewhere in
the proper operating range. Push the dipstick all the
way back in when you are through.
What Kind of Engine Oil to Use
Look for two things:
•GM4718M
Your vehicle’s engine requires a special oil meeting
GM Standard GM4718M. Oils meeting this
standard may be identified as synthetic. However,
not allsyntheticoils will meet this GM standard.
You should look for and use only an oil that meets
GM Standard GM4718M.
Notice:If you use oils that do not have the
GM4718M Standard designation, you can cause
engine damage not covered by your warranty.
5-14