2004 CHEVROLET CORVETTE clutch

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

How to Add Fluid
Here’s how to add fluid. Refer to the Maintenance
Schedule to determine what kind of fluid to use. See
Recommended Fluids and Lubricants on page 6-11.
1. Remove the filler plug.
2. Add fluid at the filler plug hole. Add only enough
fluid to bring the fluid level up to the bottom of the
filler plug hole.
3. Install the filler plug. Be sure the plug is fully
seated.
4. Tighten the plug to 20 lb ft (27Y).
Hydraulic Clutch
The hydraulic clutch linkage in your vehicle is
self-adjusting. The master cylinder reservoir is filled with
hydraulic fluid.
It is not necessary to regularly check the fluid unless
you suspect there is a leak in the system. Adding fluid
won’t correct a leak.
A fluid loss in this system could indicate a problem.
Have the system inspected and repaired.
When to Check and What to Use
The clutch master cylinder reservoir is located at the
rear of the engine compartment on the driver’s side. See
Engine Compartment Overview on page 5-12for
more information on location.
Refer to the Maintenance Schedule to determine how
often you should check the fluid level in your master
cylinder reservoir and for the proper fluid. SeeOwner
Checks and Services on page 6-8andRecommended
Fluids and Lubricants on page 6-11.
5-22

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 LampRelay Usage
40 Blank
41 Blank
42 Ignition 1
43 Cooling Fan 2
44 Cooling Fan 3
45 Cooling Fan 1
5-98

At Least Once a Month
Tire Inspection and Ination Check
Visually inspect your tires for wear and make sure tires
are inflated to the correct pressures. SeeTires on
page 5-55for further details.
Cassette Tape Player Service
Clean cassette tape player. Cleaning should be done
every 50 hours of tape play. SeeAudio System(s)
on page 3-69for further details.
Power Antenna Service
Clean power antenna mast. SeeAudio System(s) on
page 3-69for further details.
At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-31if
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, contact your GM Goodwrench
dealer for service.
4. On manual transmission vehicles, put the shift lever
in NEUTRAL (N), push the clutch pedal down
halfway and try to start the engine. The starter
should work only when the clutch pedal is pushed
down all the way to the floor. If the starter works
when the clutch is not pushed all the way down,
contact your GM Goodwrench dealer for service.
6-9

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

Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-90
Child Restraints
Child Restraint Systems...............................1-25
Infants and Young Children...........................1-22
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-30
Older Children.............................................1-19
Securing a Child Restraint Designed for
the LATCH System...................................1-33
Securing a Child Restraint in the
Passenger Seat Position...........................1-36
Top Strap...................................................1-28
Top Strap Anchor Location............................1-30
Cigarette Lighter.............................................3-23
Cleaning
Fiberglass Springs.......................................5-90
Inside of Your Vehicle..................................5-83
Outside of Your Vehicle................................5-85
Titanium Exhaust System..............................5-89
Underbody Maintenance...............................5-89
Weatherstrips..............................................5-85
Cleaning Aluminum Wheels..............................5-88
Cleaning Coated Moldings................................5-83
Cleaning Exterior Lamps/Lenses.......................5-86
Cleaning Fabric/Carpet....................................5-83
Cleaning Glass Surfaces..................................5-84
Cleaning Interior Plastic Components.................5-84Cleaning Leather............................................5-84
Cleaning Removable Roof Panel.......................5-87
Cleaning the Convertible Top............................5-88
Cleaning the Security Shade and
Convenience Net.........................................5-84
Cleaning the Top of the Instrument Panel...........5-84
Cleaning Tires................................................5-88
Cleaning Windshield and Wiper Blades..............5-87
Climate Control System
Dual Automatic............................................3-23
Outlet Adjustment........................................3-31
Clutch, Hydraulic.............................................5-22
Competitive Driving Mode................................4-12
Control of a Vehicle.......................................... 4-6
Convenience Net............................................2-43
Convertible Top..............................................2-50
Lowering the Convertible Top........................2-51
Raising the Convertible Top..........................2-55
Coolant
Engine Temperature Gage............................3-41
Heater, Engine............................................2-23
Surge Tank Pressure Cap.............................5-26
Cooling System..............................................5-29
Courtesy Lamps.............................................3-17
Cruise Control................................................3-10
Cupholder(s)..................................................2-40
Current and Past Model Order Forms................7-12
Customer Assistance Information
Courtesy Transportation.................................. 7-7
3

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