2004 CHEVROLET CORVETTE manual transmission

Z06 models do not have Extended Mobility Tires. If a
Z06 model tire goes flat, avoid further tire and wheel
damage by driving slowly to a level place and stopping.
Then do this:
1. Turn on the hazard warning flashers.
2. Set the parking brake firmly.
3. Put the shift lever (manual transmission) in
REVERSE (R).
4. Turn off the engine.
5. Inspect the flat tire.
If the tire has been separated from the wheel or has
damaged sidewalls or large tears that allow rapid
air loss, call a tire repair facility. SeeRoadside
Assistance Program on page 7-6.
If the flat tire is due to a slow leak caused by a nail or
other similar road hazard, the tire inflator kit may
be used to repair the damaged tire temporarily. The kit
uses a liquid tire sealant to seal small punctures inthe tread area of the tire. The flat tire is then inflated to
at least 26 psi (179 kPa) and driven to evenly distribute
the tire sealant. The tire pressure is checked after
driving for a maximum of 10 minutes to see if the slow
leak has been stopped. If the tire pressure is 19 psi
(131 kPa) or more, inflate the tire up to the standard
operating pressure as shown on the Tire Pressure Label
found on the rear edge of the driver’s door. See
Ination - Tire Pressure on page 5-62.
You should have the damaged tire repaired as soon as
possible. The tire sealant is a temporary repair only.
For more information regarding the tire inflator kit
see “Tire Inflator Kit (Z06 Only)” following this section.
Notice:If the tire pressure has dropped below
19 psi (131 kPa), the vehicle should not be driven
further. Damage to the tire may be severe and
the sealant will not be effective. Contact Roadside
Assistance. See “Roadside Assistance” in the Index.
5-76

Notice:The car engine must be running to avoid
draining the battery while running the air
compressor.
Follow the proper steps to be sure your vehicle will not
move. SeeParking Your Vehicle (Manual Transmission)
on page 2-35.
{CAUTION:
It can be dangerous to get out of your vehicle
with the engine running, if the shift lever is not
in NEUTRAL (N) with the parking brake rmly
set (manual transmission). Your vehicle can
roll or move suddenly even when on fairly
level ground. To be sure your vehicle won’t
move, always set your parking brake and move
the shift lever to NEUTRAL (N) when you start
or idle your engine.
{CAUTION:
Idling the engine in a closed-in place or with
the climate control system off can cause
deadly carbon monoxide (CO). See “Engine
Exhaust” in the Index.
{CAUTION:
Inating something too much can make it
explode, and you or others could be injured.
Be sure to read the inator instructions, and
inate the tire to its recommended pressure.
Do not exceed 36 psi (248 kPa).
5-79

Capacities and Specications
The following approximate capacities are given in English and metric conversions.
Please refer toRecommended Fluids and Lubricants on page 6-11for more information.
Capacities and Specications
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.75 lbs 0.79 kg
Automatic Transmission
Drain and Refill 5.0 quarts 4.7 L
Overhaul 10.8 quarts 10.2 L
Cooling System 12.6 quarts 11.9 L
Engine Oil with Filter 6.5 quarts 6.1 L
Fuel Tank 18.0 gallons 68.0 L
Manual Transmission (Overhaul) 4.1 quarts 3.8 L
Wheel Nut Torque 100 lb ft 140Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling
5-99

Engine Specications
Engine VIN Code Transmission Spark Plug Gap Firing Order
LS1 V8 G Automatic 0.040 inch
(1.016 mm)1–8–7–2–6–5–4–3
LS1 V8 G Manual 0.040 inch
(1.016 mm)1–8–7–2–6–5–4–3
LS6 V8 S Manual 0.040 inch
(1.016 mm)1–8–7–2–6–5–4–3
Engine Data
Engine Horsepower Torque Displacement Compression Ratio
LS1 Automatic
Transmission350 @ 5200 rpm 360 lb ft @ 4000 rpm 5.7 L 10.1:1
LS1 Manual
Transmission350 @ 5200 rpm 375 lb ft @ 4400 rpm 5.7 L 10.1:1
LS6 405 @ 6000 rpm 400 lb ft @ 4800 rpm 5.7 L 10.5:1
5-100

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

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

Customer Assistance Information (cont.)
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....7-11
Reporting Safety Defects to the Canadian
Government............................................7-11
Reporting Safety Defects to the United
States Government...................................7-10
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-11
D
Daytime Running Lamps..................................3-15
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-30
Disabling the Theft-Deterrent Feature.................3-87
Disarming the System.....................................2-17
Doing Your Own Service Work........................... 5-4
Door
Locks.......................................................... 2-9
Power Door Locks.......................................2-10
Downshifting (Manual Transmission)..................2-30Driver
Position, Safety Belt.....................................1-12
Driver Information Center (DIC).........................3-48
DIC Controls and Displays............................3-49
DIC Warnings and Messages........................3-58
Other Messages..........................................3-68
Driving
At Night.....................................................4-19
City...........................................................4-23
Defensive..................................................... 4-2
Drunken....................................................... 4-3
Freeway.....................................................4-24
Hill and Mountain Roads..............................4-26
In Rain and on Wet Roads...........................4-20
Winter........................................................4-28
Driving On Snow or Ice...................................4-29
Driving Through Deep Standing Water...............4-22
Driving Through Flowing Water.........................4-22
Dual Automatic Climate Control System.............3-23
E
Electrical System
Add-On Equipment......................................5-92
Fuses and Circuit Breakers...........................5-93
Headlamp Wiring.........................................5-92
Power Windows and Other Power Options......5-92
4