2009 CHEVROLET CORVETTE manual transmission

Service............................................................5-3
Accessories and Modications..........................5-3
California Proposition 65 Warning.....................5-4
California Perchlorate Materials Requirements.....5-4
Doing Your Own Service Work.........................5-5
Adding Equipment to the Outside of the
Vehicle......................................................5-5
Fuel................................................................5-6
Gasoline Octane............................................5-6
Gasoline Specications....................................5-6
California Fuel...............................................5-7
Additives.......................................................5-7
Fuels in Foreign Countries...............................5-8
Filling the Tank..............................................5-9
Filling a Portable Fuel Container.....................5-12
Checking Things Under the Hood....................5-12
Hood Release..............................................5-13
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-20
Engine Oil Life System..................................5-26
Engine Air Cleaner/Filter................................5-28
Automatic Transmission Fluid.........................5-30
Manual Transmission Fluid.............................5-31
Hydraulic Clutch...........................................5-31
Cooling System (Engine)................................5-32
Cooling System (Intercooler)...........................5-33Engine Coolant.............................................5-34
Engine Overheating.......................................5-39
Overheated Engine Protection
Operating Mode........................................5-41
Power Steering Fluid.....................................5-42
Windshield Washer Fluid................................5-43
Brakes........................................................5-44
Battery........................................................5-50
Jump Starting...............................................5-51
Rear Axle.......................................................5-55
Headlamp Aiming...........................................5-56
Bulb Replacement..........................................5-56
High Intensity Discharge (HID) Lighting............5-56
Halogen Bulbs..............................................5-57
Headlamps, Front Turn Signal, and
Parking Lamps..........................................5-57
Taillamps, Turn Signal, and Stoplamps............5-59
Replacement Bulbs.......................................5-59
Windshield Replacement.................................5-60
Windshield Wiper Blade Replacement..............5-60
Tires..............................................................5-62
Winter Tires.................................................5-63
Tire Sidewall Labeling...................................5-64
Tire Terminology and Denitions.....................5-66
Run-Flat Tires..............................................5-69
Section 5 Service and Appearance Care
5-1

4. Inspect or replace the lter. SeeMaintenance
Replacement Parts on page 6-14.
5. Reverse Steps 1 and 3 to replace the air
cleaner/lter cover.
{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned. The air
cleaner not only cleans the air; it helps to stop
ames if the engine backres. If it is not there and
the engine backres, you could be burned. Do not
drive with it off, and be careful working on the
engine with the air cleaner/lter off.
Notice:If the air cleaner/lter is off, a backre
can cause a damaging engine re. And, dirt can
easily get into the engine, which will damage it.
Always have the air cleaner/lter in place when
you are driving.
Automatic Transmission Fluid
How to Check Automatic Transmission
Fluid
It is not necessary to check the transmission uid level.
A transmission uid leak is the only reason for uid loss.
If a leak occurs, take the vehicle to your dealer/retailer
service department and have it repaired as soon as
possible.
There is a special procedure for checking and changing
the transmission uid. Because this procedure is difficult,
you should have this done at your dealer/retailer service
department. Contact your dealer/retailer for additional
information or the procedure can be found in the service
manual. To purchase a service manual, seeService
Publications Ordering Information on page 7-15.
Notice:Use of the incorrect automatic transmission
uid may damage the vehicle, and the damages may
not be covered by the vehicle’s warranty. Always
use the automatic transmission uid listed in
Recommended Fluids and Lubricants on page 6-12.
Change the uid and lter at the intervals listed in
Additional Required Services on page 6-6, and be
sure to use the uid listed inRecommended Fluids
and Lubricants on page 6-12.
5-30

Manual Transmission Fluid
It is not necessary to check the manual transmission
uid level. A transmission uid leak is the only reason
for uid loss. If a leak occurs, take the vehicle to your
dealer/retailer service department and have it repaired
as soon as possible. SeeRecommended Fluids and
Lubricants on page 6-12for the proper uid to use.
Hydraulic Clutch
It is not necessary to regularly check clutch uid unless
you suspect there is a leak in the system. Adding
uid will not correct a leak. A uid loss in this system
could indicate a problem. Have the system inspected
and repaired.
When to Check and What to Use
The hydraulic clutch uid
reservoir cap has this
symbol on it. SeeEngine
Compartment Overview
on page 5-14for reservoir
location.
Refer to the Maintenance Schedule for the proper uid
to use. SeeRecommended Fluids and Lubricants on
page 6-12. The uid requires changing every two years.
SeeAdditional Required Services on page 6-6.
How to Check and Add Fluid
Visually check the clutch uid reservoir to make sure
the uid level is at the MIN (minimum) line on the side of
the reservoir. The hydraulic clutch uid system should
be closed and sealed.
Do not remove the cap to check the uid level or
to top-off the uid level. Remove the cap only when
necessary to add the proper uid until the level reaches
the MIN line.
5-31

Jump Starting
If your battery has run down, you may want to use
another vehicle and some jumper cables to start your
vehicle. Be sure to use the following steps to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
They contain acid that can burn you.
They contain gas that can explode or ignite.
They contain enough electricity to burn you.
If you do not follow these steps exactly, some or
all of these things can hurt you.
Notice:If you try to start your vehicle by pushing
or pulling it, you could damage your vehicle. Do not
push or pull your vehicle to start it; instead, use
the jump starting procedure in this manual to start
your vehicle when the battery has run down.
1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be able
to start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling,
set the parking brake rmly on both vehicles
involved in the jump start procedure. Put an
automatic transmission in P (Park) or a manual
transmission in Neutral before setting the parking
brakes.
Notice:If you leave the radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered by
the warranty. Always turn off the radio and other
accessories when jump starting the vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or the accessory power outlet. Turn off the
radio and all lamps that are not needed. This will
avoid sparks and help save both batteries. And it
could save the radio!
5-51

Lifting the Vehicle
{CAUTION:
Lifting a vehicle can cause an injury. The vehicle
can slip off the jack and roll over you or other
people. You and they could be badly injured.
Find a level place to lift your vehicle. To help
prevent the vehicle from moving:
1. Set the parking brake rmly.
2. Put an automatic transmission shift lever in
P (Park), or shift a manual transmission to
1 (First) or R (Reverse).
3. Turn off the engine.
To be even more certain the vehicle won’t move,
you can put blocks in front of and behind the
wheels.
{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 the vehicle with the jack improperly
positioned can damage the vehicle or the vehicle
may fall and cause your or others injury.
5-86

Fuse Usage
5 Stoplamps/Back-Up Lamps
6 Oxygen Sensor
7 Battery Main 5
8 Parking Lamps
9Powertrain Relay Input/Electronic
Throttle Control
10 Manual Transmission Solenoids
11 Antilock Braking System
12 Odd Numbered Fuel Injectors
13Electronic Suspension Control
(Option)
14Canister Purge Solenoid,
Mass Air Flow Sensor
15 Air Conditioner Compressor
16 Even Numbered Fuel Injectors
17 Windshield Washer
18 Headlamp Washer
19Passenger Side Low-Beam
Headlamp
20 Fuel PumpFuse Usage
21 Driver Side Low-Beam Headlamp
22 Front Fog Lamp
23Passenger Side High-Beam
Headlamp
24 Driver Side High-Beam Headlamp
56Engine Control Module (ECM)/
Transmission Control Module (TCM)/
Easy Key Module
J-Style Fuses Usage
25 Cooling Fan
26 Battery Main 3
27 Antilock Brake System
28Heating/Ventilation/Air Conditioning
Blower
29 Battery Main 2
30 Starter
31 Audio Amplier
32 Intercooler Pump
33 Battery Main 1
5-108

ApplicationCapacities
English Metric
Transmission Fluid
Automatic Transmission (Pan Removal and Filter
Replacement)6.5 qt 6.2 L
Manual Transmission – Base 3.6 qt 3.5 L
Manual Transmission – Z51 4.2 qt 4.0 L
Manual Transmission – Z06 4.5 qt 4.3 L
Manual Transmission – ZR1 4.5 qt 4.3 L
Wheel Nut Torque 100 lb ft 140Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual. Recheck uid level after lling
5-111

Engine Specications
Engine VIN Code Transmission Spark Plug Gap Firing Order
6.2L LS3 V8 WAutomatic
Manual0.040 in (1.016 mm) 1–8–7–2–6–5–4–3
6.2L LS9 V8 R Manual 0.040 in (1.016 mm) 1–8–7–2–6–5–4–3
7.0L LS7 V8 E Manual 0.040 in (1.016 mm) 1–8–7–2–6–5–4–3
Engine Data
Engine Horsepower Torque Displacement Compression Ratio
6.2L LS3 V8 without
option NPP430 @ 5900 rpm 424 lb ft @ 4600 rpm 6.2L 10.69:1
6.2L LS3 V8 with
option NPP436 @ 5900 rpm 428 lb ft @ 4600 rpm 6.2L 10.69:1
6.2L LS9 V8
Supercharged638 @ 6500 rpm 604 lb ft @ 3800 rpm 6.2L 9.10:1
7.0L LS7 V8 505 @ 6300 rpm 470 lb ft @ 4800 rpm 7.0L 11.00:1
5-112