Chevrolet 2003 Corvette User manual

Chevrolet
Corvette
2003·

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Table of Contents
Product Information .......................................................................................................................................1
Chevrolet Releases 50th Anniversary Edition Corvette, Adds MagneticSelective Ride Control To
Lineup .........................................................................................................................................................1
A Golden.Tribute....................................................................................................................................1
Magnetic Selective Ride Control ............................................................................................................1
More Standard Equipment .....................................................................................................................1
CRAS Child Seat Hooks, Other New Features......................................................................." .............1
NewFor2002.............................................................................................................................................2
Model Lineup..............................................................................................................................................2
Specifications.................................................................................................................................................3
Overview..............................................
,......................................................................................................3
Engines ....................................................................................
;.................................................................3
Transmissions............................................................................................................................................3
Chassis/Suspension ......................................................................................................
~ .......,...................4
Brakes........................................................................................................................................................4
WheelsITires..............................................................................................................................................4
Dimensions....................................................................................................................................................5
Exterior.......................................................................................................................................................5
Interior........................................................................................................................................................5
Capacities ..................................................................................................................................................5
Vehicle Identification......................................................................................................................................6
Vehicle Identification Number (VIN) US/Canada.......................................................................................6
Vehicle Identification Number (VIN) Export...............................................................................................7
VIN Derivative ............................................................................................................................................8
Label Certification ......................................................................................................................................9
Service Parts Identification Label (SPID).................................................................................................10
Tire Placard............................................................................................................................................... 11
Engine 10 and VIN Derivative Location 5.7L ...........................................................................................12
5.7L Engine Identification Numbers,
LS1(C) ..........................................................................................12
5.7L Engine VIN Derivative Locations,
LS1(C) ........... ~ ..........................................................................13
Transmission
10 and VIN Derivative Location .........................................................................................14
Borg WarnerT-56 Transmission
10 Location.......................................................................................14
4L60-E Automatic Transmission 10 Number Location, M30(c) .............................................................15
Automatic Transmission Identification Number System...................................................................15
4L60-E Automatic Transmission VIN Derivative Locations, M30(C) ......................................................16
Axle Identification - Rear .........................................................................................................................17
Labeling -Anti-Theft.................................................................................................................................18
Notice ..........................................................................................................................................
;........18
RPO Code List.........................................................................................................................................19
Technical Information .................................................................................................................................. 21
Maintenance and Lubrication................................................................................................................... 21
CapaCities -Approximate Fluid ............................................................................................................ 21
Engine SpeCifications............................................................................................................................ 21
Engine Data....................................................................................................:..................................... 21
Maintenance Items................................................................................................................................ 21
Tire Inflation Pressure Specifications................................................................................................... 21
Fluid and Lubricant Recommendations................................................................................................22
Descriptions and Operations .......................................................................................................................23
Power Steering System ...............................................................................................................................23
Power Steering
Pump Description...................................................................:.......................................23
Power Steering
Gear Description ............................................................................................................23
Variable Effort Steering Description.........................................................................................................23
Variable Effort Steering Components........................................................................................,..........24
The Electronic
Brake Control Module (EBCM).................................................................................24
Pagei

The MAGNASTEER® Actuator ........................................................................................................24
The Power Rack Gear.......................................................................................................................24
The Power Steering Pump .................................................................................... .- ...........................25
Electronic Brake Traction Control Description .....................................................................................25
Steering Wheel and Column.........................................................................................................................25
Vehicle Steering .......................................................................................................................................25
Vehicle Security ............................:..........................................................................................................25
Driver Convenience .................................................................................................................................25
Driver Safety .............................................................................................................................................26
Tilt\Telescoping Description.....................................................................................................................26
Tilt\Telescoping Operation .......,...........................................................................................................26
Suspension Description and Operation .......................................................................................................26
Front Suspension .....................................................................................................................................26
Rear Suspension .....................................................................................................................................27
Tire Pressure Monitor System Description ..............................................................................................27
Electronic Suspension Control Description..............................................................................................28
Electronic Suspension Control Module ................................................................................................28
Electronic Suspension Control Position Sensors .................................................................................28
Electronic Suspension Control Shock Absorber or Strut .....................................................................28
Electronic Suspension Control Operation .............................................................................................29
Wheels and Tires .........................,...........................................................................................................29
General Description..............................................................................................................................29
Tires Description ...................................................................................................................................30
Passenger Tire Service Description .....................................................................................................30
Metric Wheel Nuts and Bolts Description......................................................................................•......30
Tire Inflation Description ..... ...................................................................................................................30
P-Metric Sized Tires Description ..........................................................................................................32
Driveline System Description and Operation...............................................................................................33
Driveline/Axle - Propeller Shaft................................................................................................................33
Driveline Support Assembly Description ..............................................................................................33
Propeller Shaft Assembly (Automatic Transmission)(c).......................................................................33
Propeller Shaft Assembly (Manual Transmission)(c)...........................................................................34
Wheel Drive Shafts Description and Operation ........................................................................:..............34
Seal and Clamp.......................................................................................................................,............34
Inner Joint.............................................................................................................................................35
Outer Joint ............................................................................................................................................35
Rear Drive Axle Description and Operation .............................................................................................35
Braking System Description and Operation ................................................................................................36
Hydraulic Brake System Description and Operation .. ,.......................................... ~ .................................36
System Component Description...........................................................................................................36
Hydraulic Brake Master Cylinder Fluid Reservoir..................................:..........................................36
Hydraulic Brake Master Cylinder ......................................................................................................36
Hydraulic Brake Pressure Balance Control System .........................................................................36
Hydraulic Brake Pipes and Flexible Brake Hoses ............................................................................36
Hydraulic Brake Wheel Apply Components .....................................................................................36
System Operation.................................................................................................................................36
Brake Assist System Description and Operation ... ..................................................................................36
System Component Description...........................................................................................................36
Brake Pedal .........................................................................................,............................................36
Brake Pedal Pushrod ........................................................................................................................36
Vacuum Brake Booster.....................................................................................................................36
Vacuum Source ..............•.................................................................................................................37
Vacuum Source Delivery System .....................................................................................................37
System Operation.................................................................................................................................37
Disc Brake System Description and Operation........................................................................................37
System Component Description...........................................................................................................37
Pageii

Disc Brake Pads ...............................................................................................................................37
Disc Brake Rotors..............................................................................................................................37
Disc Brake Pad Hardware ................................................................................................................37
Disc Brake Caliper Hardware ........................................................................................................... 37
System Operation................................................................................................................................. 37
Park Brake System Description and Operation....................................................................................... 38
System Component Description........................................................................................................... 38
Park Brake Lever Assembly............................................................................................................. 38
Park Brake Cables............................................................................................................................ 38
Park Brake Cable Equalizer .............................................................................................................38
Park Brake Apply Lever....................................................................................................................
38
Park Brake Actuator/Adjuster...........................................................................................,...............38
Park Brake Shoe (Rear Disc, Drum-In-Hat System)................................................,....................... 38
System Operation................................................................................................................................. 38
ABS Description and Operation............................................................................................................... 38
Antilock Brake System ......................................................................................................................... 38
Engine Description and Operation...............................................................................................................40
Engine Mechanical- LS1 5.7L................................................................................................................40
General Specifications .........................................................................................................................40
General .............................................................................................................................................40
Block.................................................................................................................................................40
Camshaft ..........................................................................................................................................40
Connecting Rod ........................................................................................................................... ~ .... 40
Crankshaft ........................................................................................................................................ 41
Cylinder Head................................................................................................................................... 41
Intake Manifold ................................................................................,................................................ 41
Lubrication System ........................................................................................................................... 41
Oil Pan .............................................................................................................................................. 41
Piston Rings......................................................................................................................................42
Pistons and .Pins...............................................................................................................................42
Valve System....,...............................................................................................................................42
Engine Mechanical ~ LS6 5.7L ................................................................................................................44
General Specifications .........................................................................................................................44
General .............................................................................................................................................44
Block..................................................................................................................................................44
Camshaft .......................................................................................................................................... 4.4
Connecting Rod................................................................................................................................44
Crankshaft ........................................................................................................................................45
Cylinder Head..................................................................................
~ ................................................45
Intake Manifold .................................................................:...............................................................45
Lubrication System ...........................................................................................................................45
Oil Pan ..............................................................................................................................................45
Piston Rings......................................................................................................................................46
Pistons and Pins...............................................................................................................................46
Valve System...,................................................................................................................................46
FastenerTightening Specifications - LS1 & LS6.................................................................................48
Engine Component Description ....................................................................................
;...................... 51
Camshaft and Drive System.............................................................................................................. 51 .
Crankshaft ........................................................................................................................................ 51
Cylinder Heads .....................................................................................:............................................. 51
Engine Block..................................................................................................................................... 51
Exhaust Manifolds ............................................................................................................................ 52
Intake Manifold ................................................................................................................................. 52
Oil Pan ............................................................................................................................................... 52
Piston and Connecting Rod Assemblies .......................................................................................... 52
Valve Rocker Arm CoverAssemblies............................................................................................... 52
Page iii

Valve Train.........................................................................................................................................52
Drive Belt System Description..............................................................................................................53
Lubrication............................................................................................................................................54
Engine Cooling ..........................................................................................................................,.................55
Engine Cooling System Approximate Capacities ........ ~ ............................:..............................................55
Coolant..................................................................................................................................................55
Cooling Fans ........................................................................................................................................55
Cooling System Coolant Capacity..........................................,.............................................................55
Radiator....................................:...........................................................................................................55
Thermostat Test (33% Glycol Solution) ...........
~ ...................................................................................55
Fastener Tightening Specifications..........................................................................................................55
Cooling System Description and Operation.............................................................................................56
General Description...............................................................................................................................56
Cooling Cycle .............................................,.........................................................................................56
Coolant..................................................................................................................................................57
Radiator................................................................................................................................................57
Pressure Cap ........................................................................................... ~ ...........................................57
Coolant Recovery System....................................................................................................................57
.
Air Baffles and Seals......................................................:.....................................................................58
Water Pump .........................................................................................................................................58
Thermostat ............................................................................................................................................58
Engine Oil Cooler ............................................................•....................................................................58
Transmission Oil Cooler.......................................................................................................................58
EngineElectrical..........................................................................................................................................59
Fastener Tightening Specifications..........................................................................................................59
Battery Usage ..........................................................................................................................................59
BatteryTemperature vs Minimum Voltage ..............................................................................................59
Starter Motor Usage.................................................................................................................................59
Generator Usage .....................................................................................................................................59
Ignition System Specifications.................................................................................................................60
Battery Description and Operation......,....................................................................................................60
Reserve Capacity...............................................................................,.................................................. 61
Cold Cranking Amperage..................................................................................................................... 61
Circuit Description ................................................................................................................................ 61
Starting System Description and Operation............................................................................................. 61
Charging System Description and Operation ..........................................................................................62
Charging System Circuit Description ...................................................................................................62
Ignition System Description .....................................................................................................................63
Engine Controls ...........................................................................................................................................64
Engine Controls -5.7L ...........................-.................................................................................................64
Fastener Tightening SpeCifications......................................................................................................64
Fuel System Specifications..................................................................................................................64
Exhaust System...........................................................................................................................................65
Fastener Tightening Specifications..........................................................................................................65
Exhaust System Description....................................................................................................................65
Resonator.............................................................................................................................................66
Catalytic Converter...............................................................................................................................66
Muffler ..................................................................................................................................................66
TransmissionlTransaxle Description and Operation .. ,................................................................................67
Manual Transmission -MM6/M12...........................................................................................................67
Lubrication Specifications.....................................•...............................................................................67
Manual Transmission Description and Operation................................................................................67
Shift Control and Shift Rod ...............................................................................................................68
Gear Select (Skip Shift)....................................................................................................................69
Reverse Lockout...............................................................................................................................69
Page iv

Clutch.................................................................................•.....................................................................70
Fastener Tightening Specifications.....................................:................................................................70
Hydraulic Clutch System Description and Operation ...........................................................................70
Clutch Driving Members ................................................................................................................... 71
Clutch Driven Members.................................................................................................................... 71
Clutch Operating Members......... ~ ..................................................................................................... 71
Hydraulic Clutch Description ............................................................................................................ 71
Automatic Transmission -4L60E.............................................................................................................72
FastenerTightening Specifications......................................................................................................72
Transmission General Specifications...................................................................................................73
Fluid Capacity Specifications ...............................................................................................................73
Transmission Component and System Description.............................................................................73
Adapt Function .....................................................................................................................................74
Transmission Adapt Function ...........................................................................................................74
Automatic Transmission Shift Lock Control Description ......................................................................74
Abbreviations and Meanings..........................................................................................................................i
Conversion -English/Metric............................................................................................................................i
Equivalents -Decimal and Metric..................................................................................................................
ii
Fasteners..................................................................................................................................,.....................i
Metric Fasteners ..............................
,..........................................................................................................i
Fastener Strength Identification ..............................................................................................................i
Prevailing Torque Fasteners...................................................................................................................... ii
All Metal Prevailing Torque Fasteners ................................................................................................... ii
Nylon Interface Prevailing Torque Fasteners......................................................................................... ii
Adhesive Coated Fasteners....................................................................................................................... ii
Metric Prevailing Torque Fastener Minimum Torque Development......................................................... iii
All Metal Prevailing Torque Fasteners ..................................................................................................iii
Nylon Interface Prevailing Torque Fasteners........................................................................................iii
English Prevailing Torque Fastener Minimum Torque Development.......................................................iv
All Metal Prevailing Torque Fasteners ..................................................................................................iv
Nylon Interface Prevailing Torque Fasteners........................................................................................iv
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intentionally left
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Page vi

2003 Chevrolet Corvette Restoration Kit
Product Information
Chevrolet Releases 50th Anniversary Edition Corvette, Adds Magnetic Selective
Ride Control To Lineup
For 50 years, the Chevrolet Corvette has been carefully crafted from a precise blend of power,
performance, style and comfort. As it celebrates five colorful decades in the automotive business in 2003,
Chevrolet's flagship continues its reign as one
of GM's technology and style bellwethers.
For 2003, Corvette unveils a 50th Anniversary Edition, more standard equipment on the coupe and
convertible models, and Magnetic Selective Ride Control, the industry's fastest and most powerful real-
time damping suspension.
"Fewvehicles have had the staying power of Corvette," said Rick Baldick, Corvette marketing director.
'We believe much of that success comes from a willingness to embrace advancing technology while
remaining true to Corvette's glorious history. As we celebrate our golden anniversary in 2003, we honor
our past and cast a bright eye toward the future."
A Golden Tribute
The 50th Anniversary Edition, available only during the 2003 model year on coupe and convertible
models, is a tribute to a half-century
of automotive leadership. It includes special 50th Anniversary Red
exterior paint, specific badging, unique Shale interior including color coordinated instrument panel and
console, and champagne-painted anniversarywheels with special emblems. It also features embroidered
badges on the seats and floormats, padded door armrests and grips and a Shale convertible top, The
Anniversary Edition includes the standard Corvette
LS1 engine, as well as Magnetic Selective Ride
Control. A special 50th Anniversary Edition of the 2003 Corvette was the Official Pace Car of the
Indianapolis 500 last May, marking the fifth time that a Corvette has paced the race.
Magnetic Selective Ride Control
New on the Corvette for 2003, MagnetiC Selective Ride Control uses a revolutionary damper design that
controls wheel and body motion with Magneto-Rheological fluid in the shocks. By controlling the current
to an electromagnetic coil inside the piston
of the damper, the MR fluid's consistency can be changed,
resulting in continuously variable real time damping. As a result, drivers feel a greater sense of security, a
quieter, flatter ride and more precise, responsive handling, particularly during sudden, high-speed
maneuvers.
The system isolates and smoothes the action
of each tire, resulting in less bo.uncing, vibration and noise.
On bumpy or slick surfaces, the system integrates with traction control to assure maximum stability. It
also works with ABS to keep the vehicle balanced and poised. It is the only system without electro-
mechanical values and no small moving parts. It consists
of MR fluid-based, monotube shock absorbers,
a sensor set and on-board controller.
MagnetiC Selective Ride Control is available on Corvette coupe and convertible models for 2003. It is
included with the 50th Anniversary Edition.
More Standard Equipment
Corvette adds new standard equipment on coupe and convertible models for 2003, including foglamps,
sport seats, power passenger seat, dual-zone auto HVAC, and a parcel net and luggage shade on coupe.
CRAS Child Seat Hooks, Other New Features
For those who bring their little ones along for the ride, the 2003 Corvette includes Child Restraint
Attachment System (CRAS) child seat hooks on the passenger seat to allow easier child seat connection.
The Corvette's air bag-"off" switch must be used to disable the passenger-side air bag when using child
seats inthe vehicle.
During 2003 only, all Corvettes feature a special 50th anniversary emblem on the front and rear. The
emblem is silver and features the number "50" with the signature cross-flag design.
Page 1

2003 Chevrolet Corvette Restoration Kit
In addition, Medium Spiral Gray Metallic exterior paint replaces Pewterfor 2003.
New For 2002
• 50th Anniversary Edition
• Available MagneticSelective Ride Control
• Coupe and convertible have more standard equipment: fog lamps, sport seats, power passenger
seat, dual zone auto HVAC, parcel net and luggage shade (coupe only)
• Medium Spiral Gray Metallic replaces Pewter
• Special 50th Anniversary exterior badges
• Child Restraint Attachment System (CRAS) child seat hooks
Model Lineup
Standard 5
Optional 0
Notavailable
Page 2

2003 Chevrolet Corvette Restoration Kit
Specifications
mated fuel economy (mpg
/ hwy / combined):
catalytic converter AIR 6-speed
manual
19/28/23 (manual Z06)
Page 3

2003 Chevrolet Corvette Restoration Kit
size and type:
ong arm (SLA) double wishbone, cast aluminum upper & lower
ntrol arms, transverse-mounted composite
leaf spring, monotube shock
arm (SLA) double wishbone, cast aluminum upper & lower
arms, transverse-mounted composite
leaf spring, monotube shock
cast aluminum
opt: forged aluminum high polish
front:
17 x 8 rear: 18 x 9.5
Goodyear Eagle F1 GS
Extended Mobility
front: P245/45ZR-17
rear: P275/40ZR-18
cast spun aluminum
front: 17 x 9.5; rear:
18 x 10.5
Goodyear Eagle F1 SC
AsymmetricTread
front: P265/40ZR-17 .
rear: P295/35ZR-18
Page 4

2003 Chevrolet Corvette Restoration Kit
Dimensions
coupe: 24.8 1 702;
convertible: 13.9/394;
13.3 377
automatic: 11.5/10.9;
manual: 11.8111.2
PageS

2003 Chevrolet Corvette Restoration Kit
Vehicle Identification
Vehicle Identification Number (VIN) US/Canada
1
The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located
on the upper LH corner of the instrument panel (liP) and can be seen through the windshield from the
outside
of the vehicle.
The last five digits of the assembly plant sequential number are stamped onto the rear side of the front sill
(tie bar). This number is the same as the last five digits on the VIN plate. The VIN plate also has bar code
characteristics.
6 BodyType
2
7 Restraint System Inflatable
4
8 Engine
12-17 Plant Sequence Number
Page 6

2003 Chevrolet Corvette Restoration Kit
Vehicle Identification Number (YIN) Export
(1) Vehicle Identification Number Stamping (Export)
Export vehicles have the vehicle identification number (VIN) stamped onto the vehicle frame rail, as
shown.
Page?

2003 Chevrolet Corvette Restoration Kit
VIN Derivative
All engines and transmissions are stamped or laser etched with a partial vehicle identification number
(VIN), which was derived from the complete VIN. A VIN derivative contains the following nine positions:
A VIN derivative can
be used to determine ifa vehicle contains the original engine or transmission, by
matching the VIN derivative positions to their accompanying positions in the complete VIN:
Page 8

2003 Chevrolet Corvette Restoration Kit
Label Certification
THIS VEHICLE CONFORMS TO AlL APPLICABLE u.S.
FEDERAL MOTOR VEHICLE SAFETY; BUMPER AND
THEFT PREVENTION STANDARDS IN EFFECT ON
THE DATE OF MANUFACTURE SHOWN ABOVE.
T~
7 6
(1) Name of Manufacturer
(2) Gross Vehicle Weight-Rating
(3) Gross Axle Weight-Rating, Front, Rear
(4) Canadian Safety Mark (w/RPO Z49)
(5) Certification Statement
(6) Vehicle Class Type (Pass Car, etc.)
(7) Vehicle Identification Number
(8) Date of Manufacture (MolYr)
5
MFD. BY GENERAL MOTORS CORP.
~I
D I:==~~=B=V=;-;=.~=~=E=:'V=RT=;-;=~=~=E=~=R=:I
I II
THIS VEHICLE CONFORMS TO ALL
APPLICABLE CANADA MOTOR
VEHICLE SAFElY, BUMPER AND
THEFT PREVENTION STANDARDS
IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
I I
4
The vehicle certification label is permanently located on the edge of the driver's door. Refer to this label in
order to obtain the following information:
• The Gross Vehicle Weight Rating (GVWR)
• The Gross Axle Weight Rating (GAWR), front and rear
The Gross Vehicle Weight (GVW) must not exceed the Gross Vehicle Weight Rating (GVWR).
The GVW is the weight
of the vehicle and everything the vehicle carries. Include the following items when
figuring the GVW:
• The base vehicle weight (factory weight)
• The weight of any added vehicle accessories
• The weight of the driver and the passenger
• The weight of any cargo being carried
The front and rear Gross Axle Weights (GAW) must not exceed the Gross Axle Weight Ratings (GAWR),
front and rear .
The GAW is the weight exerted on one of the axles (front or rear).
Page 9

2003 Chevrolet Corvette Restoration Kit
Service Parts Identification Label (SPID)
SE'J'CE PARTS IDENTIFICATION DO I'JD- RFi,IOVE
t~ .... PAS
(1) Vehicle Identification Number
(2) Engineering Model Number (Vehicle Division, Vehicle Line and BodyStyle)
(3) InteriorTrim and Decor Level
(4) Exterior (Paint Color) WA Number
(5) Paint Technology
(6) Special Order Paint Colors and Numbers
(7) Vehicle Option Content
The service parts identification label is used to identifythe original equipment options built into the
specific vehicle being serviced. The option content
of a vehicle is very important information to properly
service the vehicle.
Page 10

2003 Chevrolet Corvette Restoration Kit
Tire Placard
1
(1) Specified Occupant Seating Positions
(2) Total Occupant Seating
(3) Maximum Vehicle Capacity Weight
(4) Tire Pressures, Front,
Rear, and Spare
(5) Tire Speed Rating, Front, Rear, and Spare
(6) Tire Label Code
(7) Engineering Model Minus First Character
(8) Tire Sizes, Front; Rear,
and Spare
(9) Vehicle Identification Number
7
COLD TIRE
PRESSURE
PSIJl(Pa
5
The Tire Placard is permanently located on the edge ofthe driver's door. Refer to the placard to obtain:
• The maximum vehicle capacity weight
• The cold tire inflation pressures
• The tire sizes (original equipment tires)
• The tire speed ratings (original equipment tires)
Page 11

2003 Chevrolet Corvette Restoration Kit
Engine 10 and VIN Derivative Location 5.7L
5.7L Engine Identification Numbers, LS1 (e)
(1) Engine 10 Number, Primary Location
(2) Engine
10 Number, Secondary Location
The eighth digit of the vehicle identification number (VIN) is the engine code letter, which identifies the
engine as a 5.7L VB (VIN eighth digit: G) (RPO code LS1).
Stick-on labels attached to the engine, laser etching, or stampings in the engine block indicate the engine
unit number/build date code.
The engine 10 number will be located on the rear of LH cylinder head or the front part of LH oil pan rail
(1 ).
Page 12