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Chevrolet Corvette 2005-2009 Service Repair Manual

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This manual covers the Chevrolet Corvette, a performance sports car produced from 2005 to 2009. The C6 generation represents a significant evolution, featuring a hydroformed steel frame for enhanced rigidity...
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Chevrolet Corvette 2005-2009 Service Repair Manual
This manual covers the Chevrolet Corvette, a performance sports car produced from 2005 to 2009. The C6 generation represents a significant evolution, featuring a hydroformed steel frame for enhanced rigidity and a cleaner, more aerodynamic design with exposed headlights. Known for its engineering quality and reliability, the Corvette targets enthusiasts with its premium driving experience. Powered by potent LS V8 engines, ranging from the 6.0L LS2 to the 6.2L LS3, and available with either a 6-speed manual or automatic transmission, this model offers exhilarating performance. Its chassis dynamics are further supported by advanced safety features like traction control, active handling, and ABS. This comprehensive factory service manual provides detailed information essential for the maintenance, diagnosis, and repair of your 2005-2009 Chevrolet Corvette. It covers all major systems, including the powertrain, drivetrain, brakes, chassis, body, and electrical systems. Within its extensive pages, you will find step-by-step procedures for scheduled maintenance, fluid changes, component disassembly and reassembly, and troubleshooting common issues, such as clutch pedal stiffness or HVAC blend door actuator failures. Detailed technical specifications, including torque values and fluid capacities, are also included, empowering owners and technicians to effectively maintain and preserve the performance and longevity of their Corvette.
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Corvette
Generation:
C6
Model Years:
2005-2009
👋 Introduction
Market Position
Position:
Performance sports car, targeting enthusiasts and those seeking a premium driving experience
Competitive Analysis
Competitors:
Porsche 911, Jaguar XK, Aston Martin V8 Vantage, BMW M series, Mercedes-Benz AMG models
Key Features
Chassis:
Hydroformed steel frame construction for rigidity and weight savings
Design:
C6 generation marked a significant evolution with a cleaner, more modern aesthetic compared to C5, featuring exposed headlights and improved aerodynamics
Value Proposition
Manual Value:
Provides dealer-level diagnostic and repair information, empowering owners and independent mechanics to maintain and repair the vehicle cost-effectively.
📋 Manual Details
Coverage Areas
Coverage:
Complete service and repair for 2005-2009 Chevrolet Corvette
Page Count
Page Count:
Estimated 2000+ pages (typical for comprehensive dealer service manuals of this era)
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Lubrication System, Intake & Exhaust Systems, Ignition System, Starting & Charging Systems, Automatic Transmission, Manual Transmission, Clutch
Drivetrain:
Driveshaft, Differential, Axles, Suspension (Front & Rear), Steering System (Column & Power Steering), Wheels & Tires
Brakes:
Brake Control, Brake System (Front & Rear), Parking Brake System
Chassis & Body:
Chassis, Body Structure, Exterior & Interior Trim, Doors, Hood, Glass, Mirrors
Electrical & Electronics:
Instrument Panel, Lighting, Wipers & Washers, Horn, Power Accessories, Climate Control (Air Conditioning), Restraint Systems (SRS), Seat Belts, Cruise Control, Engine Immobilizer, Meter/Audio/Visual Systems, Multiplex/CAN Communication Systems, Wiring Diagrams
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), electrical system diagnosis
Repair:
Component disassembly and reassembly, system repairs, adjustments
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds; detailed diagnostic and electrical troubleshooting
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing all pages
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Compatibility:
Windows, Mac, Linux (with WinZip and Adobe PDF Reader)
Usability
Searchable:
Likely searchable text within PDF
Printable:
Yes, all pages are printable
⚙️ Engine Specifications
Primary Engine
Engine Family:
LS V8
Engine Variant 2005 2007
Engine Code:
LS2
Displacement:
6.0L (364 cu in)
Horsepower:
400 hp @ 5200 rpm
Torque:
400 lb-ft @ 4400 rpm
Engine Variant 2008 2009
Engine Code:
LS3
Displacement:
6.2L (376 cu in)
Horsepower:
430 hp @ 5900 rpm (436 hp with performance exhaust)
Torque:
424 lb-ft @ 4600 rpm (428 lb-ft with performance exhaust)
Fuel System
Fuel Delivery:
Sequential Fuel Injection (SFI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Ignition System
Ignition Type:
Distributorless Electronic Ignition (DIS)
Cooling System
Cooling Type:
Liquid-cooled, pressurized system with electric cooling fans
Lubrication System
Oil Capacity Ls2:
7.0 Quarts (6.6 Liters) with filter (approx.)
Oil Capacity Ls3:
9.5 Quarts (9.0 Liters) with dry sump lubrication system (for Z51/Grand Sport models), 7.0 Quarts for standard models
Oil Specification
Oil Type API:
API SN or newer, SAE 5W-30 Synthetic (Dexos1 or equivalent recommended)
🔧 Transmission
Standard Transmission
Type:
6-speed Manual Transmission (Tremec TR6060)
Optional Transmission
Type:
6-speed Automatic Transmission with Paddle Shift (GM 6L80)
Clutch Manual
Clutch Type:
Hydraulic actuated, single plate dry clutch
Fluid Manual
Fluid Type:
GM Manual Transmission Fluid (MTF) P/N 88861800 or equivalent
Fluid Automatic
Fluid Type:
Dexron VI Synthetic
📐 Dimensions
Exterior Length
Length:
179.7 inches (4564 mm)
Exterior Width
Width:
72.6 inches (1844 mm)
Exterior Height
Height:
49.0 inches (1245 mm)
Wheelbase
Wheelbase:
104.5 inches (2654 mm)
Weights
Curb Weight Approx:
3100-3250 lbs (1406-1474 kg), varies by model and options
Wheel Size
Wheel Size Std:
18 x 8.5 inches (Front), 19 x 10 inches (Rear)
Tire Size
Tire Size Std:
245/40ZR18 (Front), 285/35ZR19 (Rear)
Wheel Bolt Pattern
Bolt Pattern:
5 x 120.65 mm (5 x 4.75 inches)
🛡️ Safety Features
Ratings
NHTSA Front Crash:
5 Stars (for 2005-2009 models, typically)
IIHS Frontal Offset:
Good (for applicable models/years)
Active Features
Traction Control:
Standard (Traction Control System - TCS)
Stability Control:
Standard (Active Handling System - AH)
Brakes:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist
Passive Features
Airbags:
Driver and front passenger airbags, side-impact airbags (optional or standard depending on trim/year)
Seat Belts:
3-point active belts with pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Available Bose premium audio system, Navigation system (optional), OnStar communication system (depending on trim/year)
Driver Assistance
Driver Assistance:
Traction Control System (TCS), Active Handling System (AH)
Connectivity
Connectivity Features:
OnStar telematics system (subscription-based, varies by year)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first, using synthetic oil. Refer to specific owner's manual for exact intervals.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. The manual will detail replacement procedure.
Brake Fluid Flush:
Every 45,000 miles (72,000 km) or 3 years, whichever comes first. Manual will specify fluid type (DOT 3). OE Part Number for Brake Fluid: 19299818.
Fluid Specifications
Coolant Type:
GM P/N 12346290, Dex-Cool (OAT) Long Life Coolant (50/50 mix with distilled water)
Power Steering Fluid:
GM P/N 12345573 or equivalent, Dexron III/VI compatible
Known Issues
Clutch Pedal Assembly:
Potential for stiffness or failure in clutch pedal assembly, especially on manual transmission models.
Valve Springs Ls3:
Some early LS3 engines had issues with valve springs breaking; the manual will detail inspection and replacement procedures.
Hud Display:
Head-Up Display (HUD) pixels can fail over time; diagnostic steps included in manual.
HVAC Blend Door Actuators:
Blend door actuators in the HVAC system can fail, causing improper air temperature control. Manual covers diagnostics and replacement.
📚 Vehicle History
Brand Heritage
Heritage:
Chevrolet has a long history of performance vehicles, with the Corvette being its flagship sports car since 1953.
Model Evolution
C6 Introduction:
The C6 generation debuted for the 2005 model year, representing a significant departure from the C5 with its updated styling, improved chassis dynamics, and larger displacement engines.
Key C6 Updates:
2005: Introduction of LS2 6.0L V8, exposed headlights return. 2008: Introduction of LS3 6.2L V8, updated interior, revised styling. Z06 and ZR1 variants offered higher performance levels.
Production
Production Location:
Bowling Green, Kentucky, USA
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Corvette was frequently recognized on Car and Driver's 10Best list during this generation.
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