🏷️ Basic Information

Make:

Chevrolet

Model:

Corvette

Year:

2004

Chassis Code:

C5

👋 Introduction

Positioning:

The Chevrolet Corvette C5 generation (1997-2004) represented a significant leap forward in performance, handling, and design for American sports cars, aiming to compete with established European benchmarks.

Competitors:

Primary competitors included the Porsche 911, BMW M3, and Nissan 300ZX. The C5 Corvette was renowned for its powerful V8 engine and aggressive styling, often offering superior straight-line performance for its price point.

Performance Highlights:

The 2004 model, particularly the Z06 variant, offered exceptional performance with its potent LS6 engine and advanced chassis dynamics.

Design Philosophy:

The C5 featured a hydroformed steel frame and a transaxle design for improved weight distribution and handling characteristics, setting it apart from previous generations.

📋 Manual Details

All Models And Trims:

Yes

Repair Scope:

All Repairs A-Z

Estimated Pages:

Approx. 2000-3000 (typical for full dealership service manuals)

Type:

Dealership Service and Repair Manual

Language:

English

Format:

Likely Printed Book (original dealership format), potentially available as PDF

📖 Manual Coverage

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of all engine components.

Engine Electrical:

Ignition system, fuel injection, starting, charging, engine control module (ECM) diagnostics and wiring diagrams.

Transmission Manual:

Service and repair procedures for the manual transmission.

Transmission Automatic:

Service and repair procedures for the automatic transmission (if applicable, though 2004 Corvette predominantly had manual).

Drivetrain:

Driveshaft, differential, axles, and related components.

Suspension:

Front and rear suspension, shock absorbers, springs, control arms, and alignment specifications.

Steering:

Power steering system, steering column, rack and pinion assembly.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), traction control, brake rotor and pad replacement, caliper service.

Body And Frame:

Body panel removal and installation, frame inspection and repair, structural components.

Heating Ventilation Air Conditioning HVAC:

System operation, refrigerant handling, component diagnosis and replacement (compressor, condenser, evaporator, etc.).

Electrical And Electronics:

Lighting, wipers, power accessories, body control module (BCM), instrument cluster, diagnostics.

Fuel System:

Fuel pump, injectors, fuel tank, lines, and evaporative emission control (EVAP).

Exhaust System:

Catalytic converters, mufflers, pipes, and oxygen sensors.

Cooling System:

Radiator, water pump, thermostat, hoses, and cooling fan operation.

Tire And Wheel:

Tire specifications, wheel torque, balance and rotation procedures.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid checks and top-offs.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for various systems.

Component Repair:

Detailed step-by-step instructions for removing, repairing, and reinstalling individual components.

Diagnosis:

OBD-II diagnostic trouble codes (DTCs), sensor testing, actuator testing.

Specifications And Tolerances:

Precise measurements, clearances, torque values, and alignment settings.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Nomenclature:

Identification of all parts and systems.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Depth:

Factory-level diagnostic, repair, and maintenance procedures.

Diagnostic Capabilities:

Advanced diagnostics including component testing, signal tracing, and ECM programming considerations.

Rebuild Procedures:

Complete engine and transmission rebuild instructions.

📊 Manual Specifications

Digital Format:

PDF (if available) - searchable text, bookmarked chapters, high-resolution diagrams.

Print Quality:

High-quality printing with clear diagrams and legible text (for printed versions).

Binding:

Perfect bound or coil-bound for durability in a workshop environment (typical for printed).

Paper:

Durable, high-gloss or matte finish paper to withstand workshop conditions.

⚙️ Engine Specifications

Engine Code:

LS1 (standard), LS6 (Z06)

Displacement:

5.7L (350 cu in)

Configuration:

V8, Overhead Valve (OHV), 2 valves per cylinder

Horsepower Ls1:

350 hp @ 5600 rpm

Torque Ls1:

375 lb-ft @ 4000 rpm

Horsepower Ls6:

405 hp @ 6000 rpm (Z06)

Torque Ls6:

400 lb-ft @ 4800 rpm (Z06)

Induction:

Sequential Fuel Injection (SFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended for optimal performance

ECU:

Engine Control Unit (ECU) with extensive diagnostic capabilities.

🔧 Transmission

Type:

6-speed manual (Tremec T-56) for all models, including Z06.

Type:

4-speed automatic (4L60-E) was optional on standard coupes and convertibles, but not the Z06.

Transaxle Layout:

Rear-mounted transaxle for optimal weight distribution (50/50 target).

Manual Transmission Fluid:

Dexron III/VI or equivalent synthetic manual transmission fluid, GM P/N 12345349 is often cited.

Automatic Transmission Fluid:

Dexron III/VI or equivalent, GM P/N 12378482 is often cited.

📐 Dimensions

Length:

179.7 inches

Width:

73.6 inches

Height:

47.8 inches

Wheelbase:

104.5 inches

Curb Weight:

Approx. 3,100 - 3,250 lbs (depending on model and options)

Gross Vehicle Weight Rating Gvw:

Approx. 4,200 lbs

Cargo Volume Trunk:

13.9 cubic feet (coupe), 13.0 cubic feet (convertible)

🛡️ Safety Features

NHTSA Front Impact:

5-star rating

NHTSA Side Impact:

5-star rating

ABS:

Standard Anti-lock Braking System (ABS) with electronic brake force distribution (EBD).

Traction Control:

Standard Active Handling (Traction Control and Stability Enhancement) system.

Airbags:

Driver and passenger front airbags. Side-impact airbags were optional or standard on some later models.

Structure:

Reinforced passenger compartment, front and rear crush zones.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, Bose premium audio system available on most trims.

Navigation:

Optional DVD-based navigation system available.

Active Handling:

The C5's Active Handling system was a precursor to modern stability control, integrating ABS, traction control, and yaw rate sensors.

Telematics:

OnStar telematics system available as an option.

🔧 Maintenance

Oil Change:

Every 7,500 miles or 12 months, whichever comes first. Check owner's manual for specific oil life monitoring system behavior.

Air Filter Replacement:

Every 15,000-30,000 miles, or as per inspection. Check owner's manual for specifics.

Spark Plug Replacement:

Typically around 100,000 miles for iridium-tipped plugs (standard on later LS engines).

Coolant Flush:

Every 5 years or 100,000 miles with Dex-Cool coolant (GM P/N 12346290).

Engine Oil:

SAE 5W-30 synthetic or synthetic blend meeting GM specification GM6094M (e.g., Mobil 1 5W-30).

Coolant:

GM P/N 12346290, Dex-Cool (orange) antifreeze/coolant, pre-mixed 50/50 with distilled water.

Brake Fluid:

DOT 3, GM P/N 12377990.

Power Steering Fluid:

Dexron III/VI automatic transmission fluid, GM P/N 12378482.

Clutch Hydraulic System:

Some instances of clutch master cylinder leaks or slave cylinder issues have been reported.

Fuel Pump:

Early C5 models sometimes experienced fuel pump failures, though improved by 2004. Check for recalls or service bulletins.

Exhaust System:

Corrosion on exhaust components, particularly in salt-belt regions, can occur over time.

Active Handling System:

Occasionally, the Active Handling system may trigger or malfunction due to sensor issues or control module glitches.

📚 Vehicle History

Chevrolet Legacy:

Chevrolet has a long history of performance vehicles, with the Corvette being its flagship sports car since 1953, embodying American automotive passion and engineering.

C5 Generation:

The C5 generation, introduced in 1997, marked a radical departure from previous Corvettes, featuring a modern unibody construction with a separate backbone frame and a rear-mounted transaxle for superior handling.

2004 Updates:

The 2004 model year was the final year of the C5 generation. It received minor updates, including the introduction of the Commemorative Edition Z06 and other appearance packages. The Z06 was specifically designed for track performance.

Manufacturing Location:

Bowling Green, Kentucky, USA

Production Years:

1997-2004

🏆 Awards & Recognition

Car And Driver 10Best:

The C5 Corvette was a consistent recipient of Car and Driver's 10Best award throughout its production run, including for 2004.

Motor Trend Car Of The Year:

While the C5 generation did not win MotorTrend Car of the Year, it was a highly regarded performance vehicle in its class.

Value For Money:

Widely praised for delivering supercar performance at a sports car price point.