Driving the C6's New,
400-hp Engine

The 2005 Corvette's six-liter (366 cubic inch), 400 horsepower, LS2 V8 is the largest, most powerful standard engine ever put in a Vette. It's, also, the most refined, most fuel efficient and least polluting.

This new engine powers a C6 coupe with a six-speed manual transmission and the Z51 Performance Handling Package to 0-60 and quarter miles times just short of those of a 2004 Z06 and the only things that keeps the '05 from waxing the 405-hp, "zed-ought-six" is 61 pounds and rear tires a bit less wide.

With 400 horsepower and 400 pound/feet of torque Corvette's new base engine, the six-liter LS2, is the biggest standard engine ever put in a Vette.
Image: Richard Prince.

Anyone who's a good drag racer can get in an '05 like that and, as long as the elevation is relatively low, the air temperature cool and adequate traction is available, go mid/high 12s at 110-115-mph.

This is what 400 pounds of torque can do. Do not try this on public roads. Save it for a race track. Image: Richard Prince.

Top speed? Last spring, a production 2005 coupe went 186 mph in testing done to validate Chevrolet advertising. Fold the mirrors back and tape over the directional signal lights and you'll get 190.

So–what's this new engine like to drive? THR's test driver, after taking his first freeway onramp in an '05 Vette and feeling the new engine's improved low-end and mid-range acceleration, remarked to Tom Peters, who was riding with him at the time, "Whoa... this baby has some low-end grunt!"

Later, he had a second torque experience, this time inadvertently starting out in second gear at a stop sign. Because of the LS2's greater torque and better throttle response off-idle; he almost didn’t notice the error.

Jordan Lee is a GM Powertrain Division Staff Engineer who worked on the LS2. He told THR, "At the bottom end, the LS2 is so much fatter than the LS6 (346-cuin., 405-hp engine in '02-'04 Z06es). A lot of people think, when they drive high-performance sports cars, they're tuned only for high rpm. People perceive that because the bottom end is so weak. You step in the throttle at low rpm and the engine's flat, but then, all of a sudden, it feels like it's 'comin' on the cam.'

This chart graphs the C5's base engine, the LS1, against the C6's LS2. Graphic: GM Powertrain Communications CLICK for Larger PDF


“The LS2 has a fat, broad torque curve so it's very satisfying down low, but you never have that rapid, flip-the-switch feel at higher engine speed. For my taste, and I think the majority of sports car drivers agree, it's more satisfying to have all that responsiveness and still have all the top end."

Because of the LS2's greater torque output, we found all the 2005 Corvettes we drove at the June 4th ride-and-drive, even the heaviest and most sedate, a convertible with power top and automatic, to have a better feel in street driving compared to any '97-'04 model. They, also, all have significantly more top-end power than any C5, other than '02-'04 Z06es. This engine has atorque curve almost as flat as Kansas and you can feel the difference compared to a C5's base engine. Not only does that make C6es go like stink; it also makes the car easier and more fun to drive. While the LS2 and the '02-'04 LS6 have virtually the same torque curve above 3500-4000 rpm, below that; LS2 wins the torque contest, hands down.

LS2 Techside

The key to the LS2 making 50 more horsepower from a package that: is the same physical size, weighs a little less than, gets about the same mileage as and emits less pollutants than C5's LS1 was improved engine controls and better air flow in and exhaust flow out of the engine. Add 20 more cubic inches of displacement and a slight increase in compression and you get 400-hp@6000 rpm, 400-lbs/ft torque@4400 rpm and a 6500-rpm red line.

The LS2's new engine block. The arrows show the bosses cast into it for the Displacement on Demand hardware used in the 5.3-liter version which powers GM's mid-sized SUVs.
Image: GM Powertrain Communications

A new aluminum engine block was required because of LS2's larger bores and that GM wanted a stronger and lighter part. To make way for GM's Displacement on Demand hardware (not used on C6, but is on GM's mid-sized SUVs using the same block casting) the knock sensors moved from the valley to the sides of the block. Computational Fluid Dynamics (CFD) was used model a redesign of the block's cooling passages to ensure proper cooling in-spite of elimination of the LS1's partially-siamesed bores in the interest of increased strength in the block decks.

The new Corvette oil pan, is small, lighter and less costly. It holds a quart less oil but performs as well or better than the '97-'04 "batwing" pan.
Image: GM Powertrain Communications.

 

Other LS1/6 block features, such as the deep-skirted design, six-bolt main bearing caps and a gerotor oil pump continue. The large crankcase "windows" which improve bay-to-bay breathing and reduce crankcase oil windage, also, carry-over from the LS1/6. The LS2 block is made the same way as was the LS1/6 block. It's a sand cast part that goes through a controlled cooling process. The aluminum is poured with the block's centrifugally-cast iron liners in place.

 

 

The crankshaft is cast from spheroidal graphite iron, has rolled-fillet journals and is a rebalanced version of the LS1/6 unit. The connecting rod is based on the LS1/6 forging but its small-end is, now, bushed for a floating wrist pin. The oil pan is a new, lighter design which has oil control better than the "batwing" pan used on the LS1 and LS6 and does that with a quart less oil.

This vertical saw-cut of an LS2 head's intake port shows two reasons why it flows so well, 1) cross-sectional area is maintained with the port growing wider at the points where it grows shorter and 2) the smoothly-curved, short side radius–the area where the port floor curves down to the intake valve seat.
 Image: GM Communications.

LS2 pistons are still cast from a eutectic, aluminum/silicon alloy which contains traces of copper and nickel. They are 101.6-mm in diameter and have full-floating wrist pins. While GM cites noise reduction as the reason for going to floating pins, we'll bet another reason is improved durability at the 480-500-hp level which next year's LS7 will be capable. The new pistons are responsible for an increase in compression ratio to 10.87:1. Anodized ring lands and polymer-coated skirts, introduced on the LS6, continue. The rings use the same general design as the '02-'04 LS6 but they fit the larger bore, are slightly more narrow and have lower tension.

LS2's camshaft is from the '01 (385-hp) LS6. The LS2 cylinder head assembly uses the proven, LS6 casting and is fitted with '01 LS6 valves. The rest of LS2's valve gear carries over from the LS6.

A horizontal saw-cut shows more of the LS2 intake port's uniform cross-sectional area. As the port widens, the port roof drops down and this helps keep air flow at a consistent velocity. Image: GM Communications.

C6's induction system, from the air inlet to the intake manifold is new. The air filter assembly, intake duct, mass airflow sensor, 90-mm. throttle body and intake manifold are improved designs. In total, there is a huge, 31% reduction in intake restriction compared to the LS1.

There has been a major change in the engine's crankcase ventilation system. Both air-oil separators were redesigned for improved efficiency. CFD, with the addition of a proprietary GM software code called "rain drop analysis," allows modeling airflow systems where liquid droplets are present. It was used to analyze crankcase vapor flow through the engine and that information was applied to the new separator design. The net result is less oil consumption, especially at high rpm.

LS2's exhaust manifolds are 33% lighter and 4% less restrictive. C6es use only two catalytic converters and they are a low-restriction, close-coupled design which increases performance and reduces emissions. The exhaust system downstream of the cats has, also, been redesigned with higher-flow mufflers which mount lengthwise, eliminating four 90-degree pipe bends. All of this was worth a 10%, total reduction in back pressure, compared to the '01-'04 LS1.

For 2005, because higher compression makes the engine a little more liable to detonate, the knock sensing needed more speed and accuracy. In addition, more accurate control of air metering, fuel metering, exhaust emissions controls were desired.

The engine's rev limiter is now at 6600. Lastly, GM wanted to move the electronic throttle functions from a separate module into the ECM. All this required a more robust controller and the new, LS2 Engine Control Module (ECM) is faster acting, has more memory and can control more devices..

The C6 air filter assembly is vastly different than that of the C5. It uses two filters and flows more air. Image: Richard Prince.
These mass air flow sensors meter air going into a Corvette engine. The '05 model has gone back to the screen (more properly: a flow straightener) used in '97-'04 LS1s and the '01 LS6. The LS2 needs the straightener to get more accurate air meter signals. Image: Tom Henry Racing.

The LS2 intake manifold is made of three plastic parts which are "vibration welded" together. The parts are vibrated at high frequency. The friction generated at their interface causes the plastic to melt and
weld the parts together.
Image: GM Powertrain Communications

The 2005 exhaust is much different from the '04. The mufflers now mount lengthwise at the rear of the car. Image: Tom Henry Racing.

 


Transmission Transformations
Not only does the 2005 Corvette have a new engine, but both its transmissions are revised.

The standard, T56 six-speed manual was upgraded. The shift lever is 3/4-in. shorter. Inside the transmission, the synchronizers were modified with less travel. The combination of a shorter lever and less synchro travel reduced shift throw by a welcome, 10%.

A cutaway version of the TREMEC T56, six-speed transmission as used in C5 and C6. This is actually, the front half of the car's transaxle assembly. Image: Tom Henry Racing.

Shortening the lever increased shift effort. To bring it back down and refine it; GM and TREMEC (the transmission supplier) modified the synchro sleeve tooth configuration; switched to a roller, fore-aft detent and a ball-bearing, cross-car detent and changed from bushings to linear bearings on the main shift rail. Individually, these updates don't have a great effect, but together; they make a noticeable improvement in feel.

This computer-generated drawing of the shift rail, shift forks and synchronizer sleeve shows some of the changes made to reduce shift throw and improve shift feel. Drawing: TREMEC

The first time you drive a C6 six-speed, you'll notice the shorter throw and the more precise feel. When measured, shift effort goes up 3% but that's virtually impossible to feel. Judged subjectively, the effort seems the same as that of a C5.


Six-speed transmissions in Z51s are different in two ways: 1) they have lower ratios in the first three gears resulting in better acceleration and 2) because they are intended for severe duty, have a cooling system. A pump on the front of the trans., driven by the countershaft, sends lubricant through the same cooler in the radiator used by automatics.

Optional on the '05 Corvette is the, new Hydra-matic, 4L65-E, electronically-controlled, four-speed automatic. It is a beefed-up version of the 4L60-E, used from 1993 to 2004. The "L65" uses the same gear ratios but has a higher input torque rating of 380 lbs/ft. Its key new features are: 1) planetary gearsets with five rather than four pinion gears. Spreading the load over five pinions increases torque capacity; 2) the stator shaft splines, which engage the stator roller clutch, are now heat-treated; 3) the turbine shaft, which transfers torque from the converter to the input planetary, is now induction-hardened; 4) stronger low/reverse roller clutch assembly; 5) seven plates in the 3-4 clutch rather than six; 6) shotpeened output shaft and 7) a revised valve body.


The L65 uses a separate transmission controller. Transmission control was taken out of the ECM so transmission controls evolution could stay in lockstep with transmission hardware changes. This new controller has "Performance Algorithm Shifting" technology which tries to anticipate what the driver is doing with the car in a performance driving environment then alters the shift schedule accordingly. Performance Algorithm Shifting makes the C6 automatic better suited to aggressive driving.


Finally, there are changes in the rear axle. Limited-slip differential preload was increased to improve handling, which we'll discuss later and all Corvettes get the shotpeened ring-and-pinion previously used only on manuals.


The new engine and the revised transmission combine to make a powertrain that is noticeably better in performance, drivability and refinement than the generation that preceded it.
 

 C6 Ride and Handling