air condition CHEVROLET EXPRESS 2003 User Guide

California Fuel
If your vehicle is certied to meet California Emission
Standards (see the underhood emission control label), it
is designed to operate on fuels that meet California
specications. If this fuel is not available in states
adopting California emissions standards, your vehicle
will operate satisfactorily on fuels meeting federal
specications, but emission control system performance
may be affected. The malfunction indicator lamp may
turn on and your vehicle may fail a smog-check test. See
Malfunction Indicator Lamp on page 3-32. If this
occurs, return to your authorized GM dealer for
diagnosis. If it is determined that the condition is caused
by the type of fuel used, repairs may not be covered
by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. In most cases, you should not have to add
anything to your fuel. However, some gasolines contain
only the minimum amount of additive required to
meet U.S. Environmental Protection Agency regulations.
General Motors recommends that you buy gasolines
that are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems
due to dirty injectors or valves, try a different brand of
gasoline. Also, your GM dealer has additives that
will help correct and prevent most deposit-related
problems.
5-6

When to Inspect the Engine Air
Cleaner/Filter
Inspect the air cleaner/lter at the MaintenanceII
intervals and replace at the rst oil change after
50,000 miles (83 000 km). SeeScheduled Maintenance
on page 6-4for more information. If you are driving
in dusty/dirty conditions, inspect the lter at each engine
oil change.
How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/lter, remove the lter from
the vehicle and lightly shake the lter to release
loose dust and dirt. If the lter remains caked with dirt, a
new lter is required.
To inspect or replace the engine air cleaner/lter, do the
following:
1. Unhook the retainer clips and remove the cover.
2. Lift the lter out of the engine air cleaner/lter
housing. Care should be taken to dislodge as
little dirt as possible.3. Clean the engine air cleaner/lter housing.
4. Inspect or replace the engine air cleaner/lter. Make
sure that the lter ts properly into the housing.
5. Reinstall the cover and fasten the retaining clips.
{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 ame 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 your engine, which will damage it.
Always have the air cleaner/lter in place when you
are driving.
5-18

Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the fan is spinning slower and the clutch is
not fully engaged. This improves fuel economy and
reduces fan noise. Under heavy vehicle loading, trailer
towing, and/or high outside temperatures, the fan
speed increases as the clutch more fully engages, so
you may hear an increase in fan noise. This is
normal and should not be mistaken as the transmission
slipping or making extra shifts. It is merely the cooling
system functioning properly. The fan will slow down
when additional cooling is not required and the clutch
partially disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
Power Steering Fluid
The power steering uid
reservoir is located in the
engine compartment
on the driver’s side of the
vehicle. SeeEngine
Compartment Overview on
page 5-12for reservoir
location.
When to Check Power Steering Fluid
It is not necessary to regularly check power steering uid
unless you suspect there is a leak in the system or
you hear an unusual noise. A uid loss in this system
could indicate a problem. Have the system inspected
and repaired.
How to Check Power Steering Fluid
To check the power steering uid, do the following:
1. Turn the key off and let the engine compartment
cool down.
2. Wipe the cap and the top of the reservoir clean.
5-32

Brake Wear
Your vehicle has four-wheel disc brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving, except when you are pushing on the
brake pedal rmly.
{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque specications.
Brake linings should always be replaced as complete
axle sets.
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in
pedal travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a brake stop, your disc brakes
adjust for wear.
5-36

Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kiloPascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and
air conditioning.
Aspect Ratio:The relationship of a tire’s height to
its width.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.Cold Ination Pressure:The amount of air pressure in
a tire, measured in pounds per square inch (psi) or
kilopascals (kPa) before a tire has built up heat
from driving. SeeInation - Tire Pressure on page 5-58.
Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the U.S.
Department of Transportation (DOT) motor vehicle
safety standards. The DOT code includes the Tire
Identication Number (TIN), an alphanumeric designator
which can also identify the tire manufacturer, production
plant, brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-29.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-29.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-29.
5-56

Wheel Replacement
Replace any wheel that is bent, cracked, or badly rusted
or corroded. If wheel nuts keep coming loose, the
wheel, wheel bolts and wheel nuts should be replaced.
If the wheel leaks air, replace it (except some
aluminum wheels, which can sometimes be repaired).
See your dealer if any of these conditions exist.
Your dealer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.
If you need to replace any of your wheels, wheel
bolts or wheel nuts, replace them only with new
GM original equipment parts. This way, you will be sure
to have the right wheel, wheel bolts and wheel nuts
for your vehicle.{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
Whenever a wheel, wheel bolt or wheel nut is replaced
on a dual wheel setup, check the wheel nut torque
after 100, 1,000 and 6,000 miles (160, 1 600 and
10 000 km) of driving. For proper torque, see “Wheel Nut
Torque” underCapacities and Specications on
page 5-97.
SeeChanging a Flat Tire on page 5-68for more
information.
5-65

Sheet Metal Damage
If the vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti-corrosion material to parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide the
corrosion protection while maintaining the warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the
nish should be repaired right away. Bare metal
will corrode quickly and may develop into major
repair expense.
Minor chips and scratches can be repaired with touch-up
materials available from your GM dealer. Larger areas
of nish damage can be corrected in your GM
dealer’s body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are not
removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, oor pan,
and exhaust system even though they have corrosion
protection.At least every spring, ush these materials from the
underbody with plain water. Clean any areas where mud
and debris can collect. Dirt packed in close areas of
the frame should be loosened before being ushed.
Your GM dealer or an underbody car washing system
can do this for you.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on the vehicle. This damage can
take two forms: blotchy, ring-shaped discolorations,
and small, irregular dark spots etched into the
paint surface.
Although no defect in the paint job causes this, GM will
repair, at no charge to the owner, the surfaces of
new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs rst.
5-89

Fuse Usage
6 Ignition 0
7 Stoplamp
8 Right Rear Defogger/Heated Mirror
9Right Daytime Running
Lamp/Turn Signal
10Left Daytime Running
Lamp/Turn Signal
11 Truck Body Control Module 4
12 Fuel Pump
13 Trailer
14 Flasher
15 Horn
16 Truck Body Control Module 3
17 Trailer Stop/Turn Signal
18 Truck Body Control Module 2
19 Truck Body Control Module
20 Remote Function Actuator
21 Engine 2Fuse Usage
22 Ignition E
23 Engine 1
24Truck Body Control Module
Ignition 1
25 Spare
26 RPA/Inside Rearview Mirror
27 Crankcase
28Brake Transmission Shift
Interlock System
29 Auxiliary Power Outlets
30 Cigarette Lighter
31 Instrument Panel Cluster
32 Air Conditioning
33 Spare
34 Vent
35 Spare
36 Vehicle Back Up
37Supplemental Inatable
Restraint System
5-95

Fuse Usage
38 Powertrain Control Module Ignition 1
39 Oxygen Sensor B
40 Oxygen Sensor A
41 Windshield Wipers
42 Right Headlamp - Low Beam
43 Left Headlamp - Low Beam
44 Left Headlamp - High Beam
45 Right Headlamp - High Beam
46Truck Body Control
Module-Accessory
47 Front Windshield Wiper
48 Anti-Lock Brakes
49 Ignition A
50 Trailer
51 Climate Control Blower
52 Ignition B
63 Spare
64 SpareFuse Usage
Relays Usage
53 Windshield Wiper
54 Air Conditioning
55 Spare
56 Headlamp - High Beam
57 Fuel Pump
58 Headlamp - Low Beam
59 Horn
61 Starter
62 Spare
Circuit Breaker Usage
60 Power Seat
5-96

Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeeRecommended Fluids and
Lubricants on page 6-13for more information. When adding, be sure to ll to the appropriate level or as
recommended in this manual.
See refrigerant charge label under the hood for charge capacity information and requirements.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a
Front A/C
Front and Rear A/C1.8 lbs
3.1 lbs0.81 kg
1.41 kg
Cooling System
4300 V6
4800 V8, 5300 V8
6000 V811.0 quarts
13.4 quarts
14.8 quarts10.4 L
12.7 L
14.0 L
Cooling System with Rear Heat
4300 V6
4800 V8, 5300 V8
6000 V814.0 quarts
16.4 quarts
17.8 quarts13.2 L
15.5 L
17.0 L
Engine Oil with Filter
4300 V6
4800 V, 5300 V8
6000 V84.5 quarts
6.0 quarts
6.0 quarts4.3 L
5.7 L
5.7 L
5-97