check engine CHEVROLET EXPRESS 2003 Service Manual

Owner Checks and Services
These owner checks and services should be performed
at the intervals specied to help ensure the safety,
dependability and emission control performance of your
vehicle. Your GM Goodwrench dealer can assist you
with these checks and services.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-13.
At the First 100, 1,000 and
6,000 Miles (160, 1 600
and 10 000km)
For vehicles with dual wheels, check dual wheel nut
torque. For proper torque, seeCapacities and
Specications on page 5-97.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
Engine Coolant Level Check
Check the engine coolant level and add
DEX-COOL®coolant mixture if necessary. SeeEngine
Coolant on page 5-22for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer tank and add the proper uid if necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your tires and make sure tires are
inated to the correct pressures. Do not forget to check
your spare tire. SeeTires on page 5-52for further
details. Check to make sure the spare tire is stored
securely. Push, pull and then try to turn the spare tire. If
it moves, tighten it. SeeChanging a Flat Tire on
page 5-68.
6-10

At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the
regular brake. SeeParking Brake on page 2-24
if necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The starter
should work only in PARK (P) or NEUTRAL (N).
If the starter works in any other position, contact
your GM Goodwrench dealer for service.
Automatic Transmission Shift Lock
Control System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough
room around the vehicle. It should be parked
on a level surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-24if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the ignition to RUN, but do
not start the engine. Without applying the regular
brake, try to move the shift lever out of PARK (P)
with normal effort. If the shift lever moves out
of PARK (P), contact your GM Goodwrench dealer
for service.
6-11

Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn
the ignition to LOCK in each shift lever position.
The ignition should turn to LOCK only when the
shift lever is in PARK (P).
The key should come out only in LOCK.
Contact your GM Goodwrench dealer if service
is required.
Parking Brake and Automatic
Transmission Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
To check the parking brake’s holding ability: With
the engine running and transmission in
NEUTRAL (N), slowly remove foot pressure from
the regular brake pedal. Do this until the vehicle is
held by the parking brake only.
To check the PARK (P) mechanism’s holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Contact your GM Goodwrench dealer if service
is required.
Underbody Flushing Service
At least every spring, use plain water to ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-12

Audio System(s) (cont.)
Setting the Time for Radios with
Radio Data Systems (RDS).......................3-40
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-40
Theft-Deterrent Feature................................3-71
Understanding Radio Reception.....................3-72
Automatic Transmission
Fluid..........................................................5-19
Operation...................................................2-22
B
Battery..........................................................5-37
Run-Down Protection...................................3-16
Before Leaving on a Long Trip.........................4-21
Brake
Anti-Lock Brake System (ABS)........................ 4-6
Emergencies................................................ 4-7
Parking......................................................2-24
System Warning Light..................................3-29
Brakes..........................................................5-34
Braking........................................................... 4-5
Braking in Emergencies..................................... 4-7
Break-In, New Vehicle.....................................2-18
Bulb Replacement...........................................5-46
Center High-Mounted Stoplamp (CHMSL)........5-49
Front Turn Signal, Sidemarker and
Parking Lamps.........................................5-48Bulb Replacement (cont.)
Halogen Bulbs............................................5-47
Headlamps.................................................5-47
Replacement Bulbs......................................5-50
Taillamps....................................................5-49
Buying New Tires...........................................5-62
C
California Fuel.................................................. 5-6
Canadian Owners................................................ ii
Capacities and Specications............................5-97
Carbon Monoxide...........................2-27, 4-24, 4-34
Care of
Safety Belts................................................5-85
Your Cassette Tape Player............................3-72
Your CD Player...........................................3-74
Your CDs ...................................................3-74
Cargo Door Relocking....................................... 2-8
Center High-Mounted Stoplamp (CHMSL)...........5-49
Center Passenger Position, Safety Belts.......1-23, 1-24
Chains, Tire...................................................5-66
Charging System Light....................................3-28
Check
Engine Light...............................................3-32
Gages Warning Light...................................3-38
Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-89
2

D
Daytime Running Lamps..................................3-14
Daytime Running Lamps Indicator Light.............3-37
Defensive Driving............................................. 4-2
Doing Your Own Service Work........................... 5-4
Dome Lamp Override......................................3-15
Dome Lamps.................................................3-15
Door
60/40 Swing-Out Side Door...........................2-12
Cargo Door Relocking.................................... 2-8
Locks.......................................................... 2-7
Power Door Locks......................................... 2-8
Rear Door Security Locks............................... 2-8
Rear Doors.................................................2-13
Sliding Side Door........................................2-10
Driver
Position, Safety Belt.....................................1-15
Driving
At Night.....................................................4-15
City...........................................................4-19
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-20
Hill and Mountain Roads..............................4-22
In Rain and on Wet Roads...........................4-16
Rocking Your Vehicle to Get it Out.................4-28
Winter........................................................4-24
Dual Tire Operation.........................................5-59
E
Electrical System
Add-On Equipment......................................5-92
Engine Compartment Fuse Block...................5-94
Floor Console Fuse Block.............................5-93
Fuses and Circuit Breakers...........................5-92
Headlamp Wiring.........................................5-92
Windshield Wiper Fuses...............................5-92
Engine
Air Cleaner/Filter.........................................5-17
Battery.......................................................5-37
Change Engine Oil Light...............................3-35
Check and Service Engine Soon Light............3-32
Coolant......................................................5-22
Coolant Heater............................................2-21
Coolant Temperature Gage...........................3-31
Engine Compartment Overview......................5-12
Exhaust.....................................................2-27
Fan Noise..................................................5-32
Fuel Regulator............................................2-20
Oil .............................................................5-13
Overheating................................................5-24
Reduced Power Light...................................3-37
Speed Limiter.............................................3-24
Starting......................................................2-20
Entry Lighting.................................................3-16
Event Data Recorders (EDR)............................. 7-9
Exit Lighting...................................................3-16
4

Extender, Safety Belt.......................................1-30
Exterior Lamps...............................................3-13
F
Filter
Engine Air Cleaner......................................5-17
Finish Damage...............................................5-89
Fixed Mast Antenna........................................3-74
Flash-to-Pass................................................... 3-9
Flat Tire........................................................5-67
Flat Tire, Changing.........................................5-68
Flat Tire, Storing.............................................5-80
Fluid
Automatic Transmission................................5-19
Power Steering...........................................5-32
Windshield Washer......................................5-33
Front Axle......................................................5-44
Fuel............................................................... 5-5
Additives...................................................... 5-6
California Fuel.............................................. 5-6
Filling a Portable Fuel Container....................5-10
Filling Your Tank........................................... 5-8
Fuels in Foreign Countries.............................. 5-7
Gage.........................................................3-38
Gasoline Octane........................................... 5-5
Gasoline Specications.................................. 5-5
Regulator...................................................2-20Fuses
Engine Compartment Fuse Block...................5-94
Floor Console Fuse Block.............................5-93
Fuses and Circuit Breakers...........................5-92
Windshield Wiper.........................................5-92
G
Gage
Check Gages Warning Light..........................3-38
Engine Coolant Temperature.........................3-31
Fuel..........................................................3-38
Oil Pressure...............................................3-34
Speedometer..............................................3-24
Voltmeter Gage...........................................3-28
Gasoline
Octane........................................................ 5-5
Specications............................................... 5-5
GM Mobility Reimbursement Program.................. 7-5
H
Hazard Warning Flashers................................... 3-6
Headlamp Wiring............................................5-92
Headlamps....................................................5-47
Bulb Replacement.......................................5-46
Daytime Running Lamps...............................3-14
Flash-to-Pass............................................... 3-9
5

Light (cont.)
Brake System Warning.................................3-29
Change Engine Oil......................................3-35
Charging System.........................................3-28
Check Gages Warning.................................3-38
Cruise Control.............................................3-36
Daytime Running Lamps Indicator..................3-37
Highbeam On.............................................3-37
Malfunction Indicator....................................3-32
Reduced Engine Power................................3-37
Safety Belt Reminder...................................3-25
Security.....................................................3-36
Stabilitrak
®Indicator.....................................3-31
Stabilitrak®Not Ready..................................3-30
Tow/Haul Mode...........................................3-38
Lighting
Entry.........................................................3-16
Exit...........................................................3-16
Locking Rear Axle............................................ 4-7
Lockout Protection............................................ 2-9
Locks
Cargo Door Relocking.................................... 2-8
Door........................................................... 2-7
Lockout Protection......................................... 2-9
Power Door.................................................. 2-8
Rear Door Security Locks............................... 2-8
Loss of Control...............................................4-14
M
Maintenance Schedule
Additional Required Services........................... 6-6
At Each Fuel Fill.........................................6-10
At Least Once a Month................................6-10
At Least Once a Year..................................6-11
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000km).......................6-10
Introduction.................................................. 6-2
Maintenance Footnotes.................................. 6-8
Maintenance Record....................................6-16
Maintenance Requirements............................. 6-2
Normal Maintenance Replacement Parts.........6-15
Owner Checks and Services.........................6-10
Recommended Fluids and Lubricants.............6-13
Scheduled Maintenance................................. 6-4
Using Your................................................... 6-3
Your Vehicle and the Environment................... 6-2
Malfunction Indicator Light................................3-32
Manual Seats................................................... 1-3
Manual Windows............................................2-15
Mirrors
Manual Rearview Mirror................................2-29
Outside Camper-Type Mirrors........................2-29
Outside Convex Mirror.................................2-30
Outside Heated Mirrors................................2-31
7

Mirrors (cont.)
Outside Manual Mirror..................................2-29
Outside Power Mirrors..................................2-30
MyGMLink.com................................................ 7-3
N
New Vehicle Break-In......................................2-18
Noise Control System, Tampering......................5-45
Normal Maintenance Replacement Parts............6-15
O
Odometer......................................................3-24
Odometer, Trip...............................................3-24
Off-Road Recovery..........................................4-12
Oil
Change Engine Oil Light...............................3-35
Engine.......................................................5-13
Pressure Gage............................................3-34
Older Children, Restraints................................1-31
Online Owner Center........................................ 7-3
OnStar
®System.............................................2-31
Other Warning Devices...................................... 3-6
Outlet Adjustment............................................3-20Outside
Camper-Type Mirrors....................................2-29
Convex Mirror.............................................2-30
Heated Mirrors............................................2-31
Manual Mirror.............................................2-29
Power Mirrors.............................................2-30
Owner Checks and Services.............................6-10
Owners, Canadian............................................... ii
P
Park (P)
Shifting Into................................................2-25
Shifting Out of............................................2-26
Parking
Brake........................................................2-24
Over Things That Burn.................................2-27
Passing.........................................................4-12
Passlock
®......................................................2-18
Power
Accessory Outlets........................................3-16
Door Locks.................................................. 2-8
Reduced Engine Light..................................3-37
Retained Accessory (RAP)............................2-19
Seat............................................................ 1-4
Steering Fluid.............................................5-32
Windows....................................................2-16
Pretensioners, Safety Belt................................1-30
8

Q
Questions and Answers About Safety Belts.........1-14
R
Radiator Pressure Cap....................................5-24
Radios..........................................................3-39
AM-FM Radio.............................................3-40
Care of Your Cassette Tape Player................3-72
Care of Your CD Player...............................3-74
Care of Your CDs........................................3-74
Radio with Cassette and CD.........................3-47
Radio with CD............................................3-43
Radio with Six-Disc CD................................3-60
Setting the Time for Radios with
Radio Data Systems (RDS).......................3-40
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-40
Theft-Deterrent............................................3-71
Understanding Reception..............................3-72
Reading Lamps..............................................3-16
Rear Air Conditioning and Heating System.........3-21
Rear Axle......................................................5-44
Locking........................................................ 4-7
Rear Door Security Locks.................................. 2-8Rear Doors....................................................2-13
Rear Heating System......................................3-20
Rear Safety Belt Comfort Guides......................1-28
Rear Seat Operation......................................... 1-6
Rear Seat Passengers, Safety Belts..................1-25
Rearview Mirrors.............................................2-29
Reclining Seatbacks.......................................... 1-4
Recommended Fluids and Lubricants.................6-13
Recreational Vehicle Towing.............................4-34
Reduced Engine Power Light............................3-37
Remote Keyless Entry System............................ 2-3
Remote Keyless Entry System, Operation............ 2-4
Removing the Flat Tire and Installing the
Spare Tire..................................................5-72
Removing the Spare Tire and Tools...................5-69
Replacement Bulbs.........................................5-50
Reporting Safety Defects
Canadian Government..................................7-11
General Motors...........................................7-11
United States Government............................7-10
Restraint System Check
Checking Your Restraint Systems...................1-70
Replacing Restraint System Parts
After a Crash..........................................1-71
Restraint Systems
Checking....................................................1-70
Replacing Parts...........................................1-71
9