belt CHEVROLET EXPRESS 2004 Workshop Manual

Doors and Locks
Door Locks
{CAUTION:
Unlocked doors can be dangerous.
Passengers — especially children — can
easily open the doors and fall out of a
moving vehicle. When a door is locked, the
handle will not open it. You increase the
chance of being thrown out of the vehicle
in a crash if the doors are not locked. So,
wear safety belts properly and lock the
doors whenever you drive.
Young children who get into unlocked
vehicles may be unable to get out. A child
can be overcome by extreme heat and can
suffer permanent injuries or even death
from heat stroke. Always lock your vehicle
whenever you leave it.
Outsiders can easily enter through an
unlocked door when you slow down or
stop your vehicle. Locking your doors can
help prevent this from happening.There are several ways to lock and unlock your vehicle.
If your vehicle is equipped with keyless entry, see
Remote Keyless Entry System on page 2-3for more
information.
From the outside, use your key.
To lock the door from the
inside, slide the manual
lever on your door down.
To unlock the door, slide
the manual lever up.
2-7

To open the rear portion of a 60/40 door from the
outside, pull the handle on the side of the rear door and
pull it toward you.
To close the 60/40 side doors, close the rear door rst.
Then close the front door. Check to make sure that
both doors are completely closed.
The front side swing-out door has a check strap
assembly in the door frame to keep the door from
opening beyond 90 degrees.
To open the door beyond 90 degrees, close the door
partially, pull the check strap toward you and then open
the door. When you close the door, the check strap
will automatically re-engage.
Rear Doors
{CAUTION:
Unlocked doors can be dangerous.
Passengers — especially children — can
easily open the doors and fall out of a
moving vehicle. When a door is locked, the
handle will not open it. You increase the
chance of being thrown out of the vehicle
in a crash if the doors are not locked. So,
wear safety belts properly and lock the
doors whenever you drive.
Young children who get into unlocked
vehicles may be unable to get out. A child
can be overcome by extreme heat and can
suffer permanent injuries or even death
from heat stroke. Always lock your vehicle
whenever you leave it.
Outsiders can easily enter through an
unlocked door when you slow down or
stop your vehicle. Locking your doors can
help prevent this from happening.
2-13

Instrument Panel Overview...............................3-4
Hazard Warning Flashers................................3-6
Other Warning Devices...................................3-6
Horn.............................................................3-6
Tilt Wheel.....................................................3-6
Turn Signal/Multifunction Lever.........................3-7
Turn and Lane-Change Signals........................3-8
Headlamp High/Low-Beam Changer..................3-8
Flash-to-Pass.................................................3-9
Windshield Wipers..........................................3-9
Windshield Washer.......................................3-10
Cruise Control..............................................3-10
Exterior Lamps.............................................3-13
Headlamps on Reminder................................3-14
Daytime Running Lamps (DRL).......................3-14
Instrument Panel Brightness...........................3-15
Dome Lamps...............................................3-15
Dome Lamp Override....................................3-15
Entry Lighting...............................................3-16
Exit Lighting.................................................3-16
Reading Lamps............................................3-16
Battery Run-Down Protection..........................3-16
Accessory Power Outlets...............................3-16
Ashtrays and Cigarette Lighter........................3-17Climate Controls............................................3-18
Climate Control System.................................3-18
Outlet Adjustment.........................................3-20
Rear Heating System....................................3-20
Rear Air Conditioning and Heating System.......3-21
Warning Lights, Gages, and Indicators............3-22
Instrument Panel Cluster................................3-23
Speedometer and Odometer...........................3-24
Trip Odometer..............................................3-24
Engine Speed Limiter....................................3-24
Safety Belt Reminder Light.............................3-25
Airbag Readiness Light..................................3-25
Airbag Off Light............................................3-26
Charging System Light..................................3-28
Voltmeter Gage............................................3-28
Brake System Warning Light..........................3-29
Anti-Lock Brake System Warning Light.............3-30
StabiliTrak Not Ready Light............................3-30
StabiliTrak Indicator Light...............................3-31
Engine Coolant Temperature Gage..................3-31
Malfunction Indicator Lamp.............................3-32
Oil Pressure Gage........................................3-34
Change Engine Oil Light................................3-35
Security Light...............................................3-36
Section 3 Instrument Panel
3-1

Safety Belt Reminder Light
When the key is turned to RUN or START, a chime will
be provided for several seconds to remind people to
buckle their safety belts. The driver safety belt light will
also be provided and stay on for several seconds,
then it will ash for several more. You should buckle
your seat belt.
This chime and light will be
repeated if the driver
remains unbuckled and the
vehicle is in motion.
If the driver’s belt is buckled, neither the chime nor the
light will be provided.
Airbag Readiness Light
There is an airbag readiness light on the instrument
panel, which shows the airbag symbol. The system
checks the airbag’s electrical system for malfunctions.
The light tells you if there is an electrical problem.
The system check includes the airbag sensor, the airbag
modules, the wiring and the crash sensing and
diagnostic module. For more information on the airbag
system, seeAirbag System on page 1-59.
This light will come on
when you start your
vehicle, and it will ash for
a few seconds. Then
the light should go out.
This means the system
is ready.
3-25

Charging System Light
This light should come on
briey when you turn on
the ignition, before starting
the engine, as a check
to show you it is working.
After the engine starts, the light should go out. If it stays
on or comes on while you are driving, you may have
a problem with your charging system. It could indicate a
problem with the generator drive belt, or some other
charging system problem. Have it checked right away.
Driving while this light is on could drain your battery.
If you must drive a short distance with this light
on, it helps to turn off all your accessories, such as the
radio and air conditioner.
Voltmeter Gage
When your engine is not
running, but the ignition is
on (in the RUN position),
this gage shows your
battery’s state of charge in
DC volts.
When the engine is running, the gage shows the
condition of the charging system. Readings between the
low and high warning zones indicate the normal
operating range.
Readings in the low warning zone may occur when a
large number of electrical accessories are operating in
the vehicle and the engine is left at an idle for an
extended period. This condition is normal since the
charging system is not able to provide full power
at engine idle. As engine speeds are increased, this
condition should correct itself as higher engine speeds
allow the charging system to create maximum power.
3-28

When cleaning the cassette tape player with the
recommended non-abrasive cleaning cassette, it is
possible that the cassette may eject, because the cut
tape detection feature on the radio may recognize it as a
broken tape, in error. To prevent the cleaning cassette
from being ejected, use the following steps:
1. Turn the ignition on.
2. Turn the radio off.
3. Press and hold the TAPE DISC button for
ve seconds. READY will appear on the display and
the cassette symbol will ash for ve seconds.
4. Insert the scrubbing action cleaning cassette.
5. Eject the cleaning cassette after the manufacturer’s
recommended cleaning time.
When the cleaning cassette has been ejected, the
cut tape detection feature will be active again.A non-scrubbing action, wet-type cleaner which uses a
cassette with a fabric belt to clean the tape head
can be used. This type of cleaning cassette will not
eject on its own. A non-scrubbing action cleaner may not
clean as thoroughly as the scrubbing type cleaner.
The use of a non-scrubbing action, dry-type cleaning
cassette is not recommended.
After the player is cleaned, press and hold the eject
button for ve seconds to reset the CLEAN indicator.
The radio will display --- or CLEANED to show the
indicator was reset.
Cassettes are subject to wear and the sound quality
may degrade over time. Always make sure the cassette
tape is in good condition before the tape player is
serviced.
3-73

Your Driving, the Road, and
Your Vehicle
Defensive Driving
The best advice anyone can give about driving is:
Drive defensively.
Please start with a very important safety device in your
vehicle: Buckle up. SeeSafety Belts: They Are for
Everyone on page 1-10.
Defensive driving really means “be ready for anything.”
On city streets, rural roads, or freeways, it means
“always expect the unexpected.”
Assume that pedestrians or other drivers are going to
be careless and make mistakes. Anticipate what
they might do. Be ready for their mistakes.
Rear-end collisions are about the most preventable of
accidents. Yet they are common. Allow enough following
distance. It is the best defensive driving maneuver, in
both city and rural driving. You never know when the
vehicle in front of you is going to brake or turn suddenly.
Defensive driving requires that a driver concentrate on
the driving task. Anything that distracts from the driving
task — such as concentrating on a cellular telephone call,
reading, or reaching for something on the oor — makesproper defensive driving more difficult and can even
cause a collision, with resulting injury. Ask a passenger to
help do things like this, or pull off the road in a safe place
to do them yourself. These simple defensive driving
techniques could save your life.Drunken Driving
Death and injury associated with drinking and driving is
a national tragedy. It is the number one contributor
to the highway death toll, claiming thousands of victims
every year.
Alcohol affects four things that anyone needs to drive
a vehicle:
Judgment
Muscular Coordination
Vision
Attentiveness
Police records show that almost half of all motor
vehicle-related deaths involve alcohol. In most cases,
these deaths are the result of someone who was
drinking and driving. In recent years, more than
16,000 annual motor vehicle-related deaths have been
associated with the use of alcohol, with more than
300,000 people injured.
4-2

Speed limit signs near curves warn that you should
adjust your speed. Of course, the posted speeds
are based on good weather and road conditions. Under
less favorable conditions you will want to go slower.
If you need to reduce your speed as you approach
a curve, do it before you enter the curve, while your front
wheels are straight ahead.
Try to adjust your speed so you can “drive” through the
curve. Maintain a reasonable, steady speed. Wait to
accelerate until you are out of the curve, and then
accelerate gently into the straightaway.
Steering in Emergencies
There are times when steering can be more effective
than braking. For example, you come over a hill and nd
a truck stopped in your lane, or a car suddenly pulls out
from nowhere, or a child darts out from between parked
cars and stops right in front of you. You can avoid these
problems by braking — if you can stop in time. But
sometimes you cannot; there is not room. That is the time
for evasive action — steering around the problem.
Your vehicle can perform very well in emergencies like
these. First apply your brakes.
SeeBraking on page 4-5. It is better to remove as much
speed as you can from a possible collision. Then
steer around the problem, to the left or right depending
on the space available.An emergency like this requires close attention and a
quick decision. If you are holding the steering wheel at
the recommended 9 and 3 o’clock positions, you
can turn it a full 180 degrees very quickly without
removing either hand. But you have to act fast, steer
quickly, and just as quickly straighten the wheel
once you have avoided the object.
The fact that such emergency situations are always
possible is a good reason to practice defensive driving
at all times and wear safety belts properly.
4-11

When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store
the chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission uid (don’t overll),
engine oil, axle lubricant, belt, cooling system and
brake system. Each of these is covered in this manual,
and the Index will help you nd them quickly. If
you’re trailering, it’s a good idea to review these sections
before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Trailer Wiring Harness
The optional heavy-duty trailer wiring package includes
a seven-wire harness assembly at the rear of the
vehicle and a four-wire harness assembly under the left
hand side of the instrument panel. The seven-wire
harness assembly is taped together and located in a
frame pocket at the driver side rear left corner of
the frame. The seven-wire harness includes a 30-amp
feed wire. Both harnesses come without connectors and
should be wired by a qualied electrical technician.
The technician can use the following color code chart
when connecting the wiring harness to your trailer
and trailer brake controller.
Seven-Wire Harness
Light Green: Back-up lamps
Brown: Parking lamps
Yellow: Left stoplamp and turn signal
Dark Green: Right stoplamp and turn signal
Dark Blue: Use for electric trailer brakes
Orange: Trailer accessory
White (heavy gage): Ground wire
Four-Wire Harness (Trailer Brake Controller)
Black: Ground
Red/White Stripe: Fused Battery
Dark Blue: Trailer Brake Feed
Light Blue: Fused Stoplamp/CHMSL
4-46

Buying New Tires.........................................5-62
Uniform Tire Quality Grading..........................5-63
Wheel Alignment and Tire Balance..................5-64
Wheel Replacement......................................5-65
Tire Chains..................................................5-66
If a Tire Goes Flat........................................5-67
Changing a Flat Tire.....................................5-68
Removing the Spare Tire and Tools................5-69
Removing the Flat Tire and Installing the
Spare Tire................................................5-72
Secondary Latch System...............................5-77
Storing a Flat or Spare Tire and Tools............5-80
Spare Tire...................................................5-82
Appearance Care............................................5-82
Fabric/Carpet...............................................5-83
Vinyl...........................................................5-85
Instrument Panel..........................................5-85
Interior Plastic Components............................5-85
Glass Surfaces.............................................5-85
Care of Safety Belts......................................5-85
Weatherstrips...............................................5-86
Washing Your Vehicle...................................5-86Cleaning Exterior Lamps/Lenses.....................5-86
Finish Care..................................................5-86
Windshield and Wiper Blades.........................5-87
Aluminum Wheels.........................................5-88
Tires...........................................................5-88
Sheet Metal Damage.....................................5-89
Finish Damage.............................................5-89
Underbody Maintenance................................5-89
Chemical Paint Spotting.................................5-89
Vehicle Care/Appearance Materials..................5-90
Vehicle Identication......................................5-91
Vehicle Identication Number (VIN).................5-91
Service Parts Identication Label.....................5-91
Electrical System............................................5-92
Add-On Electrical Equipment..........................5-92
Headlamp Wiring..........................................5-92
Windshield Wiper Fuses................................5-92
Fuses and Circuit Breakers............................5-92
Floor Console Fuse Block..............................5-93
Engine Compartment Fuse Block....................5-94
Capacities and Specications..........................5-97
Section 5 Service and Appearance Care
5-2