brake CHEVROLET EXPRESS 2004 Workshop Manual

Floor Console Fuse Block
The oor console fuse block is located under the
driver’s seat.
Fuse Usage
1 Spare
2 Outside Rear View Mirror
3 Courtesy Lamp/SEO
Fuse Usage
4 Left Rear Stop/Turn Signal
5 Cargo Locks
6 Right Rear Stop/Turn Signal
7 Driver Locks
8Stop/Center High Mounted
Stop Lamp
9 Climate Control 1
10 Climate Control
11 Brakes
12 Heated Mirror/Defogger
13 Right Rear Blower
14 Driver Turn Mirror
15 Door Locks
16 Uptter Park
17 Not Available
18 Left Rear Park Lamp
19 Pass Turn Mirror
20 Right Rear Park Lamp
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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
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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

Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-13. Reset oil
life system. SeeEngine Oil Life System on page 5-16.An Emission
Control Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner lter or change indicator (if equipped). If necessary,
replace lter. SeeEngine Air Cleaner/Filter on page 5-17.An Emission Control
Service. See footnotes † and (l).•
Rotate tires and check ination pressures and wear. SeeTires on page 5-52.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels and add uid
as needed.••
Perform any needed additional services. See “Additional Required Services” in
this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
Check transmission uid level and add uid as needed.•
Inspect shields, vehicles with GVWR above 10,000 lbs (4 536 kg) only.See
footnote (g).•
Inspect throttle system.See footnote (m).•
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Maintenance Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, kingpin bushings,
steering linkage and rear driveline center splines.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chang, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts,
signs of wear or lack of lubrication. Inspect power
steering lines and hoses for proper hook-up, binding,
leaks, cracks, chang, etc.
(c)Visually inspect hoses and have them replaced if
they are cracked, swollen or deteriorated. Inspect
all pipes, ttings and clamps; replace with genuine
GM parts as needed. To help ensure proper operation,a pressure test of the cooling system and pressure cap
and cleaning the outside of the radiator and air
conditioning condenser is recommended at least
once a year.
(d)Visually inspect wiper blades for wear or cracking.
Replace blade inserts that appear worn or damaged
or that streak or miss areas of the windshield.
(e)Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced. Also look for any opened or broken airbag
coverings, and have them repaired or replaced.
(The airbag system does not need regular maintenance.)
(f)Lubricate all key lock cylinders, hood hinges, hood
prop rod pivot, hood latch assembly, secondary
latch, pivots, spring anchor, release pawl, rear
compartment hinges, latches, locks, fuel door hinge and
any moving seat hardware. More frequent lubrication
may be required when exposed to a corrosive
environment. Applying silicone grease on weatherstrips
with a clean cloth will make them last longer, seal
better and not stick or squeak.
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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.
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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.
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Recommended Fluids and
Lubricants
Fluids and lubricants identied below by name,
part number or specication may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certied for Gasoline Engines
starburst symbol. GM Goodwrench
oil meets all the requirements for
your vehicle. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
®Coolant. SeeEngine
Coolant on page 5-22.
Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Parking Brake
Cable GuidesChassis Lubricant (GM Part
No. U.S. 12377985, in
Canada 88901242) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Power Steering
SystemGM Power Steering Fluid
(GM Part No. U.S. 89021184, in
Canada 89021186).
Automatic
TransmissionDEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specication”
on the label.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
6-13

Courtesy Transportation is available only at participating
GM dealers and all program options, such as shuttle
service, may not be available at every dealer. Please
contact your GM dealer for specic information
about availability. All Courtesy Transportation
arrangements will be administered by appropriate
dealer personnel.
Canadian Vehicles:For warranty repairs during the
Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s performance.
Your vehicle uses on-board vehicle computers to monitor
emission control components to optimize fuel economy,
to monitor conditions for airbag deployment and, if so
equipped, to provide anti-lock braking and to help the
driver control the vehicle in difficult driving situations.
Some information may be stored during regular
operations to facilitate repair of detected malfunctions;
other information is stored only in a crash event by
computer systems, such as those commonly called event
data recorders (EDR).
In a crash event, computer systems, such as the Airbag
Sensing and Diagnostic Module (SDM) in your vehicle
may record information about the condition of the vehicle
and how it was operated, such as data related to
engine speed, brake application, throttle position, vehicle
speed, safety belt usage, airbag readiness, airbag
performance, and the severity of a collision. If your
vehicle is equipped with Stabilitrak
®, steering
performance, including yaw rate, steering wheel angle,
and lateral acceleration, is also recorded. This
information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety.
7-9

To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you will notify
General Motors. Please call the Chevrolet Customer
Assistance Center at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle suspension,
brakes, electrical, steering, body, etc.
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