check engine CHEVROLET EXPRESS CARGO VAN 2004 1.G Owner's Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.......................5-9
Checking Things Under
the Hood....................................................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-18
Automatic Transmission Fluid.........................5-19
Engine Coolant.............................................5-22
Radiator Pressure Cap..................................5-25
Engine Overheating.......................................5-26
Cooling System............................................5-28Engine Fan Noise.........................................5-36
Power Steering Fluid.....................................5-36
Windshield Washer Fluid................................5-38
Brakes........................................................5-39
Battery........................................................5-42
Jump Starting...............................................5-43
All-Wheel Drive..............................................5-48
Rear Axle.......................................................5-49
Front Axle......................................................5-50
Noise Control System.....................................5-51
Tampering with Noise Control System
Prohibited.................................................5-51
Bulb Replacement..........................................5-52
Halogen Bulbs..............................................5-52
Headlamps..................................................5-52
Front Turn Signal, Sidemarker and
Parking Lamps..........................................5-54
Taillamps.....................................................5-54
Replacement Bulbs.......................................5-56
Windshield Wiper Blade Replacement..............5-56
Section 5 Service and Appearance Care
5-1

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 (seeMalfunction Indicator Lamp on page 3-34)
and your vehicle may fail a smog-check test. 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. 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.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specications described earlier.
5-6

Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
Hood Release
To open the hood, do the following:
1. Pull this handle inside
the vehicle. It is located
in front of the driver’s
side door frame
near the oor.
5-10

A. Battery. SeeBattery on page 5-42.
B. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-25.
C. Coolant Recovery Tank. SeeCooling System on
page 5-28.
D. Transmission Fluid Dipstick. SeeAutomatic
Transmission Fluid on page 5-19.
E. Engine Oil Fill. SeeEngine Oil on page 5-13.
F. Engine Oil Dipstick. SeeEngine Oil on page 5-13.
G. Air Filter Restriction Indicator. SeeEngine Air
Cleaner/Filter on page 5-18.
H. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-18.
I. Power Steering Reservoir. SeePower Steering Fluid
on page 5-36.
J. Brake Master Cylinder. SeeBrakes on page 5-39.
K. Windshield Washer Fluid. SeeWindshield Washer
Fluid on page 5-38.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
Pull out the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it again,
keeping the tip down, and check the level.
5-13

Notice:Use only engine oil identied as meeting GM
Standard GM6094M and showing the American
Petroleum Institute Certied For Gasoline Engines
starburst symbol. Failure to use the recommended oil
can result in engine damage not covered by your
warranty.
GM Goodwrench
®oil meets all the requirements for
your vehicle.
If you are in an area of extreme cold, where the
temperature falls below−20°F (−29°C), it is
recommended that you use either an SAE 5W-30
synthetic oil or an SAE 0W-30 oil. Both will provide
easier cold starting and better protection for your engine
at extremely low temperatures.
Engine Oil Additives
Do not add anything to your oil. The recommended oils
with the starburst symbol that meet GM Standard
GM6094M are all you will need for good performance
and engine protection.
When to Change Engine Oil (GM Oil
Life System)
Your vehicle has a computer system that lets you know
when to change the engine oil and lter. This is based on
engine revolutions and engine temperature, and not on
mileage. Based on driving conditions, the mileage at
which an oil change will be indicated can vary
considerably. For the oil life system to work properly, you
must reset the system every time the oil is changed.
When the system has calculated that oil life has been
diminished, it will indicate that an oil change is
necessary. A Change Engine Oil light will come on.
Change your oil as soon as possible within the next two
times you stop for fuel. It is possible that, if you are
driving under the best conditions, the oil life system may
not indicate that an oil change is necessary for over a
year. However, your engine oil and lter must be
changed at least once a year and at this time the system
must be reset. Your dealer has GM-trained service
people who will perform this work using genuine GM
parts and reset the system. It is also important to check
your oil regularly and keep it at the proper level.
If the system is ever reset accidentally, you must change
your oil at 3,000 miles (5 000 km) since your last oil
change. Remember to reset the oil life system whenever
the oil is changed.
5-16

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. Install the new engine air cleaner/lter into the
engine air cleaner/lter housing. Make sure that
it 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.
Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission uid
level is when the engine oil is changed.
Change both the uid and lter every 50,000 miles
(83,000 km) if the vehicle’s GVWR is over 8,600 or if
the vehicle is mainly driven under one or more of these
conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.
If your vehicle’s GVWR is not over 8,600 and you do
not use your vehicle under any of these conditions,
change the uid and lter every 100,000 miles
(166 000 km).
SeeScheduled Maintenance on page 6-4.
5-19

How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage
your transmission. Too much can mean that some
of the uid could come out and fall on hot engine
part or exhaust system parts, starting a re.
Too little uid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission uid.
Wait at least 30 minutes before checking the
transmission uid level if you have been driving:
When outside temperatures are above 90°F (32°C).
At high speed for quite a while.
In heavy traffic – especially in hot weather.
While pulling a trailer.To get the right reading, the uid should be at normal
operating temperature, which is 180°F to 200°F
(82°C to 93°C).
Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50°F
(10°C). If it’s colder than 50°F (10°C), drive the vehicle
in DRIVE (D) until the engine temperature gage
moves and then remains steady for 10 minutes.
A cold uid check can be made after the vehicle has
been sitting for eight hours or more with the engine off,
but this is used only as a reference. Let the engine
run at idle for ve minutes if outside temperatures are
50°F (10°C) or more. If it’s colder than 50°F (10°C), you
may have to idle the engine longer. Should the uid
level be low during this cold check, youmustcheck the
uid hot before adding uid. Checking the uid hot
will give you a more accurate reading of the uid level.
5-20

Checking the Fluid Level
Prepare your vehicle as follows:
Park your vehicle on a level place. Keep the engine
running.
With the parking brake applied, place the shift lever
in PARK (P).
With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the shift
lever in PARK (P).
Let the engine run at idle for three minutes or more.
Then, without shutting off the engine, follow these steps:
The transmission dipstick
is located near the center
of the engine compartment
and will be labeled with
this graphic shown.
SeeEngine Compartment Overview on page 5-12for
more information on location.1. Flip the handle up and then pull out the dipstick
and wipe it with a clean rag or paper towel.
2. Push it back in all the way, wait three seconds and
then pull it back out again.
3. Check both sides of the dipstick, and read the lower
level. The uid level must be in the COLD area for
a cold check or in the HOT area or cross-hatched
area for a hot check. Be sure to keep the dipstick
pointed down to get an accurate reading.
4. If the uid level is in the acceptable range, push the
dipstick back in all the way; then ip the handle
down to lock the dipstick in place.
5-21

How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission uid to use. SeeRecommended
Fluids and Lubricants on page 6-12.
Using a funnel, add uid down the transmission dipstick
tube only after checking the transmission uid while it
is hot. (A cold check is used only as a reference.) If the
uid level is low, add only enough of the proper uid
to bring the level up to the HOT area for a hot check.
It doesn’t take much uid, generally less than one pint
(0.5 L).Don’t overll.
Notice:We recommend you use only uid labeled
DEXRON
®-III, because uid with that label is
made especially for your automatic transmission.
Damage caused by uid other than DEXRON
®-III is
not covered by your new vehicle warranty.
After adding uid, recheck the uid level as
described under “How to Check.”
When the correct uid level is obtained, push the
dipstick back in all the way; then ip the handle
down to lock the dipstick in place.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs rst, if you add
only DEX-COOL
®extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating on
page 5-26.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as they
should.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-22

What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOL®coolant which won’t damage
aluminum parts. If you use this coolant mixture,
you don’t need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and the proper coolant.Notice:If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost would not be covered by your
warranty. Too much water in the mixture can freeze
and crack the engine, radiator, heater core and
other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice:If you use the proper coolant, you do not
have to add extra inhibitors or additives which claim
to improve the system. These can be harmful.
5-23