service CHEVROLET EXPRESS CARGO VAN 2004 1.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-34
Air Bag System
.......................................1-70
Restraint System Check
............................1-81
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-19
Starting and Operating Your Vehicle
...........2-20
Mirrors
....................................................2-32
OnStar
®System
......................................2-35
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-24
Audio System(s)
.......................................3-42
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-32Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under
the Hood
.............................................5-10
All-Wheel Drive
........................................5-48
Rear Axle
...............................................5-49
Front Axle
...............................................5-50
Noise Control System
...............................5-51
Bulb Replacement
....................................5-52
Windshield Wiper Blade Replacement
.........5-56
Tires
......................................................5-58
Appearance Care
.....................................5-92
Vehicle Identication
...............................5-100
Electrical System
....................................5-101
Capacities and Specications
...................5-106
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2004 Chevrolet Express Owner ManualM

{CAUTION:
If the air bag readiness light ever comes on
when you have turned off the air bag, it means
that something may be wrong with the air bag
system. The right front passenger’s air bag
could inate even though the switch is off. If
this ever happens, don’t let anyone whom the
national government has identied as a
member of a passenger air bag risk group sit
in the right front passenger’s position (for
example, don’t secure a rear-facing child
restraint in your vehicle) until you have your
vehicle serviced. See″Air Bag Off Switch″in
the Index.
1. If your vehicle has a passenger air bag and an air
bag off switch, and you are using a rear-facing child
restraint in this seat, make sure the air bag is
turned off. SeeAir Bag Off Switch on page 1-77.
If your child restraint is forward-facing, always move
the seat as far back as it will go before securing
it in this seat. SeePower Seat on page 1-4or
Manual Seats on page 1-3.2. Find the LATCH anchorages for the seating
position you want to use, where the bottom of the
seatback meets the back of the seat cushion.
3. Put the child restraint on the seat.
4. Attach and tighten the LATCH attachments on the
child restraint to the LATCH anchorages in the
vehicle. The child restraint instructions will show
you how.
5. If the child restraint is forward-facing, attach and
tighten the top tether to the top tether anchorage.
The child restraint instructions will show you
how. Also seeTop Strap on page 1-50.
6. Push and pull the child restraint in different
directions to be sure it is secure.
To remove the child restraint, simply unhook the top
tether from the top tether anchorage and then
disconnect the LATCH attachments from the LATCH
anchorages.
1-57

{CAUTION:
If the air bag readiness light ever comes on
when you have turned off the air bag, it means
that something may be wrong with the air bag
system. The right front passenger’s air bag
could inate even though the switch is off. If
this ever happens, don’t let anyone whom the
national government has identied as a
member of a passenger air bag risk group sit
in the right front passenger’s position (for
example, don’t secure a rear-facing child
restraint in your vehicle) until you have your
vehicle serviced. See″Air Bag Off Switch″in
the Index.If your child restraint does not have the LATCH system,
you will be using the lap-shoulder belt to secure the
child restraint in this position. Be sure to follow the
instructions that came with the child restraint. Secure
the child in the child restraint when and as the
instructions say.
1. If your vehicle has a passenger air bag and an air
bag off switch, and you are using a rear-facing child
restraint in this seat, make sure the air bag is
turned off. SeeAir Bag Off Switch on page 1-77.If
your child restraint is forward-facing, always
move the seat as far back as it will go before
securing it in this seat. SeePower Seat on page 1-4
orManual Seats on page 1-3.
2. Put the restraint on the seat.
3. Pick up the latch plate, and run the lap and shoulder
portions of the vehicle’s safety belt through or
around the restraint. The child restraint instructions
will show you how.
1-67

What Will You See After an Air Bag
Inates?
After an air bag inates, it quickly deates, so quickly that
some people may not even realize the air bag inated.
Some components of the air bag module — the steering
wheel hub for the driver’s air bag, or the instrument panel
for the right front passenger’s bag — will be hot for a
short time. The parts of the bag that come into contact
with you may be warm, but not too hot to touch. There will
be some smoke and dust coming from the vents in the
deated air bags. Air bag ination doesn’t prevent the
driver from seeing or being able to steer the vehicle, nor
does it stop people from leaving the vehicle.
{CAUTION:
When an air bag inates, there is dust in the air.
This dust could cause breathing problems for
people with a history of asthma or other
breathing trouble. To avoid this, everyone in the
vehicle should get out as soon as it is safe to do
so. If you have breathing problems but can not
get out of the vehicle after an air bag inates,
then get fresh air by opening a window or a
door. If you experience breathing problems
following an air bag deployment, you should
seek medical attention.
Air bags are designed to inate only once. After they
inate, you’ll need some new parts for your air bag
system. If you don’t get them, the air bag system
won’t be there to help protect you in another crash.
A new system will include air bag modules and
possibly other parts. The service manual for your
vehicle covers the need to replace other parts.
1-76

Your vehicle is equipped with a crash sensing and
diagnostic module, which records information about
the air bag system. The module records information
about the readiness of the system, when the system
commands air bag ination and driver’s safety belt
usage at deployment. The module also records
speed, engine rpm, brake and throttle data.
Let only qualied technicians work on your air bag
system. Improper service can mean that your air bag
system won’t work properly. See your dealer for
service.
Notice:If you damage the covering for the driver’s
or the right front passenger’s air bag, the bag
may not work properly. You may have to replace the
air bag module in the steering wheel or both the
air bag module and the instrument panel for
the right front passenger’s air bag. Do not open or
break the air bag coverings.
Air Bag Off Switch
If the GVWR (Gross Vehicle Weight Rating) of your
vehicle is 8600 or above, your vehicle has an air bag off
switch. You can nd the GVWR on the certication/tire
label on the rear edge of the driver’s door. SeeLoading
Your Vehicle on page 4-33for more information.
You can use the air bag off switch on the instrument
panel to turn off the right front passenger’s air bag.
1-77

To turn off the right front passenger’s air bag, insert
your ignition key into the switch, push in, and move the
switch to AIR BAG OFF.
The AIR BAG OFF light will come on to let you know
that the right front passenger’s air bag is off. The
right front passenger’s air bag will remain off until you
turn it back on again, and the AIR BAG OFF light
will stay on to remind you that the air bag is off.
{CAUTION:
If the air bag readiness light ever comes on
when you have turned off the air bag, it means
that something may be wrong with the air bag
system. The right front passenger’s air bag
could inate even though the switch is off. If
this ever happens, don’t let anyone whom the
national government has identied as a
member of a passenger air bag risk group sit
in the right front passenger’s position (for
example, don’t secure a rear-facing child
restraint in your vehicle) until you have your
vehicle serviced.
1-79

To turn the right front passenger’s air bag on again,
insert your ignition key into the switch, push in,
and move the switch to the on position.
Servicing Your Air Bag-Equipped
Vehicle
Air bags affect how your vehicle should be serviced.
There are parts of the air bag system in several places
around your vehicle. You don’t want the system to
inate while someone is working on your vehicle. Your
dealer and the service manual have information
about servicing your vehicle and the air bag system.
To purchase a service manual, seeService Publications
Ordering Information on page 7-12.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still inate during improper
service. You can be injured if you are close to
an air bag when it inates. Avoid wires
wrapped with yellow tape or yellow
connectors. They are probably part of the air
bag system. Be sure to follow proper service
procedures, and make sure the person
performing work for you is qualied to do so.
The air bag system does not need regular maintenance.
1-80

This vehicle has one
double-sided key for the
ignition and door locks. It
will t with either side up.
When a new vehicle is delivered, the dealer provides the
owner with a pair of identical keys and a bar-coded tag.
The bar-coded tag has a code on it that tells your dealer
or a qualied locksmith how to make extra keys. Keep
this tag in a safe place. If you lose your keys, you’ll be
able to have new ones made easily using this tag.
Notice:If you ever lock your keys in your vehicle,
you may have to damage the vehicle to get in.
Be sure you have spare keys.
If you ever do get locked out of your vehicle, call GM
Roadside Assistance Center. SeeRoadside Assistance
Program on page 7-6.Remote Keyless Entry System
If equipped, the remote keyless entry system operates
on a radio frequency subject to Federal Communications
Commission (FCC) Rules and with Industry Canada.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modications to this system by other than
an authorized service facility could void authorization to
use this equipment.
2-3

At times you may notice a decrease in range. This is
normal for any remote keyless entry system. If the
transmitter does not work or if you have to stand closer
to your vehicle for the transmitter to work, try this:
Check the distance. You may be too far from your
vehicle. You may need to stand closer during
rainy or snowy weather.
Check the location. Other vehicles or objects may
be blocking the signal. Take a few steps to the
left or right, hold the transmitter higher, and
try again.
Check to determine if battery replacement or
resynchronization is necessary. See “Battery
Replacement” and “Resynchronization” under
“Remote Keyless Entry System Operation” following
this section.
If you are still having trouble, see your dealer or a
qualied technician for service.
Remote Keyless Entry System
Operation
Your vehicle may have this feature.
Q(Lock):Press this
button once to lock all of
the doors. The parking
lamps will ash and
the interior lamps will turn
on briey. Press the
lock button again within ve
seconds and the parking
lamps will ash and
the horn will chirp briey.
W(Unlock):Press this button once to unlock the
driver’s door. The parking lamps will ash twice and the
interior lamps will turn on. Press the unlock button
again within ve seconds to unlock the remaining doors.
The parking lamps will ash.
2-4

L(Panic Alarm):The remote keyless entry transmitter
comes equipped with an instant panic alarm. To use
the alarm, press the horn symbol while the ignition
is turned off. The horn will sound and both the interior
and exterior lamps will ash for up to thirty seconds.
To stop the instant panic alarm, press the panic button
again, wait for thirty seconds, or start the vehicle.
j(Cargo Door):Press this button to unlock the cargo
doors only.
Matching Transmitter(s) to Your
Vehicle
Each remote keyless entry transmitter is coded to
prevent another transmitter from unlocking your vehicle.
If a transmitter is lost or stolen, a replacement can
be purchased through your dealer. Remember to bring
any remaining transmitters with you when you go to
your dealer. When the dealer matches the replacement
transmitter to your vehicle, any remaining transmitters
must also be matched. Once your dealer has coded the
new transmitter, the lost transmitter will not unlock
your vehicle. Each vehicle can have a maximum of four
transmitters matched to it.
Resynchronization
Resynchronization may be necessary due to the
security method used by this system. The transmitter
does not send the same signal twice to the receiver.
The receiver will not respond to a signal that has been
sent previously. This prevents anyone from recording
and playing back the signal from the transmitter.
To resynchronize your transmitter, stand close to your
vehicle and press and hold the lock and unlock
buttons on the transmitter at the same time for seven
seconds. The door locks should cycle to conrm
synchronization. If the locks do not cycle, see your
dealer for service.
2-5