light CHEVROLET EXPRESS 1997 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does
not mean something is wrong with
your brakes.
Properly torqued wheel
nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly torque wheel nuts in the
proper sequence to
GM specifications.
Your rear drum brakes don’t have wear indicators, but
if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected. Also, the rear brake drums
should be removed and inspected each time the tires
are removed for rotation or changing. When you have
the front brake pads replaced, have the rear brakes
inspected,
too.
Brake linings should always be replaced as complete
axle sets.
See “Brake System Inspection” in Section
7 of this
manual under Part
C “Periodic Maintenance
Inspections”.
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be
a sign of brake trouble.
Brake Adjustment
Every time you make a brake stop, your disc brakes
adjust for wear.
If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them by
backing up and firmly applying the brakes a few times.
Replacing Brake System Parts
The braking system on a modern vehicle is complex.
Its many parts have to be
of top quality and work well
together if the vehicle is to have really good braking.
Your vehicle was designed and tested with top-quality
GM brake parts. When you replace parts of your braking
system
-- for example, when your brake linings wear
down and you have
to have new ones put in -- be sure
you get new approved
GM replacement parts. If you
don’t, your brakes may no longer work properly. For
example,
if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change
-- for the worse. The braking
performance you’ve come to expect can change in many
other ways
if someone puts in the wrong replacement
brake parts.

Downloaded from www.Manualslib.com manuals search engine Mixing tires could cause you to lose control while
driving.
If you mix tires of different sizes or types
(radial and bias-belted tires), the vehicle may not
handle properly, and you could have a crash.
Using tires
of different sizes may also cause
damage to your vehicle.
Be sure to use the same
size and type tires on all wheels.
1
Uniform Tire Quality Grading
The following information relates to the system developed
by the United States National Highway Traffic Safety
Administration, which grades tires by treadwear, traction and temperature performance. (This applies only to
vehicles sold in the United States.) The grades are molded
on the sidewalls of most passenger car tires. The Uniform
Tire Quality Grading system does
not apply to deep tread,
winter-type snow tires, space-saver
or temporary use spare
tires, tires with nominal rim diameters
of 10 to 12 inches
(25 to 30 cm), or to some limited-production tires.
While
the tires available on General Motors passenger
cars and light trucks may vary with respect to these grades,
they must also conform to Federal safety
requirements and additional General Motors Tire
Performance Criteria
(TPC) standards.
Treadwear
The treadwear grade is a comparative rating based on
the wear rate of the tire when tested under controlled
conditions on a specified government test course. For
example, a tire graded
150 would wear one and a half
( 1 1/2) times as well on the government course as a tire
graded
100. The relative performance of tires depends
upon the actual conditions
of their use, however, and
may depart significantly from the norm due
to variations
in driving habits, service practices and differences in
road characteristics and climate.
Traction -- A, B, C
The traction grades, from highest to lowest, are A, B, and
C, and they represent the tire’s ability to stop on wet
pavement as measured under controlled conditions
on
specified government test surfaces of asphalt and concrete.
A tire marked C may have poor traction performance.
Warning: The traction grade assigned to this tire is based
on braking (straightahead) traction tests and does not
include cornering (turning) traction.

Downloaded from www.Manualslib.com manuals search engine Don’t use any of these unless this manual says you can.
In many uses, these will damage your vehicle:
Alcohol
Laundry Soap
Bleach
Reducing Agents
Cleaning the Inside of Your Vehicle
Use a vacuum cleaner often to get rid of dust and loose
dirt. Wipe vinyl or leather with a clean, damp cloth.
Your
GM dealer has two cleaners, a solvent-type spot
lifter and a foam-type powdered cleaner. They will clean
normal spots and stains very well.
Do not use them on
vinyl or leather.
Here are some cleaning tips:
1. Always read the instructions on the cleaner label.
Using Foam-Type Cleaner on Fabric
1. Vacuum and brush the area to remove any loose dirt.
2. Always clean a whole trim panel or section. Mask
surrounding trim along stitch or welt lines.
3. Mix Multi-Purpose Powdered Cleaner following the
directions on the container label.
4. Use suds only and apply with a clean sponge. Don’t
saturate the material and don’t rub it roughly.
5. As soon as you’ve cleaned the section, use a sponge
to remove the
suds.
6. Rinse the section with a clean, wet sponge.
7. Wipe off what’s left with a slightly damp paper towel
or cloth.
8. Dry it immediately with a blow dryer.
9. Wipe with a clean cloth.
2. Clean up stains as soon as you can -- before they set.
3. Use a clean cloth or sponge, and change to a clean area
4. Use solvent-type cleaners in a well-ventilated area
often.
A soft brush may be used
if stains are stubborn.
only.
If you use them, don’t saturate the stained area.
5. If a ring forms after spot cleaning, clean the entire
area immediately
or it will set.

Downloaded from www.Manualslib.com manuals search engine Using Solvent-Type Cleaner on Fabric
First, see if you have to use solvent-type cleaner at all.
Some
spots and stains will clean off better with just
water and mild soap.
If
you need to use a solvent:
1. Gently scrape excess soil from the trim material with
a clean, dull knife or scraper.
2. Use very little cleaner, light pressure and clean cloths
(preferably cheesecloth). Cleaning should start at the
outside
of the stain, “feathering” toward the center.
3. Keep changing to
a clean section of the cloth.
4. When you clean a stain from fabric, immediately
dry the area with a blow dryer to help prevent a
cleaning ring.
Fabric Protection
Your vehicle has upholstery and carpet that has been
treated with Scotchgard
TM Fabric Protector, a 3M
product. It protects fabrics by repelling oil and water,
which are the carriers of most stains. Even with this
protection, you
still need to clean your upholstery and
carpet often to keep
it looking new.
Further information
on cleaning is available by calling
1-800-433-3296
(in Minnesota, 1-800-642-6 167).
Special Cleaning Problems
Greasy or Oily Stains
Stains caused by grease, oil, butter, margarine, shoe
polish, coffee with cream, chewing gum, cosmetic
creams, vegetable oils, wax crayon, tar and asphalt can
be removed as follows:
1. Carefully scrape off excess stain.
2. Follow the solvent-type instructions described earlier.
Shoe polish, wax crayon, tar and asphalt will stain if left
on a vehicle’s seat fabric. They should be removed as
soon as possible. Be careful, because the cleaner will
dissolve them and may cause them to spread.
Non-Greasy Stains
Stains caused by catsup, coffee (black), egg, fruit, fruit
juice, milk, soft drinks, wine, vomit, urine and
blood can
be removed as follows:
1. Carefully scrape off excess stain, then sponge the
soiled area with cool water.
2. If a stain remains, follow the foam-type instructions
described earlier.

Downloaded from www.Manualslib.com manuals search engine 3. If an odor lingers after cleaning vomit or urine,
treat the area with
a waterhaking soda solution:
1 teaspoon (5 ml) of baking soda to I cup (250 ml)
of lukewarm water.
4. If needed, clean lightly with solvent-type cleaner.
Combination Stains
Stains caused by candy, ice cream, mayonnaise, chili
sauce and unknown stains can be removed
as follows:
1. Carefully scrape off excess stain.
2. Clean with cool water and allow to dry.
3. If a stain remains, clean it with solvent-type cleaner.
Cleaning Vinyl
use warm water and a clean cloth.
0 Rub with a clean, damp cloth to remove dirt. You
may have to do it more than once.
0 Things like tar, asphalt and shoe polish will stain if you
don’t get them
off quickly. Use a clean cloth and a
vinylheather cleaner. See your dealer for this product.
Cleaning Leather
Use a soft cloth with lukewarm water and a mild soap or
saddle soap and wipe dry with a soft cloth. Then, let the
leather dry naturally.
Do not use heat to dry.
0 For stubborn stains, use a leather cleaner. See your
dealer for this product.
Never use oils, varnishes, solvent-based or abrasive
cleaners, furniture polish or shoe polish on leather.
Soiled or stained leather should be cleaned
immediately.
If dirt is allowed to work into the
finish, it can harm the leather.
Cleaning the Top of the Instrument Panel
Use only mild soap and water to clean the top surfaces
of the instrument panel. Sprays containing silicones or
waxes may cause annoying reflections
in the windshield
and even make
it difficult to see through the windshield
under certain conditions.

Downloaded from www.Manualslib.com manuals search engine Instrument Panel Fuse Block
The fuse block access door
is on the driver's side of the
instrument panel above the
hood release lever.
You can remove the cover
by turning the fastener
counterclockwise.
You can remove fuses with a fuse extractor. The fuse
extractor
is mounted to the fuse block access door.
To remove fuses if you don't have a fuse extractor, hold
the end of the fuse between your thumb and index finger
and pull straight out. Be sure to use
the correct fuse.
If you ever have a
problem on the road and don't have a spare fuse,
you can "borrow" one of the correct value. Just pick
some feature of your vehicle that you can get along
without
-- like the radio or cigarette lighter -- and use
its fuse, if it is of the value you need. Replace it
as soon
as you can. See "Fuses and Circuit Breakers'' in the
Index for more information.
6-60

Downloaded from www.Manualslib.com manuals search engine POSITION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1s.
16.
NAME
STOP
HTD MIR
CTSY
GAUGES
HAZARD
CRUISE
PWR AUX
Crank
PARK LPS
AIR BAGS
WIPER
HTR-A/C
CIG LTR
ILLUM
DRL
TURN B/U
CIRCUITS PROTECTED
Stop/CHMSL, Stoplamps
Electric Heated Mirrors
Courtesy
Lamps, Dorne/RDG Lamps, Vanity Mirrors, Power Mirrors
IP Cluster, DRL Relay, DRL Module, HDLP Switch, Keyless Entry
Illumination, Low Coolant Module, CHIME Module, DRAB Module
Hazard Lamps/CHIME Module
Cruise Control
Auxiliary Power Outlet, ALDL
.
License Plate Lamp, Parking Lamps, Tdillamps, Front Sidemarkers,
Glove
Box Ashtray
SDM
Wiper Motor, Washer Pump
A/C, A/C Blower, High Blower Relay, HTD Mirror
Power Amp, Cigarette Lighter, Door Lock Relay
LP Cluster, HVAC Controls, RR HVAC Controls, IP Switches, Radio
Illumination, Door Switch Illumination
DRL Relay
Front Turn,
RR Turn, Back-up Lamps, BTSI Solenoid

Downloaded from www.Manualslib.com manuals search engine Engine Compartment Fuse Relay Center
The fuse block is on the driver’s side of the engine
compartment at the rear.
,
[T)
Name
BLOWR
ABS
Circuits Protected
Blower Motor
Electronic Brake Control Module
Name
IGN-B
IGN-A
BATT
LIGHTING
RR BLOWER
ENG-
1
AIC
SPARE
AUX A
AUX-B
RH-HDLP
Circuits Protected
Ignition Switch
Starter Relay, Ignition Switch
Instrument Panel Fuse Block
Instrument Panel Fuse Block,
Headlamp Switch
Rear Auxiliary Blower
Motor Relays
Heated
02 Sensors, Mass Air
Flow Sensor, EGR Valve
Solenoid, Evap Canister Purge
Valve, Crankshaft Position Sensor,
Secondary Air Injection Relay
(Diesel), Water in Fuel Sensor
(Diesel), Fuel Heater (Diesel),
Glowplug
Relay (Diesel),
Wastegate Solenoid (Diesel)
Air Conditioning Clutch Relay
Spare Fuses
Upfitter Provisions
Upfitter Provisions
Right-hand Headlamp (Export Only)
6-63

Downloaded from www.Manualslib.com manuals search engine At Least Twice a Year At Least Once a Year
Restraint System Check
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 air bag coverings,
and have them repaired
or replaced. (The air bag system
does not need regular maintenance.)
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace blade
inserts that appear worn or damaged or that streak or
miss areas of the windshield. Also
see “Wiper Blades,
Cleaning” in the Index.
Automatic Transmission Check
Check the transmission fluid level; add if needed. See
“Automatic Transmission” in the Index. A fluid loss
may indicate a problem. Check the system and repair
if needed.
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part
D.
Body Lubrication Service
Lubricate all hood hinges, hood prop rod pivot, fuel
filler door, rear compartment hinges, latches, locks and
any moving seat hardware. Part
D tells you what to use.
More frequent lubrication may be required when
exposed
to a corrosive environment.
Starter Switch Check
A CAUTION:
rn
When you are doing this check, the vehicle could
move suddenly.
If it does, you or others could be
injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle.

Downloaded from www.Manualslib.com manuals search engine ROADSIDE Courtesy Care PROVIDES:
0 Roadside Basic Care services (as outlined above)
Plus:
0 FREE Non-Warranty Towing (to the closest dealer
@ FREE LocksmithKey Service (when keys are lost
from a legal roadway)
on the road or locked inside)
0 FREE Flat Tire Service (spare installed on the road)
FREE Jump Start (at
home or on the road)
0 FREE Fuel Delivery ($5 of fuel delivered on
the road) ChevroletlGeo offers Courtesy Transportation for
customers needing warranty service. Courtesy
Transportation will be offered in conjunction with the coverage provided by the Bumper to Bumper
New Vehicle Limited Warranty to eligible purchasers
of
1997 ChevroletlGeo passenger car and light duty
trucks. (Please
see your selling dealer for details.)
Note:
Courtesy Care is available to Retail and Retail Lease
Customers operating
1997 and newer ChevroletlGeo
vehicles for a period of 3 years/36,000 miles
(60 0o0 km),
whichever occurs first. All Courtesy Care services must
be pre-arranged by Chevrolet Roadside or dealer
Service Management.
Basic Care and Courtesy Care are not part of or
included in the coverage provided
by the New Vehicle
Limited Warranty. Chevrolet reserves the right to
modify or discontinue
Basic Care and Courtesy Care
at any time.