service CHEVROLET EXPRESS 2003 Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-31
Airbag System
.........................................1-59
Restraint System Check
............................1-70
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-15
Theft-Deterrent Systems
............................2-18
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-29
OnStar
®System
......................................2-31
Storage Areas
.........................................2-32
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-18
Warning Lights, Gages, and Indicators
........3-22
Audio System(s)
.......................................3-39
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
........ 4-2
Towing
...................................................4-34Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
All-Wheel Drive
........................................5-43
Rear Axle
...............................................5-44
Front Axle
...............................................5-44
Noise Control System
...............................5-45
Bulb Replacement
....................................5-46
Windshield Wiper Blade Replacement
.........5-51
Tires
......................................................5-52
Appearance Care
.....................................5-82
Vehicle Identication
.................................5-91
Electrical System
......................................5-92
Capacities and Specications
.....................5-97
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index.................................................................1
2005 Chevrolet Express Owner ManualM

{CAUTION:
If the airbag readiness light ever comes on
when you have turned off the airbag, it means
that something may be wrong with the airbag
system. The right front passenger’s airbag
could inate even though the switch is off. If
this ever happens, do not let anyone whom the
national government has identied as a
member of a passenger airbag risk group sit in
the right front passenger’s position (for
example, do not secure a rear-facing child
restraint in your vehicle) until you have your
vehicle serviced. SeeAirbag Off Switch on
page 1-66.
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 airbag and an
airbag off switch, and you are using a rear-facing
child restraint in this seat, make sure the airbag isturned off. SeeAirbag Off Switch on page 1-66.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 child 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.
4. Buckle the belt. Make sure the release button is
positioned so you would be able to unbuckle the
safety belt quickly if you ever had to.
1-57

How Does an Airbag Restrain?
In moderate to severe frontal or near-frontal collisions,
even belted occupants can contact the steering wheel or
the instrument panel. Airbags supplement the protection
provided by safety belts. Airbags distribute the force
of the impact more evenly over the occupant’s upper
body, stopping the occupant more gradually. But airbags
would not help you in many types of collisions,
including rollovers, rear impacts and many side impacts,
primarily because an occupant’s motion is not toward
those airbags. Airbags should never be regarded
as anything more than a supplement to safety belts, and
then only in moderate to severe frontal or near-frontal
collisions.
What Will You See After an
Airbag Inates?
After an airbag inates, it quickly deates, so quickly
that some people may not even realize the airbag
inated. Some components of the airbag module — the
steering wheel hub for the driver’s airbag, 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 airbags. Airbagination does not prevent the driver from seeing or
being able to steer the vehicle, nor does it stop people
from leaving the vehicle.
{CAUTION:
When an airbag 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 airbag
inates, then get fresh air by opening a
window or a door. If you experience breathing
problems following an airbag deployment, you
should seek medical attention.
Airbags are designed to inate only once. After an
airbag inates, you will need some new parts for
your airbag system. If you do not get them,
the airbag system will not be there to help protect
you in another crash. A new system will include
airbag modules and possibly other parts. The
service manual for your vehicle covers the need to
replace other parts.
1-65

Your vehicle is equipped with a crash sensing and
diagnostic module which records information after
a crash. SeeVehicle Data Collection and Event
Data Recorders on page 7-9.
Let only qualied technicians work on your airbag
system. Improper service can mean that your
airbag system will not work properly. See your
dealer for service.
Notice:If you damage the covering for the driver’s
or the right front passenger’s airbag, the bag
may not work properly. You may have to replace the
airbag module in the steering wheel or both the
airbag module and the instrument panel for the right
front passenger’s airbag. Do not open or break
the airbag coverings.
Airbag Off Switch
If the GVWR (Gross Vehicle Weight Rating) of your
vehicle is 8,500 lb (3 855 kg) or above, your vehicle has
an airbag 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 4-29for
more information.
You can use the airbag off switch on the instrument
panel to turn off the right front passenger’s airbag.United States
Canada
1-66

To turn off the right front passenger’s airbag, insert your
ignition key into the switch, push in, and move the
switch to the off position.
The airbag off light will come on to let you know that the
right front passenger’s airbag is off. The light will stay
on to remind you that the airbag is off. The right
front passenger’s airbag will remain off until you turn it
back on.
{CAUTION:
If the airbag readiness light ever comes on
when you have turned off the airbag, it means
that something may be wrong with the airbag
system. The right front passenger’s airbag
could inate even though the switch is off. If
this ever happens, do not let anyone whom the
national government has identied as a
member of a passenger airbag risk group sit in
the right front passenger’s position (for
example, do not secure a rear-facing child
restraint in your vehicle) until you have your
vehicle serviced. United States
Canada
1-68

To turn the right front passenger’s airbag on, insert your
ignition key into the switch, push in, and move the
switch to the on position.
Servicing Your Airbag-Equipped
Vehicle
Airbags affect how your vehicle should be serviced.
There are parts of the airbag 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 airbag system. To
purchase a service manual, seeService Publications
Ordering Information on page 7-11.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
airbag can still inate during improper service.
You can be injured if you are close to an
airbag when it inates. Avoid wires wrapped
with yellow tape or yellow connectors. They
are probably part of the airbag system. Be sure
to follow proper service procedures, and make
sure the person performing work for you is
qualied to do so.
The airbag system does not need regular maintenance. United States
Canada
1-69

Changes or modications to this system by other than
an authorized service facility could void authorization to
use this equipment.
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 on
page 2-4.
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 replacementtransmitter 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

Theft-Deterrent Systems
Vehicle theft is big business, especially in some cities.
Although your vehicle has a number of theft-deterrent
features, we know that nothing we put on it can make it
impossible to steal.
Passlock®
Your vehicle is equipped with the Passlock®
theft-deterrent system.
Passlock®is a passive theft-deterrent system. Passlock®
enables fuel if the ignition lock cylinder is turned with
a valid key. If a correct key is not used or the ignition
lock cylinder is tampered with, fuel is disabled.
During normal operation, the SECURITY light will go off
approximately ve seconds after the key is turned to
RUN. SeeSecurity Light on page 3-36.
If the engine stalls and the SECURITY light ashes,
wait until the light stops ashing before trying to restart
the engine. Remember to release the key from
START as soon as the engine starts.
If the engine is running and the SECURITY light comes
on, you will be able to restart the engine if you turn the
engine off. However, your Passlock
®system is not
working properly and must be serviced by your dealer.
Your vehicle is not protected by Passlock
®at this time.
You may also want to check the fuse. SeeFuses
and Circuit Breakers on page 5-92. See your dealer
for service.
Starting and Operating Your
Vehicle
New Vehicle Break-In
Notice:Your vehicle does not need an elaborate
break-in. But it will perform better in the long run if
you follow these guidelines:
Keep your speed at 55 mph (88 km/h) or less for
the rst 500 miles (805 km).
Do not drive at any one speed — fast or
slow — for the rst 500 miles (805 km). Do not
make full-throttle starts.
Avoid making hard stops for the rst 200 miles
(322 km) or so. During this time your new brake
linings are not yet broken in. Hard stops with new
linings can mean premature wear and earlier
replacement. Follow this breaking-in guideline
every time you get new brake linings.
Do not tow a trailer during break-in. SeeTowing a
Trailer on page 4-34for more information.
2-18

Ignition Positions
Use the key to turn the ignition switch to four different
positions.
A (Lock):This position locks the ignition and
transmission. It is a theft-deterrent feature. You will only
be able to remove the key when the ignition is turned
to LOCK.Notice:Using a tool to force the key from the
ignition switch could cause damage or break the
key. Use the correct key and turn the key only with
your hand. Make sure the key is in all the way. If
none of this works, then your vehicle needs service.
B (Accessory):This position lets you use things like
the radio and the windshield wipers when the engine
is off.
Notice:Lengthy operation of features such as the
radio in the accessory ignition position may
drain the battery and prevent your vehicle from
starting. Do not operate your vehicle in the
accessory ignition position for a long period
of time.
C (Run):This is the position for driving.
D (Start):This position starts the engine.
Retained Accessory Power (RAP)
The Retained Accessory Power (RAP) feature will allow
certain features on your vehicle to continue to work
for up to 10 minutes after the ignition key is turned to
LOCK or until one of the doors is opened.
2-19