CHEVROLET EXPRESS CARGO VAN 2003 1.G Owners Manual

Vehicle* Axle Ratio Maximum Trailer Weight GCWR
G2500 Passenger Van 2WD Long Wheelbase*
6000 V83.73
4.107,600 lbs. (3 450 kg)
9,600 lbs. (4 358 kg)14,000 lbs. (6 356 kg)
16,000 lbs. (7 264 kg)
* Tongue weight should be 10 percent to 15 percent of trailer weight up to 1,000 lbs (454 kg).
Vehicle* Axle Ratio Maximum Trailer Weight GCWR
G3500 Cargo Van 2WD Short Wheelbase*
6000 V83.73
4.108,300 lbs. (3 768 kg)
10,000 lbs. (4 540 kg)14,000 lbs. (6 356 kg)
16,000 lbs. (7 264 kg)
* Tongue weight should be 10 percent to 15 percent of trailer weight up to 1,500 lbs (680 kg).
Vehicle* Axle Ratio Maximum Trailer Weight GCWR
G3500 Cargo Van 2WD Long Wheelbase*
6000 V83.73
4.108,100 lbs. (3 677 kg)
10,000 lbs. (4 540 kg)14,000 lbs. (6 356 kg)
16,000 lbs. (7 264 kg)
* Tongue weight should be 10 percent to 15 percent of trailer weight up to 1,500 lbs (680 kg).
4-37

Vehicle* Axle Ratio Maximum Trailer Weight GCWR
G3500 Passenger Van 2WD Short Wheelbase*
6000 V83.73
4.107,700 lbs. (3 496 kg)
9,700 lbs. (4 404 kg)14,000 lbs. (6 356 kg)
16,000 lbs. (7 264 kg)
* Tongue weight should be 10 percent to 15 percent of trailer weight up to 1,500 lbs (680 kg).
Vehicle* Axle Ratio Maximum Trailer Weight GCWR
G3500 Passenger Van 2WD Long Wheelbase*
6000 V83.73
4.107,400 lbs. (3 360 kg)
9,400 lbs. (4 268 kg)14,000 lbs. (6 356 kg)
16,000 lbs. (7 264 kg)
* Tongue weight should be 10 percent to 15 percent of trailer weight up to 1,500 lbs (680 kg).
Maximum trailer weight is calculated assuming the
driver is in the towing vehicle and it has all the required
trailering equipment. The weight of additional
equipment, passengers and cargo in the towing vehicle
must be subtracted from the above maximum trailer
weights.You can ask your dealer for our trailering information or
advice, or you can write us at the address listed in
your Warranty and Owner Assistance Information
Booklet.
In Canada, write to:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
4-38

Weight of the Trailer Tongue
The tongue load (A) of any trailer is an important weight
to measure because it affects the total or gross weight of
your vehicle. The Gross Vehicle Weight (GVW) includes
the curb weight of the vehicle, any cargo you may carry in
it, and the people who will be riding in the vehicle. And if
you will tow a trailer, you must add the tongue load to the
GVW because your vehicle will be carrying that weight,
too. See
Loading Your Vehicle on page 4-29about your
vehicle's maximum load capacity.
If you're using a weight-carrying or a weight-distributing
hitch, the trailer tongue weight (A) should be 10 percent
to 15 percent of the total loaded trailer weight (B).Do not exceed the maximum allowable tongue weight
for your vehicle.
After you've loaded your trailer, weigh the trailer and then
the tongue, separately, to see if the weights are proper. If
they aren't, you may be able to get them right simply by
moving some items around in the trailer.
Total Weight on Your Vehicle's Tires
Be sure your vehicle's tires are in¯ated to the upper limit
for cold tires. You'll ®nd these numbers on the
Certi®cation label at the rear edge of the driver's door or
see
Loading Your Vehicle on page 4-29. Then be
sure you don't go over the GVW limit for your vehicle,
including the weight of the trailer tongue.
Hitches
It's important to have the correct hitch equipment.
Crosswinds, large trucks going by and rough roads are
a few reasons why you'll need the right hitch. Here
are some rules to follow:
·The bumpers on your vehicle are not intended for
hitches. Do not attach rental hitches or other
bumper-type hitches to them. Use only a
frame-mounted hitch that does not attach to the
bumper. Do not use a ball hitch, because it could
pull the bumper loose.
4-39

·If you'll be pulling a trailer that, when loaded, will
weigh more than 4,000 lbs (1 800 kg), be sure to
use a properly mounted, weight-distributing
hitch and sway control of the proper size. This
equipment is very important for proper vehicle
loading and good handling when you're driving.
·Will you have to make any holes in the body of
your vehicle when you install a trailer hitch?
If you're using the wiring provided by the
factory-installed hitch, you should not need to make any
holes in the body of your vehicle. However, if you
have an aftermarket hitch installed, you may need to
make holes in the body.
If you do, then be sure to seal the holes later when you
remove the hitch. If you don't seal them, deadly
carbon monoxide (CO) from your exhaust can get into
your vehicle. Dirt and water can, too.
Safety Chains
You should always attach chains between your
vehicle and your trailer. Cross the safety chains under
the tongue of the trailer to help prevent the tongue from
contacting the road if it becomes separated from the
hitch. Instructions about safety chains may be provided
by the hitch manufacturer or by the trailer manufacturer.Follow the manufacturer's recommendation for attaching
safety chains and do not attach them to the bumper.
Always leave just enough slack so you can turn with your
rig. Never allow safety chains to drag on the ground.
Trailer Brakes
If your trailer weighs more than 1,000 lbs (450 kg)
loaded, then it needs its own brakes ± and they must be
adequate. Be sure to read and follow the instructions
for the trailer brakes so you'll be able to install,
adjust and maintain them properly.
Your trailer brake system can tap into your vehicle's
hydraulic brake system, except:
·Don't tap into your vehicle's brake system if the
trailer's brake system will use more than 0.02 cubic
inch (0.3 cc) of ¯uid from your vehicle's master
cylinder. If it does, both braking systems won't work
well. You could even lose your brakes.
·Will the trailer parts take 3,000 psi (20 650 kPa) of
pressure? If not, the trailer brake system must not
be used with your vehicle.
·If everything checks out this far, then make the
brake ¯uid tap at the port on the master cylinder that
sends ¯uid to the rear brakes. But don't use
copper tubing for this. If you do, it will bend and
®nally break off. Use double-walled steel tubing.
4-40

Driving with a Trailer
{CAUTION:
If you have a rear-most window open and you
pull a trailer with your vehicle, carbon
monoxide (CO) could come into your vehicle.
You can't see or smell CO. It can cause
unconsciousness or death. See ªEngine
Exhaustº in the Index. To maximize your safety
when towing a trailer:
·Have your exhaust system inspected for
leaks, and make necessary repairs before
starting on your trip.
·Keep the rear-most windows closed.
·If exhaust does come into your vehicle
through a window in the rear or another
opening, drive with your front, main
heating or cooling system on and with the
fan on any speed. This will bring fresh,
outside air into your vehicle. Do not use
the climate control setting for maximum air
because it only recirculates the air inside
your vehicle. See ªClimate Controlsº in
the Index.Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you'll want to get
to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
Before you start, check the trailer hitch and platform
(and attachments), safety chains, electrical connector,
lamps, tires and mirror adjustment. If the trailer has
electric brakes, start your vehicle and trailer moving and
then apply the trailer brake controller by hand to be
sure the brakes are working. This lets you check your
electrical connection at the same time.
During your trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer
brakes are still working.Following Distance
Stay at least twice as far behind the vehicle ahead as
you would when driving your vehicle without a trailer.
This can help you avoid situations that require
heavy braking and sudden turns.
4-41

Passing
You'll need more passing distance up ahead when
you're towing a trailer. And, because you're a good deal
longer, you'll need to go much farther beyond the
passed vehicle before you can return to your lane.
Backing Up
Hold the bottom of the steering wheel with one hand.
Then, to move the trailer to the left, just move that hand
to the left. To move the trailer to the right, move your
hand to the right. Always back up slowly and, if possible,
have someone guide you.
Making Turns
Notice:Making very sharp turns while trailering
could cause the trailer to come in contact with the
vehicle. Your vehicle could be damaged. Avoid
making very sharp turns while trailering.
When you're turning with a trailer, make wider turns than
normal. Do this so your trailer won't strike soft shoulders,
curbs, road signs, trees or other objects. Avoid jerky or
sudden maneuvers. Signal well in advance.
Turn Signals When Towing a Trailer
When you tow a trailer, your vehicle has to have extra
wiring and a heavy-duty turn signal ¯asher (included
in the optional trailering package).The arrows on your instrument panel will ¯ash whenever
you signal a turn or lane change. Properly hooked up,
the trailer lamps will also ¯ash, telling other drivers
you're about to turn, change lanes or stop.
When towing a trailer, the arrows on your instrument
panel will ¯ash for turns even if the bulbs on the trailer
are burned out. Thus, you may think drivers behind
you are seeing your signal when they are not. It's
important to check occasionally to be sure the trailer
bulbs are still working.
Driving On Grades
Reduce speed and shift to a lower gearbeforeyou start
down a long or steep downgrade. If you don't shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
When towing at high altitude on steep uphill grades,
consider the following: Engine coolant will boil at a lower
temperature than at normal altitudes. If you turn your
engine off immediately after towing at high altitude
on steep uphill grades, your vehicle may show signs
similar to engine overheating. To avoid this, let the
engine run while parked (preferably on level ground)
with the automatic transmission in PARK (P) for a
few minutes before turning the engine off. If you do get
the overheat warning, see
Engine Overheating on
page 5-24.
4-42

Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here's
how to do it:
1. Apply your regular brakes, but don't shift into
PARK (P) yet. Then turn your wheels into the curb
if facing downhill or into traffic if facing uphill.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake and then shift to PARK (P).
5. Release the regular brakes.
When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
·start your engine,
·shift into a gear, and
·release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you're
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission ¯uid (don't over®ll),
engine oil, axle lubricant, belt, cooling system and
brake system. Each of these is covered in this manual,
and the Index will help you ®nd them quickly. If
you're trailering, it's a good idea to review these sections
before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
4-43

Trailer Wiring Harness
The optional heavy-duty trailer wiring package includes
a seven-wire harness assembly at the rear of the
vehicle and a four-wire harness assembly under the left
hand side of the instrument panel. The seven-wire
harness assembly is taped together and located in a
frame pocket at the driver side rear left corner of
the frame. The seven-wire harness includes a
30-amp feed wire. Both harnesses come without
connectors and should be wired by a quali®ed electrical
technician. The technician can use the following
color code chart when connecting the wiring harness to
your trailer and trailer brake controller.Seven-Wire Harness·Light Green: Back-up lamps
·Brown: Parking lamps
·Yellow: Left stoplamp and turn signal
·Dark Green: Right stoplamp and turn signal
·Dark Blue: Use for electric trailer brakes
·Orange: Trailer accessory
·White (heavy gage): Ground wire
Four-Wire Harness (Trailer Brake Controller)
·Black: Ground
·Red/White Stripe: Fused Battery
·Dark Blue: Trailer Brake Feed
·Light Blue: Fused Stop/CHMSL
4-44

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Your Vehicle and the Environment....................6-2
Maintenance Requirements..............................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Scheduled Maintenance...................................6-5
Part B: Owner Checks and Services................6-11
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000km)........................6-11
At Each Fuel Fill..........................................6-11
At Least Once a Month.................................6-11
At Least Twice a Year...................................6-12At Least Once a Year...................................6-13
Part C: Periodic MaintenanceInspections.........6-16
Steering and Suspension Inspection................6-16
Exhaust System Inspection............................6-16
Fuel System Inspection..................................6-16
Engine Cooling System Inspection...................6-16
Throttle System Inspection.............................6-17
Rear Axle Service.........................................6-17
Transfer Case and Front Axle
(All-Wheel Drive) Inspection........................6-17
Brake System Inspection................................6-17
Part D: Recommended Fluids and
Lubricants................................................6-18
Part E: Maintenance Record...........................6-20
Section 6 Maintenance Schedule
6-1

Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Have you purchased the GM Protection Plan? The Plan
supplements your new vehicle warranties. See your
Warranty and Owner Assistance booklet or your dealer
for details.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. Improper vehicle maintenance can
even affect the quality of the air we breathe. Improper
¯uid levels or the wrong tire in¯ation can increase
the level of emissions from your vehicle. To help protect
our environment, and to keep your vehicle in good
condition, be sure to maintain your vehicle properly.
Maintenance Requirements
Maintenance intervals, checks, inspections and
recommended ¯uids and lubricants as prescribed in this
manual are necessary to keep your vehicle in good
working condition. Any damage caused by failure
to follow scheduled maintenance may not be covered
by warranty.
6-2