fuel CHEVROLET EXPRESS CARGO VAN 2003 1.G Owner's Manual

50,000 Miles (83 000 km)
qChange automatic transmission ¯uid and ®lter if the
vehicle's GVWR is over 8,600 lbs or if the vehicle is
mainly driven under one or more of these conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC) or
higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, change the ¯uid and ®lter at 100,000 miles
(166 000 km).
52,500 Miles (87 500 km)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-58for proper rotation pattern and additional
information.(See footnote +.)
60,000 Miles (100 000 km)
qInspect engine air cleaner ®lter change indicator. If
necessary, replace the ®lter. If vehicle is driven in
dusty/dirty conditions, inspect ®lter change indicator
at every engine oil change. See
Engine Air
Cleaner/Filter on page 5-17for more information.An Emission Control Service. (See footnote ².)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qClean and repack the front wheel bearings
(or at each brake relining, whichever occurs ®rst).
qRotate tires. See
Tire Inspection and Rotation on
page 5-58for proper rotation pattern and additional
information.(See footnote +.)
qReplace fuel ®lter.An Emission Control Service.
(See footnote ².)
qVehicles With GVWR Above 10,000 lbs. Only:
Inspect shields for damage or looseness. Adjust or
replace as required.
This is a Noise Emission Control
Service. Applicable only to vehicles sold in the
United States.
qInspect Evaporative Control System. Check all fuel
and vapor lines and hoses for proper hook-up,
routing and condition. Check that the purge valve
works properly, if equipped. Replace as needed.
An Emission Control Service. (See footnote ².)
6-8

67,500 Miles (112 500 km)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-58for proper rotation pattern and additional
information.(See footnote +.)
75,000 Miles (125 000 km)
qInspect engine air cleaner ®lter change indicator. If
necessary, replace the ®lter. If vehicle is driven in
dusty/dirty conditions, inspect ®lter change indicator
at every engine oil change. See
Engine Air
Cleaner/Filter on page 5-17for more information.An Emission Control Service. (See footnote ².)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qVehicles With GVWR Above 10,000 lbs. Only:
Inspect shields for damage or looseness. Adjust or
replace as required.
This is a Noise Emission Control
Service. Applicable only to vehicles sold in the
United States.
qRotate tires. SeeTire Inspection and Rotation on
page 5-58for proper rotation pattern and additional
information.(See footnote +.)
82,500 Miles (137 500 km)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-58for proper rotation pattern and additional
information.(See footnote +.)
90,000 Miles (150 000 km)
qInspect engine air cleaner ®lter change indicator. If
necessary, replace the ®lter. If vehicle is driven in
dusty/dirty conditions, inspect ®lter change indicator
at every engine oil change. See
Engine Air
Cleaner/Filter on page 5-17for more information.An Emission Control Service. (See footnote ².)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle
seals for leaking.
qClean and repack the front wheel bearings
(or at each brake relining, whichever occurs ®rst.)
qReplace fuel ®lter.
An Emission Control Service.
(See footnote ².)
qVehicles With GVWR Above 10,000 lbs. Only:
Inspect shields for damage or looseness. Adjust or
replace as required.
This is a Noise Emission Control
Service. Applicable only to vehicles sold in the
United States.
6-9

Part B: Owner Checks and Services
Listed in this part are owner checks and services
which should be performed at the intervals speci®ed to
help ensure the safety, dependability and emission
control performance of your vehicle.
Be sure any necessary repairs are completed at once.
Whenever any ¯uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Part D.
At the First 100, 1,000 and 6,000
Miles (160, 1 600 and 10 000km)
For vehicles with dual wheels, check dual wheel nut
torque. For proper torque, seeCapacities and
Speci®cations on page 5-97.
At Each Fuel Fill
It is important for you or a service station attendant to
perform these underhood checks at each fuel ®ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOLž
coolant mixture if necessary. SeeEngine Coolant
on page 5-21for further details.
Windshield Washer Fluid Level Check
Check the windshield washer ¯uid level in the windshield
washer tank and add the proper ¯uid if necessary.
See
Windshield Washer Fluid on page 5-35for further
details.
At Least Once a Month
Tire In¯ation Check
Visually inspect your tires and make sure tires are
in¯ated to the correct pressures. Don't forget to check
your spare tire. See
Tires on page 5-56for further
details.
6-11

At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
speci®ed in Part D.
Body Lubrication Service
Lubricate all hood hinges, hood prop rod pivot, fuel ®ller
door, rear compartment hinges, latches, locks, hood
latch assembly, secondary latch, pivots, spring anchor,
release pawl 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
{CAUTION:
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.
2. Firmly apply both the parking brake and the regular
brake. See
Parking Brake on page 2-26if
necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The starter
should work only in PARK (P) or NEUTRAL (N).
If the starter works in any other position, your
vehicle needs service.
6-13

Part C: Periodic
MaintenanceInspections
Listed in this part are inspections and services which
should be performed at least twice a year (for instance,
each spring and fall).
You should let your dealer's
service department do these jobs. Make sure any
necessary repairs are completed at once.
Proper procedures to perform these services may be
found in a service manual. SeeService Publications
Ordering Information on page 7-9.
Steering and Suspension Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
lines and hoses for proper hook-up, binding, leaks,
cracks, cha®ng, etc.
Exhaust System Inspection
Inspect the complete exhaust system. Inspect the body
near the exhaust system. Look for broken, damaged,
missing or out-of-position parts as well as open seams,
holes, loose connections or other conditions which
could cause a heat build-up in the ¯oor pan or could let
exhaust fumes into the vehicle. See
Engine Exhaust
on page 2-30.
Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
®ttings and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser.
To help ensure proper operation, a pressure test of
the cooling system and pressure cap is recommended
at least once a year.
6-16

RoadsideCourtesy Careprovides:
·RoadsideBasic Careservices
(as outlined previously)
Plus:
·FREE Non-Warranty Towing (to the closest dealer
from a legal roadway)
·FREE Locksmith/Key Service (when keys are lost
on the road or locked inside)
·FREE Flat Tire Service (spare installed on the road)
·FREE Jump Start (at home or on the road)
·FREE Fuel Delivery ($5 of fuel delivered
on the road)
Chevrolet 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 2003 Chevrolet
passenger cars and light duty trucks. (See your selling
dealer for details.)
Courtesy Careis available to retail and retail lease
customers operating 2003 and newer Chevrolet vehicles
for a period of 3 years/36,000 miles (60 000 km),
whichever occurs ®rst. All
Courtesy Careservices must
be pre-arranged by Chevrolet Roadside or dealer
service management.
Basic CareandCourtesy Careare not part of or
included in the coverage provided by the New Vehicle
Limited Warranty. Chevrolet reserves the right to
modify or discontinue
Basic CareandCourtesy Careat
any time.
The Roadside Assistance Center uses companies that
will provide you with quality and priority service.
When roadside services are required, our advisors will
explain any payment obligations that may be incurred
for utilizing outside services.
For prompt assistance when calling, please have the
following available to give to the advisor;
·Vehicle Identi®cation Number (VIN)
·License plate number
·Vehicle color
·Vehicle location
·Telephone number where you can be reached
·Vehicle mileage
·Description of problem
Canadian Roadside Assistance
Vehicles purchased in Canada have an extensive
Roadside Assistance program accessible from anywhere
in Canada or the United States. Please refer to the
Warranty and Owner Assistance Information book.
7-6

Courtesy Transportation
Chevrolet has always exempli®ed quality and value in
its offering of motor vehicles. To enhance your
ownership experience, we and our participating dealers
are proud to offer Courtesy Transportation, a customer
support program for new vehicles.
The Courtesy Transportation program is offered to retail
purchase/lease customers in conjunction with the
Bumper-to-Bumper coverage provided by the New
Vehicle Limited Warranty. Several transportation options
are available when warranty repairs are required. This will
reduce your inconvenience during warranty repairs.
Plan Ahead When Possible
When your vehicle requires warranty service, you
should contact your dealer and request an appointment.
By scheduling a service appointment and advising
your service consultant of your transportation needs,
your dealer can help minimize your inconvenience.
If your vehicle cannot be scheduled into the service
department immediately, keep driving it until it can be
scheduled for service, unless, of course, the problem is
safety-related. If it is, please call your dealership, let
them know this, and ask for instructions.
If the dealer requests that you simply drop the vehicle
off for service, you are urged to do so as early in
the work day as possible to allow for same day repair.
Transportation Options
Warranty service can generally be completed while you
wait. However, if you are unable to wait Chevrolet
helps minimize your inconvenience by providing several
transportation options. Depending on the circumstances,
your dealer can offer you one of the following:
Shuttle Service
Participating dealers can provide you with shuttle
service to get you to your destination with minimal
interruption of your daily schedule. This includes a one
way shuttle ride to a destination up to 10 miles from
the dealership.
Public Transportation or Fuel
Reimbursement
If your vehicle requires overnight warranty repairs,
reimbursement up to $30 per day (®ve day maximum)
may be available for the use of public transportation
such as taxi or bus. In addition, should you arrange
transportation through a friend or relative,
reimbursement for reasonable fuel expenses up to
$10 per day (®ve day maximum) may be available.
Claim amounts should re¯ect actual costs and be
supported by original receipts.
7-7

Courtesy Rental Vehicle
When your vehicle is unavailable due to overnight
warranty repairs, your dealer may arrange to provide
you with a courtesy rental vehicle or reimburse you for a
rental vehicle you obtained, at actual cost, up to a
maximum of $30.00 per day supported by receipts. This
requires that you sign and complete a rental agreement
and meet state, local and rental vehicle provider
requirements. Requirements vary and may include
minimum age requirements, insurance coverage, credit
card, etc. You are responsible for fuel usage charges
and may also be responsible for taxes, levies,
usage fees, excessive mileage or rental usage beyond
the completion of the repair.
Generally it is not possible to provide a like-vehicle as a
courtesy rental.
Additional Program Information
Courtesy Transportation is available during the
Bumper-to-Bumper warranty coverage period, but itis
notpart of the New Vehicle Limited Warranty. A
separate booklet entitled ªWarranty and Owner
Assistance Informationº furnished with each new vehicle
provides detailed warranty coverage information.
Courtesy Transportation is available only at participating
dealers and all program options, such as shuttle
service, may not be available at every dealer.Please contact you dealer for speci®c information about
availability. All Courtesy Transportation arrangements
will be administered by appropriate dealer personnel.
Canadian Vehicles:For warranty repairs during
the Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.
Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
7-8

Service............................................................5-3
Doing Your Own Service Work.........................5-3
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-4
Gasoline Speci®cations....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under
the Hood......................................................5-9
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transmission Fluid.........................5-19
Engine Coolant.............................................5-21
Radiator Pressure Cap..................................5-24
Engine Overheating.......................................5-24Cooling System............................................5-26
Engine Fan Noise.........................................5-34
Power Steering Fluid.....................................5-34
Windshield Washer Fluid................................5-35
Brakes........................................................5-37
Battery........................................................5-40
Jump Starting...............................................5-41
All-Wheel Drive..............................................5-46
Rear Axle.......................................................5-47
Front Axle......................................................5-48
Noise Control System.....................................5-49
Tampering with Noise Control System
Prohibited.................................................5-49
Bulb Replacement..........................................5-50
Halogen Bulbs..............................................5-50
Headlamps..................................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps.....................................................5-52
Taillamps.....................................................5-52
Replacement Bulbs.......................................5-54
Section 5 Service and Appearance Care
5-1

CAUTION: (Continued)
·
Be sure to use the proper nuts, bolts and
other fasteners. ªEnglishº and ªmetricº
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the air¯ow around it. This may cause wind
noise and affect windshield washer performance. Check
with your dealer before adding equipment to the
outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. Otherwise, you might damage
your engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
5-4