brake CHEVROLET EXPRESS CARGO VAN 2003 1.G Repair Manual

Fuse Usage
1 Radio Battery
2 Powertrain Control Module Battery
3 Left Rear Turn Lamp
4 Right Rear Turn Lamp
5 Backup Lamps Trailer Wiring
6 Ignition 0
7 Stop Lamp
8 Right Rear Defogger/Heated Mirror
9Right Daytime Running Lamp/Turn
Signal
10Left Daytime Running Lamp/Turn
Signal
11 Truck Body Control Module 4
12 Fuel Pump
13 Trailer
14 Flasher
15 Horn
16 Truck Body Control Module 3
17 Trailer Stop/Turn Signal
18 Truck Body Control Module 2
19 Truck Body Control Module
20 Remote Function Actuator
21 Engine 2Fuse Usage
22 Ignition E
23 Engine 1
24Truck Body Control Module
Ignition 1
25 Spare
26 RPA/Inside Rearview Mirror
27 Crankcase
28Brake Transmission Shift Interlock
System
29 Auxiliary Power Outlets
30 Cigarette Lighter
31 Instrument Panel Cluster
32 Air Conditioning
33 Spare
34 Vent
35 Spare
36 Vehicle Back Up
37Supplemental In¯atable Restraint
System
38 Powertrain Control Module Ignition 1
39 Oxygen Sensor B
40 Oxygen Sensor A
41 Windshield Wipers
5-95

Fuse Usage
42 Right Headlamp Ð Low Beam
43 Left Headlamp Ð Low Beam
44 Left Headlamp Ð High Beam
45 Right Headlamp Ð High Beam
46Truck Body Control
Module-Accessory
47 Front Windshield Wiper
48 Anti-Lock Brakes
49 Ignition A
50 Trailer
51 Climate Control Blower
52 Ignition B
63 Spare
64 SpareFuse Usage
Relay Usage
53 Windshield Wiper
54 Air Conditioning
55 Spare
56 Headlamp Ð High Beam
57 Fuel Pump
58 Headlamp Ð Low Beam
59 Horn
61 Starter
62 Spare
Circuit Breaker Usage
60 Power Seat
5-96

A
Accessory Power Outlets.................................3-18
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-74
Adding Washer Fluid.......................................5-36
Additional Program Information........................... 7-8
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-91
Add-On Equipment..........................................4-31
Adjusting the Speakers (Balance/Fade).....3-43, 3-46,
3-51, 3-62
Air Bag System..............................................1-63
Adding Equipment to Your Air Bag-Equipped
Vehicle...................................................1-74
Air Bag Off Switch.......................................1-70
How Does an Air Bag Restrain?....................1-68
Servicing Your Air Bag-Equipped Vehicle.........1-73
What Makes an Air Bag In¯ate?....................1-68
What Will You See After an Air
Bag In¯ates?...........................................1-68
When Should an Air Bag In¯ate?...................1-67
Where Are the Air Bags?..............................1-65
Air Bag Systems.............................................1-68
Air Bag .........................................................3-28
Off Light.....................................................3-28
Readiness Light..........................................3-27Air Cleaner/Filter, Engine.................................5-17
All-Wheel Drive (AWD) System.........................2-26
All-Wheel Drive...............................................5-46
AM-FM Radio.................................................3-41
AM ...............................................................3-73
Antenna, Fixed Mast.......................................3-75
Anti-Lock Brake, System Warning Light..............3-32
Anti-lock Brake System..................................... 4-6
Appearance Care............................................5-80
Care of Safety Belts....................................5-83
Chemical Paint Spotting...............................5-87
Cleaning the Inside of Your Vehicle................5-80
Cleaning the Outside of Your Vehicle..............5-83
Finish Damage............................................5-86
Sheet Metal Damage...................................5-86
Underbody Maintenance...............................5-87
Vehicle Care/Appearance Materials................5-88
Weatherstrips..............................................5-83
Ashtrays........................................................3-18
Audio System(s).............................................3-40
AM-FM Radio.............................................3-41
Care of Your Cassette Tape Player................3-74
Care of Your CD Player...............................3-75
Care of Your CDs........................................3-75
Chime Level Adjustment...............................3-75
Fixed Mast Antenna.....................................3-75
Radio with Cassette and CD.........................3-48
1

Audio System(s) (cont.)
Radio with CD............................................3-44
Radio with Six-Disc CD................................3-59
Rear Seat Audio (RSA)................................3-71
Setting the Time for Radios with Radio Data
Systems (RDS)........................................3-41
Setting the Time for Radios without Radio
Data Systems (RDS)................................3-40
Theft-Deterrent Feature................................3-73
Understanding Radio Reception.....................3-73
Automatic Transmission Check..........................6-12
Automatic Transmission Shift Lock Control
System Check.............................................6-14
Automatic Transmission...................................5-19
Fluid..........................................................5-19
Operation...................................................2-24
B
Backing Up....................................................4-42
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-17
Battery..........................................................5-40
Before Leaving on a Long Trip.........................4-20
Body Lubrication Service..................................6-13
Brake............................................................2-26
Parking......................................................2-26
System Inspection.......................................6-17Brake (cont.)
System Warning Light..................................3-31
Brake Adjustment............................................5-39
Brake Fluid....................................................5-37
Brake Pedal Travel.........................................5-39
Brake Wear...................................................5-39
Brakes..........................................................5-37
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-5
Break-In, New Vehicle.....................................2-20
Bulb Replacement...........................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps....................................................5-52
Halogen Bulbs............................................5-50
Headlamps.................................................5-50
Replacement Bulbs......................................5-54
Taillamps....................................................5-52
Buying New Tires...........................................5-60C
California Fuel.................................................. 5-5
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-6
Capacities and Speci®cations............................5-97
Capacities......................................................5-98
Carbon Monoxide...........................4-24, 4-31, 2-30
2

Care of.........................................................5-83
Safety Belts................................................5-83
Your Cassette Tape Player............................3-74
Your CD Player...........................................3-75
Your CDs ...................................................3-75
Cargo Door Relocking....................................... 2-8
Cargo Vans and Cab and Chassis Models with
an Air Bag Off Switch..................................1-48
Cargo Vans and Cab and Chassis Models
without an Air Bag Off Switch........................1-47
Cargo Vans with a Passenger Air Bag and an
Air Bag Off Switch, Passenger Vans and Cab
and Chassis Models....................................1-37
Cargo Vans with a Passenger Air Bag and
without an Air Bag Off Switch........................1-40
Cassette Tape Messages.................................3-56
Cassette Tape Player Service...........................6-12
CD Adapter Kits.............................................3-56
Center High Mounted
Stoplamp (CHMSL)......................................5-54
Center High-Mounted Stoplamp.........................3-15
Center Passenger Position, Safety Belts.....1-25, 1-26
Chains, Tires..................................................5-63
Charging System Light....................................3-29
Check Engine Light.........................................3-33
Checking Brake Fluid......................................5-38
Checking Coolant............................................5-23
Checking Engine Oil........................................5-13
Checking Things Under the Hood....................... 5-9
Checking Your Restraint Systems......................1-74Check...........................................................3-33
Engine Light...............................................3-33
Gages Warning Light...................................3-38
Chemical Paint Spotting...................................5-87
Child Restraints..............................................1-42
Child Restraint Systems...............................1-42
Infants and Young Children...........................1-36
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-51
Older Children.............................................1-34
Securing a Child Restraint Designed for the
LATCH System........................................1-53
Securing a Child Restraint in a Center
Seat Position...........................................1-56
Securing a Child Restraint in a Rear Outside
Seat Position...........................................1-53
Securing a Child Restraint in the Right Front
Seat Position...........................................1-58
Top Strap Anchor Location............................1-50
Top Strap...................................................1-48
Where to Put the Restraint...........................1-45
Chime Level Adjustment..................................3-75
Cigarette Lighter.............................................3-18
Cleaning Aluminum Wheels..............................5-85
Cleaning Exterior Lamps/Lenses.......................5-84
Cleaning Fabric/Carpet....................................5-80
Cleaning Glass Surfaces..................................5-82
Cleaning Interior Plastic Components.................5-82
Cleaning Leather............................................5-82
Cleaning the Top of the Instrument Panel...........5-82
3

H
Hazard Warning Flashers................................... 3-5
Headlamp High/Low Beam Changer.................... 3-8
Headlamp Wiring............................................5-91
Headlamps....................................................5-50
Bulb Replacement.......................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps....................................................5-52
Halogen Bulbs............................................5-50
Highway Hypnosis...........................................4-21
Hill and Mountain Roads..................................4-22
Hitches..........................................................4-39
Hood.............................................................. 5-9
Checking Things Under.................................. 5-9
Release.....................................................5-10
Horn............................................................... 3-6
How to Add Coolant to the Coolant
Recovery Tank............................................5-28
How to Add Coolant to the Radiator..................5-31
How to Add Fluid............................................5-21
How to Check Lubricant...................................5-47
How to Check Power Steering Fluid..................5-35
How to Check........................................5-19, 5-57
How to Inspect the Engine Air Cleaner/Filter.......5-18How to Reset the CHANGE ENGINE
OIL Light....................................................5-16
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-15
Hydroplaning..................................................4-16
I
If No Steam Is Coming From Your Engine..........5-25
If Steam Is Coming From Your Engine...............5-24
If the Light Is Flashing.....................................3-34
If the Light Is On Steady.................................3-35
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-32
If You're Caught in a Blizzard...........................4-26
Ignition Positions.............................................2-20
Ignition Transmission Lock Check......................6-14
Infants and Young Children, Restraints...............1-36
In¯ation -- Tire Pressure..................................5-56
Inside Day/Night Rearview Mirror......................2-31
Inspection......................................................6-17
Brake System.............................................6-17
Engine Cooling System................................6-16
Exhaust System..........................................6-16
Fuel System...............................................6-16
Part C - Periodic Maintenance.......................6-16
7

Inspection (cont.)
Steering and Suspension..............................6-16
Throttle System...........................................6-17
Transfer Case and Front Axle
(All-Wheel Drive)......................................6-17
Instrument Panel Brightness Control..................3-16
Instrument Panel.............................................3-24
Cluster.......................................................3-24
Overview..................................................... 3-4
Interior Lamps................................................3-16
J
Jump Starting.................................................5-41
K
Key Lock Cylinders Service..............................6-13
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps On Reminder.......................................3-14
Lamps...........................................................3-13
Exterior......................................................3-13
Interior.......................................................3-16Lap Belt........................................................1-26
Lap-Shoulder Belt...........................................1-16
LATCH System...............................................1-51
Child Restraints...........................................1-51
Securing a Child Restraint Designed for the
LATCH System........................................1-53
Leaving Your Vehicle With the Engine
Running.....................................................2-28
Leaving Your Vehicle.......................................2-10
Light.............................................................3-28
Air Bag Off .................................................3-28
Air Bag Readiness.......................................3-27
Anti-Lock Brake System Warning...................3-32
Brake System Warning.................................3-31
Change Engine Oil......................................3-37
Charging System.........................................3-29
Check Gages Warning.................................3-38
Cruise Control.............................................3-38
Daytime Running Lamps Indicator..................3-38
Low Coolant Warning...................................3-33
Malfunction Indicator....................................3-33
Safety Belt Reminder...................................3-26
Security.....................................................3-37
Tow/Haul Mode...........................................3-38
Loading Your Vehicle.......................................4-29
Locking Rear Axle............................................ 4-8
Lockout Protection..........................................2-10
8

Locks............................................................. 2-8
Cargo Door Relocking.................................... 2-8
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-8
Rear Door Security Locks............................... 2-8
Loss of Control...............................................4-12
Low Coolant Warning Light..............................3-33
M
Maintenance, Normal Replacement Parts..........5-100
Maintenance Schedule.....................................6-11
At Each Fuel Fill.........................................6-11
At Least Once a Month................................6-11
At Least Once a Year..................................6-13
At Least Twice a Year..................................6-12
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000km).......................6-11
Brake System Inspection..............................6-17
Engine Cooling System Inspection.................6-16
Exhaust System Inspection...........................6-16
Fuel System Inspection................................6-16
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4Maintenance Schedule (cont.)
Part B - Owner Checks and Services.............6-11
Part C - Periodic MaintenanceInspections......6-16
Part D - Recommended Fluids and
Lubricants...............................................6-18
Part E - Maintenance Record........................6-20
Rear Axle Service........................................6-17
Scheduled Maintenance................................. 6-5
Steering and Suspension Inspection...............6-16
Throttle System Inspection............................6-17
Transfer Case and Front Axle
(All-Wheel Drive) Inspection.......................6-17
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-43
Making Turns.................................................4-42
Malfunction Indicator Light................................3-33
Manual Seats................................................... 1-3
Manual Windows............................................2-16
Matching Transmitter(s) to Your Vehicle............... 2-5
Mexico, Central America and Caribbean Islands/
Countries (Except Puerto Rico and
U.S. Virgin Islands) ± Customer Assistance....... 7-4
Mirrors..........................................................2-31
Manual Rearview Mirror................................2-31
Outside Camper-Type Mirrors........................2-32
Outside Convex Mirror.................................2-34
Outside Heated Mirrors................................2-34
9

Mirrors (cont.)
Outside Manual Mirror..................................2-31
Outside Power Mirrors..................................2-33
Outside Remote Control Mirror......................2-32
Model Reference................................................ vi
MyGMLink.com................................................ 7-3
N
New Vehicle Break-In......................................2-20
Noise Control System, Tampering......................5-49
Normal Maintenance Replacement Parts...........5-100
O
Off-Road Recovery..........................................4-10
Oil ................................................................3-37
Change Engine Oil Light...............................3-37
Engine.......................................................5-13
Pressure Gage............................................3-36
Older Children, Restraints................................1-34
Online Owner Center........................................ 7-3
OnStar
žPersonal Calling.................................2-36
OnStaržServices............................................2-35
OnStaržSystem.............................................2-35
OnStaržVirtual Advisor....................................2-36
Other Warning Devices...................................... 3-6Outside.........................................................2-32
Camper-Type Mirrors....................................2-32
Convex Mirror.............................................2-34
Heated Mirrors............................................2-34
Manual Mirror.............................................2-31
Power Mirrors.............................................2-33
Remote Control Mirror..................................2-32
Overseas ± Customer Assistance........................ 7-4
Owners, Canadian............................................... ii
Owner's Information........................................7-10
P
Park (P)........................................................2-26
Shifting Into................................................2-26
Shifting Out of............................................2-29
Parking Brake and Automatic Transmission
Park (P) Mechanism Check...........................6-15
Parking on Hills..............................................4-43
Parking.........................................................2-26
Brake........................................................2-26
Over Things That Burn.................................2-29
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-11
Part C - Periodic MaintenanceInspections..........6-16
Part D - Recommended Fluids and Lubricants....6-18
Part E - Maintenance Record...........................6-20
10

Rear Door Security Locks.................................. 2-8
Rear Doors....................................................2-14
Rear Heating System......................................3-20
Rear Safety Belt Comfort Guides......................1-31
Rear Seat Audio (RSA)....................................3-71
Rear Seat Operation......................................... 1-6
Rear Seat Outside Passenger Positions.............1-28
Rear Seat Passengers, Safety Belts..................1-28
Rear Seat Radio Controls................................3-71
Rear Window Defogger....................................3-23
Rearview Mirrors.............................................2-31
Reclining Seatbacks.......................................... 1-4
Recreational Vehicle Towing.............................4-29
Remote Keyless Entry System, Operation............ 2-4
Remote Keyless Entry System............................ 2-3
Removing the Flat Tire and Installing the
Spare Tire..................................................5-72
Removing the Rear Seat................................... 1-6
Removing the Spare Tire and Tools...................5-66
Removing the Wheel Covers............................5-72
Replacement Bulbs.........................................5-54
Replacing Brake System Parts..........................5-40
Replacing Restraint System Parts After
a Crash.....................................................1-75
Replacing the Rear Seats.................................. 1-8
Reporting Safety Defects................................... 7-9
Canadian Government................................... 7-9
General Motors............................................. 7-9
United States Government.............................. 7-8Restraint System Check...................................6-12
Checking Your Restraint Systems...................1-74
Replacing Restraint System Parts After
a Crash..................................................1-75
Restraint Systems...........................................1-74
Checking....................................................1-74
Replacing Parts...........................................1-75
Resynchronization............................................. 2-5
Retained Accessory Power (RAP)......................2-21
Right Front Passenger Position, Safety Belts......1-25
Roadside......................................................... 7-5
Assistance Program....................................... 7-5
Rocking Your Vehicle To Get It Out...................4-28
Running Your Engine While You Are Parked.......2-30
S
Safety Belt.....................................................3-26
Reminder Light............................................3-26
Safety Belts...................................................5-83
Care of......................................................5-83
Center Passenger Position....................1-25, 1-26
Driver Position............................................1-16
How to Wear Safety Belts Properly................1-15
Questions and Answers About Safety Belts.....1-14
Rear Safety Belt Comfort Guides for Children
and Small Adults......................................1-31
Rear Seat Passengers.................................1-28
Right Front Passenger Position......................1-25
12