lock CHEVROLET EXPRESS CARGO VAN 2003 1.G Repair Manual

GM Mobility Program for Persons
with Disabilities
This program, available to
quali®ed applicants, can
reimburse you up to
$1,000 toward aftermarket
driver or passenger
adaptive equipment you
may require for your
vehicle (hand controls,
wheelchair/scooter
lifts, etc.).
This program can also provide you with free resource
information, such as area driver assessment centers and
mobility equipment installers. The program is available
for a limited period of time from the date of vehicle
purchase/lease. See your dealer for more details or call
the GM Mobility Assistance Center at 1-800-323-9935.
Text telephone (TTY) users, call 1-800-833-9935.
GM of Canada also has a Mobility Program. Call
1-800-GM-DRIVE (463-7483) for details. All TTY users
call 1-800-263-3830.
Roadside Assistance Program
To enhance Chevrolet's strong commitment to customer
satisfaction, Chevrolet is excited to announce the
establishment of the Chevrolet Roadside Assistance
Center. As the owner of a 2003 Chevrolet, membership
in Roadside Assistance is free.
Roadside Assistance is available 24 hours a day,
365 days a year, by calling 1-800-CHEV-USA
(243-8872). This toll-free number will provide you
over-the-phone roadside assistance with minor
mechanical problems. If your problem cannot be
resolved over the phone, our advisors have access to a
nationwide network of dealer recommended service
providers. Roadside membership is free; however some
services may incur costs.
Roadside offers two levels of service to the customer,
Basic CareandCourtesy Care:
RoadsideBasic Careprovides:
·Toll-free number, 1-800-CHEV-USA (243-8872),
text telephone (TTY) users, call 1-888-889-2438
·Free towing for warranty repairs
·Basic over-the-phone technical advice
·Available dealer services at reasonable costs
(i.e., wrecker services, locksmith/key service,
glass repair, etc.)
7-5

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

To remove the fuel cap,
turn it slowly to the left
(counterclockwise). While
refueling, place the
fuel cap in the holder
provided.
{CAUTION:
If you get fuel on yourself and then something
ignites it, you could be badly burned. Fuel can
spray out on you if you open the fuel cap too
quickly. This spray can happen if your tank is
nearly full, and is more likely in hot weather.
Open the fuel cap slowly and wait for any
ªhissº noise to stop. Then unscrew the cap all
the way.Be careful not to spill fuel. Clean fuel from painted
surfaces as soon as possible. See
Cleaning the Outside
of Your Vehicle on page 5-83. When ®lling the tank
do not over®ll by squeezing in much more fuel after the
pump shuts off.
When you put the fuel cap back on, turn it to the right
(clockwise) until you hear a clicking sound. Make
sure you fully install the cap. The diagnostic system can
determine if the fuel cap has been left off or improperly
installed. This would allow fuel to evaporate into the
atmosphere. See
Malfunction Indicator Lamp on
page 3-33.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not ®t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. See ªMalfunction Indicator Lampº in the
Index.
5-8

·Check both sides of the dipstick, and read the lower
level. The ¯uid level must be in the COLD area for
a cold check or in the HOT area or cross-hatched
area for a hot check.
·If the ¯uid level is in the acceptable range, push the
dipstick back in all the way; then ¯ip the handle
down to lock the dipstick in place.
How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission ¯uid to use. SeePart D:
Recommended Fluids and Lubricants on page 6-18.
Using a funnel, add ¯uid down the transmission dipstick
tube only after checking the transmission ¯uid while it
is hot. (A cold check is used only as a reference.) If the
¯uid level is low, add only enough of the proper ¯uid
to bring the level up to the HOT area for a hot check.
It doesn't take much ¯uid, generally less than one pint
(0.5 L).
Don't over®ll.
Notice:We recommend you use only ¯uid labeled
DEXRONž-III, because ¯uid with that label is
made especially for your automatic transmission.
Damage caused by ¯uid other than DEXRON
ž-III is
not covered by your new vehicle warranty.
·After adding ¯uid, recheck the ¯uid level as
described under ªHow to Check.º
·When the correct ¯uid level is obtained, push the
dipstick back in all the way; then ¯ip the handle
down to lock the dipstick in place.
Engine Coolant
The cooling system in your vehicle is ®lled with
DEX-COOLžengine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs ®rst, if you add
only DEX-COOL
žextended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, see
Engine Overheating on
page 5-24.
5-21

How to Add Coolant to the Radiator
1. You can remove the radiator pressure cap when
the cooling system, including the radiator pressure
cap and upper radiator hose, is no longer hot.
Turn the pressure cap slowly counterclockwise until
it ®rst stops. (Don't press down while turning the
pressure cap.)
If you hear a hiss, wait for that to stop. A hiss
means there is still some pressure left.2. Then keep turning the pressure cap, but now push
down as you turn it. Remove the pressure cap.
5-31

Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your dealer.
For the type of bulbs, see
Replacement Bulbs on
page 5-54.
Halogen Bulbs
{CAUTION:
Halogen bulbs have pressurized gas inside
and can burst if you drop or scratch the bulb.
You or others could be injured. Be sure to read
and follow the instructions on the bulb
package.
Headlamps
1. Remove the two bolts from the headlamp assembly.
2. Remove the two pins on the top of the headlamp
assembly. To remove the pins, turn the outer pin
clockwise and pull it straight up. To remove
the inner pin, turn it counterclockwise and pull it
straight up.
3. Lift the inboard side of the headlamp to release the
inboard tab from the radiator support.
4. Lift the outboard side of the headlamp to release
the outboard tab from the radiator support.
5. Lower the headlamp to allow the vertical adjustor to
clear tie bar.
6. Turn the headlamp forward and upward to remove
it from the grille.
7. Turn the bulb connector counterclockwise and pull it
out of the housing.
5-50

8. Without removing the headlamp assembly itself,
remove the bulb socket from the back of the
headlamp on the driver's side.
9. Turn the bulb counterclockwise one quarter turn to
remove it from the socket.
10. On the passenger's side, turn the bulb clockwise
one turn. Do not touch the glass part of the bulb.11. Install the new bulb into the socket and return it to
the headlamp assembly.
12. Put the headlamp assembly back into the vehicle
and reinstall the two pins.
5-51

Front Turn Signal, Sidemarker and
Parking Lamps
1. Use a small tool to unlatch the outboard clip on
this lamp.
2. Pull the lamp forward to completely unlatch the clip.
Move the lamp outboard to loosen the tabs.
3. Remove the lamp from the grille.
4. Squeeze the tab on the side of the bulb assembly
while turning it counterclockwise.
5. Remove the bulb assembly from the back of the
lens and replace the bulb.
6. Turn the socket clockwise to reinstall it in the lens
assembly.
Taillamps
1. Remove the two inboard nuts on the side assembly.
2. Pull side assembly rearward to clear studs.
3. Turn the side assembly on the outboard side,
releasing the upper clip.
4. Slide assembly slightly upward to release lower clip.
5. Reinstall the clips to the side assembly.
6. Remove the three nuts on the taillamp.
7. Remove the taillamp from the vehicle.
5-52

8. To remove, squeeze the tab on the side of the
sockets while turning them counterclockwise.9. Turn the bulb counterclockwise to remove it. Install
the new bulb.
10. Reverse the above steps to reinstall the lamp.
5-53

Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking. See²Wiper
Blade Checkº in
At Least Twice a Year on page 6-12for
more information.Replacement blades come in different types and are
removed in different ways. To remove the type with a
release clip, do the following:
1. Lift the wiper arm until it locks into a vertical
position.
2. Press down on the blade assembly pivot locking
tab. Pull down on the blade assembly to release it
from the wiper arm hook.
3. The insert has two notches at one end that are
locked by bottom claws of the blade assembly.
At the notched end, pull the insert from the blade
assembly.
4. To install the new wiper insert, slide the notched
end last, into the end with two blade claws. Then
slide the insert all the way through the blade claws
at the opposite end.
5. Make sure that the notches are locked by the
bottom claws. Make sure that all other claws
are properly locked on both sides of the insert slot.
6. Put the blade assembly pivot in the wiper arm hook.
Pull it up until the pivot locking tab locks in the
hook slot.
7. Carefully lower the wiper arm and blade assembly
into the windshield.
5-55