fuel CHEVROLET EXPRESS CARGO VAN 2003 1.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-34
Air Bag System
.......................................1-63
Restraint System Check
............................1-74
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-19
Starting and Operating Your Vehicle
...........2-20
Mirrors
....................................................2-31
OnStar
žSystem
......................................2-35
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages and Indicators
.........3-23
Audio System(s)
.......................................3-40
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
................. 5-9
All-Wheel Drive
........................................5-46
Rear Axle
...............................................5-47
Front Axle
...............................................5-48
Noise Control System
...............................5-49
Bulb Replacement
....................................5-50
Windshield Wiper Blade Replacement
.........5-55
Tires
......................................................5-56
Appearance Care
.....................................5-80
Vehicle Identi®cation
.................................5-90
Electrical System
......................................5-91
Capacities and Speci®cations
.....................5-97
Normal Maintenance
Replacement Parts
..............................5-100
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information.................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects
............................ 7-8
Index................................................................ 1
2003 Chevrolet Express Owner ManualM

Sun Visors
To block out glare, you can swing down the visors.
You can also swing them from side to side.
Visor Vanity Mirror
Some visors have mirrors built in, with or without lamps.
Just lift the mirror cover on each visor to turn the
lamps on, if you have them.
Theft-Deterrent Systems
Vehicle theft is a 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. However, there are ways you
can help.
Passlockž
Your vehicle is equipped with the Passlockž
theft-deterrent system.
Passlock
žis a passive theft-deterrent system. Passlockž
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.
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
žsystem is not
working properly and must be serviced by your
dealer. Your vehicle is not protected by Passlock
žat
this time. You may also want to check the fuse.
See
Fuses and Circuit Breakers on page 5-92. See your
dealer for service.
2-19

Starting Your Engine
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won't start in any other position ± that's a
safety feature. To restart when you're already moving,
use NEUTRAL (N) only.
Notice:Don't try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as
your engine gets warm.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about
15 seconds between each try to help avoid draining
your battery or damaging your starter.
2. If it doesn't start within 10 seconds, push the
accelerator pedal all the way to the ¯oor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.When starting your engine in very cold weather
(below 0ÉF or-18ÉC), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go of
the key.
2. If your engine still won't start (or starts but then
stops), it could be ¯ooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
¯oor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the
vehicle starts brie¯y but then stops again, do the
same thing, but this time keep the pedal down
for ®ve or six seconds. This clears the extra
gasoline from the engine.
Notice:Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer. If you don't, your engine
might not perform properly.
Fuel Regulator
You have a fuel regulator that shuts the fuel off when
the engine reaches 5,600 rpm.
2-22

Engine Coolant Heater
In very cold weather, 0ÉF (-18ÉC) or colder, the engine
coolant heater can help. You'll get easier starting
and better fuel economy during engine warm-up.
Usually, the coolant heater should be plugged in a
minimum of four hours prior to starting your vehicle.
At temperatures above 32ÉF (0ÉC), use of the coolant
heater is not required.
To Use the Engine Coolant Heater
1. Turn off the engine.
2. Open the hood and unwrap the electrical cord.
The cord for the engine coolant heater is located
on the driver's side of the engine compartment and
is attached to the hose for the power steering
reservoir.
3. Plug it into a normal, grounded 110-volt AC outlet.
{CAUTION:
Plugging the cord into an ungrounded outlet
could cause an electrical shock. Also, the
wrong kind of extension cord could overheat
and cause a ®re. You could be seriously
injured. Plug the cord into a properly grounded
three-prong 110-volt AC outlet. If the cord
won't reach, use a heavy-duty three-prong
extension cord rated for at least 15 amps.
4. Before starting the engine, be sure to unplug and
store the cord as it was before to keep it away
from moving engine parts. If you don't, it could be
damaged.
How long should you keep the coolant heater plugged
in? The answer depends on the outside temperature, the
kind of oil you have, and some other things. Instead
of trying to list everything here, we ask that you contact
your dealer in the area where you'll be parking your
vehicle. The dealer can give you the best advice for that
particular area.
2-23

{CAUTION:
Shifting into a drive gear while your engine is
ªracingº (running at high speed) is dangerous.
Unless your foot is ®rmly on the brake pedal,
your vehicle could move very rapidly. You
could lose control and hit people or objects.
Don't shift into a drive gear while your engine
is racing.
Notice:Damage to your transmission caused by
shifting out of PARK (P) or NEUTRAL (N) with
the engine racing isn't covered by your warranty.
DRIVE (D):This position is for normal driving. If
you need more power for passing, and you're:
·Going less than about 35 mph (55 km/h), push your
accelerator pedal about halfway down.
·Going about 35 mph (55 km/h) or more, push the
accelerator all the way down.
You'll shift down to the next gear and have more power.
THIRD (3):This position is also used for normal
driving, however, it offers more power and lower fuel
economy than DRIVE (D). You should use THIRD (3)
when carrying a heavy load or driving on steep hills.You should use THIRD (3) (or, as you need to, a lower
gear) when towing a trailer to minimize heat build-up
and extend the life of your transmission.
SECOND (2):This position gives you more power but
lower fuel economy than THIRD (3). You can use
SECOND (2) on hills. It can help control your speed as
you go down steep mountain roads, but then you
would also want to use your brakes off and on. If you
manually select SECOND (2), the transmission will drive
in SECOND (2). You may use this feature for reducing
torque to the rear wheels when you are trying to
start your vehicle from a stop on slippery road surfaces.
FIRST (1):This position gives you even more power but
lower fuel economy than SECOND (2). You can use it on
very steep hills, or in deep snow or mud. If the shift lever
is put in FIRST (1), the transmission won't shift into ®rst
gear until the vehicle is going slowly enough.
Notice:If your wheels won't turn, don't try to drive.
This might happen if you were stuck in very deep
sand or mud or were up against a solid object. You
could damage your transmission. Also, if you
stop when going uphill, don't hold your vehicle there
with only the accelerator pedal. This could overheat
and damage the transmission. Use your brakes
or shift into PARK (P) to hold your vehicle in
position on a hill.
2-25

Oil Pressure Gage........................................3-36
Change Engine Oil Light................................3-37
Security Light...............................................3-37
Cruise Control Light......................................3-38
Daytime Running Lamps
Indicator Light...........................................3-38
Tow/Haul Mode Light....................................3-38
Check Gages Warning Light...........................3-38
Fuel Gage...................................................3-39
Audio System(s).............................................3-40
Setting the Time for Radios without Radio
Data Systems (RDS)..................................3-40
Setting the Time for Radios with Radio Data
Systems (RDS).........................................3-41
AM-FM Radio...............................................3-41Radio with CD..............................................3-44
Radio with Cassette and CD..........................3-48
Radio with Six-Disc CD.................................3-59
Rear Seat Audio (RSA).................................3-71
Theft-Deterrent Feature
(Non-RDS Radios).....................................3-73
Theft-Deterrent Feature
(RDS Radios)...........................................3-73
Understanding Radio Reception......................3-73
Care of Your Cassette Tape Player.................3-74
Care of Your CDs.........................................3-75
Care of Your CD Player................................3-75
Fixed Mast Antenna......................................3-75
Chime Level Adjustment................................3-75
Section 3 Instrument Panel
3-2

Instrument Panel Cluster
Your instrument panel cluster is designed to let you know at a glance how your vehicle is running. You'll know how
fast you're going, how much fuel you're using, and many other things you'll need to know to drive safely, and
economically.United States version shown, Canada similar
3-24

Low Coolant Warning Light
This message is displayed when the cooling system is
low on coolant.
The engine may overheat. See
Engine Coolant on
page 5-21and have your vehicle serviced as soon as
you can.
Malfunction Indicator Lamp
Check Engine Light
Your vehicle is equipped
with a computer which
monitors operation of the
fuel, ignition and emission
control systems.
This system is called OBD II (On-Board
Diagnostics-Second Generation) and is intended to
assure that emissions are at acceptable levels for the
life of the vehicle, helping to produce a cleaner
environment. The Check Engine light comes on to
indicate that there is a problem and service is required.
Malfunctions often will be indicated by the system
before any problem is apparent. This may prevent more
serious damage to your vehicle. This system is also
designed to assist your service technician in correctly
diagnosing any malfunction. United States
Canada
3-33

Notice:If you keep driving your vehicle with this
light on, after a while, your emission controls
may not work as well, your fuel economy may not
be as good and your engine may not run as
smoothly. This could lead to costly repairs that may
not be covered by your warranty.
Notice:Modi®cations made to the engine,
transmission, exhaust, intake or fuel system of your
vehicle or the replacement of the original tires
with other than those of the same Tire Performance
Criteria (TPC) can affect your vehicle's emission
controls and may cause this light to come on.
Modi®cations to these systems could lead to costly
repairs not covered by your warranty. This may
also result in a failure to pass a required Emission
Inspection/Maintenance test.
This light should come on, as a check to show you it is
working, when the ignition is on and the engine is
not running. If the light doesn't come on, have it
repaired. This light will also come on during a
malfunction in one of two ways:
·Light FlashingÐ A mis®re condition has been
detected. A mis®re increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
·Light On SteadyÐ An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
·Reducing vehicle speed.
·Avoiding hard accelerations.
·Avoiding steep uphill grades.
·If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible.
If the light stops ¯ashing and remains on steady, see ªIf
the Light Is On Steadyº following.
If the light continues to ¯ash, when it is safe to do so,
stop the vehicle.Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see ªIf
the Light Is On Steadyº following. If the light is still
¯ashing, follow the previous steps, and see your dealer
for service as soon as possible.
3-34

If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. See
Filling Your Tank on page 5-7. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel. See
Gasoline Octane on page 5-4. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, mis®ring, hesitation
on acceleration or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to ®x any
mechanical or electrical problems that may have
developed.
Emissions Inspection and Maintenance
Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this
inspection could prevent you from getting a vehicle
registration.
Here are some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection if the Check
Engine light is on or not working properly.
Your vehicle will not pass this inspection if the OBD
(on-board diagnostic) system determines that critical
emission control systems have not been completely
diagnosed by the system. The vehicle would be
considered not ready for inspection.
3-35