maintenance CHEVROLET EXPRESS CARGO VAN 2004 1.G User Guide

2. Lift the lter out of the engine air cleaner/lter
housing. Care should be taken to dislodge as
little dirt as possible.
3. Clean the engine air cleaner/lter housing.
4. Install the new engine air cleaner/lter into the
engine air cleaner/lter housing. Make sure that
it ts properly into the housing.
5. Reinstall the cover and fasten the retaining clips.
{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned. The
air cleaner not only cleans the air, it helps to
stop ame if the engine backres. If it is not
there and the engine backres, you could be
burned. Do not drive with it off, and be careful
working on the engine with the air cleaner/
lter off.
Notice:If the air cleaner/lter is off, a backre can
cause a damaging engine re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/lter in place when you
are driving.
Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission uid
level is when the engine oil is changed.
Change both the uid and lter every 50,000 miles
(83,000 km) if the vehicle’s GVWR is over 8,600 or if
the vehicle is mainly driven under one or more of these
conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.
If your vehicle’s GVWR is not over 8,600 and you do
not use your vehicle under any of these conditions,
change the uid and lter every 100,000 miles
(166 000 km).
SeeScheduled Maintenance on page 6-4.
5-19

How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission uid to use. SeeRecommended
Fluids and Lubricants on page 6-12.
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 overll.
Notice:We recommend you use only uid labeled
DEXRON
®-III, because uid with that label is
made especially for your automatic transmission.
Damage caused by uid other than DEXRON
®-III is
not covered by your new vehicle warranty.
After adding uid, recheck the uid level as
described under “How to Check.”
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-COOL®engine 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
®extended 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, seeEngine Overheating on
page 5-26.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as they
should.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-22

Brakes
Brake Fluid
Your brake master cylinder reservoir is lled with DOT-3
brake uid. SeeEngine Compartment Overview on
page 5-12for the location of the reservoir.
There are only two reasons why the brake uid level in
the reservoir might go down. The rst is that the
brake uid goes down to an acceptable level during
normal brake lining wear. When new linings are put in,
the uid level goes back up. The other reason is
that uid is leaking out of the brake system. If it is, youshould have your brake system xed, since a leak
means that sooner or later your brakes will not work
well, or will not work at all.
So, it is not a good idea to “top off” your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add (or remove) brake uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system. See “Checking Brake Fluid”
in this section.
Refer to the Maintenance Schedule to determine when
to check your brake uid. SeeScheduled Maintenance
on page 6-4.
5-39

Battery
Your new vehicle comes with a maintenance free
ACDelco®battery. When it is time for a new battery, get
one that has the replacement number shown on the
original battery’s label. We recommend an ACDelco
®
battery. SeeEngine Compartment Overview on
page 5-12for battery location.
Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days or
more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-43for tips on working around a battery
without getting hurt.
Contact your dealer to learn how to prepare your
vehicle for longer storage periods.
Also, for your audio system, seeTheft-Deterrent
Feature (Non-RDS Radios) on page 3-72or
Theft-Deterrent Feature (RDS Radios) on page 3-72.
5-42

All-Wheel Drive
Lubricant checks in this section also apply to these
vehicles. However, there are two additional systems that
need lubrication.
Transfer Case
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the bottom of the ller plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
Use care not to overtighten the plug.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-12.
5-48

Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.If you have the 1500 Series, the proper level is from
5/8 inch (15 mm) to 1 5/8 inch (40 mm) below the bottom
of the ller plug hole. The proper level for the 2500
and 3500 Series is from 0 to 1/4 (6 mm) below
the bottom of the ller plug hole. Add only enough uid
to reach the proper level.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-12.
5-49

Front Axle
When to Check and Change Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
Scheduled Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the
bottom of the ller plug
hole, you may need to add
some lubricant.When the differential is cold, add enough lubricant to
raise the level to 3/8 inch (10 mm) below the ller
plug hole.
When the differential is at operating temperature
(warm), add enough lubricant to raise the level to the
bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-12.
5-50

Noise Control System
Tampering with Noise Control
System Prohibited
The following information relates to compliance with
federal noise emission standards for vehicles with a
Gross Vehicle Weight Rating (GVWR) of more than
10,000 lbs (4 536 kg). The Maintenance Schedule
provides information on maintaining the noise control
system to minimize degradation of the noise emission
control system during the life of your vehicle. The noise
control system warranty is given in your warranty booklet.
These standards apply only to vehicles sold in the
United States.
Federal law prohibits the following acts or the causing
thereof:
1. The removal or rendering inoperative by any
person, other than for purposes of maintenance,
repair or replacement, of any device or element of
design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser or while it is in
use; or
2. The use of the vehicle after such device or element
of design has been removed or rendered inoperative
by any person.Among those acts presumed to constitute tampering are
the acts listed below.
Insulation:

Removal of the noise shields or any underhood
insulation.
Engine:

Removal or rendering engine speed governor (if
equipped) inoperative so as to allow engine
speed to exceed manufacturer specications.
Fan and Drive:

Removal of fan clutch (if equipped) or rendering
clutch inoperative.
Removal of the fan shroud (if equipped).
Air Intake:

Removal of the air cleaner silencer.
Modication of the air cleaner.
Exhaust:

Removal of the muffler and/or resonator.
Removal of the exhaust pipes and exhaust pipe
clamps.
5-51

Replacement Bulbs
Exterior Lamp Bulb Number
Back-up Lamp 3157
CHMSL 912
Composite High-Beam
Headlamps9005
Composite Low-Beam
Headlamps9006GS
Front Parking and Turn Lamp 3157KX
Front Sidemarker Lamp 194
Sealed Beam Headlamps H6054
Rear Parking, Stop, and
Turn Lamp3157
For any bulb not listed here, contact your dealer.
Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking. See″Wiper
Blade Check” inScheduled Maintenance on page 6-4.
5-56

When to Check
Check your tires once a month or more.
Also, check the tire pressure of the spare tire.
How to Check
Use a good quality pocket-type gage to check tire
pressure. You can’t tell if your tires are properly inated
simply by looking at them. Radial tires may look
properly inated even when they’re underinated. Check
the tire’s ination pressure when the tires are cold.
Cold means your vehicle has been sitting for at least
three hours or driven no more than 1 mile (1.6 km).
Remove the valve cap from the tire valve stem. Press
the tire gage rmly onto the valve to get a pressure
measurement. If the cold tire ination pressure matches
the recommended pressure on the tire and loading
information label, no further adjustment is necessary.
If the pressure is low, add air until you reach the
recommended amount.
If you overll the tire, release air by pushing on the
metal stem in the center of the tire valve. Recheck the
tire pressure with the tire gage.
Be sure to put the valve caps back on the valve stems.
They help prevent leaks by keeping out dirt and moisture.
Dual Tire Operation
When the vehicle is new, or whenever a wheel, wheel
bolt or wheel nut is replaced, check the wheel nut torque
after 100, 1,000 and 6,000 miles (160, 1 600 and
10 000 km) of driving. For proper wheel nut tightening
information, see “Removing the Flat Tire and Installing
the Spare Tire” later in this section, underChanging
a Flat Tire on page 5-76. Also see “Wheel Nut Torque”
underCapacities and Specications on page 5-106.
The outer tire on a dual wheel setup generally wears
faster than the inner tire. Your tires will wear more
evenly and last longer if you rotate the tires periodically.
SeeTire Inspection and Rotation on page 5-68. Also
seeScheduled Maintenance on page 6-4.
{CAUTION:
If you operate your vehicle with a tire that is
badly underinated, the tire can overheat. An
overheated tire can lose air suddenly or catch
re. You or others could be injured. Be sure all
tires (including the spare) are properly inated.
SeeTires on page 5-58andInation - Tire Pressure on
page 5-66for more information on proper tire ination.
5-67