radiator CHEVROLET EXPRESS CARGO VAN 2004 1.G User Guide

{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the radiator
pressure cap — even a little — they can come
out at high speed. Never turn the cap when the
cooling system, including the radiator pressure
cap, is hot. Wait for the cooling system and
radiator pressure cap to cool if you ever have
to turn the pressure cap.
5-32

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.
5-33

3. Fill the radiator with the proper DEX-COOL®
coolant mixture, up to the base of the ller
neck. SeeEngine Coolant on page 5-22for more
information about the proper coolant mixture.4. Then ll the coolant recovery tank to the COLD
FILL mark.
5. Put the cap back on the coolant recovery tank, but
leave the radiator pressure cap off.
5-34

6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fan.
7. By this time, the coolant level inside the radiator
ller neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the ller neck until the level reaches
the base of the ller neck.8. Then replace the pressure cap. At any time during
this procedure if coolant begins to ow out of the
ller neck, reinstall the pressure cap.
5-35

Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your dealer.
For the type of bulbs, seeReplacement Bulbs on
page 5-56.
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.
5-52

(c)Visually inspect hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
ttings and clamps; replace with genuine GM parts as
needed. To help ensure proper operation, a pressure test
of the cooling system and pressure cap and cleaning the
outside of the radiator and air conditioning condenser is
recommended at least once a year.
(d)Visually inspect wiper blades for wear or cracking.
Replace blade inserts that appear worn or damaged
or that streak or miss areas of the windshield.
(e)Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced. Also look for any opened or broken air bag
coverings, and have them repaired or replaced. (The air
bag system does not need regular maintenance.)
(f)Lubricate all key lock cylinders, hood hinges, hood
prop rod pivot, hood latch assembly, secondary
latch, pivots, spring anchor, release pawl, rear
compartment hinges, latches, locks, fuel door hinge and
any moving seat hardware. More frequent lubrication
may be required when exposed to a corrosive
environment. Applying silicone grease on weatherstrips
with a clean cloth will make them last longer, seal
better and not stick or squeak.(g)Vehicles 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.
(h)Change automatic transmission uid and lter 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.
(i)Drain, ush and rell cooling system. See Engine
Coolant on page 5-22for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and ller neck.
Pressure test the cooling system and pressure cap.
(j)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired and
the uid level checked. Add uid if needed.
6-8

Fuel (cont.)
Fuels in Foreign Countries.............................. 5-7
Gage.........................................................3-41
Gasoline Octane........................................... 5-5
Gasoline Specications.................................. 5-5
Fuel Regulator................................................2-22
Fuses
Fuses and Circuit Breakers.........................5-102
Windshield Wiper.......................................5-101
G
Gage
Check Gages Warning Light..........................3-41
Engine Coolant Temperature.........................3-34
Fuel..........................................................3-41
Oil Pressure...............................................3-37
Speedometer..............................................3-26
Voltmeter Gage...........................................3-30
Gasoline
Octane........................................................ 5-5
Specications............................................... 5-5
GM Mobility Program for Persons with
Disabilities.................................................... 7-6
H
Hazard Warning Flashers................................... 3-6
Headlamp High/Low Beam Changer.................... 3-9
Headlamp Wiring...........................................5-101
Headlamps....................................................5-52
Bulb Replacement.......................................5-52
Front Turn Signal, Sidemarker and
Parking Lamps.........................................5-54
Halogen Bulbs............................................5-52
Highway Hypnosis...........................................4-24
Hill and Mountain Roads..................................4-25
Hitches..........................................................4-46
Hood
Checking Things Under................................5-10
Release.....................................................5-10
Horn............................................................... 3-7
How to Add Coolant to the Coolant
Recovery Tank............................................5-30
How to Add Coolant to the Radiator..................5-33
How to Check Power Steering Fluid..................5-37
How to Inspect the Engine Air Cleaner/Filter.......5-18
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-15
Hydroplaning..................................................4-20
6

Q
Questions and Answers About Safety Belts.........1-14
R
Radiator Pressure Cap....................................5-25
Radio Data System (RDS).......................3-53, 3-64
Radio Messages.............................3-45, 3-48, 3-56
Radios..........................................................3-42
AM-FM Radio.............................................3-43
Care of Your Cassette Tape Player................3-73
Care of Your CD Player...............................3-75
Care of Your CDs........................................3-74
Radio with Cassette and CD.........................3-50
Radio with CD............................................3-46
Radio with Six-Disc CD................................3-61
Setting the Time for Radios with Radio Data
Systems (RDS)........................................3-43
Setting the Time for Radios without Radio
Data Systems (RDS)................................3-43
Theft-Deterrent............................................3-72
Understanding Reception..............................3-73
RDS Messages......................................3-55, 3-66
Reading Lamps..............................................3-17
Rear Air Conditioning and Heating System.........3-22
Rear Axle......................................................5-49
Locking........................................................ 4-8
Rear Door Security Locks.................................. 2-8
Rear Doors....................................................2-14Rear Heating System......................................3-22
Rear Safety Belt Comfort Guides......................1-31
Rear Seat Operation......................................... 1-6
Rear Seat Outside Passenger Positions.............1-27
Rear Seat Passengers, Safety Belts..................1-27
Rear Window Defogger....................................3-21
Rearview Mirrors.............................................2-32
Reclining Seatbacks.......................................... 1-4
Recommended Fluids and Lubricants.................6-12
Recreational Vehicle Towing.............................4-32
Reduced Engine Power Light............................3-40
Remote Keyless Entry System............................ 2-3
Remote Keyless Entry System, Operation............ 2-4
Removing the Flat Tire and Installing
the Spare Tire.............................................5-84
Removing the Rear Seat................................... 1-6
Removing the Spare Tire and Tools...................5-77
Removing the Wheel Covers............................5-83
Replacement Bulbs.........................................5-56
Replacing Brake System Parts..........................5-41
Replacing the Rear Seats.................................. 1-8
Reporting Safety Defects
Canadian Government..................................7-11
General Motors...........................................7-11
United States Government............................7-11
Restraint System Check
Checking Your Restraint Systems...................1-81
Replacing Restraint System Parts
After a Crash..........................................1-82
10