transmission CHEVROLET EXPRESS CARGO VAN 2004 1.G Owner's Manual

Checking the Fluid Level
Prepare your vehicle as follows:
Park your vehicle on a level place. Keep the engine
running.
With the parking brake applied, place the shift lever
in PARK (P).
With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the shift
lever in PARK (P).
Let the engine run at idle for three minutes or more.
Then, without shutting off the engine, follow these steps:
The transmission dipstick
is located near the center
of the engine compartment
and will be labeled with
this graphic shown.
SeeEngine Compartment Overview on page 5-12for
more information on location.1. Flip the handle up and then pull out the dipstick
and wipe it with a clean rag or paper towel.
2. Push it back in all the way, wait three seconds and
then pull it back out again.
3. 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. Be sure to keep the dipstick
pointed down to get an accurate reading.
4. 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.
5-21

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

Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the fan is spinning slower and the clutch is
not fully engaged. This improves fuel economy and
reduces fan noise. Under heavy vehicle loading, trailer
towing and/or high outside temperatures, the fan
speed increases as the clutch more fully engages. So
you may hear an increase in fan noise. This is
normal and should not be mistaken as the transmission
slipping or making extra shifts. It is merely the cooling
system functioning properly. The fan will slow down
when additional cooling is not required and the clutch
partially disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
Power Steering Fluid
The power steering uid reservoir is located in the
engine compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12
for more information on location.
5-36

Jump Starting
If your battery has run down, you may want to use
another vehicle and some jumper cables to start your
vehicle. Be sure to follow the steps below to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
They contain acid that can burn you.
They contain gas that can explode
or ignite.
They contain enough electricity to
burn you.
If you do not follow these steps exactly, some
or all of these things can hurt you.
Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not work, and it could damage your vehicle.1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren’t touching
each other. If they are, it could cause a ground
connection you don’t want. You wouldn’t be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake rmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in NEUTRAL before setting the parking brake.
Notice:If you leave your radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered
by your warranty. Always turn off your radio and
other accessories when jump starting your vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or in the accessory power outlet. Turn off
the radio and all lamps that aren’t needed. This will
avoid sparks and help save both batteries. And it
could save your radio!
5-43

Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to its
width.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure in
a tire, measured in pounds per square inch (psi) or
kilopascals (kPa) before a tire has built up heat
from driving. SeeInation - Tire Pressure on page 5-66.Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the U.S.
Department of Transportation motor vehicle safety
standards. The DOT code includes the Tire Identication
Number (TIN), an alphanumeric designator which can
also identify the tire manufacturer, production plant,
brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-33.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-33.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-33.
Intended Outboard Sidewall:The side of an
asymmetrical tire, that must always face outward when
mounted on a vehicle.
Kilopascal (kPa):The metric unit for air pressure.
There are 6.9 kPa’s to one psi.
5-64

Fuse Usage
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
24 Truck 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 Inatable Restraint
System
5-104

Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. Reset oil life system. SeeEngine Oil on
page 5-13.An Emission Control Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner lter or change indicator (if equipped). If necessary,
replace lter. SeeEngine Air Cleaner/Filter on page 5-18.An Emission Control
Service. See footnote †.••
Rotate tires and check ination pressures and wear. SeeTires on page 5-58.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels and add uid as
needed.••
Perform any needed additional services. See “Additional Required Services” in
this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
Check transmission uid level and add uid as needed.•
Inspect shields (vehicles with GVWR above 10,000 lbs. only).See footnote (g).•
Inspect throttle system.See footnote (m).•
6-5

Additional Required Services
The following services should be performed at the rst maintenance service (IorII) after the indicated miles
(kilometers) shown for each item.
Additional Required Services
Service and Miles (Kilometers)25,000
(41 500)50,000
(83 000)75,000
(125 000)100,000
(166 000)125,000
(207 500)150,000
(240 000)
Inspect fuel system for damage or
leaks.••••••
Inspect exhaust system for loose or
damaged components.••••••
Vehicles without a lter restriction
indicator: Replace engine air
cleaner lter. SeeEngine Air
Cleaner/Filter on page 5-18.An
Emission Control Service.••••••
Change automatic transmission
uid and lter (severe service).See
footnote (h).•••
Change automatic transmission
uid and lter (normal service).•
Replace spark plugs and inspect
spark plug wires.An Emission
Control Service.•
6-6

(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

Automatic Transmission Shift Lock
Control System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-26if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the key to the RUN
position, but do not start the engine. Without
applying the regular brake, try to move the shift
lever out of PARK (P) with normal effort. If the shift
lever moves out of PARK (P), contact your GM
Goodwrench dealer for service.
Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to LOCK in each shift lever position.
The key should turn to LOCK only when the
shift lever is in PARK (P).
The key should come out only in LOCK.
Contact your GM Goodwrench dealer if service is
required.
Parking Brake and Automatic
Transmission Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.
6-11