Fuel CHEVROLET EXPRESS CARGO VAN 2004 1.G Service Manual

GM Mobility Program for Persons
with Disabilities
This program, available to
qualied applicants, can
reimburse you up to $1,000
toward eligible 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 offer is available for
a limited period of time from the date of vehicle
purchase/lease. For more details, or to determine your
vehicle’s eligibility, see your GM dealer 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
Security While You Travel
1-800-CHEV-USA (243-8872)
As the proud owner of a new Chevrolet vehicle, you are
automatically enrolled in the Chevrolet Roadside
Assistance program. This value-added service is
intended to provide you with peace of mind as you drive
in the city or travel the open road. Chevrolet’s Roadside
Assistance toll-free number is staffed by courteous
and capable Roadside Assistance Representatives who
are available 24 hours a day, 365 days a year.
We will provide the following services during the
Bumper-to-Bumper warranty period, at no expense
to you:
Fuel Delivery:Delivery of enough fuel
($5 maximum) for the customer to get to the
nearest service station.
Lock-out Service (identication required):
Replacement keys or locksmith service will
be covered at no charge if you are unable to gain
entry into your vehicle. Delivery of the replacement
key will be covered within 10 miles.
7-6

Public Transportation or Fuel
Reimbursement
If your vehicle requires overnight warranty repairs,
reimbursement (ve day maximum) may be available for
the use of public transportation such as taxi or bus. In
addition, should you arrange transportation through
a friend or relative, reimbursement for reasonable fuel
expenses (ve day maximum) may be available.
Claim amounts should reect actual costs and be
supported by original receipts.
Courtesy Rental Vehicle
Your dealer may arrange to provide you with a courtesy
rental vehicle or reimburse you for a rental vehicle
you obtained if your vehicle is kept for a warranty repair.
Reimbursement will be limited to a maximum of
$30.00 a day and must be supported by receipts. This
requires that you sign and complete a rental agreement
and meet state, local and rental vehicle provider
requirements. Requirements vary and may include
minimum age requirements, insurance coverage, credit
card, etc. You are responsible for fuel usage charges
and may also be responsible for taxes, levies,
usage fees, excessive mileage or rental usage beyond
the completion of the repair.
Generally it is not possible to provide a like-vehicle as a
courtesy rental.
Additional Program Information
Courtesy Transportation is available during the
Bumper-to-Bumper warranty coverage period, but itis
notpart of the New Vehicle Limited Warranty. A
separate booklet entitled “Warranty and Owner
Assistance Information” furnished with each new vehicle
provides detailed warranty coverage information.
Courtesy Transportation is available only at participating
dealers and all program options, such as shuttle
service, may not be available at every dealer. Please
contact you dealer for specic information about
availability. All Courtesy Transportation arrangements
will be administered by appropriate dealer personnel.
Canadian Vehicles:For warranty repairs during
the Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.
7-9

Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s
performance. Your vehicle uses on-board vehicle
computers to monitor emission control components to
optimize fuel economy, to monitor conditions for air bag
deployment and, if so equipped, to provide anti-lock
braking and to help the driver control the vehicle
in difficult driving situations. Some information may be
stored during regular operations to facilitate repair
of detected malfunctions; other information is stored only
in a crash or near crash event by computer systems
commonly called event data recorders (EDR).
In a crash or near crash event, computer systems, such
as the Air Bag Sensing and Diagnostic Module (SDM)
in your vehicle may record information about the
condition of the vehicle and how it was operated, such
as engine speed, brake applications, throttle position,
vehicle speed, safety belt usage, air bag readiness, air
bag performance data, and the severity of a collision.
This information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.To read this information, special equipment is needed
and access to the vehicle or the SDM is required. GM will
not access information about a crash event or share it
with others other thanwith the consent of the vehicle owner or, if the vehicle
is leased, with the consent of the lessee,
in response to an official request of police or similar
government office,
as part of GM’s defense of litigation through the
discovery process, or
as required by law.
In addition, once GM collects or receives data, GM may
use the data for GM research needs,
make it available for research where appropriate
condentiality is to be maintained and need is
shown, or
share summary data which is not tied to a specic
vehicle with non-GM organizations for research
purposes.
Others, such as law enforcement, may have access to
the special equipment that can read the information
if they have access to the vehicle or SDM.
If your vehicle is equipped with OnStar
®, please check
the OnStar®subscription service agreement or manual
for information on its operations and data collection.
7-10

A
Accessory Power Outlets.................................3-18
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-81
Adding Washer Fluid.......................................5-38
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment...........................5-101
Add-On Equipment..........................................4-38
Adjusting the Speakers
(Balance/Fade)....................3-45, 3-47, 3-53, 3-63
Air Bag
Off Light.....................................................3-28
Readiness Light..........................................3-27
Air Bag System..............................................1-70
Adding Equipment to Your Air Bag-Equipped
Vehicle...................................................1-81
Air Bag Off Switch.......................................1-77
How Does an Air Bag Restrain?....................1-75
Servicing Your Air Bag-Equipped Vehicle.........1-80
What Makes an Air Bag Inate?....................1-75
What Will You See After an Air Bag Inates?......1-76
When Should an Air Bag Inate?...................1-74
Where Are the Air Bags?..............................1-72
Air Bag Systems.............................................1-75
Air Cleaner/Filter, Engine.................................5-18
Airbag Sensing and Diagnostic Module (SDM)....7-10
All-Wheel Drive...............................................5-48
All-Wheel Drive (AWD) System.........................2-26AM ...............................................................3-73
AM-FM Radio.................................................3-43
Antenna, Fixed Mast.......................................3-75
Anti-lock Brake System..................................... 4-7
Anti-Lock Brake, System Warning Light..............3-32
Appearance Care............................................5-92
Care of Safety Belts....................................5-95
Chemical Paint Spotting...............................5-98
Cleaning the Inside of Your Vehicle................5-92
Cleaning the Outside of Your Vehicle..............5-95
Finish Damage............................................5-98
Sheet Metal Damage...................................5-98
Underbody Maintenance...............................5-98
Vehicle Care/Appearance Materials................5-99
Weatherstrips..............................................5-95
Ashtrays........................................................3-18
Audio System(s).............................................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
Chime Level Adjustment...............................3-75
Fixed Mast Antenna.....................................3-75
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
1

Audio System(s) (cont.)
Theft-Deterrent Feature................................3-72
Understanding Radio Reception.....................3-73
Automatic Transmission
Fluid..........................................................5-19
Operation...................................................2-24
B
Backing Up....................................................4-48
Battery..........................................................5-42
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-17
Before Leaving on a Long Trip.........................4-23
Brake
Parking......................................................2-26
System Warning Light..................................3-31
Brake Adjustment............................................5-41
Brake Fluid....................................................5-39
Brake Pedal Travel.........................................5-41
Brake Wear...................................................5-41
Brakes..........................................................5-39
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-20
Bulb Replacement...........................................5-52
Front Turn Signal, Sidemarker and Parking
Lamps....................................................5-54
Halogen Bulbs............................................5-52Bulb Replacement (cont.)
Headlamps.................................................5-52
Replacement Bulbs......................................5-56
Taillamps....................................................5-54
Buying New Tires...........................................5-70
C
California Fuel.................................................. 5-6
Canada – Customer Assistance.......................... 7-5
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-8
Capacities and Specications..........................5-106
Carbon Monoxide...........................2-30, 4-27, 4-38
Care of
Safety Belts................................................5-95
Your Cassette Tape Player............................3-73
Your CD Player...........................................3-75
Your CDs ...................................................3-74
Cargo Door Relocking....................................... 2-8
Cargo Van.....................................................1-51
Cargo Vans and Cab and Chassis Models with
an Air Bag Off Switch..................................1-49
Cargo Vans and Cab and Chassis Models
without an Air Bag Off Switch........................1-48
Cargo Vans with a Passenger Air Bag and an
Air Bag Off Switch, Passenger Vans and Cab
and Chassis Models....................................1-37
2

E
Electrical System
Add-On Equipment.....................................5-101
Fuses and Circuit Breakers.........................5-102
Headlamp Wiring.......................................5-101
Windshield Wiper Fuses.............................5-101
Electronic Road-Speed Governor.......................3-26
Emissions Inspection and Maintenance
Programs...................................................3-37
Engine
Air Cleaner/Filter.........................................5-18
Battery.......................................................5-42
Change Engine Oil Light...............................3-38
Check and Service Engine Soon Light............3-34
Coolant......................................................5-22
Coolant Heater............................................2-23
Coolant Temperature Gage...........................3-34
Drive Belt Routing.......................................6-15
Engine Compartment Overview......................5-12
Exhaust.....................................................2-30
Fan Noise..................................................5-36
Oil .............................................................5-13
Overheating................................................5-26
Reduced Power Light...................................3-40
Starting......................................................2-21
Engine Compartment Fuse Block.....................5-103
Engine Oil Additives........................................5-16
Entry Lighting.................................................3-17
Event Data Recorders (EDR)............................7-10Exit Lighting...................................................3-17
Extender, Safety Belt.......................................1-33
Exterior Lamps...............................................3-14
F
Filter
Engine Air Cleaner......................................5-18
Finding a Program Type (PTY) Station.......3-54, 3-64
Finding a Station....................3-44, 3-46, 3-51, 3-62
Finish Care....................................................5-96
Finish Damage...............................................5-98
Fixed Mast Antenna........................................3-75
Flash-To-Pass Feature....................................... 3-9
Flat Tire........................................................5-75
Flat Tire, Changing.........................................5-76
Floor Console Fuse Block..............................5-102
Fluid
Automatic Transmission................................5-19
Power Steering...........................................5-36
Windshield Washer......................................5-38
FM ...............................................................3-73
Following Distance..........................................4-48
Front Axle......................................................5-50
Fuel............................................................... 5-5
Additives...................................................... 5-6
California Fuel.............................................. 5-6
Filling a Portable Fuel Container..................... 5-9
Filling Your Tank........................................... 5-8
5

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

Light (cont.)
Tow/Haul Mode...........................................3-40
Loading Your Vehicle.......................................4-33
Locking Rear Axle............................................ 4-8
Lockout Protection..........................................2-10
Locks
Cargo Door Relocking.................................... 2-8
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-8
Rear Door Security Locks............................... 2-8
Loss of Control...............................................4-15
M
Maintenance Schedule
Additional Required Services........................... 6-6
At Each Fuel Fill........................................... 6-9
At Least Once a Month................................6-10
At Least Once a Year..................................6-10
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000km)......................... 6-9
Introduction.................................................. 6-2
Maintenance Footnotes.................................. 6-7
Maintenance Record....................................6-16
Maintenance Requirements............................. 6-2
Normal Maintenance Replacement Parts.........6-14
Owner Checks and Services........................... 6-9Maintenance Schedule (cont.)
Recommended Fluids and Lubricants.............6-12
Scheduled Maintenance................................. 6-4
Using Your................................................... 6-3
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-50
Making Turns.................................................4-48
Malfunction Indicator Light................................3-34
Manual Seats................................................... 1-3
Manual Windows............................................2-16
Matching Transmitter(s) to Your Vehicle............... 2-5
Mexico, Central America and Caribbean Islands/
Countries (Except Puerto Rico and U.S.
Virgin Islands) – Customer Assistance................ 7-5
Mirrors
Manual Rearview Mirror................................2-32
Outside Camper-Type Mirrors........................2-32
Outside Convex Mirror.................................2-34
Outside Heated Mirrors................................2-35
Outside Manual Mirror..................................2-32
Outside Power Mirrors..................................2-33
Model Reference................................................ vi
MyGMLink.com................................................ 7-4
N
New Vehicle Break-In......................................2-20
Noise Control System, Tampering......................5-51
Normal Maintenance Replacement Parts............6-14
8