tow CHEVROLET EXPRESS CARGO VAN 2004 1.G Repair Manual

Cleaning the Windshield and Wiper
Blades
If the windshield is not clear after using the windshield
washer, or if the wiper blade chatters when running,
wax, sap or other material may be on the blade or
windshield.
Clean the outside of the windshield with a full-strength
glass cleaning liquid. The windshield is clean if beads do
not form when you rinse it with water.
Grime from the windshield will stick to the wiper blades
and affect their performance. Clean the blade by
wiping vigorously with a cloth soaked in full-strength
windshield washer solvent. Then rinse the blade
with water.
Check the wiper blades and clean them as necessary;
replace blades that look worn.
Cleaning Aluminum Wheels
Keep your wheels clean using a soft clean cloth with
mild soap and water. Rinse with clean water. After
rinsing thoroughly, dry with a soft clean towel. A wax
may then be applied.
The surface of these wheels is similar to the painted
surface of your vehicle. Do not use strong soaps,
chemicals, abrasive polishes, abrasive cleaners,
cleaners with acid, or abrasive cleaning brushes on
them because you could damage the surface. Do not
use chrome polish on aluminum wheels.
Do not take your vehicle through an automatic car wash
that has silicone carbide tire cleaning brushes. These
brushes can also damage the surface of these wheels.
Cleaning Tires
To clean your tires, use a stiff brush with tire cleaner.
Notice:Using petroleum-based tire dressing
products on your vehicle may damage the paint
nish and/or tires. When applying a tire dressing,
always wipe off any overspray from all painted
surfaces on your vehicle.
5-97

(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

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

Emergency Tow:Tow to the nearest dealership for
warranty service or in the event of a
vehicle-disabling accident. Assistance when the
vehicle is mired in sand, mud or snow.
Flat Tire Change:Installation of a spare tire will be
covered at no charge. (The customer is responsible
for the repair or replacement of the tire if not
covered by a warrantable failure.)
Jump Start:No-start occurrences which require a
battery jump start will be covered at no charge.
Dealer Locator Service
In many instances, mechanical failures are covered
under Chevrolet’s Bumper-to-Bumper warranty.
However, when other services are utilized, our Roadside
Assistance Representatives will explain any payment
obligations you might incur.
For prompt and efficient assistance when calling, please
provide the following to the Roadside Assistance
Representative:
Your name, home address, and home telephone
number
Telephone number of your location
Location of the vehicle
Model, year, color, and license plate number
Mileage, Vehicle Identication Number and delivery
date of the vehicle
Description of the problem
While we hope you never have the occasion to use our
service, it is added security while traveling for you
and your family. Remember, we are only a phone call
away. Chevrolet Roadside Assistance:
1-800-CHEV-USA (1-800-234-8872), text telephone
(TTY) users, call 1-888-889-2438.
Chevrolet reserves the right to limit services or
reimbursement to an owner or driver when, in
Chevrolet’s judgement, the claims become excessive in
frequency or type of occurrence.
Roadside Assistance is not part of or included in the
coverage provided by the New Vehicle Limited Warranty.
Chevrolet reserves the right to make any changes or
discontinue the Roadside Assistance program at
any time without notication.
7-7

Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
If NHTSA receives similar complaints, it may open an
investigation, and if it nds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you’ll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
7-11

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

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

Setting the Time
Radios with Radio Data Systems (RDS).........3-43
Radios without Radio Data Systems (RDS).....3-43
Setting the Tone (Bass/Treble) . . 3-44, 3-47, 3-52, 3-63
Sheet Metal Damage.......................................5-98
Shifting Into Park (P).......................................2-27
Shifting Out of Park (P)...................................2-29
Shoulder Belt Height Adjuster...........................1-17
Single Stage Air Bags.....................................1-74
Skidding........................................................4-15
Sliding Side Door............................................2-11
Some Other Rainy Weather Tips.......................4-20
Special Fabric Cleaning Problems.....................5-93
Specications, Capacities...............................5-106
Speedometer..................................................3-26
Stabilitrak
®System........................................... 4-9
Stabilitrak®System Operation...........................4-10
Stabilitrak®Indicator Light.................................3-33
Stabilitrak®Not Ready Light..............................3-33
Starting Your Engine.......................................2-21
Steering........................................................4-11
Steering in Emergencies..................................4-12
Steering Tips..................................................4-11
Steering Wheel, Tilt Wheel................................. 3-7
Storage Areas................................................2-36
Storing a Flat or Spare Tire and Tools...............5-90
Stuck in Sand, Mud, Ice or Snow......................4-31
Sun Visors.....................................................2-18
Swing-Out Side Door, 60/40.............................2-13
Swing-Out Windows........................................2-18
T
Taillamps.......................................................5-54
Theft-Deterrent, Radio.....................................3-72
Theft-Deterrent Systems...................................2-19
Passlock
®...................................................2-19
Tilt Wheel........................................................ 3-7
Tire Sidewall Labeling......................................5-58
Tire Size.......................................................5-62
Tire Terminology and Denitions........................5-64
Tires.............................................................5-58
Buying New Tires........................................5-70
Chains.......................................................5-74
Changing a Flat Tire....................................5-76
Dual Tire Operation.....................................5-67
If a Tire Goes Flat.......................................5-75
Ination - Tire Pressure................................5-66
Inspection and Rotation................................5-68
Uniform Tire Quality Grading.........................5-71
Wheel Alignment and Tire Balance.................5-72
Wheel Replacement.....................................5-72
When It Is Time for New Tires......................5-69
To Use the Engine Coolant Heater....................2-23
Top Strap......................................................1-50
Top Strap Anchor Location...............................1-51
Torque Lock...................................................2-29
Total Weight on Your Vehicle’s Tires..................4-45
Tow/Haul Mode...............................................4-39
Tow/Haul Mode Light.......................................3-40
12

Towing
Recreational Vehicle.....................................4-32
Towing a Trailer..........................................4-38
Your Vehicle...............................................4-32
Traction
Stabilitrak
®System........................................ 4-9
Traction Control Operation................................4-11
Trailer Brakes.................................................4-47
Trailer Wiring Harness.....................................4-51
Transfer Case................................................5-48
Transmission
Fluid, Automatic...........................................5-19
Transmission Operation, Automatic....................2-24
Transmission, Transaxle, Transfer Case Unit
Repair Manual............................................7-12
Transportation Options...................................... 7-8
Trip Odometer................................................3-26
Turn and Lane Change Signals.......................... 3-8
Turn Signal/Multifunction Lever........................... 3-8
Turn Signals When Towing a Trailer..................4-49
U
Understanding Radio Reception........................3-73
Uniform Tire Quality Grading............................5-71
United States – Customer Assistance.................. 7-5
Using Cleaner on Fabric..................................5-93
Using Song List Mode.....................................3-70
V
Vehicle
Control........................................................ 4-5
Damage Warnings........................................... iv
Loading......................................................4-33
Symbols......................................................... iv
Vehicle Data Collection and Event Data
Recorders..................................................7-10
Vehicle Identication
Number (VIN)............................................5-100
Service Parts Identication Label..................5-100
Vehicle Storage..............................................5-42
Ventilation Adjustment......................................3-21
Visor Vanity Mirror..........................................2-18
Visors...........................................................2-18
Voltmeter Gage..............................................3-30
W
Warning Lights, Gages and Indicators................3-24
Warnings
Hazard Warning Flashers............................... 3-6
Other Warning Devices.................................. 3-7
Safety and Symbols......................................... iii
Vehicle Damage.............................................. iv
Washing Your Vehicle......................................5-95
Weight of the Trailer........................................4-40
13