Fuel CHEVROLET EXPRESS CARGO VAN 2004 1.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-34
Air Bag System
.......................................1-70
Restraint System Check
............................1-81
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-19
Starting and Operating Your Vehicle
...........2-20
Mirrors
....................................................2-32
OnStar
®System
......................................2-35
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-24
Audio System(s)
.......................................3-42
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-32Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under
the Hood
.............................................5-10
All-Wheel Drive
........................................5-48
Rear Axle
...............................................5-49
Front Axle
...............................................5-50
Noise Control System
...............................5-51
Bulb Replacement
....................................5-52
Windshield Wiper Blade Replacement
.........5-56
Tires
......................................................5-58
Appearance Care
.....................................5-92
Vehicle Identication
...............................5-100
Electrical System
....................................5-101
Capacities and Specications
...................5-106
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2004 Chevrolet Express Owner ManualM

Theft-Deterrent Systems
Vehicle theft is a big business, especially in some cities.
Although your vehicle has a number of theft-deterrent
features, we know that nothing we put on it can make it
impossible to steal. However, there are ways you
can help.
Passlock®
Your vehicle is equipped with the Passlock®
theft-deterrent system.
Passlock
®is a passive theft-deterrent system. Passlock®
enables fuel if the ignition lock cylinder is turned with
a valid key. If a correct key is not used or the ignition
lock cylinder is tampered with, fuel is disabled.
During normal operation, the SECURITY light will go off
approximately ve seconds after the key is turned
to RUN.If the engine stalls and the SECURITY light ashes,
wait until the light stops ashing before trying to restart
the engine. Remember to release the key from
START as soon as the engine starts.
If the engine is running and the SECURITY light comes
on, you will be able to restart the engine if you turn
the engine off. However, your Passlock
®system is not
working properly and must be serviced by your
dealer. Your vehicle is not protected by Passlock
®at
this time. You may also want to check the fuse.
SeeFuses and Circuit Breakers on page 5-102. See
your dealer for service.
2-19

1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as
your engine gets warm.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about
15 seconds between each try to help avoid draining
your battery or damaging your starter.
2. If it doesn’t start within 10 seconds, push the
accelerator pedal all the way to the oor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.
When starting your engine in very cold weather (below
0°F or−18°C), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go
of the key.2. If your engine still won’t start (or starts but then
stops), it could be ooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
oor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the
vehicle starts briey but then stops again, do the
same thing, but this time keep the pedal down
for ve or six seconds. This clears the extra
gasoline from the engine.
Notice:Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer. If you do not, your engine
might not perform properly.
Fuel Regulator
You have a fuel regulator that shuts the fuel off when
the engine reaches 5,600 rpm.
2-22

Engine Coolant Heater
In very cold weather, 0°F (−18°C) or colder, the engine
coolant heater can help. You’ll get easier starting
and better fuel economy during engine warm-up.
Usually, the coolant heater should be plugged in a
minimum of four hours prior to starting your vehicle.
At temperatures above 32°F (0°C), use of the coolant
heater is not required.
To Use the Engine Coolant Heater
1. Turn off the engine.
2. Open the hood and unwrap the electrical cord.
The cord for the engine coolant heater is located
on the driver’s side of the engine compartment and
is attached to the hose for the power steering
reservoir.
3. Plug it into a normal, grounded 110-volt AC outlet.
{CAUTION:
Plugging the cord into an ungrounded outlet
could cause an electrical shock. Also, the
wrong kind of extension cord could overheat
and cause a re. You could be seriously
injured. Plug the cord into a properly grounded
three-prong 110-volt AC outlet. If the cord will
not reach, use a heavy-duty three-prong
extension cord rated for at least 15 amps.
4. Before starting the engine, be sure to unplug and
store the cord as it was before to keep it away
from moving engine parts. If you don’t, it could be
damaged.
How long should you keep the coolant heater plugged
in? The answer depends on the outside temperature, the
kind of oil you have, and some other things. Instead
of trying to list everything here, we ask that you contact
your dealer in the area where you’ll be parking your
vehicle. The dealer can give you the best advice for that
particular area.
2-23

{CAUTION:
Shifting into a drive gear while your engine is
running at high speed is dangerous. Unless
your foot is rmly on the brake pedal, your
vehicle could move very rapidly. You could lose
control and hit people or objects. Do not shift
into a drive gear while your engine is running at
high speed.
Notice:Shifting out of PARK (P) or NEUTRAL (N)
with the engine running at high speed may damage
the transmission. The repairs would not be
covered by your warranty. Be sure the engine is not
running at high speed when shifting your vehicle.
DRIVE (D):This position is for normal driving. If
you need more power for passing, and you’re:
Going less than about 35 mph (55 km/h), push your
accelerator pedal about halfway down.
Going about 35 mph (55 km/h) or more, push the
accelerator all the way down.
You’ll shift down to the next gear and have more power.THIRD (3):This position is also used for normal
driving, however, it offers more power and lower fuel
economy than DRIVE (D). You should use THIRD (3)
when carrying a heavy load or driving on steep hills.
You should use THIRD (3) (or, as you need to, a lower
gear) when towing a trailer to minimize heat build-up
and extend the life of your transmission.
SECOND (2):This position gives you more power but
lower fuel economy than THIRD (3). You can use
SECOND (2) on hills. It can help control your speed as
you go down steep mountain roads, but then you
would also want to use your brakes off and on. If you
manually select SECOND (2), the transmission will drive
in SECOND (2). You may use this feature for reducing
torque to the rear wheels when you are trying to
start your vehicle from a stop on slippery road surfaces.
FIRST (1):This position gives you even more power
but lower fuel economy than SECOND (2). You can use
it on very steep hills, or in deep snow or mud. If the
shift lever is put in FIRST (1), the transmission
won’t shift into rst gear until the vehicle is going slowly
enough.
Notice:Spinning the tires or holding the vehicle in
one place on a hill using only the accelerator
pedal may damage the transmission. If you are
stuck, do not spin the tires. When stopping on a hill,
use the brakes to hold the vehicle in place.
2-25

Instrument Panel Overview...............................3-4
Hazard Warning Flashers................................3-6
Other Warning Devices...................................3-7
Horn.............................................................3-7
Tilt Wheel.....................................................3-7
Turn Signal/Multifunction Lever.........................3-8
Exterior Lamps.............................................3-14
Interior Lamps..............................................3-16
Accessory Power Outlets...............................3-18
Ashtrays and Cigarette Lighter........................3-18
Climate Controls............................................3-19
Climate Control System.................................3-19
Outlet Adjustment.........................................3-21
Rear Heating System....................................3-22
Rear Air Conditioning and Heating System.......3-22
Warning Lights, Gages, and Indicators............3-24
Instrument Panel Cluster................................3-25
Speedometer...............................................3-26
Safety Belt Reminder Light.............................3-27Air Bag Readiness Light................................3-27
Air Bag Off Light..........................................3-28
Charging System Light..................................3-30
Voltmeter Gage............................................3-30
Brake System Warning Light..........................3-31
Anti-Lock Brake System Warning Light.............3-32
Stabilitrak
®Not Ready Light...........................3-33
Stabilitrak®Indicator Light...............................3-33
Engine Coolant Temperature Gage..................3-34
Malfunction Indicator Lamp.............................3-34
Oil Pressure Gage........................................3-37
Change Engine Oil Light................................3-38
Security Light...............................................3-39
Cruise Control Light......................................3-39
Reduced Engine Power Light.........................3-40
Daytime Running Lamps Indicator Light...........3-40
Tow/Haul Mode Light....................................3-40
Check Gages Warning Light...........................3-41
Fuel Gage...................................................3-41
Section 3 Instrument Panel
3-1

Instrument Panel Cluster
The instrument panel cluster is designed to let you know at a glance how the vehicle is running. You will know how
fast you are going, how much fuel you are using, and many other things you will need to know to drive safely
and economically.United States version shown, Canada similar
3-25

Engine Coolant Temperature Gage
This gage shows the engine coolant temperature.
If the gage pointer moves into the red area your engine
is too hot!
It means that your engine coolant has overheated.
If you have been operating your vehicle under normal
operating conditions, you should pull off the road, stop
your vehicle, and turn off the engine as soon as possible.
SeeEngine Overheating on page 5-26.
Malfunction Indicator Lamp
Check Engine Light
Your vehicle is equipped
with a computer which
monitors operation of the
fuel, ignition, and emission
control systems.
This system is called OBD II (On-Board Diagnostics-
Second Generation) and is intended to assure that
emissions are at acceptable levels for the life of the
vehicle, helping to produce a cleaner environment.
The Check Engine light comes on to indicate that there is
a problem and service is required. Malfunctions often will
be indicated by the system before any problem is
apparent. This may prevent more serious damage to your
vehicle. This system is also designed to assist your
service technician in correctly diagnosing any
malfunction. United States
Canada
3-34

Notice:If you keep driving your vehicle with this
light on, after a while, your emission controls
may not work as well, your fuel economy may not
be as good, and your engine may not run as
smoothly. This could lead to costly repairs that may
not be covered by your warranty.
Notice:Modications made to the engine,
transmission, exhaust, intake, or fuel system of
your vehicle or the replacement of the original tires
with other than those of the same Tire Performance
Criteria (TPC) can affect your vehicle’s emission
controls and may cause this light to come on.
Modications to these systems could lead to costly
repairs not covered by your warranty. This may
also result in a failure to pass a required Emission
Inspection/Maintenance test.
This light should come on, as a check to show you it is
working, when the ignition is on and the engine is
not running. If the light does not come on, have it
repaired. This light will also come on during a
malfunction in one of two ways:
Light Flashing— A misre condition has been
detected. A misre increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
Light On Steady— An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
Reducing vehicle speed
Avoiding hard accelerations
Avoiding steep uphill grades
If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible
If the light stops ashing and remains on steady, see “If
the Light Is On Steady” following.
If the light continues to ash, when it is safe to do so,
stop the vehicle. Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see “If
the Light Is On Steady” following. If the light is still
ashing, follow the previous steps, and see your dealer
for service as soon as possible.
3-35

If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. SeeFilling Your Tank on page 5-8. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel. See
Gasoline Octane on page 5-5. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, misring, hesitation
on acceleration, or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.
If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to x any
mechanical or electrical problems that may have
developed.
3-36