maintenance CHEVROLET EXPRESS CARGO VAN 2005 1.G User Guide

Engine Air Cleaner/Filter
The engine air cleaner/lter is located near the center of
the engine compartment. SeeEngine Compartment
Overview on page 5-12for more information on location.
When to Inspect the Engine Air
Cleaner/Filter
Inspect the air cleaner/lter at the MaintenanceII
intervals and replace it at the rst oil change after each
50,000 mile (83 000 km) interval. SeeScheduled
Maintenance on page 6-4for more information. If you
are driving in dusty/dirty conditions, inspect the lter
at each engine oil change.
How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/lter, remove the lter from
the vehicle and lightly shake the lter to release
loose dust and dirt. If the lter remains caked with dirt, a
new lter is required.
To inspect or replace the engine air cleaner/lter, do the
following:
1. Unhook the retainer clips and remove the cover.
2. Lift the lter out of the engine air cleaner/lter
housing. Care should be taken to dislodge as
little dirt as possible.
3. Clean the engine air cleaner/lter housing.
4. Inspect or replace the engine air cleaner/lter. Make
sure that the lter ts properly into the housing.
5. Reinstall the cover and fasten the retaining clips.
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SeeEngine Compartment Overview on page 5-12for
more information on location.
Flip the handle up and then pull out the dipstick and
wipe it with a clean rag or paper towel.
Push it back in all the way, wait three seconds and
then pull it back out again.
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 or cross-hatched
area for a hot check. Be sure to keep the dipstick
pointed down to get an accurate reading.
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.
How to Add Automatic Transmission
Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission uid to use. SeeRecommended
Fluids and Lubricants on page 6-13.
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 does not
take much uid, generally less than one pint (0.5 L).
Do not overll.
Notice:Use of the incorrect automatic transmission
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transmission uid listed in
Recommended Fluids and Lubricants on page 6-13.
After adding uid, recheck the uid level as
described under “How to Check Automatic
Transmission Fluid,” earlier in this section.
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.
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So, it is not a good idea to top off your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add or remove brake uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system. See “Checking Brake Fluid”
in this section.
Refer to the Maintenance Schedule to determine when
to check your brake uid. SeeScheduled Maintenance
on page 6-4.
Checking Brake Fluid
You can check the brake uid without taking off the cap.
Look at the brake uid
reservoir. The uid level
should be above MIN. If it
is not, have your brake
system checked to
see if there is a leak.
After work is done on the brake hydraulic system,
make sure the level is above the MIN but not over the
MAX mark.
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Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality GM
brake parts. When you replace parts of your braking
system — for example, when your brake linings
wear down and you need new ones put in — be sure
you get new approved GM replacement parts. If you do
not, your brakes may no longer work properly. For
example, if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change — for the worse. The braking
performance you have come to expect can change
in many other ways if someone puts in the wrong
replacement brake parts.
Battery
Your vehicle has a maintenance free battery. When it is
time for a new battery, get one that has the replacement
number shown on the original battery’s label. We
recommend an ACDelco
®replacement battery. See
Engine Compartment Overview on page 5-12for battery
location.Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days or
more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-39for tips on working around a battery
without getting hurt.
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3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the remote positive (+) terminal cover to its
original position.
All-Wheel Drive
Lubricant checks in this section also apply to these
vehicles. However, there are two additional systems that
need lubrication.
Transfer Case
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.If the level is below the bottom of the ller plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
Use care not to overtighten the plug.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
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Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.If you have the 1500 Series, the proper level is from
5/8 inch (15 mm) to 1 5/8 inch (40 mm) below the bottom
of the ller plug hole. The proper level for the 2500
and 3500 Series is from 0 to 1/4 (6 mm) below
the bottom of the ller plug hole. Add only enough uid
to reach the proper level.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
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Front Axle
When to Check and Change Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it.
SeeScheduled Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the
bottom of the ller plug
hole, you may need to add
some lubricant.
When the differential is cold, add enough lubricant to
raise the level to 3/8 inch (10 mm) below the ller
plug hole.When the differential is at operating temperature (warm),
add enough lubricant to raise the level to the bottom of
the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
Noise Control System
Tampering with Noise Control
System Prohibited
The following information relates to compliance with
federal noise emission standards for vehicles with a
Gross Vehicle Weight Rating (GVWR) of more than
10,000 lbs (4 536 kg). The Maintenance Schedule
provides information on maintaining the noise control
system to minimize degradation of the noise emission
control system during the life of your vehicle. The noise
control system warranty is given in your warranty booklet.
These standards apply only to vehicles sold in the
United States.
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Federal law prohibits the following acts or the causing
thereof:
1. The removal or rendering inoperative by any
person, other than for purposes of maintenance,
repair or replacement, of any device or element of
design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser or while it is in
use; or
2. The use of the vehicle after such device or element
of design has been removed or rendered inoperative
by any person.
Among those acts presumed to constitute tampering are
the acts listed below.
Insulation:

Removal of the noise shields or any underhood
insulation.
Engine:

Removal or rendering engine speed governor (if
equipped) inoperative so as to allow engine
speed to exceed manufacturer specications.
Fan and Drive:

Removal of fan clutch (if equipped) or rendering
clutch inoperative.
Removal of the fan shroud (if equipped).
Air Intake:

Removal of the air cleaner silencer.
Modication of the air cleaner.
Exhaust:

Removal of the muffler and/or resonator.
Removal of the exhaust pipes and exhaust pipe
clamps.
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Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking. SeeScheduled
Maintenance on page 6-4for more information on wiper
blade inspection.
Replacement blades come in different types and are
removed in different ways. To remove the type with a
release clip, do the following:
1. Lift the wiper arm until it locks into a vertical position.2. Press down on the blade assembly pivot locking
tab. Pull down on the blade assembly to release it
from the wiper arm hook.
3. The insert has two notches at one end that are
locked by bottom claws of the blade assembly.
At the notched end, pull the insert from the blade
assembly.
4. To install the new wiper insert, slide the notched
end last, into the end with two blade claws. Then
slide the insert all the way through the blade claws
at the opposite end.
5. Make sure that the notches are locked by the
bottom claws. Make sure that all other claws
are properly locked on both sides of the insert slot.
6. Put the blade assembly pivot in the wiper arm hook.
Pull it up until the pivot locking tab locks in the
hook slot.
7. Carefully lower the wiper arm and blade assembly
into the windshield.
5-52

Dual Tire Operation
When the vehicle is new, or whenever a wheel, wheel
bolt or wheel nut is replaced, check the wheel nut torque
after 100, 1,000 and 6,000 miles (160, 1 600 and
10 000 km) of driving. For proper wheel nut tightening
information, see “Removing the Flat Tire and Installing
the Spare Tire” later in this section, underChanging
a Flat Tire on page 5-70. Also see “Wheel Nut Torque”
underCapacities and Specications on page 5-100.
The outer tire on a dual wheel setup generally wears
faster than the inner tire. Your tires will wear more
evenly and last longer if you rotate the tires periodically.
SeeTire Inspection and Rotation on page 5-62. Also
seeScheduled Maintenance on page 6-4.
{CAUTION:
If you operate your vehicle with a tire that is
badly underinated, the tire can overheat. An
overheated tire can lose air suddenly or catch
re. You or others could be injured. Be sure all
tires (including the spare) are properly inated.
SeeTires on page 5-53andInation - Tire Pressure on
page 5-60for more information on proper tire ination.
Tire Inspection and Rotation
Tires should be rotated every 5,000 to 8,000 miles
(8 000 to 13 000 km).
Any time you notice unusual wear, rotate your tires as
soon as possible and check wheel alignment. Also
check for damaged tires or wheels. SeeWhen It Is Time
for New Tires on page 5-64andWheel Replacement
on page 5-67for more information.
Make sure the spare tire is stored securely. Push, pull,
and then try to rotate or turn the tire. If it moves,
use the ratchet/wheel wrench to tighten the cable. See
Changing a Flat Tire on page 5-70.
If your vehicle has dual rear wheels, also seeDual Tire
Operation on page 5-62.
The purpose of regular rotation is to achieve more
uniform wear for all tires on the vehicle. The rst rotation
is the most important. SeeScheduled Maintenance
on page 6-4.
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