2004 Chevrolet Express Owners Manual

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Axle Ratio Maximum Trailer Weight GCWR G3500 Cargo Van 2WD Short Wheelbase 3.73 4.10 8,300 lbs. (3 765 kg) 10,000 lbs. (4 536 kg) 14,000 lbs. (6 350 kg) 16,000 lbs. (7 257 kg) 4300 V6 4800 V8 5300 V8 6000 V8 6000 V8 6000 V8 6000 V8 4-42 Vehicle Axle Ratio Maximum Trailer Weight GCWR G3500 Cargo Van 2WD Long Wheelbase 3.73 4.10 8,100 lbs. (3 674 kg) 10,000 lbs. (4 536 kg) 14,000 lbs. (6 350 kg) 16,000 lbs. (7 257 kg) Vehicle Axle Ratio Maximum Trailer Weight GCWR G3500 Passenger Van 2WD Short Wheelbase 3.73 4.10 7,800 lbs. (3 538 kg) 9,800 lbs. (4 445 kg) 14,000 lbs. (6 350 kg) 16,000 lbs. (7 257 kg) Vehicle Axle Ratio Maximum Trailer Weight GCWR G3500 Passenger Van 2WD Long Wheelbase 3.73 4.10 7,400 lbs. (3 357 kg) 9,400 lbs. (4 264 kg) 14,000 lbs. (6 350 kg) 16,000 lbs. (7 257 kg) 6000 V8 6000 V8 6000 V8 The Gross Combined Weight Rating (GCWR) is the total allowable weight of the completely loaded vehicle and trailer including any passengers, cargo equipment and conversion. The GCWR for your vehicle should not be exceeded. You can ask your dealer for our trailering information or advice, or you can write us at the address listed in your Warranty and Owner Assistance Information Booklet. In Canada, write to: General Motors of Canada Limited Customer Communication Centre, 163-005 1908 Colonel Sam Drive Oshawa, Ontario L1H 8P7 4-43 Weight of the Trailer Tongue The tongue load (A) of any trailer is an important weight to measure because it affects the total or gross weight of your vehicle. The Gross Vehicle Weight (GVW) includes the curb weight of the vehicle, any cargo you may carry in it, and the people who will be riding in the vehicle. If you have a lot of options, equipment, passengers or cargo in your vehicle, it will reduce the tongue weight your vehicle can carry, which will also reduce the trailer weight your vehicle can tow. And if you will tow a trailer, you must add the tongue load to the GVW because your vehicle will be carrying that weight, too. See Loading Your Vehicle on page 4-31 about your vehicle’s maximum load capacity. 4-44 The trailer tongue weight (A) should be 10 percent to 15 percent of the total loaded trailer weight, up to a maximum of 400 lbs (181 kg) with a weight carrying hitch. The trailer tongue weight (A) should be 10 percent to 15 percent of the total loaded trailer weight, up to a maximum of 1 000 lbs (454 kg) with a weight distributing hitch. Do not exceed the maximum allowable tongue weight for your vehicle. Choose the shortest hitch extension that will position the hitch ball closest to the vehicle. This will help reduce the effect of trailer tongue weight on the rear axle. After you’ve loaded your trailer, weigh the trailer and then the tongue, separately, to see if the weights are proper. If they aren’t, you may be able to get them right simply by moving some items around in the trailer. Total Weight on Your Vehicle’s Tires Be sure your vehicle’s tires are inﬂated to the upper limit for cold tires. You’ll ﬁnd these numbers on the Certiﬁcation label at the rear edge of the driver’s door or see Loading Your Vehicle on page 4-31. Then be sure you don’t go over the GVW limit for your vehicle, or the GAWR, including the weight of the trailer tongue. If you use a weight distributing hitch, make sure you don’t go over the rear axle limit before you apply the weight distribution spring bars. Hitches It’s important to have the correct hitch equipment. Crosswinds, large trucks going by and rough roads are a few reasons why you’ll need the right hitch. 4-45 Weight-Distributing Hitches and Weight Carrying Hitches (A) Body to Ground Distance, (B) Front of Vehicle When using a weight-distributing hitch, the hitch must be adjusted so that the distance (A) remains the same both before and after coupling the trailer to the tow vehicle. 4-46 If you use a step-bumper hitch, your bumper could be damaged in sharp turns. Make sure you have ample room when turning to avoid contact between the trailer and the bumper. If you’ll be pulling a trailer that, when loaded, will weigh more than 5,000 lbs (2 270 kg), be sure to use a properly mounted weight-distributing hitch and sway control of the proper size. This equipment is very important for proper vehicle loading and good handling when you’re driving. You should always use a sway control if your trailer will weigh more than these limits. You can ask a hitch dealer about sway controls. Will you have to make any holes in the body of your vehicle when you install a trailer hitch? If you’re using the wiring provided with the factory-installed trailering package, you should not need to make any holes in the body of your vehicle. However, if you have an aftermarket hitch installed, you may need to make holes in the body. If you do, then be sure to seal the holes later when you remove the hitch. If you don’t seal them, deadly carbon monoxide (CO) from your exhaust can get into your vehicle as well as dirt and water. See “Carbon Monoxide” under Engine Exhaust on page 2-30. Safety Chains You should always attach chains between your vehicle and your trailer. Cross the safety chains under the tongue of the trailer to help prevent the tongue from contacting the road if it becomes separated from the hitch. Instructions about safety chains may be provided by the hitch manufacturer or by the trailer manufacturer. Follow the manufacturer’s recommendation for attaching safety chains and do not attach them to the bumper. Always leave just enough slack so you can turn with your rig. Never allow safety chains to drag on the ground. Trailer Brakes If your trailer weighs more than 1,000 lbs (450 kg) loaded, then it needs its own brakes – and they must be adequate. Be sure to read and follow the instructions for the trailer brakes so you’ll be able to install, adjust and maintain them properly. Since your vehicle is equipped with Stabilitrak®, your trailer brake system cannot tap into the vehicle’s hydraulic brake system. 4-47 Towing a trailer requires a certain amount of experience. Before setting out for the open road, you’ll want to get to know your rig. Acquaint yourself with the feel of handling and braking with the added weight of the trailer. And always keep in mind that the vehicle you are driving is now a good deal longer and not nearly as responsive as your vehicle is by itself. Before you start, check all trailer hitch parts and attachments, safety chains, electrical connector, lamps, tires and mirror adjustment. If the trailer has electric brakes, start your vehicle and trailer moving and then apply the trailer brake controller by hand to be sure the brakes are working. This lets you check your electrical connection at the same time. During your trip, check occasionally to be sure that the load is secure, and that the lamps and any trailer brakes are still working. Driving with a Trailer {CAUTION: If you have a rear-most window open and you pull a trailer with your vehicle, carbon monoxide (CO) could come into your vehicle. You can not see or smell CO. It can cause unconsciousness or death. See Engine Exhaust on page 2-30. To maximize your safety when towing a trailer: (cid:127) Have your exhaust system inspected for leaks, and make necessary repairs before starting on your trip. (cid:127) Keep the rear-most windows closed. If exhaust does come into your vehicle through a window in the rear or another opening, drive with your front, main heating or cooling system on and with the fan on any speed. This will bring fresh, outside air into your vehicle. Do not use the climate control setting for maximum air because it only recirculates the air inside your vehicle. See Climate Control System in the Index. 4-48 (cid:127) Following Distance Stay at least twice as far behind the vehicle ahead as you would when driving your vehicle without a trailer. This can help you avoid situations that require heavy braking and sudden turns. Passing You’ll need more passing distance up ahead when you’re towing a trailer. And, because you’re a good deal longer, you’ll need to go much farther beyond the passed vehicle before you can return to your lane. Backing Up Hold the bottom of the steering wheel with one hand. Then, to move the trailer to the left, just move that hand to the left. To move the trailer to the right, move your hand to the right. Always back up slowly and, if possible, have someone guide you. Making Turns Notice: Making very sharp turns while trailering could cause the trailer to come in contact with the vehicle. Your vehicle could be damaged. Avoid making very sharp turns while trailering. When you’re turning with a trailer, make wider turns than normal. Do this so your trailer won’t strike soft shoulders, curbs, road signs, trees or other objects. Avoid jerky or sudden maneuvers. Signal well in advance. Turn Signals When Towing a Trailer When you tow a trailer, your vehicle has to have extra wiring and a heavy-duty turn signal ﬂasher (included in the optional trailering package). The arrows on your instrument panel will ﬂash whenever you signal a turn or lane change. Properly hooked up, the trailer lamps will also ﬂash, telling other drivers you’re about to turn, change lanes or stop. When towing a trailer, the arrows on your instrument panel will ﬂash for turns even if the bulbs on the trailer are burned out. Thus, you may think drivers behind you are seeing your signal when they are not. It’s important to check occasionally to be sure the trailer bulbs are still working. 4-49 Driving On Grades Reduce speed and shift to a lower gear before you start down a long or steep downgrade. If you don’t shift down, you might have to use your brakes so much that they would get hot and no longer work well. You can tow in DRIVE (D). You may want to shift the transmission to THIRD (3) or a lower gear under heavy loads and/or hilly conditions. When towing at high altitude on steep uphill grades, consider the following: Engine coolant will boil at a lower temperature than at normal altitudes. If you turn your engine off immediately after towing at high altitude on steep uphill grades, your vehicle may show signs similar to engine overheating. To avoid this, let the engine run while parked (preferably on level ground) with the automatic transmission in PARK (P) for a few minutes before turning the engine off. If you do get the overheat warning, see Engine Overheating on page 5-26. Parking on Hills {CAUTION: You really should not park your vehicle, with a trailer attached, on a hill. If something goes wrong, your rig could start to move. People can be injured, and both your vehicle and the trailer can be damaged. But if you ever have to park your rig on a hill, here’s how to do it: 1. Apply your regular brakes, but don’t shift into PARK (P) yet. Then turn your wheels into the curb if facing downhill or into traffic if facing uphill. 2. Have someone place chocks under the trailer wheels. 3. When the wheel chocks are in place, release the regular brakes until the chocks absorb the load. 4. Reapply the regular brakes. Then apply your parking brake and then shift to PARK (P). 5. Release the regular brakes. 4-50 When You Are Ready to Leave After Parking on a Hill 1. Apply your regular brakes and hold the pedal down while you: start your engine, shift into a gear, and release the parking brake. 2. Let up on the brake pedal. 3. Drive slowly until the trailer is clear of the chocks. 4. Stop and have someone pick up and store the chocks. Maintenance When Trailer Towing Your vehicle will need service more often when you’re pulling a trailer. See the Maintenance Schedule for more on this. Things that are especially important in trailer operation are automatic transmission ﬂuid (don’t overﬁll), engine oil, axle lubricant, belt, cooling system and brake system. Each of these is covered in this manual, and the Index will help you ﬁnd them quickly. If you’re trailering, it’s a good idea to review these sections before you start your trip. Check periodically to see that all hitch nuts and bolts are tight. 4-51 (cid:127) (cid:127) (cid:127) Trailer Wiring Harness The optional heavy-duty trailer wiring package includes a seven-wire harness assembly at the rear of the vehicle and a four-wire harness assembly under the left hand side of the instrument panel. The seven-wire harness assembly is taped together and located in a frame pocket at the driver side rear left corner of the frame. The seven-wire harness includes a 30-amp feed wire. Both harnesses come without connectors and should be wired by a qualiﬁed electrical technician. The technician can use the following color code chart when connecting the wiring harness to your trailer and trailer brake controller. Seven-Wire Harness Light Green: Back-up lamps (cid:127) Brown: Parking lamps (cid:127) Yellow: Left stoplamp and turn signal (cid:127) Dark Green: Right stoplamp and turn signal (cid:127) Dark Blue: Use for electric trailer brakes (cid:127) Orange: Trailer accessory (cid:127) White (heavy gage): Ground wire Four-Wire Harness (Trailer Brake Controller) (cid:127) Black: Ground (cid:127) Red/White Stripe: Fused Battery (cid:127) Dark Blue: Trailer Brake Feed Light Blue: Fused Stop/CHMSL 4-52 (cid:127) (cid:127) Section 5 Service and Appearance Care Service ............................................................5-3 Doing Your Own Service Work .........................5-3 Adding Equipment to the Outside of Your Vehicle ......................................................5-4 Fuel ................................................................5-4 Gasoline Octane ............................................5-4 Gasoline Speciﬁcations ....................................5-5 California Fuel ...............................................5-5 Additives .......................................................5-6 Fuels in Foreign Countries ...............................5-6 Filling Your Tank ............................................5-7 Filling a Portable Fuel Container .......................5-9 Checking Things Under the Hood .....................5-9 Hood Release ..............................................5-10 Engine Compartment Overview .......................5-12 Engine Oil ...................................................5-13 Engine Air Cleaner/Filter ................................5-18 Automatic Transmission Fluid .........................5-19 Engine Coolant .............................................5-22 Radiator Pressure Cap ..................................5-25 Engine Overheating .......................................5-26 Cooling System ............................................5-28 Engine Fan Noise .........................................5-37 Power Steering Fluid .....................................5-37 Windshield Washer Fluid ................................5-38 Brakes ........................................................5-40 Battery ........................................................5-43 Jump Starting ...............................................5-44 All-Wheel Drive ..............................................5-49 Rear Axle .......................................................5-50 Front Axle ......................................................5-51 Noise Control System .....................................5-52 Tampering with Noise Control System Prohibited .................................................5-52 Bulb Replacement ..........................................5-53 Halogen Bulbs ..............................................5-53 Headlamps ..................................................5-53 Front Turn Signal, Sidemarker and Parking Lamps .....................................................5-55 Taillamps .....................................................5-55 Replacement Bulbs .......................................5-57 Windshield Wiper Blade Replacement ..............5-58 5-1 Section 5 Service and Appearance Care Tires ..............................................................5-59 Inﬂation - Tire Pressure .................................5-67 Dual Tire Operation .......................................5-68 Tire Inspection and Rotation ...........................5-68 When It Is Time for New Tires .......................5-70 Buying New Tires .........................................5-71 Uniform Tire Quality Grading ..........................5-72 Wheel Alignment and Tire Balance ..................5-73 Wheel Replacement ......................................5-74 Tire Chains ..................................................5-75 If a Tire Goes Flat ........................................5-76 Changing a Flat Tire .....................................5-77 Appearance Care ............................................5-92 Cleaning the Inside of Your Vehicle .................5-92 Care of Safety Belts ......................................5-95 Weatherstrips ...............................................5-95 Cleaning the Outside of Your Vehicle ..............5-95 Sheet Metal Damage .....................................5-98 Finish Damage .............................................5-98 Underbody Maintenance ................................5-98 Chemical Paint Spotting .................................5-98 Vehicle Care/Appearance Materials ..................5-99 Vehicle Identiﬁcation .....................................5-100 Vehicle Identiﬁcation Number (VIN) ................5-100 Service Parts Identiﬁcation Label ...................5-100 Electrical System ..........................................5-101 Add-On Electrical Equipment .........................5-101 Headlamp Wiring ........................................5-101 Windshield Wiper Fuses ...............................5-101 Fuses and Circuit Breakers ..........................5-102 Capacities and Speciﬁcations ........................5-106 5-2 Service Your dealer knows your vehicle best and wants you to be happy with it. We hope you will go to your dealer for all your service needs. You will get genuine GM parts and GM-trained and supported service people. We hope you will want to keep your GM vehicle all GM. Genuine GM parts have one of these marks: Doing Your Own Service Work If you want to do some of your own service work, you will want to use the proper service manual. It tells you much more about how to service your vehicle than this manual can. To order the proper service manual, see Service Publications Ordering Information on page 7-11. Your vehicle may have an air bag system. If it does, see Servicing Your Air Bag-Equipped Vehicle on page 1-75 before attempting to do your own service work. You should keep a record with all parts receipts and list the mileage and the date of any service work you perform. See Maintenance Record on page 6-18. {CAUTION: You can be injured and your vehicle could be damaged if you try to do service work on a vehicle without knowing enough about it. (cid:127) Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. CAUTION: (Continued) 5-3 CAUTION: (Continued) (cid:127) Be sure to use the proper nuts, bolts and other fasteners. “English” and “metric” fasteners can be easily confused. If you use the wrong fasteners, parts can later break or fall off. You could be hurt. Adding Equipment to the Outside of Your Vehicle Things you might add to the outside of your vehicle can affect the airﬂow around it. This may cause wind noise and affect windshield washer performance. Check with your dealer before adding equipment to the outside of your vehicle. Fuel Use of the recommended fuel is an important part of the proper maintenance of your vehicle. Gasoline Octane Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and hear heavy knocking, your engine needs service. 5-4 Gasoline Speciﬁcations It is recommended that gasoline meet speciﬁcations which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org. Gasoline meeting these speciﬁcations could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the “Auto Makers’ Choice” label on the pump. California Fuel If your vehicle is certiﬁed to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California speciﬁcations. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal speciﬁcations, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp on page 3-36 ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. Canada Only 5-5 Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. Fuels in Foreign Countries If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to ﬁnd. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Additives To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasolines contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasolines that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area to contribute to clean air. General Motors recommends that you use these gasolines, particularly if they comply with the speciﬁcations described earlier. Notice: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. 5-6 Filling Your Tank {CAUTION: Fuel vapor is highly ﬂammable. It burns violently, and that can cause very bad injuries. Do not smoke if you are near fuel or refueling your vehicle. Keep sparks, ﬂames and smoking materials away from fuel. The fuel cap is located behind a hinged door on the driver’s side of your vehicle. To remove the fuel cap, turn it slowly to the left (counterclockwise). While refueling, place the fuel cap in the holder provided. 5-7 {CAUTION: If you get fuel on yourself and then something ignites it, you could be badly burned. Fuel can spray out on you if you open the fuel cap too quickly. This spray can happen if your tank is nearly full, and is more likely in hot weather. Open the fuel cap slowly and wait for any “hiss” noise to stop. Then unscrew the cap all the way. Be careful not to spill fuel. Clean fuel from painted surfaces as soon as possible. See Cleaning the Outside of Your Vehicle on page 5-95. When ﬁlling the tank do not overﬁll by squeezing in much more fuel after the pump shuts off. When you put the fuel cap back on, turn it to the right (clockwise) until you hear a clicking sound. Make sure you fully install the cap. The diagnostic system can determine if the fuel cap has been left off or improperly installed. This would allow fuel to evaporate into the atmosphere. See Malfunction Indicator Lamp on page 3-36. Notice: the right type. Your dealer can get one for you. If you get the wrong type, it may not ﬁt properly. This may cause your malfunction indicator lamp to light and may damage your fuel tank and emissions system. See Malfunction Indicator Lamp on page 3-36. If you need a new fuel cap, be sure to get 5-8 Filling a Portable Fuel Container {CAUTION: Never ﬁll a portable fuel container while it is in your vehicle. Static electricity discharge from the container can ignite the gasoline vapor. You can be badly burned and your vehicle damaged if this occurs. To help avoid injury to you and others: (cid:127) Dispense gasoline only into approved containers. (cid:127) Do not ﬁll a container while it is inside a vehicle, in a vehicle’s trunk, pickup bed or on any surface other than the ground. (cid:127) Bring the ﬁll nozzle in contact with the inside of the ﬁll opening before operating the nozzle. Contact should be maintained until the ﬁlling is complete. (cid:127) Do not smoke while pumping gasoline. Checking Things Under the Hood {CAUTION: Things that burn can get on hot engine parts and start a ﬁre. These include liquids like fuel, oil, coolant, brake ﬂuid, windshield washer and other ﬂuids, and plastic or rubber. You or others could be burned. Be careful not to drop or spill things that will burn onto a hot engine. 5-9 Hood Release To open the hood, do the following: 1. Pull this handle inside the vehicle. It is located in front of the driver’s side door frame near the ﬂoor. 5-10 2. Then go to the front of the vehicle and lift up the secondary hood release underneath the middle of the hood. 3. Lift the hood. 4. Release the hood prop from its retainer and put the hood prop into the slot in the hood hinge on the driver’s side. If your vehicle has an underhood lamp, it will automatically come on and stay on until the hood is closed. Before closing the hood, be sure all of the ﬁller caps are on properly. Then lift the hood to relieve pressure on the hood prop. Remove the hood prop from the slot in the hood and return the prop to its retainer. then let the hood down and close it ﬁrmly. 5-11 Engine Compartment Overview When you lift the hood, you’ll see these items: 5-12 A. Battery. See Battery on page 5-43. B. Radiator Pressure Cap. See Radiator Pressure Cap on page 5-25. C. Coolant Recovery Tank. See Cooling System on page 5-28. D. Transmission Fluid Dipstick. See Automatic Transmission Fluid on page 5-19. E. Engine Oil Fill. See Engine Oil on page 5-13. F. Engine Oil Dipstick. See Engine Oil on page 5-13. G. Air Filter Restriction Indicator. See Engine Air Cleaner/Filter on page 5-18. H. Engine Air Cleaner/Filter. See Engine Air Cleaner/Filter on page 5-18. I. Power Steering Reservoir. See Power Steering Fluid on page 5-37. J. Brake Master Cylinder. See Brakes on page 5-40. K. Windshield Washer Fluid. See Windshield Washer Fluid on page 5-38. Engine Oil Checking Engine Oil It is a good idea to check your engine oil every time you get fuel. In order to get an accurate reading, the oil must be warm and the vehicle must be on level ground. The engine oil dipstick handle is a yellow loop. See Engine Compartment Overview on page 5-12 for the location of the engine oil dipstick. Turn off the engine and give the oil several minutes to drain back into the oil pan. If you don’t, the oil dipstick might not show the actual level. Pull out the dipstick and clean it with a paper towel or cloth, then push it back in all the way. Remove it again, keeping the tip down, and check the level. 5-13 What Kind of Engine Oil to Use Look for two things: (cid:127) GM6094M Your vehicle’s engine requires oil meeting GM Standard GM6094M. You should look for and use only an oil that meets GM Standard GM6094M. When to Add Engine Oil If the oil is at or below the cross-hatched area at the tip of the dipstick, then you will need to add at least one quart of oil. But you must use the right kind. This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities and Speciﬁcations on page 5-106. Notice: Do not add too much oil. If your engine has so much oil that the oil level gets above the cross-hatched area that shows the proper operating range, your engine could be damaged. See Engine Compartment Overview on page 5-12 for the location of the engine oil ﬁll cap. Be sure to add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when you are through. 5-14 (cid:127) SAE 5W-30 As shown in the viscosity chart, SAE 5W-30 is best for your vehicle. However, if it is going to be 0°F (–18°C) or above and SAE 5W-30 is not available, you may use SAE 10W-30. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certiﬁed by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identiﬁed as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. 5-15 Notice: Use only engine oil identiﬁed as meeting GM Standard GM6094M and showing the American Petroleum Institute Certiﬁed For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below −20°F (−29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. Engine Oil Additives Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. When to Change Engine Oil (GM Oil Life System) Your vehicle has a computer system that lets you know when to change the engine oil and ﬁlter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A Change Engine Oil light will come on. Change your oil as soon as possible within the next two times you stop for fuel. It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and ﬁlter must be changed at least once a year and at this time the system must be reset. Your dealer has GM-trained service people who will perform this work using genuine GM parts and reset the system. It is also important to check your oil regularly and keep it at the proper level. If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. 5-16 How to Reset the Change Engine Oil Light The GM Oil Life System calculates when to change your engine oil and ﬁlter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a Change Engine Oil light being turned on, reset the system. To reset the Change Engine Oil light, do the following: 1. Turn the ignition key to RUN with the engine off. 2. Fully press and release the accelerator pedal slowly three times within ﬁve seconds. 3. If the Change Engine Oil light ﬂashes for ﬁve seconds, the system is reset. 4. Turn the key to LOCK. If the Change Engine Oil light comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does not reset, see your dealer for service. See Change Engine Oil Light on page 3-39. What to Do with Used Oil Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer’s warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the ﬁlter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. 5-17 Engine Air Cleaner/Filter See Engine Compartment Overview on page 5-12 for the location of the engine air cleaner/ﬁlter and change indicator (if equipped). How to Inspect the Engine Air Cleaner/Filter To inspect the air cleaner/ﬁlter, remove the ﬁlter from the vehicle and lightly shake ﬁlter to release loose dust and dirt. If the ﬁlter remains caked with dirt, a new ﬁlter is required. To remove and reinstall the ﬁlter and reset the indicator (if equipped), do the following: When to Inspect the Engine Air Cleaner/Filter If your vehicle is equipped with a ﬁlter change indicator it will let you know when the ﬁlter needs to be replaced. Inspect the air cleaner/ﬁlter restriction indicator at every oil change and replace the ﬁlter when the indicator tells you to. When the change indicator turns black or is in the red/orange change zone, change the ﬁlter and reset the indicator. Vehicles without a change indicator, inspect the air cleaner/ﬁlter at every oil change and replace at the ﬁrst oil change after 25,000 miles (40,000 km). 5-18 The engine air cleaner/ﬁlter is located near the center of the engine compartment. 1. Unhook the retainer clips and remove the cover. 2. Lift the ﬁlter out of the engine air cleaner/ﬁlter housing. Care should be taken to dislodge as little dirt as possible. 3. Clean the engine air cleaner/ﬁlter housing. 4. Install the new engine air cleaner/ﬁlter into the engine air cleaner/ﬁlter housing. Make sure that it ﬁts properly into the housing. 5. Reinstall the cover and fasten the retaining clips. {CAUTION: Operating the engine with the air cleaner/ﬁlter off can cause you or others to be burned. The air cleaner not only cleans the air, it helps to stop ﬂame if the engine backﬁres. If it is not there and the engine backﬁres, you could be burned. Do not drive with it off, and be careful working on the engine with the air cleaner/ﬁlter off. If the air cleaner/ﬁlter is off, a backﬁre can Notice: cause a damaging engine ﬁre. And, dirt can easily get into your engine, which will damage it. Always have the air cleaner/ﬁlter in place when you are driving. Automatic Transmission Fluid When to Check and Change A good time to check your automatic transmission ﬂuid level is when the engine oil is changed. Change both the ﬂuid and ﬁlter every 50,000 miles (83,000 km) if the vehicle’s GVWR is over 8,600 or 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. (cid:127) When doing frequent trailer towing. (cid:127) Uses such as found in taxi, police or delivery service. If your vehicle’s GVWR is not over 8,600 and you do not use your vehicle under any of these conditions, change the ﬂuid and ﬁlter every 100,000 miles (166 000 km). See Scheduled Maintenance on page 6-4. How to Check Because this operation can be a little difficult, you may choose to have this done at the dealership service department. 5-19 (cid:127) (cid:127) If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. Notice: Too much or too little ﬂuid can damage your transmission. Too much can mean that some of the ﬂuid could come out and fall on hot engine part or exhaust system parts, starting a ﬁre. Too little ﬂuid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission ﬂuid. Wait at least 30 minutes before checking the transmission ﬂuid level if you have been driving: (cid:127) When outside temperatures are above 90°F (32°C). (cid:127) At high speed for quite a while. In heavy traffic – especially in hot weather. (cid:127) While pulling a trailer. To get the right reading, the ﬂuid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it’s colder than 50°F (10°C), drive the vehicle in DRIVE (D) until the engine temperature gage moves and then remains steady for 10 minutes. A cold ﬂuid check can be made after the vehicle has been sitting for eight hours or more with the engine off, but this is used only as a reference. Let the engine run at idle for ﬁve minutes if outside temperatures are 50°F (10°C) or more. If it’s colder than 50°F (10°C), you may have to idle the engine longer. Should the ﬂuid level be low during this cold check, you must check the ﬂuid hot before adding ﬂuid. Checking the ﬂuid hot will give you a more accurate reading of the ﬂuid level. 5-20 (cid:127) Checking the Fluid Level Prepare your vehicle as follows: (cid:127) Park your vehicle on a level place. Keep the engine running. (cid:127) With the parking brake applied, place the shift lever in PARK (P). (cid:127) 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. See Engine Compartment Overview on page 5-12 for more information on location. Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel. (cid:127) Push it back in all the way, wait three seconds and then pull it back out again. (cid:127) Check both sides of the dipstick, and read the lower level. The ﬂuid 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. If the ﬂuid level is in the acceptable range, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. 5-21 (cid:127) (cid:127) (cid:127) How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission ﬂuid to use. See Recommended Fluids and Lubricants on page 6-14. Using a funnel, add ﬂuid down the transmission dipstick tube only after checking the transmission ﬂuid while it is hot. (A cold check is used only as a reference.) If the ﬂuid level is low, add only enough of the proper ﬂuid to bring the level up to the HOT area for a hot check. It doesn’t take much ﬂuid, generally less than one pint (0.5 L). Don’t overﬁll. Notice: We recommend you use only ﬂuid labeled DEXRON® -III, because ﬂuid with that label is made especially for your automatic transmission. Damage caused by ﬂuid other than DEXRON® -III is not covered by your new vehicle warranty. (cid:127) After adding ﬂuid, recheck the ﬂuid level as described under “How to Check.” (cid:127) When the correct ﬂuid level is obtained, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. 5-22 Engine Coolant The cooling system in your vehicle is ﬁlled 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 ﬁrst, 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, see Engine Overheating on page 5-26. A 50/50 mixture of clean, drinkable water and DEX-COOL® coolant will: (cid:127) Give freezing protection down to −34°F (−37°C). (cid:127) Give boiling protection up to 265°F (129°C). (cid:127) Protect against rust and corrosion. (cid:127) 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 ﬁrst. Any repairs would not be covered by your warranty. Always use DEX-COOL®(silicate-free) coolant in your vehicle. (cid:127) If you use an improper coolant mixture, Notice: your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, have your dealer check your cooling system. Notice: have to add extra inhibitors or additives which claim to improve the system. These can be harmful. If you use the proper coolant, you do not What to Use Use a mixture of one-half clean, drinkable water and one-half DEX-COOL® coolant which won’t damage aluminum parts. If you use this coolant mixture, you don’t need to add anything else. {CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch ﬁre and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and the proper coolant. 5-23 Checking Coolant The coolant recovery tank is located near the center of the engine compartment. See Engine Compartment Overview on page 5-12 for more information on location. The vehicle must be on a level surface. When your engine is cold, the coolant level should be at COLD FILL, or a little higher. Adding Coolant If you need more coolant, add the proper DEX-COOL® coolant mixture at the coolant recovery tank. {CAUTION: Turning the radiator pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly. With the coolant recovery tank, you will almost never have to add coolant at the radiator. Never turn the radiator pressure cap — even a little — when the engine and radiator are hot. Add coolant mixture at the recovery tank, but be careful not to spill it. 5-24 Radiator Pressure Cap {CAUTION: You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol, and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine. Occasionally check the coolant level in the radiator. For information on how to add coolant to the radiator, see Cooling System on page 5-28. The radiator pressure cap is located near the center of the engine compartment. See Engine Compartment Overview on page 5-12 for more information on location. Notice: coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured. If the pressure cap is not tightly installed, 5-25 Engine Overheating You will ﬁnd a coolant temperature gage on your vehicle’s instrument panel. If Steam Is Coming From Your Engine {CAUTION: Steam from an overheated engine can burn you badly, even if you just open the hood.Stay away from the engine if you see or hear steam coming from it. Just turn it off and get everyone away from the vehicle until it cools down. Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when your engine is overheated, the liquids in it can catch ﬁre. You or others could be badly burned. Stop your engine if it overheats, and get out of the vehicle until the engine is cool. See “Overheated Engine Protection Operating Mode” under Engine Overheating on page 5-26 for information on driving to a safe place in an emergency. 5-26 If your engine catches ﬁre because you Notice: keep driving with no coolant, your vehicle can be badly damaged. The costly repairs would not be covered by your warranty. See “Overheated Engine Protection Operating Mode” under Engine Overheating on page 5-26 for information on driving to a safe place in an emergency. If No Steam Is Coming From Your Engine If you get an engine overheat warning but see or hear no steam, the problem may not be too serious. Sometimes the engine can get a little too hot when you: (cid:127) Climb a long hill on a hot day. (cid:127) Stop after high-speed driving. Idle for long periods in traffic. Tow a trailer. See “Driving on Grades” in Towing a Trailer on page 4-37. If you get the overheat warning with no sign of steam, try this for a minute or so: 1. In heavy traffic, let the engine idle in NEUTRAL(N) while stopped. If it is safe to do so, pull off the road, shift to PARK (P) or NEUTRAL(N) and let the engine idle. 2. Turn on your heater to full hot at the highest fan speed and open the window as necessary. If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about 10 minutes. If the warning doesn’t come back on, you can drive normally. If the warning continues, and you have not stopped, pull over, stop, and park your vehicle right away. If there’s still no sign of steam, push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes while you’re parked. If you still have the warning, turn off the engine and get everyone out of the vehicle until it cools down. You may decide not to lift the hood but to get service help right away. 5-27 (cid:127) (cid:127) Cooling System When you decide it’s safe to lift the hood, here’s what you’ll see: If the coolant inside the coolant recovery tank is boiling, don’t do anything else until it cools down. When the engine is cold, the coolant level should be at or above the COLD FILL mark. If it isn’t, you may have a leak at the pressure cap or in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system. A. Radiator Pressure Cap B. Coolant Recovery Tank C. Engine Cooling Fan(s) 5-28 {CAUTION: Heater and radiator hoses, and other engine parts, can be very hot. Do not touch them. If you do, you can be burned. Do not run the engine if there is a leak. If you run the engine, it could lose all coolant. That could cause an engine ﬁre, and you could be burned. Get any leak ﬁxed before you drive the vehicle. If there seems to be no leak, start the engine again. See if the engine cooling fan speed increases when idle speed is doubled by pushing the accelerator pedal down. If it doesn’t, your vehicle needs service. Turn off the engine. Notice: Engine damage from running your engine without coolant is not covered by your warranty. See “Overheated Engine Protection Operating Mode” in the Index for information on driving to a safe place in an emergency. 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 ﬁrst. Any repairs would not be covered by your warranty. Always use DEX-COOL®(silicate-free) coolant in your vehicle. If there seems to be no leak, start the engine again. See if the engine cooling fan speed increases when idle speed is doubled by pushing the accelerator pedal down. If it doesn’t, your vehicle needs service. Turn off the engine. 5-29 How to Add Coolant to the Coolant Recovery Tank If you haven’t found a problem yet, but the coolant level isn’t at the COLD FILL mark, add a 50/50 mixture of clean, drinkable water and DEX-COOL® engine coolant at the coolant recovery tank. See Engine Coolant on page 5-22 for more information. Notice: Filling the engine cooling system of a V8 engine only through the radiator neck and engine coolant overﬂow reservior after the engine coolant has been drained may cause too little engine coolant to be added. Although the coolant level may appear full in the radiator neck, it may be as much as 4 to 6 quarts (3.8 to 5.7 L) low. Always ﬁll the engine cooling system throught the upper radiator hose. See your dealer for more information. {CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch ﬁre and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant. 5-30 {CAUTION: You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine. When the coolant in the coolant recovery tank is at the COLD FILL mark, start your vehicle. 5-31 If the overheat warning continues, there’s one more thing you can try. You can add the proper coolant mixture directly to the radiator, but be sure the cooling system is cool before you do it. 5-32 {CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the radiator pressure cap — even a little — they can come out at high speed. Never turn the cap when the cooling system, including the radiator pressure cap, is hot. Wait for the cooling system and radiator pressure cap to cool if you ever have to turn the pressure cap. 5-33 How to Add Coolant to the Radiator 1. You can remove the radiator pressure cap when the cooling system, including the radiator pressure cap and upper radiator hose, is no longer hot. Turn the pressure cap slowly counterclockwise until it ﬁrst stops. (Don’t press down while turning the pressure cap.) If you hear a hiss, wait for that to stop. A hiss means there is still some pressure left. 5-34 2. Then keep turning the pressure cap, but now push down as you turn it. Remove the pressure cap. 3. Fill the radiator with the proper DEX-COOL® coolant mixture, up to the base of the ﬁller neck. See Engine Coolant on page 5-22 for more information about the proper coolant mixture. 4. Then ﬁll the coolant recovery tank to the COLD FILL mark. 5. Put the cap back on the coolant recovery tank, but leave the radiator pressure cap off. 5-35 6. Start the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine cooling fan. 8. Then replace the pressure cap. At any time during this procedure if coolant begins to ﬂow out of the ﬁller neck, reinstall the pressure cap. 7. By this time, the coolant level inside the radiator ﬁller neck may be lower. If the level is lower, add more of the proper DEX-COOL® coolant mixture through the ﬁller neck until the level reaches the base of the ﬁller neck. 5-36 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 ﬂuid reservoir is located in the engine compartment on the driver’s side of the vehicle. See Engine Compartment Overview on page 5-12 for more information on location. 5-37 When to Check Power Steering Fluid It is not necessary to regularly check power steering ﬂuid unless you suspect there is a leak in the system or you hear an unusual noise. A ﬂuid loss in this system could indicate a problem. Have the system inspected and repaired. How to Check Power Steering Fluid Turn the key off, let the engine compartment cool down, wipe the cap and the top of the reservoir clean, then unscrew the cap and wipe the dipstick with a clean rag. Replace the cap and completely tighten it. Then remove the cap again and look at the ﬂuid level on the dipstick. The level should be at the COLD FILL mark. If necessary, add only enough ﬂuid to bring the level up to the mark. To prevent contamination of brake ﬂuid, never check or ﬁll the power steering reservoir with the brake master cylinder cover off. What to Use To determine what kind of ﬂuid to use, see Recommended Fluids and Lubricants on page 6-14. Always use the proper ﬂuid. Failure to use the proper ﬂuid can cause leaks and damage hoses and seals. Windshield Washer Fluid What to Use When you need windshield washer ﬂuid, be sure to read the manufacturer’s instructions before use. If you will be operating your vehicle in an area where the temperature may fall below freezing, use a ﬂuid that has sufficient protection against freezing. 5-38 Adding Washer Fluid Open the cap with the washer symbol on it. See Engine Compartment Overview on page 5-12 for more information on location. Add washer ﬂuid until the tank is full. Notice: (cid:127) When using concentrated washer ﬂuid, follow the manufacturer’s instructions for adding water. (cid:127) Do not mix water with ready-to-use washer ﬂuid. Water can cause the solution to freeze and damage your washer ﬂuid tank and other parts of the washer system. Also, water does not clean as well as washer ﬂuid. Fill your washer ﬂuid tank only three-quarters full when it is very cold. This allows for expansion if freezing occurs, which could damage the tank if it is completely full. (cid:127) Do not use engine coolant (antifreeze) in your windshield washer. It can damage your washer system and paint. 5-39 (cid:127) Brakes Brake Fluid Your brake master cylinder reservoir is ﬁlled with DOT-3 brake ﬂuid. See Engine Compartment Overview on page 5-12 for the location of the reservoir. There are only two reasons why the brake ﬂuid level in the reservoir might go down. The ﬁrst is that the brake ﬂuid goes down to an acceptable level during normal brake lining wear. When new linings are put in, the ﬂuid level goes back up. The other reason is that ﬂuid is leaking out of the brake system. 5-40 If it is, you should have your brake system ﬁxed, since a leak means that sooner or later your brakes will not work well, or will not work at all. So, it is not a good idea to “top off” your brake ﬂuid. Adding brake ﬂuid will not correct a leak. If you add ﬂuid when your linings are worn, then you will have too much ﬂuid when you get new brake linings. You should add (or remove) brake ﬂuid, as necessary, only when work is done on the brake hydraulic system. {CAUTION: If you have too much brake ﬂuid, it can spill on the engine. The ﬂuid will burn if the engine is hot enough. You or others could be burned, and your vehicle could be damaged. Add brake ﬂuid 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 ﬂuid. See Scheduled Maintenance on page 6-4. Checking Brake Fluid Always clean the brake ﬂuid reservoir cap and the area around the cap before removing it. This will help keep dirt from entering the reservoir. {CAUTION: With the wrong kind of ﬂuid in your brake system, your brakes may not work well, or they may not even work at all. This could cause a crash. Always use the proper brake ﬂuid. You can check the brake ﬂuid without taking off the cap. Just look at the brake ﬂuid reservoir. The ﬂuid 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. What to Add When you do need brake ﬂuid, use only DOT-3 brake ﬂuid. Use new brake ﬂuid from a sealed container only. See Recommended Fluids and Lubricants on page 6-14. Notice: (cid:127) Using the wrong ﬂuid can badly damage brake system parts. For example, just a few drops of mineral-based oil, such as engine oil, in your brake system can damage brake system parts so badly that they will have to be replaced. Do not let someone put in the wrong kind of ﬂuid. If you spill brake ﬂuid on your vehicle’s painted surfaces, the paint ﬁnish can be damaged. Be careful not to spill brake ﬂuid on your vehicle. If you do, wash it off immediately. See Appearance Care on page 5-92. 5-41 (cid:127) Brake Wear Your vehicle has four-wheel disc brakes. Disc brake pads have built-in wear indicators that make a high-pitched warning sound when the brake pads are worn and new pads are needed. The sound may come and go or be heard all the time your vehicle is moving (except when you are pushing on the brake pedal ﬁrmly). {CAUTION: The brake wear warning sound means that soon your brakes will not work well. That could lead to an accident. When you hear the brake wear warning sound, have your vehicle serviced. Notice: Continuing to drive with worn-out brake pads could result in costly brake repair. Some driving conditions or climates may cause a brake squeal when the brakes are ﬁrst applied or lightly applied. This does not mean something is wrong with your brakes. Properly torqued wheel nuts are necessary to help prevent brake pulsation. When tires are rotated, inspect brake pads for wear and evenly tighten wheel nuts in the proper sequence to GM torque speciﬁcations. Brake linings should always be replaced as complete axle sets. Brake Pedal Travel See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in pedal travel. This could be a sign of brake trouble. Brake Adjustment Every time you make a brake stop, your disc brakes adjust for wear. 5-42 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 new vehicle comes with a maintenance free ACDelco® 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® battery. See Engine Compartment Overview on page 5-12 for 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. See Jump Starting on page 5-44 for tips on working around a battery without getting hurt. Contact your dealer to learn how to prepare your vehicle for longer storage periods. Also, for your audio system, see Theft-Deterrent Feature (Non-RDS Radios) on page 3-76 or Theft-Deterrent Feature (RDS Radios) on page 3-76. 5-43 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: (cid:127) They contain acid that can burn you. (cid:127) They contain gas that can explode or (cid:127) They contain enough electricity to ignite. burn you. If you do not follow these steps exactly, some or all of these things can hurt you. 5-44 Ignoring these steps could result in costly Notice: 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. If the other vehicle’s system is not a 12-volt Notice: 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 ﬁrmly 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. If you leave your radio or other accessories Notice: 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! 4. Open the hoods and locate the positive (+) and negative (−) terminal locations of the other vehicle. Your vehicle has a remote positive (+) jump starting terminal and a remote negative (−) jump starting terminal. You should always use these remote terminals instead of the terminals on the battery. The remote positive (+) terminal is located behind a red plastic cover near the engine accessory drive bracket on the driver’s side below the alternator. To uncover the remote positive (+) terminal, open the red plastic cover. The remote negative (−) terminal is located on the engine drive bracket on all V8 engines and it is marked “GND.” On V6 engines the remote negative (−) terminal is located on a tab attached to the engine accessory drive bracket where it is marked “GND.” {CAUTION: Using a match near a battery can cause battery gas to explode. People have been hurt doing this, and some have been blinded. Use a ﬂashlight if you need more light. Be sure the battery has enough water. You do not need to add water to the ACDelco® battery installed in your new vehicle. But if a battery has ﬁller caps, be sure the right amount of ﬂuid is there. If it is low, add water to take care of that ﬁrst. If you do not, explosive gas could be present. Battery ﬂuid contains acid that can burn you. Do not get it on you. If you accidentally get it in your eyes or on your skin, ﬂush the place with water and get medical help immediately. 5-45 {CAUTION: Fans or other moving engine parts can injure you badly. Keep your hands away from moving parts once the engine is running. 5. Check that the jumper cables don’t have loose or missing insulation. If they do, you could get a shock. The vehicles could be damaged, too. Before you connect the cables, here are some basic things you should know. Positive (+) will go to positive (+) or to a remote positive (+) terminal if the vehicle has one. Negative (−) will go to a heavy, unpainted metal engine part or to a remote negative (−) terminal if the vehicle has one. Don’t connect positive (+) to negative (−) or you will get a short that would damage the battery and maybe other parts, too. And don’t connect the negative (−) cable to the negative (−) terminal on the dead battery because this can cause sparks. 5-46 6. Connect the red positive (+) cable to the positive (+) terminal of the dead battery. Use a remote positive (+) terminal if the vehicle has one. 7. Don’t let the other end touch metal. Connect it to the positive (+) terminal of the good battery. Use a remote positive (+) terminal if the vehicle has one. 8. Now connect the black negative (−) cable to the negative (−) terminal of the good battery. Use a remote negative (−) terminal if the vehicle has one. Don’t let the other end touch anything until the next step. The other end of the negative (−) cable doesn’t go to the dead battery. It goes to a heavy, unpainted metal engine part or to a remote negative (−) terminal on the vehicle with the dead battery. 9. Connect the other end of the negative (−) cable at least 18 inches (45 cm) away from the dead battery, but not near engine parts that move. The electrical connection is just as good there, and the chance of sparks getting back to the battery is much less. 10. Now start the vehicle with the good battery and run the engine for a while. 11. Try to start the vehicle with the dead battery. If it won’t start after a few tries, it probably needs service. If the jumper cables are removed in the Notice: wrong order, electrical shorting may occur and damage the vehicle. The repairs would not be covered by your warranty. Remove the jumper cables in the correct order, making sure that the cables do not touch each other or other metal. 5-47 To disconnect the jumper cables from both vehicles, do the following: 1. Disconnect the black negative (−) cable from the vehicle that had the dead battery. 2. Disconnect the black negative (−) cable from the vehicle with the good battery. 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 positve (+) remote terminal to its original position. Jumper Cable Removal A. Heavy, Unpainted Metal Engine Part or Remote Negative (−) Terminal B. Good Battery or Remote Positive (+) and Remote Negative (−) Terminals C. Dead Battery or Remote Positive (+) Terminal 5-48 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. See Scheduled 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 ﬁller plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the ﬁller 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. See Recommended Fluids and Lubricants on page 6-14. 5-49 Rear Axle When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See Scheduled 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 ﬁller plug hole. The proper level for the 2500 and 3500 Series is from 0 to 1/4 (6 mm) below the bottom of the ﬁller plug hole. Add only enough ﬂuid to reach the proper level. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Recommended Fluids and Lubricants on page 6-14. 5-50 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. See Scheduled Maintenance on page 6-4. How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface. When the differential is cold, add enough lubricant to raise the level to 3/8 inch (10 mm) below the ﬁller plug hole. When the differential is at operating temperature (warm), add enough lubricant to raise the level to the bottom of the ﬁller plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Recommended Fluids and Lubricants on page 6-14. If the level is below the bottom of the ﬁller plug hole, you may need to add some lubricant. 5-51 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. 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. 5-52 Among those acts presumed to constitute tampering are the acts listed below. Insulation: (cid:127) Removal of the noise shields or any underhood insulation. Engine: (cid:127) Removal or rendering engine speed governor (if equipped) inoperative so as to allow engine speed to exceed manufacturer speciﬁcations. Fan and Drive: (cid:127) Removal of fan clutch (if equipped) or rendering clutch inoperative. (cid:127) Removal of the fan shroud (if equipped). Air Intake: (cid:127) Removal of the air cleaner silencer. (cid:127) Modiﬁcation of the air cleaner. Exhaust: (cid:127) Removal of the muffler and/or resonator. (cid:127) Removal of the exhaust pipes and exhaust pipe clamps. Bulb Replacement For any bulb changing procedure not listed in this section, contact your dealer. For the type of bulbs, see Replacement Bulbs on page 5-57. Halogen Bulbs {CAUTION: Halogen bulbs have pressurized gas inside and can burst if you drop or scratch the bulb. You or others could be injured. Be sure to read and follow the instructions on the bulb package. Headlamps 1. Remove the two bolts from the headlamp assembly. 2. Remove the two pins on the top of the headlamp assembly. To remove the pins, turn the outer pin clockwise and pull it straight up. To remove the inner pin, turn it counterclockwise and pull it straight up. 3. Lift the inboard side of the headlamp to release the inboard tab from the radiator support. 4. Lift the outboard side of the headlamp to release the outboard tab from the radiator support. 5. Lower the headlamp to allow the vertical adjustor to clear tie bar. 6. Turn the headlamp forward and upward to remove it from the grille. 7. Turn the bulb connector counterclockwise and pull it out of the housing. 5-53 8. Without removing the headlamp assembly itself, remove the bulb socket from the back of the headlamp on the driver’s side. 9. Turn the bulb counterclockwise one quarter turn to remove it from the socket. 10. On the passenger’s side, turn the bulb clockwise one turn. Do not touch the glass part of the bulb. 11. Install the new bulb into the socket and return it to the headlamp assembly. 12. Put the headlamp assembly back into the vehicle and reinstall the two pins. 5-54 Front Turn Signal, Sidemarker and Parking Lamps 1. Use a small tool to unlatch the outboard clip on this lamp. 2. Pull the lamp forward to completely unlatch the clip. Move the lamp outboard to loosen the tabs. 3. Remove the lamp from the grille. 4. Squeeze the tab on the side of the bulb assembly while turning it counterclockwise. 5. Remove the bulb assembly from the back of the lens and replace the bulb. 6. Turn the socket clockwise to reinstall it in the lens assembly. Taillamps 1. Remove the two inboard nuts on the side assembly. 2. Pull side assembly rearward to clear studs. 3. Turn the side assembly on the outboard side, releasing the upper clip. 4. Slide assembly slightly upward to release lower clip. 5. Reinstall the clips to the side assembly. 6. Remove the three nuts on the taillamp. 7. Remove the taillamp from the vehicle. 5-55 8. To remove, squeeze the tab on the side of the sockets while turning them counterclockwise. 9. Turn the bulb counterclockwise to remove it. Install the new bulb. 10. Reverse the above steps to reinstall the lamp. 5-56 Center High Mounted Stoplamp (CHMSL) Replacement Bulbs It is recommended that this component be replaced as a unit by your dealer. Exterior Lamp Bulb Number Back-up Lamp CHMSL Composite High-Beam Headlamps Composite Low-Beam Headlamps 3157 912 9005 9006GS Front Parking and Turn Lamp 3157KX Front Sidemarker Lamp Sealed Beam Headlamps Rear Parking, Stop, and Turn Lamp 194 H6054 3157 For any bulb not listed here, contact your dealer. 5-57 Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear and cracking. See ″Wiper Blade Check” in Scheduled Maintenance on page 6-4. 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. 5-58 Tires Your new vehicle comes with high-quality tires made by a leading tire manufacturer. If you ever have questions about your tire warranty and where to obtain service, see your GM Warranty booklet for details. For additional information refer to the tire manufacturer’s booklet included with your vehicle’s Owner’s Manual. {CAUTION:

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2004 Chevrolet Express Owners Manual