2003 CHEVROLET EXPRESS CARGO VAN automatic transmission

Cassette Tape Player Service
Clean cassette tape player. Cleaning should be done
every 50 hours of tape play. SeeAudio System(s)
on page 3-40for further details.
At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced.
Also look for any opened or broken air bag coverings,
and have them repaired or replaced. (The air bag
system does not need regular maintenance.)
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace
blade inserts that appear worn or damaged or that
streak or miss areas of the windshield. Also see
Cleaning the Outside of Your Vehicle on page 5-84.
Spare Tire Check
At least twice a year, after the monthly in¯ation check of
the spare tire determines that the spare is in¯ated to
the correct tire in¯ation pressure, make sure that
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 5-65.
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them last
longer, seal better, and not stick or squeak. Apply
silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
required. See
Part D: Recommended Fluids and
Lubricants on page 6-18.
Automatic Transmission Check
Check the transmission ¯uid level; add if needed. SeeAutomatic Transmission Fluid on page 5-19. A ¯uid loss
may indicate a problem. Check the system and repair
if needed.
6-12

Automatic Transmission Shift Lock
Control System Check
{CAUTION:
When you are doing this check, the vehicle
could move suddenly. If it does, you or others
could be injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. See
Parking Brake
on page 2-26if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.3. With the engine off, turn the key to the RUN
position, but don't start the engine. Without applying
the regular brake, try to move the shift lever out
of PARK (P) with normal effort. If the shift lever
moves out of PARK (P), your vehicle needs service.
Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to LOCK in each shift lever position.
·The key should turn to LOCK only when the
shift lever is in PARK (P).
·The key should come out only in LOCK.
6-14

Parking Brake and Automatic
Transmission Park (P) Mechanism
Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake,
set the parking brake.
·To check the parking brake's holding
ability: With the engine running and transmission in
NEUTRAL (N), slowly remove foot pressure from
the regular brake pedal. Do this until the vehicle is
held by the parking brake only.
·To check the PARK (P) mechanism's holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Underbody Flushing Service
At least every spring, use plain water to ¯ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-15

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identi®ed below by name, part
number or speci®cation may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil with the American
Petroleum Institute Certi®ed for
Gasoline Engines starburst symbol
of the proper viscosity. To determine
the preferred viscosity for your
vehicle's engine, see
Engine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
žCoolant. SeeEngine
Coolant on page 5-21.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake ¯uid.
Windshield
Washer SolventGM Optikleen
žWasher Solvent or
equivalent.
Usage Fluid/Lubricant
Parking Brake
Cable GuidesChassis Lubricant
(GM Part No. U.S. 12377985, in
Canada 88901242, or equivalent) or
lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Power Steering
SystemGM Power Steering Fluid
(GM Part No. U.S. 1052884, in
Canada 993294, or equivalent).
Automatic
TransmissionDEXRON
ž-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474, or equivalent).
Chassis
LubricationChassis Lubricant
(GM Part No. U.S. 12377985, in
Canada 88901242, or equivalent) or
lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Front Wheel
BearingsWheel bearing lubricant meeting
requirements of NLGI #2,
Category GC or GC-LB
(GM Part No. U.S. 1051344, in
Canada 993037, or equivalent).
6-18

Usage Fluid/Lubricant
Front and
Rear AxleSAE 75W-90 Synthetic
Axle Lubricant
(GM Part No. U.S. 12378261, in
Canada 10953455) or equivalent
meeting GM Speci®cation 9986115.
Transfer CaseDEXRON
ž-III Automatic
Transmission Fluid.
One-Piece
Propshaft Slip
Yoke Spline,
Two-Piece
Propshaft
Slip-in-Tube
SplineSpline Lubricant, Special Lubricant
(GM Part No. U.S. 12345879, in
Canada 10953511) or lubricant
meeting requirements of
GM 9985830.
Usage Fluid/Lubricant
Hood HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474, or equivalent).
Weatherstrip
ConditioningDielectric Silicone Grease
(GM Part No. U.S. 12345579, in
Canada 10953014, or equivalent).
Weatherstrip
SqueaksSynthetic Grease with
Te¯on, Superlube
(GM Part No. U.S. 12371287, in
Canada 10953437, or equivalent).
6-19

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 Speci®cations....................................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................................5-17
Automatic Transmission Fluid.........................5-19
Engine Coolant.............................................5-21
Radiator Pressure Cap..................................5-24
Engine Overheating.......................................5-24Cooling System............................................5-26
Engine Fan Noise.........................................5-34
Power Steering Fluid.....................................5-34
Windshield Washer Fluid................................5-35
Brakes........................................................5-37
Battery........................................................5-40
Jump Starting...............................................5-41
All-Wheel Drive..............................................5-46
Rear Axle.......................................................5-47
Front Axle......................................................5-48
Noise Control System.....................................5-49
Tampering with Noise Control System
Prohibited.................................................5-49
Bulb Replacement..........................................5-50
Halogen Bulbs..............................................5-50
Headlamps..................................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps.....................................................5-52
Taillamps.....................................................5-52
Replacement Bulbs.......................................5-54
Section 5 Service and Appearance Care
5-1

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission ¯uid
level is when the engine oil is changed.
Change both the ¯uid and ®lter 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 90ÉF (32ÉC) or higher.
·In hilly or mountainous terrain.
·When doing frequent trailer towing.
·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 ¯uid and ®lter every 100,000 miles
(166 000 km).
See
Part A: Scheduled Maintenance Services 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.
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 ¯uid can damage
your transmission. Too much can mean that some
of the ¯uid could come out and fall on hot engine
part or exhaust system parts, starting a ®re.
Too little ¯uid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission ¯uid.
Wait at least 30 minutes before checking the
transmission ¯uid level if you have been driving:
·When outside temperatures are above 90ÉF (32ÉC).
·At high speed for quite a while.
·In heavy traffic ± especially in hot weather.
·While pulling a trailer.
To get the right reading, the ¯uid should be at
normal operating temperature, which is 180ÉF to 200ÉF
(82ÉC to 93ÉC).
5-19

·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 area or cross-hatched
area for a hot check.
·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 Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission ¯uid to use. SeePart D:
Recommended Fluids and Lubricants on page 6-18.
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 doesn't take much ¯uid, generally less than one pint
(0.5 L).
Don't over®ll.
Notice:We recommend you use only ¯uid labeled
DEXRONž-III, because ¯uid with that label is
made especially for your automatic transmission.
Damage caused by ¯uid other than DEXRON
ž-III is
not covered by your new vehicle warranty.
·After adding ¯uid, recheck the ¯uid level as
described under ªHow to Check.º
·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.
Engine Coolant
The cooling system in your vehicle is ®lled with
DEX-COOLžengine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs ®rst, if you add
only DEX-COOL
žextended 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 5-24.
5-21