2003 CHEVROLET EXPRESS CARGO VAN Owners Manual

ApplicationCapacities
QTY Without Rear
Heater QTY With Rear Heater
Fuel Tank
Standard Tank (Passenger and Cargo) 31.0 gallons 117.3 L
Standard Tank (Cab and Chassis) 35.0 gallons 132.5 L
Optional Tank* (Cab and Chassis) 55.0 gallons 208.1 L
* 159 inch wheelbase or 177 inch wheel base only
Air Conditioning Refrigerant Capacity
Air Conditioning Refrigerant R-134a (Front) 1.8 lbs (0.81 kg)
Air Conditioning Refrigerant R-134a (Front and Rear) 3.1 lbs (1.41 kg)
5-99

Normal Maintenance Replacement Parts
Replacement part numbers listed in this section are based on the latest information available at the time of printing,
and are subject to change. If a part listed in this manual is not the same as the part used in your vehicle when it was
built, or if you have any questions, please contact your GM dealer.
These speci®cations are for information only. If you have any questions, see the service manual for the chassis or
refer to the body manufacturer's publications.
VIN Code W V T U
Oil Filter* PF47 PF44 PF44 PF44
Engine Air Cleaner /Filter* A1621C A1621C A1621C A1621C
Passenger Compartment Air Filter
Kit**52485513 52485513 52485513 52485513
PCV Valve* CV 769±C CV 2001±C CV 2001±C CV 2001±C
Spark Plugs 41±932 41±974 41±974 41±974
Fuel Filter* 6F6Z6 GF626 GF626 GF626
Wiper Blades** 15153642 15153642 15153642 15153642
Wiper Blade Type ITTA ITTA ITTA ITTA
Wiper Blade Length22 inches
(56.0 cm)22 inches
(56.0 cm)22 inches
(56.0 cm)22 inches
(56.0 cm)
* ACDelco
žpart number
** GM part number
5-100

A
Accessory Power Outlets.................................3-18
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-74
Adding Washer Fluid.......................................5-36
Additional Program Information........................... 7-8
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-91
Add-On Equipment..........................................4-31
Adjusting the Speakers (Balance/Fade).....3-43, 3-46,
3-51, 3-62
Air Bag System..............................................1-63
Adding Equipment to Your Air Bag-Equipped
Vehicle...................................................1-74
Air Bag Off Switch.......................................1-70
How Does an Air Bag Restrain?....................1-68
Servicing Your Air Bag-Equipped Vehicle.........1-73
What Makes an Air Bag In¯ate?....................1-68
What Will You See After an Air
Bag In¯ates?...........................................1-68
When Should an Air Bag In¯ate?...................1-67
Where Are the Air Bags?..............................1-65
Air Bag Systems.............................................1-68
Air Bag .........................................................3-28
Off Light.....................................................3-28
Readiness Light..........................................3-27Air Cleaner/Filter, Engine.................................5-17
All-Wheel Drive (AWD) System.........................2-26
All-Wheel Drive...............................................5-46
AM-FM Radio.................................................3-41
AM ...............................................................3-73
Antenna, Fixed Mast.......................................3-75
Anti-Lock Brake, System Warning Light..............3-32
Anti-lock Brake System..................................... 4-6
Appearance Care............................................5-80
Care of Safety Belts....................................5-83
Chemical Paint Spotting...............................5-87
Cleaning the Inside of Your Vehicle................5-80
Cleaning the Outside of Your Vehicle..............5-83
Finish Damage............................................5-86
Sheet Metal Damage...................................5-86
Underbody Maintenance...............................5-87
Vehicle Care/Appearance Materials................5-88
Weatherstrips..............................................5-83
Ashtrays........................................................3-18
Audio System(s).............................................3-40
AM-FM Radio.............................................3-41
Care of Your Cassette Tape Player................3-74
Care of Your CD Player...............................3-75
Care of Your CDs........................................3-75
Chime Level Adjustment...............................3-75
Fixed Mast Antenna.....................................3-75
Radio with Cassette and CD.........................3-48
1

Audio System(s) (cont.)
Radio with CD............................................3-44
Radio with Six-Disc CD................................3-59
Rear Seat Audio (RSA)................................3-71
Setting the Time for Radios with Radio Data
Systems (RDS)........................................3-41
Setting the Time for Radios without Radio
Data Systems (RDS)................................3-40
Theft-Deterrent Feature................................3-73
Understanding Radio Reception.....................3-73
Automatic Transmission Check..........................6-12
Automatic Transmission Shift Lock Control
System Check.............................................6-14
Automatic Transmission...................................5-19
Fluid..........................................................5-19
Operation...................................................2-24
B
Backing Up....................................................4-42
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-17
Battery..........................................................5-40
Before Leaving on a Long Trip.........................4-20
Body Lubrication Service..................................6-13
Brake............................................................2-26
Parking......................................................2-26
System Inspection.......................................6-17Brake (cont.)
System Warning Light..................................3-31
Brake Adjustment............................................5-39
Brake Fluid....................................................5-37
Brake Pedal Travel.........................................5-39
Brake Wear...................................................5-39
Brakes..........................................................5-37
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-5
Break-In, New Vehicle.....................................2-20
Bulb Replacement...........................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps....................................................5-52
Halogen Bulbs............................................5-50
Headlamps.................................................5-50
Replacement Bulbs......................................5-54
Taillamps....................................................5-52
Buying New Tires...........................................5-60C
California Fuel.................................................. 5-5
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-6
Capacities and Speci®cations............................5-97
Capacities......................................................5-98
Carbon Monoxide...........................4-24, 4-31, 2-30
2

Care of.........................................................5-83
Safety Belts................................................5-83
Your Cassette Tape Player............................3-74
Your CD Player...........................................3-75
Your CDs ...................................................3-75
Cargo Door Relocking....................................... 2-8
Cargo Vans and Cab and Chassis Models with
an Air Bag Off Switch..................................1-48
Cargo Vans and Cab and Chassis Models
without an Air Bag Off Switch........................1-47
Cargo Vans with a Passenger Air Bag and an
Air Bag Off Switch, Passenger Vans and Cab
and Chassis Models....................................1-37
Cargo Vans with a Passenger Air Bag and
without an Air Bag Off Switch........................1-40
Cassette Tape Messages.................................3-56
Cassette Tape Player Service...........................6-12
CD Adapter Kits.............................................3-56
Center High Mounted
Stoplamp (CHMSL)......................................5-54
Center High-Mounted Stoplamp.........................3-15
Center Passenger Position, Safety Belts.....1-25, 1-26
Chains, Tires..................................................5-63
Charging System Light....................................3-29
Check Engine Light.........................................3-33
Checking Brake Fluid......................................5-38
Checking Coolant............................................5-23
Checking Engine Oil........................................5-13
Checking Things Under the Hood....................... 5-9
Checking Your Restraint Systems......................1-74Check...........................................................3-33
Engine Light...............................................3-33
Gages Warning Light...................................3-38
Chemical Paint Spotting...................................5-87
Child Restraints..............................................1-42
Child Restraint Systems...............................1-42
Infants and Young Children...........................1-36
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-51
Older Children.............................................1-34
Securing a Child Restraint Designed for the
LATCH System........................................1-53
Securing a Child Restraint in a Center
Seat Position...........................................1-56
Securing a Child Restraint in a Rear Outside
Seat Position...........................................1-53
Securing a Child Restraint in the Right Front
Seat Position...........................................1-58
Top Strap Anchor Location............................1-50
Top Strap...................................................1-48
Where to Put the Restraint...........................1-45
Chime Level Adjustment..................................3-75
Cigarette Lighter.............................................3-18
Cleaning Aluminum Wheels..............................5-85
Cleaning Exterior Lamps/Lenses.......................5-84
Cleaning Fabric/Carpet....................................5-80
Cleaning Glass Surfaces..................................5-82
Cleaning Interior Plastic Components.................5-82
Cleaning Leather............................................5-82
Cleaning the Top of the Instrument Panel...........5-82
3

Cleaning the Windshield and Wiper Blades.........5-85
Cleaning Tires................................................5-86
Cleaning Vinyl................................................5-82
Cleaning........................................................5-80
Inside of Your Vehicle..................................5-80
Outside of Your Vehicle................................5-83
Underbody Maintenance...............................5-87
Weatherstrips..............................................5-83
Climate Control System...................................3-19
Rear Air Conditioning and Heating System......3-21
Rear Heating System...................................3-20
Compact Disc Messages.................3-48, 3-59, 3-70
Control of a Vehicle.......................................... 4-5
Coolant.........................................................3-32
Engine Temperature Gage............................3-32
Heater, Engine............................................2-23
Low Warning Light.......................................3-33
Cooling System..............................................5-26
Cruise Control Light........................................3-38
Cruise Control................................................3-10
Current and Past Model Order Forms................7-10
Customer Assistance Information........................ 7-7
Courtesy Transportation.................................. 7-7
Customer Assistance for Text
Telephone (TTY) Users............................... 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors...... 7-9Customer Assistance Information (cont.)
Reporting Safety Defects to the Canadian
Government.............................................. 7-9
Reporting Safety Defects to the United States
Government.............................................. 7-8
Roadside Assistance Program......................... 7-5
Service Publications Ordering Information......... 7-9
D
Daytime Running Lamps Indicator Light.............3-38
Daytime Running Lamps..................................3-15
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-22
Doing Your Own Service Work........................... 5-3
Dome Lamp Override......................................3-16
Dome Lamps.................................................3-17
Door.............................................................2-13
60/40 Swing-Out Side Door...........................2-13
Cargo Door Relocking.................................... 2-8
Locks.......................................................... 2-7
Power Door Locks......................................... 2-8
Rear Door Security Locks............................... 2-8
Rear Doors.................................................2-14
Sliding Side Door........................................2-11
Driver............................................................1-16
Position, Safety Belt.....................................1-16
Driving On Grades..........................................4-42
Driving on Snow or Ice....................................4-24
4

Driving Through Deep Standing Water...............4-17
Driving Through Flowing Water.........................4-17
Driving with a Trailer.......................................4-41
Driving..........................................................4-13
At Night.....................................................4-13
City...........................................................4-18
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-19
Hill and Mountain Roads..............................4-22
In Rain and on Wet Roads...........................4-15
Winter........................................................4-24
Dual Stage Air Bags........................................1-67
Dual Tire Operation.........................................5-57
E
Electrical System............................................5-91
Add-On Equipment......................................5-91
Fuses and Circuit Breakers...........................5-92
Headlamp Wiring.........................................5-91
Windshield Wiper Fuses...............................5-91
Electronic Road-Speed Governor.......................3-26
Emissions Inspection and Maintenance
Programs...................................................3-35Engine Compartment Fuse Block......................5-94
Engine Coolant Level Check.............................6-11
Engine Oil Additives........................................5-15
Engine Oil and Chassis Lubrication Scheduled
Maintenance................................................. 6-5
Engine Oil Level Check...................................6-11
Engine..........................................................5-17
Air Cleaner/Filter.........................................5-17
Battery.......................................................5-40
Change Engine Oil Light...............................3-37
Check and Service Engine Soon Light............3-33
Compartment Overview................................5-12
Coolant Heater............................................2-23
Coolant Temperature Gage...........................3-32
Coolant......................................................5-21
Cooling System Inspection............................6-16
Exhaust.....................................................2-30
Fan Noise..................................................5-34
Oil .............................................................5-13
Overheating................................................5-24
Starting......................................................2-22
Entry Lighting.................................................3-17
Exit Lighting...................................................3-17
Extender, Safety Belt.......................................1-33
Exterior Lamps...............................................3-13
5

F
Filter.............................................................5-17
Engine Air Cleaner......................................5-17
Finding a PTY Station.............................3-52, 3-63
Finding a Station....................3-42, 3-44, 3-49, 3-60
Finish Care....................................................5-84
Finish Damage...............................................5-86
Fixed Mast Antenna........................................3-75
Flash-To-Pass Feature....................................... 3-9
Flat Tire, Changing.........................................5-65
Flat Tire........................................................5-64
Floor Console Fuse Block................................5-92
Fluid.............................................................5-19
Automatic Transmission................................5-19
Power Steering...........................................5-34
Windshield Washer......................................5-35
FM ...............................................................3-73
Following Distance..........................................4-41
Footnotes........................................................ 6-5
Front Axle......................................................5-48
Fuel Regulator................................................2-22
Fuel............................................................... 5-4
Additives...................................................... 5-6
California Fuel.............................................. 5-5
Filling a Portable Fuel Container..................... 5-9Fuel (cont.)
Filling Your Tank........................................... 5-7
Fuels in Foreign Countries.............................. 5-6
Gage.........................................................3-39
Gasoline Octane........................................... 5-4
Gasoline Speci®cations.................................. 5-5
System Inspection.......................................6-16
Fuses...........................................................5-92
Fuses and Circuit Breakers...........................5-92
Windshield Wiper.........................................5-91
G
Gage............................................................3-38
Check Gages Warning Light..........................3-38
Engine Coolant Temperature.........................3-32
Fuel..........................................................3-39
Oil Pressure...............................................3-36
Speedometer..............................................3-25
Voltmeter Gage...........................................3-30
Gasoline......................................................... 5-4
Octane........................................................ 5-4
Speci®cations............................................... 5-5
GM Mobility Program for Persons with
Disabilities.................................................... 7-5
6