2003 CHEVROLET EXPRESS CARGO VAN engine

Vehicle Damage Warnings
Also, in this book you will ®nd these notices:
Notice:These mean there is something that could
damage your vehicle.
A notice will tell you about something that can
damage your vehicle. Many times, this damage would
not be covered by your warranty, and it could be costly.
But the notice will tell you what to do to help avoid
the damage.
When you read other manuals, you might see
CAUTION and NOTICE warnings in different colors
or in different words.
You'll also see warning labels on your vehicle. They use
the same words, CAUTION or NOTICE.
Vehicle Symbols
Your vehicle has components and labels that use
symbols instead of text. Symbols, used on your vehicle,
are shown along with the text describing the operation
or information relating to a speci®c component, control,
message, gage or indicator.
If you need help ®guring out a speci®c name of
a component, gage or indicator, reference the
following topics:
·Seats and Restraint Systems in Section 1
·Features and Controls in Section 2
·Instrument Panel Overview in Section 3
·Climate Controls in Section 3
·Warning Lights, Gages and Indicators in Section 3
·Audio System(s) in Section 3
·Engine Compartment Overview in Section 5
iv

Air bag in¯ation doesn't prevent the driver from seeing
or being able to steer the vehicle, nor does it stop
people from leaving the vehicle.
{CAUTION:
When an air bag in¯ates, there is dust in the
air. This dust could cause breathing problems
for people with a history of asthma or other
breathing trouble. To avoid this, everyone in
the vehicle should get out as soon as it is safe
to do so. If you have breathing problems but
can't get out of the vehicle after an air bag
in¯ates, then get fresh air by opening a
window or a door. If you experience breathing
problems following an air bag deployment, you
should seek medical attention.
·Air bags are designed to in¯ate only once. After
they in¯ate, you'll need some new parts for your
air bag system. If you don't get them, the air
bag system won't be there to help protect you in
another crash. A new system will include air
bag modules and possibly other parts. The service
manual for your vehicle covers the need to
replace other parts.
·Your vehicle is equipped with a crash sensing and
diagnostic module, which records information
about the air bag system. The module records
information about the readiness of the system, when
the system commands air bag in¯ation and
driver's safety belt usage at deployment. The
module also records speed, engine rpm, brake and
throttle data.
·Let only quali®ed technicians work on your air bag
system. Improper service can mean that your air
bag system won't work properly. See your dealer for
service.
Notice:If you damage the covering for the driver's
or the right front passenger's air bag, the bag
may not work properly. You may have to replace the
air bag module in the steering wheel or both the
air bag module and the instrument panel for
the right front passenger's air bag. Do not open or
break the air bag coverings.
1-69

Keys...............................................................2-2
Remote Keyless Entry System.........................2-3
Remote Keyless Entry System Operation...........2-4
Doors and Locks.............................................2-7
Door Locks....................................................2-7
Power Door Locks..........................................2-8
Cargo Door Relocking.....................................2-8
Rear Door Security Locks................................2-8
Lockout Protection........................................2-10
Leaving Your Vehicle....................................2-10
Sliding Side Door..........................................2-11
60/40 Swing-Out Side Door............................2-13
Rear Doors..................................................2-14
Windows........................................................2-16
Manual Windows..........................................2-16
Power Windows............................................2-17
Swing-Out Windows......................................2-18
Sun Visors...................................................2-19
Theft-Deterrent Systems..................................2-19
Passlock
ž....................................................2-19Starting and Operating Your Vehicle................2-20
New Vehicle Break-In....................................2-20
Ignition Positions..........................................2-20
Starting Your Engine.....................................2-22
Engine Coolant Heater..................................2-23
Automatic Transmission Operation...................2-24
All-Wheel Drive............................................2-26
Parking Brake..............................................2-26
Shifting Into Park (P).....................................2-26
Shifting Out of Park (P).................................2-29
Parking Over Things That Burn.......................2-29
Engine Exhaust............................................2-30
Running Your Engine While You Are Parked. . . .2-30
Mirrors...........................................................2-31
Manual Rearview Mirror.................................2-31
Outside Manual Mirror...................................2-31
Outside Remote Control Mirror.......................2-32
Outside Camper-Type Mirrors.........................2-32
Outside Power Mirrors...................................2-33
Outside Convex Mirror...................................2-34
Outside Heated Mirrors..................................2-34
OnStar
žSystem.............................................2-35
Storage Areas................................................2-36
Section 2 Features and Controls
2-1

Sun Visors
To block out glare, you can swing down the visors.
You can also swing them from side to side.
Visor Vanity Mirror
Some visors have mirrors built in, with or without lamps.
Just lift the mirror cover on each visor to turn the
lamps on, if you have them.
Theft-Deterrent Systems
Vehicle theft is a big business, especially in some cities.
Although your vehicle has a number of theft-deterrent
features, we know that nothing we put on it can make it
impossible to steal. However, there are ways you
can help.
Passlockž
Your vehicle is equipped with the Passlockž
theft-deterrent system.
Passlock
žis a passive theft-deterrent system. Passlockž
enables fuel if the ignition lock cylinder is turned with
a valid key. If a correct key is not used or the ignition
lock cylinder is tampered with, fuel is disabled.
During normal operation, the SECURITY light will
go off approximately ®ve seconds after the key is
turned to RUN.
If the engine stalls and the SECURITY light ¯ashes,
wait until the light stops ¯ashing before trying to restart
the engine. Remember to release the key from
START as soon as the engine starts.
If the engine is running and the SECURITY light comes
on, you will be able to restart the engine if you turn
the engine off. However, your Passlock
žsystem is not
working properly and must be serviced by your
dealer. Your vehicle is not protected by Passlock
žat
this time. You may also want to check the fuse.
See
Fuses and Circuit Breakers on page 5-92. See your
dealer for service.
2-19

Notice:If your key seems stuck in LOCK and you
can't turn it, be sure you are using the correct key;
if so, is it all the way in? Turn the key only with
your hand. Using a tool to force it could break the
key or the ignition switch. If none of these works,
then your vehicle needs service.
B (ACCESSORY):This position lets you use things like
the radio and the windshield wipers when the engine
is off.
Notice:Don't operate accessories in the
ACCESSORY position for long periods of time.
Prolonged operation of accessories in the
ACCESSORY position could drain your battery and
prevent you from starting your vehicle.
C (RUN):This is the position for driving.
D (START):This position starts the engine.
Retained Accessory Power (RAP)
Your vehicle is equipped with a Retained Accessory
Power (RAP) feature which will allow certain features of
your vehicle to continue to work up to 10 minutes
after the ignition key is turned to LOCK.
Your radio and power windows will work when the
ignition key is in RUN or ACCESSORY. Once the key is
turned from RUN to LOCK, these features will continue
to work for up to 10 minutes or until a door is opened.
2-21

Starting Your Engine
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won't start in any other position ± that's a
safety feature. To restart when you're already moving,
use NEUTRAL (N) only.
Notice:Don't try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as
your engine gets warm.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about
15 seconds between each try to help avoid draining
your battery or damaging your starter.
2. If it doesn't start within 10 seconds, push the
accelerator pedal all the way to the ¯oor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.When starting your engine in very cold weather
(below 0ÉF or-18ÉC), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go of
the key.
2. If your engine still won't start (or starts but then
stops), it could be ¯ooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
¯oor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the
vehicle starts brie¯y but then stops again, do the
same thing, but this time keep the pedal down
for ®ve or six seconds. This clears the extra
gasoline from the engine.
Notice:Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer. If you don't, your engine
might not perform properly.
Fuel Regulator
You have a fuel regulator that shuts the fuel off when
the engine reaches 5,600 rpm.
2-22

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

Automatic Transmission Operation
There are several different positions for your shift lever.
PARK (P):This position locks your rear wheels. It's
the best position to use when you start your engine
because your vehicle can't move easily.
{CAUTION:
It is dangerous to get out of your vehicle if the
shift lever is not fully in PARK (P) with the
parking brake ®rmly set. Your vehicle can roll.
Don't leave your vehicle when the engine is
running unless you have to. If you have left the
engine running, the vehicle can move
suddenly. You or others could be injured. To
be sure your vehicle won't move, even when
you're on fairly level ground, always set your
parking brake and move the shift lever to
PARK (P). See ªShifting Into Park (P)º in the
Index. If you're pulling a trailer, see ªTowing a
Trailerº in the Index.Ensure the shift lever is fully in PARK (P) before starting
the engine. Your vehicle has an automatic transmission
shift lock control system. With the ignition in RUN,
you must fully apply your regular brakes before you can
shift from PARK (P).
If you cannot shift out of PARK (P), ease pressure on
the shift lever and push the shift lever all the way
into PARK (P) as you continue pressing the brake pedal.
Then move the shift lever into the gear you want. See
Shifting Out of Park (P) on page 2-29.
REVERSE (R):Use this gear to back up.
Notice:Shifting to REVERSE (R) while your vehicle
is moving forward could damage your transmission.
Shift to REVERSE (R) only after your vehicle is
stopped.
To rock your vehicle back and forth to get out of snow,
ice or sand without damaging your transmission,
see If You Are Stuck: In Sand, Mud, Ice or Snow on
page 4-28.
NEUTRAL (N):In this position, your engine doesn't
connect with the wheels. To restart when you're already
moving, use NEUTRAL (N) only. Also, use
NEUTRAL (N) when your vehicle is being towed.
2-24