2003 CHEVROLET EXPRESS CARGO VAN manual transmission

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

{CAUTION:
Shifting into a drive gear while your engine is
ªracingº (running at high speed) is dangerous.
Unless your foot is ®rmly on the brake pedal,
your vehicle could move very rapidly. You
could lose control and hit people or objects.
Don't shift into a drive gear while your engine
is racing.
Notice:Damage to your transmission caused by
shifting out of PARK (P) or NEUTRAL (N) with
the engine racing isn't covered by your warranty.
DRIVE (D):This position is for normal driving. If
you need more power for passing, and you're:
·Going less than about 35 mph (55 km/h), push your
accelerator pedal about halfway down.
·Going about 35 mph (55 km/h) or more, push the
accelerator all the way down.
You'll shift down to the next gear and have more power.
THIRD (3):This position is also used for normal
driving, however, it offers more power and lower fuel
economy than DRIVE (D). You should use THIRD (3)
when carrying a heavy load or driving on steep hills.You should use THIRD (3) (or, as you need to, a lower
gear) when towing a trailer to minimize heat build-up
and extend the life of your transmission.
SECOND (2):This position gives you more power but
lower fuel economy than THIRD (3). You can use
SECOND (2) on hills. It can help control your speed as
you go down steep mountain roads, but then you
would also want to use your brakes off and on. If you
manually select SECOND (2), the transmission will drive
in SECOND (2). You may use this feature for reducing
torque to the rear wheels when you are trying to
start your vehicle from a stop on slippery road surfaces.
FIRST (1):This position gives you even more power but
lower fuel economy than SECOND (2). You can use it on
very steep hills, or in deep snow or mud. If the shift lever
is put in FIRST (1), the transmission won't shift into ®rst
gear until the vehicle is going slowly enough.
Notice:If your wheels won't turn, don't try to drive.
This might happen if you were stuck in very deep
sand or mud or were up against a solid object. You
could damage your transmission. Also, if you
stop when going uphill, don't hold your vehicle there
with only the accelerator pedal. This could overheat
and damage the transmission. Use your brakes
or shift into PARK (P) to hold your vehicle in
position on a hill.
2-25

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.
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 ¯uid (don't over®ll),
engine oil, axle lubricant, belt, cooling system and
brake system. Each of these is covered in this manual,
and the Index will help you ®nd 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.
4-43

If NHTSA receives similar complaints, it may open an
investigation, and if it ®nds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you'll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-9

Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and speci®cations for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
Owner's Information
Owner publications are written speci®cally for owners
and intended to provide basic operational information
about the vehicle. The owner's manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner's Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00Without Portfolio: Owner's Manual only.
RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on
the World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P. O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-10

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:
·They contain acid that can burn you.
·They contain gas that can explode or
ignite.
·They contain enough electricity to
burn you.
If you don't follow these steps exactly, some
or all of these things can hurt you.
Notice:Ignoring these steps could result in costly
damage to your vehicle that wouldn't be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
won't work, and it could damage your vehicle.1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other system isn't a 12-volt system
with a negative ground, both vehicles can be
damaged.
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 ®rmly 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.
Notice:If you leave your radio on, it could be badly
damaged. The repairs wouldn't be covered by
your warranty.
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!
5-41

Capacities and Speci®cations
All capacities are approximate. When adding, be sure to ®ll to the appropriate level or as recommended in this
manual.
See refrigerant charge label under the hood for charge capacity information and requirements.
Engine Speci®cations
Engine VIN Code Transmission Spark Plug Gap Firing OrderWheel Nut
Torque
VORTECŸ 4300 V6
MFI
1W M300.060 inches
(1.52 mm)1±6±5±4±3±2140 lb ft
190Y
VORTECŸ 4800 V8
MFI
1V MT10.060 inches
(1.52 mm)1±8±7±2±6±5±4±3140 lb ft
190Y
VORTECŸ 5300 V8
MFI
1T M300.060 Inches
(1.52 mm)1±8±7±2±6±5±4±3140 lb ft
190Y
VORTECŸ 6000 V8
MFI
1U MT10.060 inches
(1.52 mm)1±8±7±2±6±5±4±3140 lb ft
190Y
1Sequential Fuel Injection
5-97

H
Hazard Warning Flashers................................... 3-5
Headlamp High/Low Beam Changer.................... 3-8
Headlamp Wiring............................................5-91
Headlamps....................................................5-50
Bulb Replacement.......................................5-50
Front Turn Signal, Sidemarker and Parking
Lamps....................................................5-52
Halogen Bulbs............................................5-50
Highway Hypnosis...........................................4-21
Hill and Mountain Roads..................................4-22
Hitches..........................................................4-39
Hood.............................................................. 5-9
Checking Things Under.................................. 5-9
Release.....................................................5-10
Horn............................................................... 3-6
How to Add Coolant to the Coolant
Recovery Tank............................................5-28
How to Add Coolant to the Radiator..................5-31
How to Add Fluid............................................5-21
How to Check Lubricant...................................5-47
How to Check Power Steering Fluid..................5-35
How to Check........................................5-19, 5-57
How to Inspect the Engine Air Cleaner/Filter.......5-18How to Reset the CHANGE ENGINE
OIL Light....................................................5-16
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-15
Hydroplaning..................................................4-16
I
If No Steam Is Coming From Your Engine..........5-25
If Steam Is Coming From Your Engine...............5-24
If the Light Is Flashing.....................................3-34
If the Light Is On Steady.................................3-35
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-32
If You're Caught in a Blizzard...........................4-26
Ignition Positions.............................................2-20
Ignition Transmission Lock Check......................6-14
Infants and Young Children, Restraints...............1-36
In¯ation -- Tire Pressure..................................5-56
Inside Day/Night Rearview Mirror......................2-31
Inspection......................................................6-17
Brake System.............................................6-17
Engine Cooling System................................6-16
Exhaust System..........................................6-16
Fuel System...............................................6-16
Part C - Periodic Maintenance.......................6-16
7