2004 CHEVROLET EXPRESS CARGO VAN maintenance

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.
If the level is below the
bottom of the ller plug
hole, you may need to add
some lubricant.When the differential is cold, add enough lubricant to
raise the level to 3/8 inch (10 mm) below the ller
plug hole.
When the differential is at operating temperature
(warm), add enough lubricant to raise the level to the
bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-12.
5-50

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.Among those acts presumed to constitute tampering are
the acts listed below.
Insulation:

Removal of the noise shields or any underhood
insulation.
Engine:

Removal or rendering engine speed governor (if
equipped) inoperative so as to allow engine
speed to exceed manufacturer specications.
Fan and Drive:

Removal of fan clutch (if equipped) or rendering
clutch inoperative.
Removal of the fan shroud (if equipped).
Air Intake:

Removal of the air cleaner silencer.
Modication of the air cleaner.
Exhaust:

Removal of the muffler and/or resonator.
Removal of the exhaust pipes and exhaust pipe
clamps.
5-51

Replacement Bulbs
Exterior Lamp Bulb Number
Back-up Lamp 3157
CHMSL 912
Composite High-Beam
Headlamps9005
Composite Low-Beam
Headlamps9006GS
Front Parking and Turn Lamp 3157KX
Front Sidemarker Lamp 194
Sealed Beam Headlamps H6054
Rear Parking, Stop, and
Turn Lamp3157
For any bulb not listed here, contact your dealer.
Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking. See″Wiper
Blade Check” inScheduled Maintenance on page 6-4.
5-56

When to Check
Check your tires once a month or more.
Also, check the tire pressure of the spare tire.
How to Check
Use a good quality pocket-type gage to check tire
pressure. You can’t tell if your tires are properly inated
simply by looking at them. Radial tires may look
properly inated even when they’re underinated. Check
the tire’s ination pressure when the tires are cold.
Cold means your vehicle has been sitting for at least
three hours or driven no more than 1 mile (1.6 km).
Remove the valve cap from the tire valve stem. Press
the tire gage rmly onto the valve to get a pressure
measurement. If the cold tire ination pressure matches
the recommended pressure on the tire and loading
information label, no further adjustment is necessary.
If the pressure is low, add air until you reach the
recommended amount.
If you overll the tire, release air by pushing on the
metal stem in the center of the tire valve. Recheck the
tire pressure with the tire gage.
Be sure to put the valve caps back on the valve stems.
They help prevent leaks by keeping out dirt and moisture.
Dual Tire Operation
When the vehicle is new, or whenever a wheel, wheel
bolt or wheel nut is replaced, check the wheel nut torque
after 100, 1,000 and 6,000 miles (160, 1 600 and
10 000 km) of driving. For proper wheel nut tightening
information, see “Removing the Flat Tire and Installing
the Spare Tire” later in this section, underChanging
a Flat Tire on page 5-76. Also see “Wheel Nut Torque”
underCapacities and Specications on page 5-106.
The outer tire on a dual wheel setup generally wears
faster than the inner tire. Your tires will wear more
evenly and last longer if you rotate the tires periodically.
SeeTire Inspection and Rotation on page 5-68. Also
seeScheduled Maintenance on page 6-4.
{CAUTION:
If you operate your vehicle with a tire that is
badly underinated, the tire can overheat. An
overheated tire can lose air suddenly or catch
re. You or others could be injured. Be sure all
tires (including the spare) are properly inated.
SeeTires on page 5-58andInation - Tire Pressure on
page 5-66for more information on proper tire ination.
5-67

Tire Inspection and Rotation
Tires should be rotated every 5,000 to 8,000 miles
(8 000 to 13 000 km).
Any time you notice unusual wear, rotate your tires as
soon as possible and check wheel alignment. Also
check for damaged tires or wheels. SeeWhen It Is Time
for New Tires on page 5-69andWheel Replacement
on page 5-72for more information.
Make sure 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 5-76.
If your vehicle has dual rear wheels, also seeDual Tire
Operation on page 5-67.
The purpose of regular rotation is to achieve more
uniform wear for all tires on the vehicle. The rst rotation
is the most important. SeeScheduled Maintenance
on page 6-4.If your vehicle has single rear wheels, always use one
of the correct rotation patterns shown here when rotating
your vehicle’s tires.
If your vehicle has dual rear wheels, always use one of
the correct rotation patterns shown here when rotating
your tires.
5-68

If a Tire Goes Flat
It’s unusual for a tire to “blowout” while you’re driving,
especially if you maintain your tires properly. If air goes
out of a tire, it’s much more likely to leak out slowly.
But if you should ever have a “blowout,” here are a few
tips about what to expect and what to do:
If a front tire fails, the at tire will create a drag that
pulls the vehicle toward that side. Take your foot off the
accelerator pedal and grip the steering wheel rmly.
Steer to maintain lane position, and then gently brake to
a stop well out of the traffic lane.
A rear blowout, particularly on a curve, acts much like a
skid and may require the same correction you’d use
in a skid. In any rear blowout, remove your foot from the
accelerator pedal. Get the vehicle under control by
steering the way you want the vehicle to go. It may be
very bumpy and noisy, but you can still steer. Gently
brake to a stop, well off the road if possible.{CAUTION:
Lifting a vehicle and getting under it to do
maintenance or repairs is dangerous without
the appropriate safety equipment and training.
The jack provided with your vehicle is
designed only for changing a at tire. If it is
used for anything else, you or others could be
badly injured or killed if the vehicle slips off
the jack. Use the jack provided with your
vehicle only for changing a at tire.
If a tire goes at, the next part shows how to use your
jacking equipment to change a at tire safely.
5-75

Sheet Metal Damage
If your vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti-corrosion material to parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide the
corrosion protection while maintaining the warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the
nish should be repaired right away. Bare metal
will corrode quickly and may develop into major repair
expense.
Minor chips and scratches can be repaired with touch-up
materials avaliable from your dealer. Larger areas of
nish damage can be corrected in your dealer’s
body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are not
removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, oor pan and
exhaust system even though they have corrosion
protection.At least every spring, ush these materials from the
underbody with plain water. Clean any areas where mud
and debris can collect. Dirt packed in close areas of
the frame should be loosened before being ushed.
Your dealer or an underbody car washing system can
do this for you.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on your vehicle. This damage
can take two forms: blotchy, ring-shaped discolorations,
and small, irregular dark spots etched into the paint
surface.
Although no defect in the paint job causes this, GM will
repair, at no charge to the owner, the surfaces of
new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs rst.
5-98

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
Using Your Maintenance Schedule....................6-3
Scheduled Maintenance...................................6-4
Additional Required Services............................6-6
Maintenance Footnotes...................................6-7
Owner Checks and Services............................6-9
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000 km).........................6-9At Each Fuel Fill............................................6-9
At Least Once a Month.................................6-10
At Least Once a Year...................................6-10
Recommended Fluids and Lubricants...............6-12
Normal Maintenance Replacement Parts..........6-14
Engine Drive Belt Routing..............................6-15
Maintenance Record.....................................6-16
Section 6 Maintenance Schedule
6-1