2004 CHEVROLET EXPRESS fuel cap

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-31
Airbag System
.........................................1-59
Restraint System Check
............................1-70
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-15
Theft-Deterrent Systems
............................2-18
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-29
OnStar
®System
......................................2-31
Storage Areas
.........................................2-32
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-18
Warning Lights, Gages, and Indicators
........3-22
Audio System(s)
.......................................3-39
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
........ 4-2
Towing
...................................................4-34Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
All-Wheel Drive
........................................5-43
Rear Axle
...............................................5-44
Front Axle
...............................................5-44
Noise Control System
...............................5-45
Bulb Replacement
....................................5-46
Windshield Wiper Blade Replacement
.........5-51
Tires
......................................................5-52
Appearance Care
.....................................5-82
Vehicle Identication
.................................5-91
Electrical System
......................................5-92
Capacities and Specications
.....................5-97
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index.................................................................1
2005 Chevrolet Express Owner ManualM

If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
Reducing vehicle speed
Avoiding hard accelerations
Avoiding steep uphill grades
If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible
If the light stops ashing and remains on steady, see “If
the Light Is On Steady” following.
If the light continues to ash, when it is safe to do so,
stop the vehicle. Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see “If
the Light Is On Steady” following. If the light is still
ashing, follow the previous steps, and see your dealer
for service as soon as possible.
If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. SeeFilling Your Tank on page 5-8. The
diagnostic system can determine if the fuel cap hasbeen left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel. See
Gasoline Octane on page 5-5. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, misring, hesitation
on acceleration, or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.
If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to x
any mechanical or electrical problems that may
have developed.
3-33

Listed are four situations you may experience with your
fuel gage:
At the gas station, the fuel pump shuts off before
the gage reads full.
It takes a little more or less fuel to ll up than the
fuel gage indicated. For example, the gage may
have indicated the tank was half full, but it actually
took a little more or less than half the tank’s
capacity to ll the tank.
The gage moves a little when you turn a corner or
speed up.
The gage doesn’t go back to empty when you turn
off the ignition.
None of these indicate a problem with the fuel gage.
Audio System(s)
Notice:Before adding any sound equipment to
your vehicle, like a tape player, CB radio, mobile
telephone, or two-way radio, make sure that it can
be added by checking with your dealer. Also,
check federal rules covering mobile radio and
telephone units. If sound equipment can be added,
it is very important to do it properly. Added
sound equipment may interfere with the operation
of your vehicle’s engine, radio, or other systems,
and even damage them. Your vehicle’s systems may
interfere with the operation of sound equipment
that has been added improperly.
Figure out which audio system is in your vehicle, nd
out what your audio system can do, and how to operate
all of its controls.
Your vehicle may have a feature called Retained
Accessory Power (RAP). With RAP, the audio system
can be played even after the ignition is turned off.
SeeRetained Accessory Power (RAP) on page 2-19for
more information.
3-39

Item Description Total
AVehicle Capacity Weight
for Example 3=1,000 lbs (453 kg)
BSubtract Occupant
Weight 200 lbs
(91 kg)×5=1000 lbs (453 kg)
CAvailable Cargo
Weight=0 lbs (0 kg)
Refer to your vehicle’s tire and loading information label
for specic information about your vehicle’s capacity
weight and seating positions. The combined weight of
the driver, passengers and cargo should never
exceed your vehicle’s capacity weight.
Certication/Tire Label
A vehicle specic Certication/Tire label is found on the
rear edge of the driver’s door. The label shows the
size of your vehicle’s original tires and the ination
pressures needed to obtain the gross weight capacity of
your vehicle. This is called Gross Vehicle Weight
Rating (GVWR). The GVWR includes the weight of the
vehicle, all occupants, fuel and cargo. Example 3
4-32

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Oil Life System..................................5-16
Engine Air Cleaner/Filter................................5-17
Automatic Transmission Fluid.........................5-19
Engine Coolant.............................................5-22
Radiator Pressure Cap..................................5-24
Engine Overheating.......................................5-24
Cooling System............................................5-26
Engine Fan Noise.........................................5-32
Power Steering Fluid.....................................5-32
Windshield Washer Fluid................................5-33Brakes........................................................5-34
Battery........................................................5-37
Jump Starting...............................................5-38
All-Wheel Drive..............................................5-43
Rear Axle.......................................................5-44
Front Axle......................................................5-44
Noise Control System.....................................5-45
Tampering with Noise Control System
Prohibited.................................................5-45
Bulb Replacement..........................................5-46
Halogen Bulbs..............................................5-47
Headlamps..................................................5-47
Front Turn Signal, Sidemarker and
Parking Lamps..........................................5-48
Center High-Mounted Stoplamp (CHMSL).........5-49
Taillamps.....................................................5-49
Replacement Bulbs.......................................5-50
Windshield Wiper Blade Replacement..............5-51
Tires..............................................................5-52
Tire Sidewall Labelling...................................5-53
Tire Terminology and Denitions.....................5-56
Ination - Tire Pressure.................................5-58
Dual Tire Operation.......................................5-59
Tire Inspection and Rotation...........................5-60
When It Is Time for New Tires.......................5-62
Section 5 Service and Appearance Care
5-1

Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is
located behind a hinged
fuel door on the driver’s
side of the vehicle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise).
While refueling, hang the tethered fuel cap from the
hook on the fuel door.
5-8

{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly.
This spray can happen if your tank is nearly
full, and is more likely in hot weather. Open
the fuel cap slowly and wait for any hiss noise
to stop. Then unscrew the cap all the way.
Be careful not to spill fuel. Do not top off or overll the
tank and wait a few seconds after you have nished
pumping before removing the nozzle. Clean fuel
from painted surfaces as soon as possible. See
Washing Your Vehicle on page 5-86.
When replacing the fuel cap, turn it to the right
(clockwise) until it clicks. Make sure the cap is fully
installed. The diagnostic system can determine if the fuel
cap has been left off or improperly installed. This
would allow fuel to evaporate into the atmosphere. See
Malfunction Indicator Lamp on page 3-32.
{CAUTION:
If a re starts while you are refueling, do not
remove the nozzle. Shut off the ow of fuel by
shutting off the pump or by notifying the
station attendant. Leave the area immediately.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. SeeMalfunction Indicator Lamp on
page 3-32.
5-9

A. Battery. SeeBattery on page 5-37.
B. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-24.
C. Coolant Recovery Tank. SeeCooling System on
page 5-26.
D. Automatic Transmission Fluid Dipstick. See
“Checking the Fluid Level” underAutomatic
Transmission Fluid on page 5-19.
E. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
F. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
G. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-17.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-32.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-34.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-33.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull out the dipstick and clean it with a paper towel
or cloth, then push it back in all the way. Remove it
again, keeping the tip down, and check the level.
5-13