2004 CHEVROLET EXPRESS radiator

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

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

How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission uid to use. SeeRecommended
Fluids and Lubricants on page 6-13.
Using a funnel, add uid down the transmission dipstick
tube only after checking the transmission uid while it
is hot. A cold check is used only as a reference. If
the uid level is low, add only enough of the proper uid
to bring the level up to the HOT area for a hot check.
It does not take much uid, generally less than one pint
(0.5 L).Do not overll.
Notice:Use of automatic transmission uid labeled
other than DEXRON
®-III, Approved for the
H-Specication, may damage your vehicle, and the
damages may not be covered by your warranty.
Always use automatic transmission uid labeled
DEXRON
®-III, Approved for the H-Specication.
After adding uid, recheck the uid level as
described under “How to Check,” earlier in
this section.
When the correct uid level is obtained, push the
dipstick back in all the way; then ip the handle
down to lock the dipstick in place.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for ve years or 150,000 miles
(240 000 km), whichever occurs rst, if you add only
DEX-COOL
®extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating on
page 5-24.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as
they should.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-22

What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOL®coolant which will not damage
aluminum parts. If you use this coolant mixture, you do
not need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and the proper coolant.
Notice:If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost would not be covered by your
warranty. Too much water in the mixture can freeze
and crack the engine, radiator, heater core and
other parts.If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice:If you use the proper coolant, you do not
have to add extra inhibitors or additives which claim
to improve the system. These can be harmful.
Checking Coolant
The coolant recovery tank
is located near the center
of the engine
compartment. SeeEngine
Compartment Overview
on page 5-12for more
information on location.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the COLD
FILL mark, or a little higher.
5-23

Adding Coolant
If you need more coolant, add the proper DEX-COOL®
coolant mixtureat the coolant recovery tank,but be
careful not to spill it.
{CAUTION:
Turning the radiator pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. With the coolant recovery tank, you will
almost never have to add coolant at the
radiator. Never turn the radiator pressure
cap — even a little — when the engine and
radiator are hot.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.Occasionally check the coolant level in the radiator. For
information on how to add coolant to the radiator,
seeCooling System on page 5-26.
Radiator Pressure Cap
The radiator pressure cap is located near the center of
the engine compartment. SeeEngine Compartment
Overview on page 5-12for more information on location.
Notice:If the pressure cap is not tightly installed,
coolant loss and possible engine damage may
occur. Be sure the cap is properly and tightly
secured.
Engine Overheating
You will nd an engine coolant temperature gage on
your vehicle’s instrument panel. SeeEngine Coolant
Temperature Gage on page 3-31for more information.
5-24

If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. In heavy traffic, let the engine idle in NEUTRAL (N)
while stopped. If it is safe to do so, pull off the road,
shift to PARK (P) or NEUTRAL (N) and let the
engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the windows as necessary.
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning does not come back on, you can drive
normally.
If the warning continues, and you have not stopped, pull
over, stop, and park your vehicle right away.
If there is still no sign of steam, push down the
accelerator until the engine speed is about twice as fast
as normal idle speed for at least three minutes while
you are parked. If you still have the warning,turn off the
engine and get everyone out of the vehicleuntil it
cools down.
You may decide not to lift the hood but to get service
help right away.Cooling System
When you decide it is safe to lift the hood, here is what
you will see:
A. Radiator Pressure Cap
B. Coolant Recovery Tank
C. Engine Cooling Fan(s)
If the coolant inside the coolant recovery tank is boiling,
do not do anything else until it cools down.
5-26

When the engine is cold, the coolant level should be at
or above the COLD FILL mark. If it is not, you may
have a leak at the pressure cap or in the radiator hoses,
heater hoses, radiator, water pump or somewhere
else in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive
the vehicle.If there seems to be no leak, start the engine again.
See if the engine cooling fan speed increases when idle
speed is doubled by pushing the accelerator pedal
down. If it does not, your vehicle needs service. Turn off
the engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-27

How to Add Coolant to the Coolant
Recovery Tank
If you have not found a problem yet, but the coolant
level is not at the COLD FILL mark, add a 50/50 mixture
ofclean, drinkable waterand DEX-COOL
®engine
coolant at the coolant recovery tank. SeeEngine
Coolant on page 5-22for more information.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.Notice:
When using concentrated washer uid,
follow the manufacturer’s instructions for
adding water.
Do not mix water with ready-to-use washer uid.
Water can cause the solution to freeze and
damage your washer uid tank and other parts
of the washer system. Also, water does not
clean as well as washer uid.
Fill your washer uid tank only three-quarters
full when it is very cold. This allows for
expansion if freezing occurs, which could
damage the tank if it is completely full.
Do not use engine coolant (antifreeze) in your
windshield washer. It can damage your washer
system and paint.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
5-28