2005 CHEVROLET EXPRESS service

Before Leaving on a Long Trip
Make sure you are ready. Try to be well rested. If you
must start when you are not fresh — such as after
a day’s work — do not plan to make too many miles that
rst part of the journey. Wear comfortable clothing
and shoes you can easily drive in.
Is your vehicle ready for a long trip? If you keep it
serviced and maintained, it is ready to go. If it needs
service, have it done before starting out. Of course, you
will nd experienced and able service experts in GM
dealerships all across North America. They will be ready
and willing to help if you need it.
Here are some things you can check before a trip:
Windshield Washer Fluid:Is the reservoir full? Are
all windows clean inside and outside?
Wiper Blades:Are they in good shape?
Fuel, Engine Oil, Other Fluids:Have you checked
all levels?
Lamps:Are they all working? Are the lenses clean?
Tires:They are vitally important to a safe,
trouble-free trip. Is the tread good enough for
long-distance driving? Are the tires all inated to the
recommended pressure?
Weather Forecasts:What is the weather outlook
along your route? Should you delay your trip a
short time to avoid a major storm system?
Maps:Do you have up-to-date maps?
Highway Hypnosis
Is there actually such a condition as highway hypnosis?
Or is it just plain falling asleep at the wheel? Call it
highway hypnosis, lack of awareness, or whatever.
There is something about an easy stretch of road with
the same scenery, along with the hum of the tires on the
road, the drone of the engine, and the rush of the
wind against the vehicle that can make you sleepy. Do
not let it happen to you! If it does, your vehicle can
leave the road in less than a second, and you could
crash and be injured.
What can you do about highway hypnosis? First, be
aware that it can happen.
Then here are some tips:
Make sure your vehicle is well ventilated, with a
comfortably cool interior.
Keep your eyes moving. Scan the road ahead and
to the sides. Check your mirrors and your
instruments frequently.
If you get sleepy, pull off the road into a rest,
service, or parking area and take a nap, get some
exercise, or both. For safety, treat drowsiness
on the highway as an emergency.
4-21

Towing
Towing Your Vehicle
Consult your dealer or a professional towing service if
you need to have your disabled vehicle towed. See
Roadside Assistance Program on page 7-6.
If you want to tow your vehicle behind another vehicle
for recreational purposes (such as behind a motorhome),
see “Recreational Vehicle Towing” following.
Recreational Vehicle Towing
Recreational vehicle towing means towing your vehicle
behind another vehicle — such as behind a motorhome.
The two most common types of recreational vehicle
towing are known as “dinghy towing” (towing your vehicle
with all four wheels on the ground) and “dolly towing”
(towing your vehicle with two wheels on the ground and
two wheels up on a device known as a “dolly”).
Notice:Towing an all-wheel-drive vehicle with all
four wheels on the ground, or even with only two of
its wheels on the ground, will damage drivetrain
components. Do not tow an all-wheel-drive vehicle if
any of its wheels will be on the ground.
Your vehicle was not designed to be towed with any of
its wheels on the ground. If your vehicle must be
towed, it should be placed on a platform trailer.
Towing a Trailer
{CAUTION:
If you do not use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well — or even
at all. You and your passengers could be
seriously injured. Pull a trailer only if you have
followed all the steps in this section. Ask your
dealer for advice and information about towing
a trailer with your vehicle.
Notice:Pulling a trailer improperly can damage
your vehicle and result in costly repairs that would
not be covered by your warranty. Always follow
the instructions in this section and check with your
dealer for more information about towing a trailer
with your vehicle.
To identify the trailering capacity of your vehicle, you
should read the information in “Weight of the Trailer” that
appears later in this section.
4-34

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 overll),
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.
Trailer Wiring Harness
The optional heavy-duty trailer wiring package includes
a seven-wire harness assembly at the rear of the
vehicle and a four-wire harness assembly under the left
hand side of the instrument panel. The seven-wire
harness assembly is taped together and located in a
frame pocket at the driver side rear left corner of
the frame. The seven-wire harness includes a 30-amp
feed wire. Both harnesses come without connectors and
should be wired by a qualied electrical technician.
The technician can use the following color code chart
when connecting the wiring harness to your trailer
and trailer brake controller.
Seven-Wire Harness
Light Green: Back-up lamps
Brown: Parking lamps
Yellow: Left stoplamp and turn signal
Dark Green: Right stoplamp and turn signal
Dark Blue: Use for electric trailer brakes
Orange: Trailer accessory
White (heavy gage): Ground wire
Four-Wire Harness (Trailer Brake Controller)
Black: Ground
Red/White Stripe: Fused Battery
Dark Blue: Trailer Brake Feed
Light Blue: Fused Stoplamp/CHMSL
4-46

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

Buying New Tires.........................................5-62
Uniform Tire Quality Grading..........................5-63
Wheel Alignment and Tire Balance..................5-64
Wheel Replacement......................................5-65
Tire Chains..................................................5-66
If a Tire Goes Flat........................................5-67
Changing a Flat Tire.....................................5-68
Removing the Spare Tire and Tools................5-69
Removing the Flat Tire and Installing the
Spare Tire................................................5-72
Secondary Latch System...............................5-77
Storing a Flat or Spare Tire and Tools............5-80
Spare Tire...................................................5-82
Appearance Care............................................5-82
Fabric/Carpet...............................................5-83
Vinyl...........................................................5-85
Instrument Panel..........................................5-85
Interior Plastic Components............................5-85
Glass Surfaces.............................................5-85
Care of Safety Belts......................................5-85
Weatherstrips...............................................5-86
Washing Your Vehicle...................................5-86Cleaning Exterior Lamps/Lenses.....................5-86
Finish Care..................................................5-86
Windshield and Wiper Blades.........................5-87
Aluminum Wheels.........................................5-88
Tires...........................................................5-88
Sheet Metal Damage.....................................5-89
Finish Damage.............................................5-89
Underbody Maintenance................................5-89
Chemical Paint Spotting.................................5-89
Vehicle Care/Appearance Materials..................5-90
Vehicle Identication......................................5-91
Vehicle Identication Number (VIN).................5-91
Service Parts Identication Label.....................5-91
Electrical System............................................5-92
Add-On Electrical Equipment..........................5-92
Headlamp Wiring..........................................5-92
Windshield Wiper Fuses................................5-92
Fuses and Circuit Breakers............................5-92
Floor Console Fuse Block..............................5-93
Engine Compartment Fuse Block....................5-94
Capacities and Specications..........................5-97
Section 5 Service and Appearance Care
5-2

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-11.
Your vehicle has an airbag system. Before attempting to
do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-69.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeeMaintenance Record on page 6-16.{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts and
other fasteners. English and metric
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
5-4

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airow around it. This may cause wind
noise and affect windshield washer performance. Check
with your dealer before adding equipment to the
outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher assoon as possible. Otherwise, you might damage your
engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of
Automobile Manufacturers at
www.autoalliance.org/fuel_charter.htm. Gasoline
meeting these specications could provide improved
driveability and emission control system performance
compared to other gasoline.
5-5