2005 CHEVROLET EXPRESS PASSANGER maintenance

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 7-12.
Your vehicle has an airbag system. Before attempting to
do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-71.
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 as soon 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.
California Fuel
If your vehicle is certied to meet California Emission
Standards, it is designed to operate on fuels that
meet California specications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, your
vehicle will operate satisfactorily on fuels meeting
federal specications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-34. If this occurs, return to your authorized GM
dealer for diagnosis. If it is determined that the
condition is caused by the type of fuel used, repairs
may not be covered by your warranty.
5-5

Engine Air Cleaner/Filter
The engine air cleaner/lter is located near the center of
the engine compartment. SeeEngine Compartment
Overview on page 5-12for more information on location.
When to Inspect the Engine Air
Cleaner/Filter
Inspect the air cleaner/lter at the MaintenanceII
intervals and replace it at the rst oil change after each
50,000 mile (83 000 km) interval. SeeScheduled
Maintenance on page 6-4for more information. If you
are driving in dusty/dirty conditions, inspect the lter
at each engine oil change.
How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/lter, remove the lter from
the vehicle and lightly shake the lter to release
loose dust and dirt. If the lter remains caked with dirt, a
new lter is required.
To inspect or replace the engine air cleaner/lter, do the
following:
1. Unhook the retainer clips and remove the cover.
2. Lift the lter out of the engine air cleaner/lter
housing. Care should be taken to dislodge as
little dirt as possible.
3. Clean the engine air cleaner/lter housing.
4. Inspect or replace the engine air cleaner/lter. Make
sure that the lter ts properly into the housing.
5. Reinstall the cover and fasten the retaining clips.
5-18

SeeEngine Compartment Overview on page 5-12for
more information on location.
Flip the handle up and then pull out the dipstick and
wipe it with a clean rag or paper towel.
Push it back in all the way, wait three seconds and
then pull it back out again.
Check both sides of the dipstick, and read the lower
level. The uid level must be in the COLD area for
a cold check or in the HOT or cross-hatched
area for a hot check. Be sure to keep the dipstick
pointed down to get an accurate reading.
If the uid level is in the acceptable range, push the
dipstick back in all the way; then ip the handle
down to lock the dipstick in place.
How to Add Automatic Transmission
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 the incorrect automatic transmission
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transmission uid listed in
Recommended Fluids and Lubricants on page 6-13.
After adding uid, recheck the uid level as
described under “How to Check Automatic
Transmission Fluid,” 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.
5-21

So, it is not a good idea to top off your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add or remove brake uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system. See “Checking Brake Fluid”
in this section.
Refer to the Maintenance Schedule to determine when
to check your brake uid. SeeScheduled Maintenance
on page 6-4.
Checking Brake Fluid
You can check the brake uid without taking off the cap.
Look at the brake uid
reservoir. The uid level
should be above MIN. If it
is not, have your brake
system checked to
see if there is a leak.
After work is done on the brake hydraulic system,
make sure the level is above the MIN but not over the
MAX mark.
5-35

Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality GM
brake parts. When you replace parts of your braking
system — for example, when your brake linings
wear down and you need new ones put in — be sure
you get new approved GM replacement parts. If you do
not, your brakes may no longer work properly. For
example, if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change — for the worse. The braking
performance you have come to expect can change
in many other ways if someone puts in the wrong
replacement brake parts.
Battery
Your vehicle has a maintenance free battery. When it is
time for a new battery, get one that has the replacement
number shown on the original battery’s label. We
recommend an ACDelco
®replacement battery. See
Engine Compartment Overview on page 5-12for battery
location.Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days or
more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-39for tips on working around a battery
without getting hurt.
5-38

3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the remote positive (+) terminal cover to its
original position.
All-Wheel Drive
Lubricant checks in this section also apply to these
vehicles. However, there are two additional systems that
need lubrication.
Transfer Case
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
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’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
Use care not to overtighten the plug.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
5-43

Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.If you have the 1500 Series, the proper level is from
5/8 inch (15 mm) to 1 5/8 inch (40 mm) below the bottom
of the ller plug hole. The proper level for the 2500
and 3500 Series is from 0 to 1/4 (6 mm) below
the bottom of the ller plug hole. Add only enough uid
to reach the proper level.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
5-44