check engine CHEVROLET EXPRESS CARGO VAN 2008 1.G Service Manual

{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 5-29.
Radiator Pressure Cap
The radiator pressure cap is located near the
center of the engine compartment. SeeEngine
Compartment Overview on page 5-14for 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
If your vehicle has the DURAMAX®Diesel engine, see
the DURAMAX®Diesel manual for more information.
You will find an engine coolant temperature gage
on your vehicle’s instrument panel. SeeEngine Coolant
Temperature Gage on page 3-36for more information.
5-27

Power Steering Fluid
The power steering fluid
reservoir is located in the
engine compartment
on the driver’s side of the
vehicle. SeeEngine
Compartment Overview on
page 5-14for reservoir
location.
When to Check Power Steering Fluid
It is not necessary to regularly check power steering fluid
unless you suspect there is a leak in the system or
you hear an unusual noise. A fluid loss in this system
could indicate a problem. Have the system inspected
and repaired.
How to Check Power Steering Fluid
To check the power steering fluid, do the following:
1. Turn the key off and let the engine compartment
cool down.
2. Wipe the cap and the top of the reservoir clean.
3. Unscrew the cap and wipe the dipstick with a
clean rag.
4. Replace the cap and completely tighten it.
5. Then remove the cap again and look at the fluid
level on the dipstick.
The level should be at the COLD FILL mark. If necessary,
add only enough fluid to bring the level up to the mark.
To prevent contamination of brake fluid, never check or
fill the power steering reservoir with the brake master
cylinder cover off.
What to Use
To determine what kind of fluid to use, see
Recommended Fluids and Lubricants on page 6-13.
Always use the proper fluid. Failure to use the proper
fluid can cause leaks and damage hoses and seals.
5-35

Brakes
Brake Fluid
The brake master cylinder
reservoir is filled with
DOT-3 brake fluid. See
Engine Compartment
Overview on page 5-14for
the location of the
reservoir.
There are only two reasons why the brake fluid level in
the reservoir might go down. The first is that the
brake fluid goes down to an acceptable level during
normal brake lining wear. When new linings are put in,
the fluid level goes back up. The other reason is
that fluid is leaking out of the brake hydraulic system.
If it is, you should have the brake hydraulic system fixed,
since a leak means that sooner or later the brakes
will not work well.It is not a good idea to top off the brake fluid. Adding
brake fluid will not correct a leak. If fluid is added when
the linings are worn, there will be too much fluid
when new brake linings are installed. Add or remove
brake fluid, 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 and/or fuel operated heater parts, if
equipped. If your vehicle has a diesel engine
and a fuel operated heater, see “Fuel Operated
Heater (FOH)” in the diesel engine supplement.
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 the brake fluid. SeeScheduled Maintenance
on page 6-4.
5-37

Checking Brake Fluid
The brake fluid can be checked without taking off the
cap by looking at the brake fluid reservoir.
The fluid level should be
above MIN. If it is not,
have the brake hydraulic
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.
What to Add
When you do need brake fluid, use only DOT-3 brake
fluid. Use new brake fluid from a sealed container only.
SeeRecommended Fluids and Lubricants on page 6-13.Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This helps keep
dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in the brake
hydraulic system, the brakes might not work
well. This could cause a crash. Always use the
proper brake uid.
Notice:
Using the wrong uid can badly damage brake
hydraulic system parts. For example, just a
few drops of mineral-based oil, such as engine
oil, in the brake hydraulic system can damage
brake hydraulic system parts so badly that they
will have to be replaced. Do not let someone
put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeWashing
Your Vehicle on page 5-102.
5-38

{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5. Check that the jumper cables do not have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged too.
Before you connect the cables, here are some
basic things you should know. Positive (+) will go to
positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a heavy,
unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.6. Connect the red positive (+) cable to the positive (+)
terminal of the dead battery. Use a remote
positive (+) terminal if the vehicle has one.
5-43

Electrical System
Add-On Electrical Equipment
Notice:Do not add anything electrical to your
vehicle unless you check with your dealer/retailer
rst. Some electrical equipment can damage
your vehicle and the damage would not be covered
by your warranty. Some add-on electrical equipment
can keep other components from working as they
should.
Add-on equipment can drain your vehicle’s battery, even
if your vehicle is not operating.
Your vehicle has an airbag system. Before attempting to
add anything electrical to your vehicle, seeServicing
Your Airbag-Equipped Vehicle on page 1-73.
Headlamp Wiring
The headlamp wiring is protected by fuses in the engine
compartment fuse block. An electrical overload will
cause the lamps to flicker on and off, or in some cases
to remain off. If this happens, have your headlamp
wiring checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker and a fuse. If the motor overheats due to heavy
snow, etc., the wiper will stop until the motor cools.
Although the circuit is protected from electrical overload,
overload due to heavy snow, etc., may cause wiper
linkage damage. Always clear ice and heavy snow from
the windshield before using the windshield wipers. If
the overload is caused by some electrical problem and
not snow, etc., be sure to get it fixed.
Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses and circuit
breakers. This greatly reduces the chance of fires
caused by electrical problems.
Look at the silver-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical
size and rating.
5-109

ApplicationCapacities
English Metric
Fuel Tank
Standard Tank (Passenger and Cargo) 31.0 gal 117.3 L
Standard Tank (Cab and Chassis) 33.0 gal 124.9 L
Optional Tank (Cab and Chassis)* 57.0 gal 215.7 L
* 159 inch (4 039 mm) wheelbase or 177 inch (4 496 mm) wheelbase only
Transmission Capacities
4-SPD 4L60-E Transmission 5.0 qt 4.7 L
4-SPD 4L80-E 7.7 qt 7.3 L
4-SPD 4L80-E Heavy Duty Transmission 7.7 qt 7.3 L
Wheel Nut Torque 140 ft lb 190Y
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this
manual. Recheck fluid level after filling.
Engine Specications
Engine VIN Code Transmission Spark Plug Gap
VORTEC™ 4300 V6 X Automatic 0.060 inches (1.52 mm)
VORTEC™ 4800 V8 C Automatic 0.040 inches (1.01 mm)
VORTEC™ 5300 V8 4 Automatic 0.040 inches (1.01 mm)
VORTEC™ 6000 V8 K Automatic 0.040 inches (1.01 mm)
5-117

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
Using the Maintenance Schedule......................6-3
Scheduled Maintenance...................................6-4
Additional Required Services
(Gasoline Engine).......................................6-6
Maintenance Footnotes (Gasoline Engine)..........6-8
Owner Checks and Services............................6-9At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000 km).......................6-10
At Each Fuel Fill..........................................6-10
At Least Once a Month.................................6-10
At Least Once a Year...................................6-11
Recommended Fluids and Lubricants...............6-13
Maintenance Replacement Parts.....................6-15
Engine Drive Belt Routing..............................6-16
Maintenance Record.....................................6-17
Section 6 Maintenance Schedule
6-1

Maintenance Schedule
Introduction
This maintenance section applies to vehicles with a
gasoline engine. If your vehicle has a diesel engine,
see the maintenance schedule section in the
DURAMAX
®Diesel manual.
Important: Keep engine oil at the proper level and
change as recommended.
Have you purchased the GM Protection Plan? The Plan
supplements your new vehicle warranties. See your
Warranty and Owner Assistance booklet or your
dealer/retailer for details.
Maintenance Requirements
Notice:Maintenance intervals, checks, inspections,
replacement parts, and recommended uids and
lubricants as prescribed in this manual are
necessary to keep your vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance might not be covered
by warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance is
important. Improper vehicle maintenance can even affect
the quality of the air we breathe. Improper fluid levels or
the wrong tire inflation can increase the level of emissions
from your vehicle. To help protect our environment, and
to keep your vehicle in good condition, be sure to
maintain your vehicle properly.
6-2

Using the Maintenance Schedule
We want to help you keep your vehicle in good working
condition. But we do not know exactly how you will
drive it. You might drive very short distances only a few
times a week. Or you might drive long distances all the
time in very hot, dusty weather. You might use your
vehicle in making deliveries. Or you might drive it to work,
to do errands, or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You might need more
frequent checks and replacements. So please read the
following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your dealer/retailer.
This schedule is for vehicles that:
•carry passengers and cargo within recommended
limits. You will find these limits on the Tire and
Loading Information label. SeeLoading Your
Vehicle on page 4-20.
•are driven on reasonable road surfaces within legal
driving limits.
•use the recommended fuel. SeeGasoline Octane
on page 5-6.The services inScheduled Maintenance on page 6-4
should be performed when indicated. SeeAdditional
Required Services (Gasoline Engine) on page 6-6and
Maintenance Footnotes (Gasoline Engine) on page 6-8
for further information.
{CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you
can be seriously injured. Do your own
maintenance work only if you have the
required know-how and the proper tools and
equipment for the job. If you have any doubt,
see your dealer/retailer to have a qualied
technician do the work. SeeDoing Your Own
Service Work on page 5-4.
Some maintenance services can be complex. So,
unless you are technically qualified and have the
necessary equipment, you should have your
dealer/retailer do these jobs.
6-3