engine CHEVROLET EXPRESS CARGO VAN 2009 1.G Owners Manual

Capacities and Specications
If your vehicle has the DURAMAX Diesel engine, see the DURAMAX Diesel manual for more information.
The following approximate capacities are given in English and metric conversions. SeeRecommended Fluids and
Lubricants on page 6-13for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134aFor the air conditioning system refrigerant charge
amount, see the refrigerant caution label located
under the hood. See your dealer/retailer for more
information.
Cooling System
4.3L V6 10.0 qt 9.5 L
4.8L V8, 5.3L V8 12.4 qt 11.8 L
6.0L V8 13.8 qt 13.1 L
Cooling System with Rear Heat
4.3L V6 13.0 qt 12.3 L
4.8L V8, 5.3L V8 15.4 qt 14.6 L
6.0L V8 17.0 qt 16.1 L
Engine Oil with Filter
4.3L V6 4.5 qt 4.3 L
4.8L V8, 5.3L V8, 6.0L V8 6.0 qt 5.7 L
5-111

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 Fluid
4-SPD 4L60-E 5.0 qt 4.7 L
4-SPD 4L80-E (Standard and Heavy Duty) 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
4.3L V6 X Automatic 0.060 in (1.52 mm)
4.8L V8 C Automatic 0.040 in (1.01 mm)
5.3L V8 4 Automatic 0.040 in (1.01 mm)
6.0L V8 K Automatic 0.040 in (1.01 mm)
5-112

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............................6-6
Maintenance Footnotes (Gasoline Engine)..........6-8
Owner Checks and Services..........................6-10At 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.................................6-11
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. For diesel engine vehicles, 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 the vehicle warranties. See the 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 this vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance might not be covered by the
vehicle warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep
the 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 the vehicle. To help protect
the environment, and to keep the vehicle in good
condition, be sure to maintain the vehicle properly.
6-2

Using the Maintenance Schedule
We want to help keep this 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 the 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 the vehicle in good condition,
see your dealer/retailer.
This schedule is for vehicles that:
•carry passengers and cargo within recommended
limits on the Tire and Loading Information label.
SeeLoading the Vehicle on page 4-19.
•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 on page 6-6andMaintenance
Footnotes (Gasoline Engine) on page 6-8for 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
qualified 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, have your dealer/retailer do these jobs.
When you go to your dealer/retailer for service, trained
and supported service technicians will perform the
work using genuine parts.
6-3

To purchase service information, seeService
Publications Ordering Information on page 7-16.
Owner Checks and Services on page 6-10tells what
should be checked, when to check it, and what can easily
be done to help keep the vehicle in good condition.
The proper replacement parts, fluids, and lubricants to
use are listed inRecommended Fluids and Lubricants
on page 6-13andMaintenance Replacement Parts
on page 6-15. When the vehicle is serviced, make sure
these are used. All parts should be replaced and all
necessary repairs done before you or anyone else
drives the vehicle. We recommend the use of genuine
parts from your dealer/retailer.
Scheduled Maintenance
This maintenance section applies to vehicles with a
gasoline engine. For diesel engine vehicles, see
the maintenance schedule section in the DURAMAX
®
Diesel manual.
When the CHANGE ENGINE OIL SOON message
displays, service is required for the vehicle. Have the
vehicle serviced as soon as possible within the next
600 miles (1 000 km). It is possible that, if driving under
the best conditions, the engine oil life system may
not indicate that vehicle service is necessary for over
a year. However, the engine oil and filter must be
changed at least once a year and at this time the systemmust be reset. Your dealer/retailer has trained service
technicians who will perform this work using genuine
parts and reset the system.
If the engine oil life system is ever reset accidentally,
service the vehicle within 3,000 miles (5 000 km)
since the last service. Remember to reset the oil life
system whenever the oil is changed. SeeEngine Oil Life
System on page 5-18for information on the Engine
Oil Life System and resetting the system.
When the CHANGE ENGINE OIL SOON message
appears, certain services, checks, and inspections are
required. Required services are described in the
following for “MaintenanceI” and “MaintenanceII.”
Generally, it is recommended that the first service be
MaintenanceI, the second service be MaintenanceII,
and then alternate MaintenanceIand MaintenanceII
thereafter. However, in some cases, MaintenanceIImay
be required more often.
MaintenanceI— Use MaintenanceIif the CHANGE
ENGINE OIL SOON message displays within 10 months
since the vehicle was purchased or MaintenanceII
was performed.
MaintenanceII— Use MaintenanceIIif the previous
service performed was MaintenanceI. Always use
MaintenanceIIwhenever the message displays
10 months or more since the last service or if the
message has not come on at all for one year.
6-4

Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and filter. SeeEngine Oil on page 5-15. Reset oil life system.
SeeEngine Oil Life System on page 5-18.An Emission Control Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner filter. If necessary, replace filter. SeeEngine Air
Cleaner/Filter on page 5-20.See footnote (l).•
Rotate tires and check inflation pressures and wear. SeeTire Inspection and
Rotation on page 5-69and “Tire Wear Inspection” inAt Least Once a Month on
page 6-11.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer fluid levels and add fluid as needed.••
Perform any needed additional services. See “Additional Required Services”
in this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
Check transmission fluid level and add fluid as needed.•
Inspect shields, vehicles with GVWR above 10,000 lbs (4 536 kg) only.
See footnote (g).•
Inspect throttle system.See footnote (m).•
6-5

Additional Required Services
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.
The following services should be performed at the first maintenance service (IorII) after the indicated miles
(kilometers) shown for each item.
Additional Required Services
Service and Miles (Kilometers)25,000
(40 000)50,000
(80 000)75,000
(120 000)100,000
(160 000)125,000
(200 000)150,000
(240 000)
Inspect fuel system for damage or
leaks.• •••••
Inspect exhaust system for loose or
damaged components.• •••••
Replace engine air cleaner filter.
SeeEngine Air Cleaner/Filter on
page 5-20.•••
Change automatic transmission
fluid and filter (severe service).
See footnote (h).•••
Change automatic transmission
fluid and filter (normal service).•
6-6

Additional Required Services (cont’d)
Service and Miles (Kilometers)25,000
(40 000)50,000
(80 000)75,000
(120 000)100,000
(160 000)125,000
(200 000)150,000
(240 000)
Four-wheel drive: Change transfer case
fluid (severe service).See footnotes (o)
and (p).•••
Four-wheel drive: Change transfer case
fluid (normal service).See footnote (o).•
Replace spark plugs and inspect spark
plug wires.An Emission Control Service.•
Engine cooling system service (or every
five years, whichever occurs first).
An Emission Control Service.
See footnote (i).•
Inspect engine accessory drive belt.
An Emission Control Service.
See footnote (n).•
Inspect evaporative control system.
An Emission Control Service.
See footnotes † and (k).•••
6-7

Maintenance Footnotes
(Gasoline Engine)
This maintenance section applies to vehicles with a
gasoline engine. For diesel engine vehicles, see
the maintenance schedule section in the DURAMAX
®
Diesel manual.
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services
be performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, kingpin bushings,
steering linkage, and rear driveline center splines.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chafing, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose, or missing parts,
signs of wear, or lack of lubrication. Inspect power
steering lines and hoses for proper hook-up, binding,
leaks, cracks, chafing, etc.(c)Visually inspect hoses and have them replaced if they
are cracked, swollen, or deteriorated. Inspect all pipes,
fittings, and clamps; replace with genuine parts as
needed. To help ensure proper operation, a pressure test
of the cooling system and pressure cap and cleaning the
outside of the radiator and air conditioning condenser is
recommended at least once a year.
(d)Inspect wiper blades for wear, cracking, or
contamination. Clean the windshield and wiper blades,
if contaminated. Replace wiper blades that are worn
or damaged. See Windshield Wiper Blade Replacement
on page 5-53 and Windshield and Wiper Blades on
page 5-102 for more information.
(e)Make sure the safety belt reminder light and safety
belt assemblies are working properly. Look for any
other loose or damaged safety belt system parts. If you
see anything that might keep a safety belt system
from doing its job, have it repaired. Have any torn or
frayed safety belts replaced. Also see Checking
the Restraint Systems on page 1-78.
(f)Lubricate all key lock cylinders, hood hinges, hood
prop rod pivot, hood latch assembly, secondary
latch, pivots, spring anchor, release pawl, rear
compartment hinges, latches, locks, fuel door hinge,
and any moving seat hardware. More frequent
lubrication may be required when exposed to a corrosive
environment. Applying silicone grease on weatherstrips
with a clean cloth will make them last longer, seal
better, and not stick or squeak.
6-8