fuel CHEVROLET EXPRESS 2009 Service Manual

A. Battery. SeeBattery on page 6-43.
B. Radiator Pressure Cap. SeeCooling System on
page 6-28.
C. Coolant Recovery Tank. SeeCooling System on
page 6-28.
D. Automatic Transmission Fluid Dipstick. See
“Checking the Fluid Level” underAutomatic
Transmission Fluid (4-Speed Transmission)
on page 6-21orAutomatic Transmission Fluid
(6-Speed Transmission) on page 6-24.
E. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 6-15.
F. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 6-15.
G. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 6-20.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 6-38.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 6-40.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 6-39.Engine Oil
For diesel engine vehicles, see “Engine Oil” in the
DURAMAX®Diesel manual.
Checking Engine Oil
It is a good idea to check the engine oil level at each
fuel fill. 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.
SeeEngine Compartment Overview on page 6-14
for 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 this is not done, 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.
6-15

Cooling System
If your vehicle has a diesel engine, see “Van Models”
under “Cooling System” in the DURAMAX®Diesel
Supplement.
The Cooling System allows the engine to maintain the
correct working temperature.
A. Radiator Pressure Cap
B. Coolant Recovery Tank
C. Engine Cooling Fan(s)
{WARNING:
An electric engine cooling fan under the hood can
start up even when the engine is not running and
can cause injury. Keep hands, clothing, and tools
away from any underhood electric fan.
{WARNING:
Heater, fuel operated heater (FOH), radiator
hoses, and other engine parts, can be very hot.
Do not touch them. If you do, you can be burned.
WARNING: (Continued)
6-28

WARNING: (Continued)
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 fire, and you could be burned.
Get any leak fixed before you drive the vehicle.
Notice:Using coolant other than DEX-COOL may
cause premature engine, heater core, radiator and
fuel operated heater (FOH) 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.
Engine Coolant
The cooling system in the vehicle is filled with
DEX-COOL®engine coolant. This coolant is designed
to remain in the vehicle for five years or 150,000 miles
(240 000 km), whichever occurs first.
The following explains the cooling system and how to
check and add coolant when it is low. If there is a problem
with engine overheating, seeEngine Overheating on
page 6-35.
6-29

If the temperature overheat gage is no longer in the
overheat zone or an overheat warning no longer
displays, the vehicle can be driven. Continue to drive
the vehicle slow for about 10 minutes. Keep a safe
vehicle distance from the car in front of you. If the
warning does not come back on, continue to drive
normally.
If the warning continues, pull over, stop, and park the
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 until it cools down.
You may decide not to lift the hood but to get service
help right away.Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When the
clutch is engaged, the fan spins faster to provide more air
to cool the engine. In most everyday driving conditions,
the fan is spinning slower and the clutch is not fully
engaged. This improves fuel economy and reduces fan
noise. Under heavy vehicle loading, trailer towing, and/
or high outside temperatures, the fan speed increases
as the clutch more fully engages, so you may hear an
increase in fan noise. This is normal and should not be
mistaken as the transmission slipping or making extra
shifts. It is merely the cooling system functioning properly.
The fan will slow down when additional cooling is not
required and the clutch partially disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
6-37

Brakes
Brake Fluid
The brake master cylinder
reservoir is filled with
DOT 3 brake fluid. See
Engine Compartment
Overview on page 6-14for
the location of the reservoir.
There are only two reasons why the brake fluid level in
the reservoir might go down:
•The brake fluid level goes down because of normal
brake lining wear. When new linings are installed,
the fluid level goes back up.
•A fluid leak in the brake hydraulic system can also
cause a low fluid level. Have the brake hydraulic
system fixed, since a leak means that sooner
or later the brakes will not work well.Do not top off the brake fluid. Adding fluid does 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.
{WARNING:
If too much brake fluid is added, it can spill on
the engine and/or fuel operated heater parts, if
equipped. If the vehicle has a diesel engine and a
fuel operated heater, see “Fuel Operated Heater
(FOH)” in the diesel engine supplement. The fluid
will burn if the engine is hot enough. You or others
could be burned, and the vehicle could be
damaged. Add brake fluid 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 7-3.
6-40

Among those acts presumed to constitute tampering are
the acts listed below.
Insulation:
•
Removal of the noise shields or any underhood
insulation.
Engine:
•
Removal or rendering engine speed governor, if the
vehicle has one, inoperative so as to allow engine
speed to exceed manufacturer specifications.
Fan and Drive:
•
Removal of fan clutch, if the vehicle has one, or
rendering clutch inoperative.
•Removal of the fan shroud, if the vehicle has one.
Air Intake:
•
Removal of the air cleaner silencer.
•Modification of the air cleaner.
Exhaust:
•
Removal of the muffler and/or resonator.
•Removal of the exhaust pipes and exhaust pipe
clamps.
Fuel Operated Heater (FOH) — Diesel
Engine:
•
Removal of the muffler.
6-52

Cold Tire Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi)
or kilopascals (kPa) before a tire has built up heat
from driving. SeeInation - Tire Pressure on
page 6-68.
Curb Weight
:The weight of a motor vehicle with
standard and optional equipment including the
maximum capacity of fuel, oil, and coolant,
but without passengers and cargo.
DOT Markings
:A code molded into the sidewall
of a tire signifying that the tire is in compliance
with the U.S. Department of Transportation (DOT)
motor vehicle safety standards. The DOT code
includes the Tire Identification Number (TIN), an
alphanumeric designator which can also identify the
tire manufacturer, production plant, brand, and date
of production.
GVWR
:Gross Vehicle Weight Rating.
SeeLoading the Vehicle on page 5-19.
GAWR FRT
:Gross Axle Weight Rating for the
front axle. SeeLoading the Vehicle on page 5-19.
GAWR RR
:Gross Axle Weight Rating for the
rear axle. SeeLoading the Vehicle on page 5-19.Intended Outboard Sidewall
:The side of an
asymmetrical tire, that must always face outward
when mounted on a vehicle.
Kilopascal (kPa)
:The metric unit for air pressure.
Light Truck (LT-Metric) Tire
:A tire used on
light duty trucks and some multipurpose passenger
vehicles.
Load Index
:An assigned number ranging from 1
to 279 that corresponds to the load carrying
capacity of a tire.
Maximum Ination Pressure
:The maximum
air pressure to which a cold tire can be inflated.
The maximum air pressure is molded onto the
sidewall.
Maximum Load Rating
:The load rating for a tire
at the maximum permissible inflation pressure
for that tire.
Maximum Loaded Vehicle Weight
:The sum of
curb weight, accessory weight, vehicle capacity
weight, and production options weight.
Normal Occupant Weight
:The number of
occupants a vehicle is designed to seat multiplied
by 150 lbs (68 kg). SeeLoading the Vehicle on
page 5-19.
6-66

Vehicle Maximum Load on the Tire:Load on
an individual tire due to curb weight, accessory
weight, occupant weight, and cargo weight.
Vehicle Placard
:A label permanently attached to
a vehicle showing the vehicle’s capacity weight and
the original equipment tire size and recommended
inflation pressure. See “Tire and Loading
Information Label” underLoading the Vehicle
on page 5-19.
Ination - Tire Pressure
Tires need the correct amount of air pressure to
operate effectively.
Notice:Do not let anyone tell you that
under-ination or over-ination is all right.
It is not. If your tires do not have enough air
(under-ination), you can get the following:
Too much exing
Too much heat
Tire overloading
Premature or irregular wear
Poor handling
Reduced fuel economyIf your tires have too much air (over-ination),
you can get the following:
Unusual wear
Poor handling
Rough ride
Needless damage from road hazards
A vehicle specific Tire and Loading Information
label is attached to your vehicle. This label shows
your vehicle’s original equipment tires and the
correct inflation pressures for your tires when they
are cold. The recommended cold tire inflation
pressure, shown on the label, is the minimum
amount of air pressure needed to support your
vehicle’s maximum load carrying capacity.
For additional information regarding how much
weight your vehicle can carry, and an example of
the Tire and Loading Information label, seeLoading
the Vehicle on page 5-19. How you load your
vehicle affects vehicle handling and ride comfort.
Never load your vehicle with more weight than it
was designed to carry.
6-68

Accordingly, when the low tire pressure telltale
illuminates, you should stop and check your tires
as soon as possible, and inflate them to the proper
pressure. Driving on a significantly under-inflated
tire causes the tire to overheat and can lead to tire
failure. Under-inflation also reduces fuel efficiency and
tire tread life, and may affect the vehicle’s handling
and stopping ability.
Please note that the TPMS is not a substitute for proper
tire maintenance, and it is the driver’s responsibility to
maintain correct tire pressure, even if under-inflation
has not reached the level to trigger illumination of
the TPMS low tire pressure telltale.
Your vehicle has also been equipped with a TPMS
malfunction indicator to indicate when the system is
not operating properly. The TPMS malfunction indicator
is combined with the low tire pressure telltale. When
the system detects a malfunction, the telltale will flash
for approximately one minute and then remain
continuously illuminated. This sequence will continue
upon subsequent vehicle start-ups as long as the
malfunction exists.When the malfunction indicator is illuminated, the system
may not be able to detect or signal low tire pressure as
intended. TPMS malfunctions may occur for a variety of
reasons, including the installation of replacement or
alternate tires or wheels on the vehicle that prevent the
TPMS from functioning properly. Always check the TPMS
malfunction telltale after replacing one or more tires or
wheels on your vehicle to ensure that the replacement or
alternate tires and wheels allow the TPMS to continue to
function properly.
SeeTire Pressure Monitor Operation on page 6-72for
additional information.
Federal Communications
Commission (FCC) and Industry
and Science Canada
SeeRadio Frequency Statement on page 8-20
for information regarding Part 15 of the Federal
Communications Commission (FCC) Rules and
RSS-210/211 of Industry and Science Canada.
6-71

Finish Damage
Any stone chips, fractures or deep scratches in the
finish should be repaired right away. Bare metal
will corrode quickly and may develop into major
repair expense.
Minor chips and scratches can be repaired with
touch-up materials available from your dealer/retailer.
Larger areas of finish damage can be corrected in
your dealer’s/retailer’s body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are
not removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, floor pan,
and exhaust system even though they have corrosion
protection.At least every spring, flush these materials from the
underbody with plain water. Clean any areas where
mud and debris can collect. Dirt packed in close areas
of the frame should be loosened before being flushed.
Your dealer/retailer or an underbody car washing system
can do this.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on the vehicle. This damage can
take two forms: blotchy, ring-shaped discolorations, and
small, irregular dark spots etched into the paint surface.
Although no defect in the paint job causes this, we will
repair, at no charge to the owner, the surfaces of
new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs first.
6-108