ECU CHEVROLET EXPRESS CARGO VAN 2008 1.G Service Manual

{CAUTION:
Things you put inside your vehicle can
strike and injure people in a sudden stop
or turn, or in a crash.
Put things in the cargo area of your
vehicle. Try to spread the weight
evenly.
Never stack heavier things, like
suitcases, inside the vehicle so that
some of them are above the tops of
the seats.
Do not leave an unsecured child
restraint in your vehicle.
When you carry something inside the
vehicle, secure it whenever you can.
Do not leave a seat folded down
unless you need to.
Add-On Equipment
When you carry removable items, you may need
to put a limit on how many people you carry
inside your vehicle. Be sure to weigh your vehicle
before you buy and install the new equipment.
Towing
Towing Your Vehicle
Consult your dealer/retailer or a professional towing
service if you need to have your disabled vehicle towed.
SeeRoadside 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.
4-25

All-Wheel-Drive Vehicles
Your vehicle was not designed to be towed with all
four wheels on the ground. To properly tow these
vehicles, they should be placed on a platform trailer with
all four wheels off the ground.
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.
Dolly Towing
Rear Towing (Rear Wheels Off the Ground)
Two-Wheel-Drive Vehicles
Use the following procedure to tow your vehicle from
the rear:
1. Drive the vehicle onto the dolly.
2. Firmly set the parking brake. SeeParking Brake on
page 2-28for more information.
3. Put the automatic transmission in PARK (P).4. Follow the dolly manufacturer’s instructions to attach
and secure the vehicle being towed to the dolly and
then the loaded dolly to the tow vehicle. Make sure
the wheels are straight before towing.
Use an adequate clamping device to ensure that
the front wheels are locked into the straight position.
5. Release the parking brake only after the vehicle
being towed is firmly attached to the tow vehicle.
6. Turn the ignition to LOCK/OFF.
If the tow vehicle will not be started or driven for
six weeks or more, remove the battery cable
from the negative terminal (post) of the battery to
prevent your battery from draining while towing.
All-Wheel-Drive Vehicles
Your vehicle was not designed to be towed with two
wheels on the ground. To properly tow these vehicles,
they should be placed on a platform trailer with all
four wheels off the ground.
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.
4-27

G3500 Cargo Van 2WD
Long WheelbaseAxle Ratio Maximum Trailer Weight GCWR*
4800 V83.73
4.106,100 lbs (2 767 kg)
7,100 lbs (3 221 kg)12,000 lbs (5 443 kg)
13,000 lbs (5 897 kg)
6000 V83.73
4.108,200 lbs (3 719 kg)
10,000 lbs (4 536 kg)14,000 lbs (6 350 kg)
16,000 lbs (7 257 kg)
G3500 Passenger Van
2WD Short WheelbaseAxle Ratio Maximum Trailer Weight GCWR*
6000 V8 3.73 7,600 lbs (3 447 kg) 14,000 lbs (6 350 kg)
G3500 Passenger Van
2WD Long WheelbaseAxle Ratio Maximum Trailer Weight GCWR*
6000 V8 3.73 7,300 lbs (3 311 kg) 14,000 lbs (6 350 kg)
*The Gross Combined Weight Rating (GCWR) is the
total allowable weight of the completely loaded vehicle
and trailer including any passengers, cargo equipment
and conversion. The GCWR for your vehicle should not
be exceeded.Ask your dealer/retailer for our trailering information or
advice, or write us at our Customer Assistance
Offices. SeeCustomer Assistance Offices on page 7-5
for more information.
4-32

Driving with a Trailer
{CAUTION:
If you have a rear-most window open and you
pull a trailer with your vehicle, carbon
monoxide (CO) could come into your vehicle.
You can not see or smell CO. It can cause
unconsciousness or death. SeeEngine
Exhaust on page 2-31. To maximize your safety
when towing a trailer:
Have your exhaust system inspected for
leaks, and make necessary repairs before
starting on your trip.
Keep the rear-most windows closed.
If exhaust does come into your vehicle
through a window in the rear or another
opening, drive with your front, main
heating or cooling system on and with the
fan on any speed. This will bring fresh,
outside air into your vehicle. Do not use
the climate control setting for maximum air
because it only recirculates the air inside
your vehicle. See Climate Control System
in the Index.Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you’ll want to get
to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
Before you start, check all trailer hitch parts and
attachments, safety chains, electrical connector, lamps,
tires and mirror adjustment. If the trailer has electric
brakes, start your vehicle and trailer moving and then
apply the trailer brake controller by hand to be sure
the brakes are working. This lets you check your
electrical connection at the same time.
During your trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer
brakes are still working.
4-38

{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

If your vehicle has dual rear wheels, always use
one of the correct rotation patterns shown
here when rotating the tires.
When you install dual wheels, be sure that vent
holes in the inner and outer wheels on each
side are lined up.
After the tires have been rotated, adjust the
front and rear inflation pressures as shown
on the Tire and Loading Information label. See
Inflation - Tire Pressure on page 5-64andLoading
Your Vehicle on page 4-20. Make certain that all
wheel nuts are properly tightened. See “Wheel Nut
Torque” underCapacities and Specifications on
page 5-116.
{CAUTION:
Rust or dirt on a wheel, or on the parts to
which it is fastened, can make wheel nuts
become loose after time. The wheel could
come off and cause an accident. When
you change a wheel, remove any rust or
dirt from places where the wheel attaches
to the vehicle. In an emergency, you can
use a cloth or a paper towel to do this;
but be sure to use a scraper or wire brush
later, if needed, to get all the rust or dirt
off. SeeChanging a Flat Tire on page 5-82.
If your vehicle has a Tire Pressure Monitor
System (TPMS), reset the TPMS sensors after
rotating the tires. SeeTire Pressure Monitor
Operation on page 5-67.
Make sure the spare tire is stored securely. Push,
pull, and then try to rotate or turn the tire. If it
moves, tighten the cable. SeeStoring a Flat or
Spare Tire and Tools on page 5-97.
Dual Rear Wheels
5-72

Tire Chains
{CAUTION:
If your vehicle has dual wheels or P245/75R16
or LT245/75R16 size tires, do not use tire
chains. They can damage your vehicle because
there is not enough clearance. Tire chains
used on a vehicle without the proper amount
of clearance can cause damage to the brakes,
suspension, or other vehicle parts. The area
damaged by the tire chains could cause you to
lose control of your vehicle and you or others
may be injured in a crash.
Use another type of traction device only if its
manufacturer recommends it for use on your
vehicle and tire size combination and road
conditions. Follow that manufacturer’s
instructions. To help avoid damage to your
vehicle, drive slowly, readjust, or remove the
device if it is contacting your vehicle, and do
not spin the vehicle’s wheels.
If you do nd traction devices that will t,
install them on the rear tires.Notice:If your vehicle does not have dual wheels
and has a tire size other than P245/75R16 or
LT245/75R16, use tire chains only where legal and
only when you must. Use chains that are the proper
size for your tires. Install them on the tires of the
rear axle. Do not use chains on the tires of the front
axle. Tighten them as tightly as possible with the
ends securely fastened. Drive slowly and follow the
chain manufacturer’s instructions. If you can
hear the chains contacting your vehicle, stop and
retighten them. If the contact continues, slow down
until it stops. Driving too fast or spinning the
wheels with chains on will damage your vehicle.
5-80

The following information tells you how to use the jack
and change a tire.
Removing the Spare Tire and Tools
If you have a cargo van or a passenger van, the
equipment you will need is located in the passenger
side rear corner of the vehicle.
Remove the retaining wing
bolt and lift it off of the
mounting bracket.
If you have a van with the 15-passenger seating
arrangement, the equipment you will need is secured on
the rear floor of the passenger side of the vehicle.
5-83

3. Pull the wheel toward the rear of the vehicle,
keeping the cable tight.
4. With the UP side facing you, attach the ratchet to
the wheel wrench.
5. Put the flat end of the wheel wrench on an angle
through the hole in the rear door frame, above the
bumper.
6. Raise the tire fully against the underside of the
vehicle. Continue turning the ratchet until the tire
is secure and the cable is tight. The spare tire hoist
cannot be overtightened.
7. Make sure the tire is stored securely. Push, pull (A),
and then try to turn (B) the tire. If the tire moves,
use the ratchet to tighten the cable.
You will hear two clicks when the tire is up all
the way.
8. Return the jacking equipment to the proper location.
Secure the items and replace the jack cover.
5-98

At the First 100, 1,000 and 6,000
Miles (160, 1 600 and 10 000 km)
For vehicles with dual wheels, check dual wheel
nut torque. For proper torque, seeCapacities and
Specifications on page 5-116.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel fill.
Engine Oil Level Check
Notice:It is important to check the engine oil
regularly and keep it at the proper level. Failure to
keep the engine oil at the proper level can cause
damage to the engine not covered by your warranty.
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil (Gasoline Engine)
on page 5-15.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
on page 5-24.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer fluid reservoir and add the proper fluid if
necessary.
At Least Once a Month
Tire Ination Check
Inspect your vehicle’s tires and make sure they are
inflated to the correct pressures. Do not forget to check
the spare tire. SeeInflation - Tire Pressure on
page 5-64. Check to make sure the spare tire is stored
securely. SeeChanging a Flat Tire on page 5-82.
Tire Wear Inspection
Tire rotation may be required for high mileage highway
drivers prior to the Engine Oil Life System service
notification. Check the tires for wear and, if necessary,
rotate the tires. SeeTire Inspection and Rotation
on page 5-71.
6-10