engine CHEVROLET EXPRESS CARGO VAN 2008 1.G Repair Manual

Tires..............................................................5-56
Tire Sidewall Labeling...................................5-56
Tire Terminology and Definitions.....................5-61
Inflation - Tire Pressure.................................5-64
Dual Tire Operation.......................................5-65
Tire Pressure Monitor System.........................5-66
Tire Pressure Monitor Operation.....................5-67
Tire Inspection and Rotation...........................5-71
When It Is Time for New Tires.......................5-73
Buying New Tires.........................................5-74
Different Size Tires and Wheels......................5-75
Uniform Tire Quality Grading..........................5-76
Wheel Alignment and Tire Balance..................5-78
Wheel Replacement......................................5-78
Tire Chains..................................................5-80
If a Tire Goes Flat........................................5-81
Changing a Flat Tire.....................................5-82
Removing the Spare Tire and Tools................5-83
Removing the Flat Tire and Installing the
Spare Tire................................................5-86
Secondary Latch System...............................5-93
Storing a Flat or Spare Tire and Tools............5-97
Spare Tire...................................................5-99
Appearance Care............................................5-99
Interior Cleaning...........................................5-99
Fabric/Carpet..............................................5-101Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-101
Care of Safety Belts....................................5-102
Weatherstrips.............................................5-102
Washing Your Vehicle..................................5-102
Cleaning Exterior Lamps/Lenses....................5-103
Finish Care................................................5-103
Windshield and Wiper Blades.......................5-104
Aluminum Wheels.......................................5-104
Tires.........................................................5-105
Sheet Metal Damage...................................5-105
Finish Damage...........................................5-106
Underbody Maintenance...............................5-106
Chemical Paint Spotting...............................5-106
Vehicle Care/Appearance Materials................5-107
Vehicle Identication.....................................5-108
Vehicle Identification Number (VIN)................5-108
Service Parts Identification Label...................5-108
Electrical System..........................................5-109
Add-On Electrical Equipment.........................5-109
Headlamp Wiring........................................5-109
Windshield Wiper Fuses...............................5-109
Fuses and Circuit Breakers..........................5-109
Floor Console Fuse Block............................5-110
Engine Compartment Fuse Block...................5-112
Capacities and Specications........................5-116
Section 5 Service and Appearance Care
5-2

California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many fluids, and
some component wear by-products contain and/or emit
these chemicals.
California Perchlorate Materials
Requirements
Certain types of automotive applications, such as airbag
initiators, seat belt pretensioners, and lithium batteries
contained in remote keyless entry transmitters, may
contain perchlorate materials. Special handling may be
necessary. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
Doing Your Own Service Work
{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

If you want to do some of your own service work, you
should 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, see
Service Publications Ordering Information on page 7-15.
Your vehicle has an airbag system. Before attempting
to do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-73.
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 6-17.
Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airflow around it. This can cause wind
noise and can affect fuel economy and windshield
washer performance. Check with your dealer/retailer
before adding equipment to the outside of your vehicle.
Fuel
If your vehicle has a diesel engine, see “Diesel Fuel
Requirements and Fuel System” in the DURAMAX®
Diesel manual.
For vehicles with gasoline engines, please read this.
Gasoline
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle. To help keep the
engine clean and maintain optimum vehicle
performance, we recommend the use of gasoline
advertised as TOP TIER Detergent Gasoline.
The 8th digit of the Vehicle Identification Number (VIN)
shows the code letter or number that identifies your
vehicle’s engine. The VIN is at the top left of the
instrument panel. SeeVehicle Identification Number
(VIN) on page 5-108.
If your vehicle has the 5.3L V8 engine (VIN Code 4),
you can use either regular unleaded gasoline or ethanol
fuel containing up to 85% ethanol (E85); also see
Fuel E85 (85% Ethanol) on page 5-8. In all other
gasoline engines, use only regular unleaded gasoline.
5-5

Gasoline Octane
Use regular unleaded gasoline with a posted octane
rating of 87 or higher. If the octane rating is less than 87,
you might notice an audible knocking noise when you
drive, commonly referred to as spark knock. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking, the
engine needs service.
Gasoline Specications
At a minimum, gasoline should meet ASTM specification
D 4814 in the United States or CAN/CGSB-3.5 or
3.511 in Canada. Some gasolines contain an
octane-enhancing additive called methylcyclopentadienyl
manganese tricarbonyl (MMT). We recommend
against the use of gasolines containing MMT. See
Additives on page 5-7for additional information.
California Fuel
If your vehicle is certified to meet California Emissions
Standards, it is designed to operate on fuels that
meet California specifications. 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 specifications, but emission control system
performance might be affected. The malfunction
indicator lamp could turn on and your vehicle might fail
a smog-check test. SeeMalfunction Indicator Lamp
on page 3-38. If this occurs, return to your authorized
dealer/retailer for diagnosis. If it is determined that
the condition is caused by the type of fuel used, repairs
might not be covered by your warranty.
5-6

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that help prevent
engine and fuel system deposits from forming, allowing
the emission control system to work properly. In most
cases, you should not have to add anything to the fuel.
However, some gasolines contain only the minimum
amount of additive required to meet U.S. Environmental
Protection Agency regulations. To help keep fuel injectors
and intake valves clean, or if your vehicle experiences
problems due to dirty injectors or valves, look for gasoline
that is advertised as TOP TIER Detergent Gasoline. Also,
your dealer/retailer has additives that will help correct and
prevent most deposit-related problems.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines might be available in
your area. We recommend that you use these gasolines,
if they comply with the specifications described earlier.
However, E85 (85% ethanol) and other fuels containing
more than 10% ethanol must not be used in vehicles that
were not designed for those fuels.Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in the fuel
system and also damage plastic and rubber parts.
That damage would not be covered under your
warranty.
Some gasolines that are not reformulated for low
emissions can contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. We recommend against
the use of such gasolines. Fuels containing MMT can
reduce the life of spark plugs and the performance of the
emission control system could be affected. The
malfunction indicator lamp might turn on. If this occurs,
return to your dealer/retailer for service.
5-7

Fuel E85 (85% Ethanol)
The 8th digit of the Vehicle Identification Number (VIN)
shows the code letter or number that identifies your
vehicle’s engine. The VIN is at the top left of the
instrument panel. SeeVehicle Identification Number
(VIN) on page 5-108.
If your vehicle has the 5.3L V8 engine (VIN Code 4 only),
you can use either regular unleaded gasoline or ethanol
fuel containing up to 85% ethanol (E85); also seeFuel on
page 5-5. In all other engines, use only the unleaded
gasoline described underGasoline Octane on page 5-6.
Only vehicles that have the 5.3L V8 engine (VIN Code 4)
can use 85% ethanol fuel (E85). We encourage the use
of E85 in vehicles that are designed to use it. The ethanol
in E85 is a “renewable” fuel, meaning it is made from
renewable sources such as corn and other crops.
Many service stations will not have an 85% ethanol
fuel (E85) pump available. The U. S. Department
of Energy has an alternative fuels website
(www.eere.energy.gov/afdc/infrastructure/locator.html)
that can help you find E85 fuel. Those stations that
do have E85 should have a label indicating ethanol
content. Do not use the fuel if the ethanol content
is greater than 85%.At a minimum, E85 should meet ASTM Specification
D 5798. By definition, this means that fuel labeled E85
will have an ethanol content between 70% and 85%.
Filling the fuel tank with fuel mixtures that do not meet
ASTM specifications can affect driveability and could
cause the malfunction indicator lamp to come on.
To ensure quick starts in the wintertime, the E85 fuel
must be formulated properly for your climate according
to ASTM specification D 5798. If you have trouble
starting on E85, it could be because the E85 fuel is not
properly formulated for your climate. If this happens,
switching to gasoline or adding gasoline to the fuel tank
can improve starting. For good starting and heater
efficiency below 32°F (0°C), the fuel mix in the fuel tank
should contain no more than 70% ethanol. It is best
not to alternate repeatedly between gasoline and E85.
If you do switch fuels, it is recommended that you
add as much fuel as possible — do not add less than
three gallons (11 L) when refueling. You should drive
the vehicle immediately after refueling for at least
seven miles (11 km) to allow the vehicle to adapt to the
change in ethanol concentration.
5-8

Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Do not use cellular phones. Keep sparks,
ames, and smoking materials away from fuel.
Do not leave the fuel pump unattended when
refueling your vehicle. This is against the law
in some places. Do not re-enter the vehicle
while pumping fuel. Keep children away from
the fuel pump; never let children pump fuel.The tethered fuel cap is
located behind a hinged
fuel door on the driver side
of the vehicle.
5-10

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the fuel vapor. You
can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense fuel only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping fuel.
Do not use a cellular phone while
pumping fuel.
Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine or fuel
operated heater (FOH) parts and start a re.
These include liquids like fuel, oil, coolant,
brake uid, windshield washer and other
uids, and plastic or rubber. You or others
could be burned. Be careful not to drop or spill
things that will burn onto a hot engine or fuel
operated heater (FOH).
5-12

Engine Compartment Overview
If your vehicle has the DURAMAX®Diesel engine, see the DURAMAX®Diesel manual for more information.
When you lift the hood, here is what you will see:
5-14

A. Battery. SeeBattery on page 5-40.
B. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-27.
C. Coolant Recovery Tank. SeeCooling System on
page 5-29.
D. Automatic Transmission Fluid Dipstick. See
“Checking the Fluid Level” underAutomatic
Transmission Fluid on page 5-21.
E. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil (Gasoline Engine) on page 5-15.
F. Engine Oil Dipstick. See “Checking Engine Oil” under
Engine Oil (Gasoline Engine) on page 5-15.
G. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-20.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-35.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-37.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-36.Engine Oil (Gasoline Engine)
If your vehicle has a diesel engine, see “Engine Oil” in
the DURAMAX®Diesel manual.
Checking Engine Oil
It is a good idea to check the engine oil every time you
get fuel. 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. See
Engine Compartment Overview on page 5-14for
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 you do not do this,
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.
5-15