automatic transmission CHEVROLET EXPRESS CARGO VAN 2009 1.G User Guide

Driving On Grades
Reduce speed and shift to a lower gearbeforestarting
down a long or steep downgrade. If the transmission is
not shifted down, the brakes might have to be used so
much that they would get hot and no longer work well.
The vehicle can tow in D (Drive). Shift the transmission
to a lower gear if the transmission shifts too often
under heavy loads and/or hilly conditions.
When towing at high altitude on steep uphill grades,
consider the following: Engine coolant will boil at a lower
temperature than at normal altitudes. If the engine is
turned off immediately after towing at high altitude on
steep uphill grades, the vehicle may show signs similar to
engine overheating. To avoid this, let the engine run while
parked, preferably on level ground, with the automatic
transmission in P (Park) for a few minutes before turning
the engine off. If the overheat warning comes on, see
Engine Overheating on page 5-31.
Parking on Hills
{CAUTION:
Parking the vehicle on a hill with the trailer attached
can be dangerous. If something goes wrong, the rig
could start to move. People can be injured, and
both the vehicle and the trailer can be damaged.
When possible, always park the rig on a flat
surface.
If parking the rig on a hill:
1. Press the brake pedal, but do not shift into P (Park)
yet for vehicles with an automatic transmission, or
into gear for vehicles with a manual transmission.
Turn the wheels into the curb if facing downhill or into
traffic if facing uphill.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
brake pedal until the chocks absorb the load.
4. Reapply the brake pedal. Then apply the parking
brake and shift into P (Park) for vehicles with an
automatic transmission or into gear for vehicles with
a manual transmission.
5. Release the brake pedal.
4-39

Leaving After Parking on a Hill
1. Apply and hold the brake pedal while you:
•start the engine,
•shift into a gear, and
•release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
The vehicle needs service more often when pulling a
trailer. See this manual’s Maintenance Schedule
or Index for more information. Things that are especially
important in trailer operation are automatic transmission
fluid, engine oil, axle lubricant, belts, cooling system
and brake system. It is a good idea to inspect
these before and during the trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Trailer Wiring Harness
The optional heavy-duty trailer wiring package includes
a wiring harness, with a seven-pin connector at the
rear of the vehicle and a four-wire harness assembly
under the driver side of the instrument panel. The
four-wire harness assembly comes without a connector.
If the vehicle does not have a trailer hitch, the
seven-wire harness assembly with connector is taped
together and located in a frame pocket at the driver side
rear left corner of the frame.
If the vehicle has a trailer hitch, the seven-wire harness
assembly with connector is attached to a bracket on
the hitch platform. In both cases, the seven-wire harness
has a connector and includes a 30-amp feed wire.
4-40

Service............................................................5-3
Accessories and Modifications..........................5-3
California Proposition 65 Warning.....................5-4
California Perchlorate Materials Requirements.....5-4
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of the
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-6
Gasoline Specifications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-7
Fuel E85 (85% Ethanol)..................................5-8
Fuels in Foreign Countries...............................5-9
Filling the Tank............................................5-10
Filling a Portable Fuel Container.....................5-12
Checking Things Under the Hood....................5-12
Hood Release..............................................5-13
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-15
Engine Oil Life System..................................5-18
Engine Air Cleaner/Filter................................5-20
Automatic Transmission Fluid.........................5-21
Cooling System............................................5-24
Engine Coolant.............................................5-25Radiator Pressure Cap..................................5-31
Engine Overheating.......................................5-31
Engine Fan Noise.........................................5-33
Power Steering Fluid.....................................5-34
Windshield Washer Fluid................................5-35
Brakes........................................................5-36
Battery........................................................5-39
Jump Starting...............................................5-40
All-Wheel Drive..............................................5-44
Rear Axle
.......................................................5-45
Front Axle......................................................5-46
Noise Control System.....................................5-47
Tampering with Noise Control System
Prohibited.................................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps..................................................5-48
Front Turn Signal, Sidemarker and
Parking Lamps..........................................5-50
Center High-Mounted Stoplamp (CHMSL).........5-51
Taillamps.....................................................5-51
Replacement Bulbs.......................................5-52
Windshield Wiper Blade Replacement..............5-53
Section 5 Service and Appearance Care
5-1

A. Battery. SeeBattery on page 5-39.
B. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-31.
C. Coolant Recovery Tank. SeeCooling System on
page 5-24.
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 on page 5-15.
F. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil 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 5-34.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-36.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-35.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 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.
SeeEngine Compartment Overview on page 5-14
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 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

3. Clean the engine air cleaner/filter housing.
4. Inspect or replace the engine air cleaner/filter.
Make sure that the filter fits properly into the
housing.
5. Reinstall the cover and fasten the retaining clips.
{CAUTION:
Operating the engine with the air cleaner/filter
off can cause you or others to be burned. The air
cleaner not only cleans the air; it helps to stop
flames if the engine backfires. If it is not there and
the engine backfires, you could be burned. Do not
drive with it off, and be careful working on the
engine with the air cleaner/filter off.
Notice:If the air cleaner/lter is off, a backre can
cause a damaging engine re. And, dirt can easily get
into the engine, which will damage it. Always have
the air cleaner/lter in place when you are driving.
Automatic Transmission Fluid
If your vehicle has the DURAMAX Diesel engine, see
the DURAMAX Diesel manual for more information.
When to Check and Change Automatic
Transmission Fluid
A good time to check your automatic transmission fluid
level is when the engine oil is changed.
Change the fluid and filter at the intervals listed in
Additional Required Services on page 6-6, and be sure
to use the transmission fluid listed inRecommended
Fluids and Lubricants on page 6-13.
5-21

How to Check Automatic Transmission
Fluid
Because this operation can be a little difficult, you may
choose to have this done at the dealer/retailer service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage
your transmission. Too much can mean that some
of the uid could come out and fall on hot engine
parts or exhaust system parts, starting a re.
Too little uid could cause the transmission to
overheat. Be sure to get an accurate reading if
you check your transmission uid.
Wait at least 30 minutes before checking the
transmission fluid level if you have been driving:
•When outside temperatures are above 90°F (32°C).
•At high speed for quite a while.
•In heavy traffic — especially in hot weather.
•While pulling a trailer.
To get the right reading, the fluid should be at normal
operating temperature, which is 180°F to 200°F
(82°C to 93°C).Get the vehicle warmed up by driving about
15 miles (24 km) when outside temperatures are above
50°F (10°C). If it is colder than 50°F (10°C), drive the
vehicle in D (DRIVE) until the engine temperature gage
moves and then remains steady for 10 minutes.
A cold fluid check can be made after the vehicle has
been sitting for eight hours or more with the engine off,
but this is used only as a reference. Let the engine run
at idle for five minutes if outside temperatures are 50°F
(10°C) or more. If it is colder than 50°F (10°C), you may
have to idle the engine longer. Should the fluid level be
low during this cold check, you must check the fluid hot
before adding fluid. Checking the fluid hot will give you a
more accurate reading of the fluid level.
Checking the Fluid Level
Prepare your vehicle as follows:
1. Park your vehicle on a level place. Keep the engine
running.
2. With the parking brake applied, place the shift lever
in P (PARK).
3. With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position
the shift lever in P (PARK).
4. Let the engine run at idle for three minutes or more.
5-22

How to Add Automatic Transmission
Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission fluid to use. SeeRecommended
Fluids and Lubricants on page 6-13.
Using a funnel, add fluid down the transmission dipstick
tube only after checking the transmission fluid while
it is hot. A cold check is used only as a reference. If the
fluid level is low, add only enough of the proper fluid
to bring the level up to the HOT area for a hot check.
It does not take much fluid, generally less than
one pint (0.5 L). Do not overfill.
Notice:Use of the incorrect automatic transmission
uid may damage the vehicle, and the damages
may not be covered by the vehicle’s warranty.
Always use the automatic transmission uid listed in
Recommended Fluids and Lubricants on page 6-13.
•After adding fluid, recheck the fluid level as described
under “How to Check Automatic Transmission Fluid,”
earlier in this section.
•When the correct fluid level is obtained, push the
dipstick back in all the way; then flip the handle down
to lock the dipstick in place.
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)
5-24

Jump Starting
If the vehicle battery has run down, you may want to
use another vehicle and some jumper cables to start your
vehicle. Be sure to use the following steps to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
•They contain acid that can burn you.
•They contain gas that can explode or ignite.
•They contain enough electricity to burn you.
If you do not follow these steps exactly, some or
all of these things can hurt you.Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not work, and it could damage your vehicle.
1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be
able to start your vehicle, and the bad grounding
could damage the electrical systems.
To avoid the possibility of the vehicles rolling,
set the parking brake firmly on both vehicles
involved in the jump start procedure. Put an
automatic transmission in P (PARK) or a manual
transmission in NEUTRAL before setting the
parking brake.
5-40

Tire Terminology and Denitions
Air Pressure:The amount of air inside the
tire pressing outward on each square inch of
the tire. Air pressure is expressed in pounds
per square inch (psi) or kilopascal (kPa).
Accessory Weight
:This means the combined
weight of optional accessories. Some examples of
optional accessories are, automatic transmission,
power steering, power brakes, power windows,
power seats, and air conditioning.
Aspect Ratio
:The relationship of a tire’s height
to its width.
Belt
:A rubber coated layer of cords that is
located between the plies and the tread. Cords
may be made from steel or other reinforcing
materials.
Bead
:The tire bead contains steel wires wrapped
by steel cords that hold the tire onto the rim.
Bias Ply Tire
:A pneumatic tire in which the plies
are laid at alternate angles less than 90 degrees
to the centerline of the tread.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. SeeInflation - Tire Pressure on
page 5-62.
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 4-19.
GAWR FRT
:Gross Axle Weight Rating for the
front axle. SeeLoading the Vehicle on page 4-19.
GAWR RR
:Gross Axle Weight Rating for the
rear axle. SeeLoading the Vehicle on page 4-19.
5-59

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