battery CHEVROLET EXPRESS CARGO VAN 2009 1.G Owner's Manual

Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. The vehicle
was designed and tested with top-quality brake parts.
When parts of the braking system are replaced — for
example, when the brake linings wear down and new
ones are installed — be sure to get new approved
replacement parts. If this is not done, the brakes might
not work properly. For example, if someone puts in
brake linings that are wrong for the vehicle, the balance
between the front and rear brakes can change — for the
worse. The braking performance expected can change in
many other ways if the wrong replacement brake parts
are installed.
Battery
This vehicle has a maintenance free battery. When it is
time for a new battery, see your dealer/retailer for one
that has the replacement number shown on the original
battery’s label. SeeEngine Compartment Overview on
page 5-14for battery location.
Warning:Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
{CAUTION:
Batteries have acid that can burn you and gas that
can explode. You can be badly hurt if you are not
careful. SeeJump Starting on page 5-40for tips
on working around a battery without getting hurt.
Infrequent Usage: If the vehicle is driven infrequently,
remove the black, negative (−) cable from the battery.
This helps keep the battery from running down.
Extended Storage: For extended storage of the vehicle,
remove the black, negative (−) cable from the battery or
use a battery trickle charger. This helps maintain the
charge of the battery over an extended period of time.
5-39

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.
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Notice:If you leave the radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered by
the warranty. Always turn off the radio and other
accessories when jump starting the vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or the accessory power outlet. Turn off
the radio and all lamps that are not needed.
This will avoid sparks and help save both
batteries. And it could save the radio!
4. Open the hoods and locate the positive (+) and
negative (−) terminal locations of the other vehicle.
Your vehicle has a remote positive (+) jump
starting terminal and a remote negative (−) jump
starting terminal. You should always use these
remote terminals instead of the terminals on the
battery.The remote positive (+) terminal is located
behind a red plastic cover near the engine accessory
drive bracket on the driver’s side of the engine
compartment, below the alternator. To uncover
the remote positive (+) terminal, open the red
plastic cover.
The remote negative (−) terminal is located on
the engine drive bracket on all V8 engines and is
marked GND (Ground).
On V6 engines the remote negative (−) terminal is
located on a tab attached to the engine accessory
drive bracket and is marked GND (Ground).
5-41

{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing this,
and some have been blinded. Use a flashlight if
you need more light.
Be sure the battery has enough water. You do not
need to add water to the battery installed in your
new vehicle. But if a battery has filler caps, be
sure the right amount of fluid is there. If it is low,
add water to take care of that first. If you do not,
explosive gas could be present.
Battery fluid contains acid that can burn you.
Do not get it on you. If you accidentally get it in
your eyes or on your skin, flush the place with
water and get medical help immediately.
{CAUTION:
Fans or other moving engine parts can injure you
badly. Keep your hands away from moving parts
once the engine is running.
5. Check that the jumper cables do not have loose
or missing insulation. If they do, you could get a
shock. The vehicles could be damaged too.
Before you connect the cables, here are some
basic things you should know. Positive (+) will go
to positive (+) or to a remote positive (+) terminal
if the vehicle has one. Negative (−) will go to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.
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6. Connect the red positive (+) cable to the positive (+)
terminal of the dead battery. Use a remote
positive (+) terminal if the vehicle has one.
7. Do not let the other end touch metal. Connect it to
the positive (+) terminal of the good battery. Use a
remote positive (+) terminal if the vehicle has one.8. Now connect the black negative (−) cable to the
negative (−) terminal of the good battery. Use a
remote negative (−) terminal if the vehicle has one.
Do not let the other end touch anything until the
next step. The other end of the negative (−) cable
does not go to the dead battery. It goes to a heavy,
unpainted metal engine part or to a remote
negative (−) terminal on the vehicle with the
dead battery.
9. Connect the other end of the negative (−) cable
to the negative (−) terminal location on the vehicle
with the dead battery. Your vehicle has a remote
negative (−) terminal for this purpose. It is
marked GND.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle that had the dead battery.
If it will not start after a few tries, it probably needs
service.
5-43

Notice:If the jumper cables are connected or
removed in the wrong order, electrical shorting may
occur and damage the vehicle. The repairs would
not be covered by your warranty. Always connect
and remove the jumper cables in the correct
order, making sure that the cables do not touch
each other or other metal.
A. Heavy, Unpainted Metal Engine Part or Remote
Negative (−) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (−) Terminals
C. Dead Battery or Remote Positive (+) TerminalTo disconnect the jumper cables from both vehicles,
do the following:
1. Disconnect the black negative (−) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (−) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the remote positive (+) terminal cover to its
original position.
All-Wheel Drive
Lubricant checks in this section also apply to these
vehicles. However, there are two additional systems that
need lubrication.
Transfer Case
When to Check Lubricant
Refer to the Maintenance Schedule to determine
how often to check the lubricant. SeeScheduled
Maintenance on page 6-4. Jumper Cable Removal
5-44

Electrical System
Add-On Electrical Equipment
Notice:Do not add anything electrical to the
vehicle unless you check with your dealer/retailer
rst. Some electrical equipment can damage
the vehicle and the damage would not be covered
by the vehicle’s warranty. Some add-on electrical
equipment can keep other components from
working as they should.
Add-on equipment can drain the vehicle battery, even if
the vehicle is not operating.
The vehicle has an airbag system. Before attempting to
add anything electrical to the vehicle, seeServicing
Your Airbag-Equipped Vehicle on page 1-76.
Headlamp Wiring
The headlamp wiring is protected by fuses in the engine
compartment fuse block. An electrical overload will
cause the lamps to flicker on and off, or in some cases
to remain off. If this happens, have your headlamp
wiring checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker and a fuse. If the motor overheats due to heavy
snow, etc., the wiper will stop until the motor cools.
Although the circuit is protected from electrical overload,
overload due to heavy snow, etc., may cause wiper
linkage damage. Always clear ice and heavy snow from
the windshield before using the windshield wipers. If the
overload is caused by some electrical problem and not
snow, etc., be sure to get it fixed.
Fuses and Circuit Breakers
The wiring circuits in the vehicle are protected from
short circuits by a combination of fuses and circuit
breakers. This greatly reduces the chance of fires
caused by electrical problems.
Look at the silver-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical
size and rating.
Floor Console Fuse Block
The floor console fuse block is located under the
driver seat.
5-105

Fuse Usage
9 Right Low-Beam Headlamp
10 Daytime Running Lamps 2 (DRL)
11Fuel System Control Module
Ignition (Gas)
12 Daytime Running Lamps 1 (DRL)
13 Auxiliary Stoplamp
14Fuel Operated Heater Module
(Diesel)
15Fuel System Control Module
Battery (Gas)
16 Left Stoplamp, Trailer Turn Signal
17 Canister Vent Solenoid (Gas)
18 Empty
19 Empty
20 Body Control Module 1
21 Special Equipment Option (SEO)
22 Body Control Module 4
23 Body Control Module 6
24 Empty
25 Body Control Module 7
26 Body Control Module 3
27 Body Control Module 5Fuse Usage
28 Empty
29 Empty
30 Instrument Panel Cluster
31 Empty
32 Brake Switch
33 Auxiliary Power Outlet
34 Airbag
35 Trailer Wiring
36 Steering Wheel Sensor (Gas)
37 Body Control Module 2
38Cigarette Lighter, Data Link
Controller
39 Windshield Wiper
40 Empty
41 Windshield Washer
42 Empty
43 Horn
44Transmission Control Module
Battery
45 Empty
46 Oxygen Sensor 1 (Gas)
5-109

Fuse Usage
47Transmission Control Module
Ignition
48 Engine Control Module Ignition
49 Mass Airflow Sensor, Canister Vent
50 Engine Control Module, Powertrain
51 Transmission
52 Even Ignition Injectors (Gas)
53 Glow Plug Module (Diesel)
54 Engine Control Module Battery
55 Odd Ignition Injectors (Gas)
56 Oxygen Sensor 2 (Gas)
57 Air Conditioning Compressor
58 Fan Clutch (Diesel)
59 V6 Fuel Injectors (Gas)
60Antilock Brake System Module
(J-Case)
61Antilock Brake System Motor
(J-Case)
62 Trailer Wiring (J-Case)
63 EmptyFuse Usage
64 Starter Solenoid (J-Case)
65Engine Control Module (ECM),
Powertrain (Diesel) (J-Case)
66 Front Blower (J-Case)
67 Empty
77 Body BEC (Mega Fuse)
Relays Usage
68 Empty
69 Run, Crank (High Current Micro)
70Windshield Wiper High
(High Current Micro)
71Windshield Wiper
(High Current Micro)
72 Fuel Pump (Mini Micro)
73 Crank (High Current Micro)
74Air Conditioning Compressor
(Mini Micro)
75 Fan Clutch (Diesel) (Solid State)
76 Powertrain (High Current Micro)
5-110

Services Provided
•Emergency Fuel Delivery:Delivery of enough fuel
for the vehicle to get to the nearest service station.
•Lock-Out Service:Service is provided to unlock the
vehicle if you are locked out. A remote unlock may be
available if you have OnStar
®. For security reasons,
the driver must present identification before this
service is given.
•Emergency Tow From a Public Road or Highway:
Tow to the nearest Chevrolet dealer for warranty
service, or if the vehicle was in a crash and cannot
be driven. Assistance is also given when the vehicle
is stuck in the sand, mud, or snow.
•Flat Tire Change:Service is provided to change a
flat tire with the spare tire. The spare tire, if equipped,
must be in good condition and properly inflated.
It is the owner’s responsibility for the repair or
replacement of the tire if it is not covered by the
warranty.
•Battery Jump Start:Service is provided to jump
start a dead battery.
•Trip Interruption Benets and Assistance:If your
trip is interrupted due to a warranty failure, incidental
expenses may be reimbursed during the 5 years/
100,000 miles (160 000 km) Powertrain warranty
period. Items considered are hotel, meals, and
rental car.
Services Not Included in Roadside
Assistance
•Impound towing caused by violation of any laws.
•Legal fines.
•Mounting, dismounting or changing of snow tires,
chains, or other traction devices.
•Towing or services for vehicles driven on a
non-public road or highway.
Services Specic to Canadian
Purchased Vehicles
•Fuel delivery:Reimbursement is approximately
$5 Canadian. Diesel fuel delivery may be restricted.
Propane and other fuels are not provided through
this service.
•Lock-Out Service:Vehicle registration is required.
•Trip Routing Service:Detailed maps of North
America are provided when requested either with
the most direct route or the most scenic route. There
is a limit of six requests per year. Additional travel
information is also available. Allow three weeks for
delivery.
7-9