ECU CHEVROLET EXPRESS CARGO VAN 2009 1.G Service Manual

Dinghy Towing
Two-Wheel-Drive Vehicles
Notice:If the vehicle is towed with all four wheels
on the ground, the drivetrain components could
be damaged. The repairs would not be covered by
the vehicle warranty. Do not tow the vehicle with all
four wheels on the ground.
Two-wheel-drive vehicles should not be towed with
all four wheels on the ground. Two-wheel-drive
transmissions have no provisions for internal lubrication
while being towed.
All-Wheel-Drive Vehicles
The 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
with any of its wheels on the ground.
Dolly Towing
Rear Towing (Rear Wheels Off the Ground)
Two-Wheel-Drive Vehicles
Use the following procedure to tow the vehicle from
the rear:
1. Attach the dolly to the tow vehicle following the
dolly manufacturer’s instructions.
2. Drive the rear wheels onto the dolly.
3. Firmly set the parking brake. SeeParking Brake on
page 2-26for more information.
4. Put the transmission in P (Park).
5. Secure the vehicle to the dolly following the
manufacturer’s instructions.
6. Use an adequate clamping device designed for
towing to ensure that the front wheels are locked
into the straight position.
7. 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 the battery from draining while towing.
4-26

Vehicle Axle Ratio Maximum Trailer Weight GCWR*
G3500 Cargo Van 2WD Short Wheelbase
4.8L V83.73
4.106,400 lbs (2 903 kg)
9,400 lbs (4 264 kg)12,000 lbs (5 443 kg)
13,000 lbs (5 897 kg)
6.0L V83.73
4.108,400 lbs (3 810 kg)
10,000 lbs (4 536 kg)14,000 lbs (6 350 kg)
16,000 lbs (7 257 kg)
G3500 Cargo Van 2WD Long Wheelbase
4.8L 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)
6.0L 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 Wheelbase
6.0L V8 3.73 7,600 lbs (3 447 kg) 14,000 lbs (6 350 kg)
G3500 Passenger Van 2WD Long Wheelbase
6.0L 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 the 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 7-6for more
information.
4-30

Driving with a Trailer
{CAUTION:
When towing a trailer, exhaust gases may collect
at the rear of the vehicle and enter if the liftgate,
trunk/hatch, or rear-most window is open.
Engine exhaust contains carbon monoxide (CO)
which cannot be seen or smelled. It can cause
unconsciousness and even death.
To maximize safety when towing a trailer:
•Have the exhaust system inspected for
leaks and make necessary repairs before
starting a trip.
•Never drive with the liftgate, trunk/hatch, or
rear-most window open.
•Fully open the air outlets on or under the
instrument panel.
•Adjust the Climate Control system to a setting
that brings in only outside air and set the fan
speed to the highest setting. See Climate
Control System in the Index.
For more information about carbon monoxide, see
Engine Exhaust on page 2-30Towing a trailer requires a certain amount of experience.
Get to know the rig before setting out for the open
road. Get acquainted 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
longer and not as responsive as the vehicle is by itself.
Before starting, check all trailer hitch parts and
attachments, safety chains, electrical connectors, lamps,
tires and mirror adjustments. If the trailer has electric
brakes, start the vehicle and trailer moving and then
apply the trailer brake controller by hand to be sure the
brakes are working. This checks the electrical connection
at the same time.
During the trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer brakes
are still working.
4-37

4. Then fill the coolant recovery tank to the
COLD FILL mark.
5. Put the cap back on the coolant recovery tank, but
leave the radiator pressure cap off.6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fan.
7. By this time, the coolant level inside the radiator
filler neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the filler neck until the level reaches
the base of the filler neck.
8. Then replace the pressure cap. At any time during
this procedure if coolant begins to flow out of the
filler neck, reinstall the pressure cap.
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.
5-30

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.
The vehicle has an indicator to warn of engine
overheating.
You will find an engine coolant temperature gage on
your vehicle’s instrument panel. SeeEngine Coolant
Temperature Gage on page 3-33for more information.You may decide not to lift the hood when this warning
appears, but instead get service help right away.
SeeRoadside Assistance Program on page 7-7.
If you do decide to lift the hood, make sure the vehicle
is parked on a level surface.
Then check to see if the engine cooling fans are
running. If the engine is overheating, both fans should
be running. If they are not, do not continue to run
the engine and have the vehicle serviced.
See if the engine cooling fan speed increases when idle
speed is doubled by pushing the accelerator pedal down.
If it does not, your vehicle needs service. Turn off the
engine.
Notice:Engine damage from running the engine
without coolant is not covered by the warranty.
Notice:If the engine catches re because of being
driven with no coolant, your vehicle can be badly
damaged. The costly repairs would not be covered
by the vehicle warranty.
5-31

If the 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.
Also seeDual Tire Operation on page 5-63for
additional information.
After the tires have been rotated, adjust the front
and rear inflation pressures as shown on the Tire
and Loading Information label. SeeInflation - Tire
Pressure on page 5-62andLoading the Vehicle on
page 4-19. Make certain that all wheel nuts are
properly tightened. See “Wheel Nut Torque” under
Capacities and Specifications on page 5-111.
{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 5-80.
If your vehicle has a Tire Pressure Monitor
System (TPMS), reset the TPMS sensors after
rotating the tires. SeeTire Pressure Monitor
Operation on page 5-65.
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 5-95.
Dual Rear Wheels
5-70

Tire Chains
{CAUTION:
If your vehicle has dual wheels or P245/70R17 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.
CAUTION: (Continued)
CAUTION: (Continued)
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 find traction devices that will fit, install
them on the rear tires.
Notice:If your vehicle does not have dual
wheels and has a tire size other than P245/70R17 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.
5-78

When the vehicle has a flat tire (B), use the following
example as a guide to assist you in the placement
of wheel blocks (A).
A. Wheel Block
B. Flat Tire
The following information explains 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.
5-81

Storing a Flat or Spare Tire
and Tools
{CAUTION:
Storing a jack, a tire, or other equipment in the
passenger compartment of the vehicle could
cause injury. In a sudden stop or collision, loose
equipment could strike someone. Store all these
in the proper place.
1. Put the tire on the ground at the rear of the vehicle
with the valve stem pointed down.2. Pull the retaining bar through the center of the
wheel, making sure it is properly attached.
3. Pull the wheel toward the rear of the vehicle,
keeping the cable tight.
4. Put the chisel end of the hoist extension on an
angle through the hole in the rear door frame,
above the bumper.
5. Raise the tire fully against the underside of the
vehicle. Continue turning the wheel wrench until
the tire is secure and the cable is tight. The spare
tire hoist cannot be overtightened.
5-95

6. Make sure the tire is stored securely. Push, pull (A),
and then try to turn (B) the tire. If the tire moves,
use the wheel wrench to tighten the cable.
You will hear two clicks when the tire is up all
the way.
7. Return the jacking equipment to the proper location.
Secure the items and replace the jack cover.
Spare Tire
This vehicle, when new, may have had a fully-inflated
spare tire. A spare tire may lose air over time, so check its
inflation pressure regularly. SeeInflation - Tire Pressure
on page 5-62andLoading the Vehicle on page 4-19for
information regarding proper tire inflation and loading the
vehicle. For instruction on how to remove, install or store
a spare tire, seeRemoving the Flat Tire and Installing the
Spare Tire on page 5-84andStoring a Flat or Spare Tire
and Tools on page 5-95.
After installing the spare tire on the vehicle, you should
stop as soon as possible and make sure the spare is
correctly inflated. The spare tire is made to perform well
at speeds up to 70 mph (112 km/h) at the recommended
inflation pressure, so you can finish your trip.
Have the damaged or flat road tire repaired or replaced
as soon as you can and installed back onto the vehicle.
This way, a spare tire will be available in case you need
it again. Do not mix tires and wheels of different sizes,
because they will not fit. Keep the spare tire and its wheel
together.
5-96