service CHEVROLET EXPRESS CARGO VAN 2009 1.G Service Manual

Tires..............................................................5-54
Tire Sidewall Labeling...................................5-55
Tire Terminology and Definitions.....................5-59
Inflation - Tire Pressure.................................5-62
Dual Tire Operation.......................................5-63
Tire Pressure Monitor System.........................5-64
Tire Pressure Monitor Operation.....................5-65
Tire Inspection and Rotation...........................5-69
When It Is Time for New Tires.......................5-71
Buying New Tires.........................................5-72
Different Size Tires and Wheels......................5-73
Uniform Tire Quality Grading..........................5-74
Wheel Alignment and Tire Balance..................5-76
Wheel Replacement......................................5-76
Tire Chains..................................................5-78
If a Tire Goes Flat........................................5-79
Changing a Flat Tire.....................................5-80
Removing the Spare Tire and Tools................5-81
Removing the Flat Tire and Installing the
Spare Tire................................................5-84
Secondary Latch System...............................5-92
Storing a Flat or Spare Tire and Tools............5-95
Spare Tire...................................................5-96
Appearance Care............................................5-97
Interior Cleaning...........................................5-97
Fabric/Carpet...............................................5-98Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-99
Care of Safety Belts....................................5-100
Weatherstrips.............................................5-100
Washing Your Vehicle..................................5-100
Cleaning Exterior Lamps/Lenses....................5-101
Finish Care................................................5-101
Windshield and Wiper Blades.......................5-102
Aluminum Wheels.......................................5-102
Tires.........................................................5-103
Sheet Metal Damage...................................5-103
Finish Damage...........................................5-103
Underbody Maintenance...............................5-103
Chemical Paint Spotting...............................5-103
Vehicle Identication.....................................5-104
Vehicle Identification Number (VIN)................5-104
Service Parts Identification Label...................5-104
Electrical System..........................................5-105
Add-On Electrical Equipment.........................5-105
Headlamp Wiring........................................5-105
Windshield Wiper Fuses...............................5-105
Fuses and Circuit Breakers..........................5-105
Floor Console Fuse Block............................5-105
Engine Compartment Fuse Block...................5-107
Capacities and Specications........................5-111
Section 5 Service and Appearance Care
5-2

Service
For service and parts needs, visit your dealer/retailer.
You will receive genuine GM parts and GM-trained and
supported service people.
Genuine GM parts have one of these marks:
Accessories and Modications
When non-dealer/non-retailer accessories are added
to the vehicle, they can affect vehicle performance and
safety, including such things as airbags, braking, stability,
ride and handling, emissions systems, aerodynamics,
durability, and electronic systems like antilock brakes,
traction control, and stability control. Some of these
accessories could even cause malfunction or damage
not covered by the vehicle warranty.
GM Accessories are designed to complement and
function with other systems on the vehicle. Your GM
dealer/retailer can accessorize the vehicle using genuine
GM Accessories. When you go to your GM dealer/retailer
and ask for GM Accessories, you will know that
GM-trained and supported service technicians will
perform the work using genuine GM Accessories.
Also, seeAdding Equipment to Your Airbag-Equipped
Vehicle on page 1-76.
5-3

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 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 the 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 attempting any vehicle
maintenance task.
•Be sure to use the proper nuts, bolts, and
other fasteners. English and metric fasteners
can be easily confused. If the wrong fasteners
are used, parts can later break or fall off.
You could be hurt.
5-4

If doing some of your own service work, use the proper
service manual. It tells you much more about how to
service the vehicle than this manual can. To order
the proper service manual, seeService Publications
Ordering Information on page 7-16.
This vehicle has an airbag system. Before attempting
to do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-76.
Keep a record with all parts receipts and list the
mileage and the date of any service work performed.
SeeMaintenance Record on page 6-17.
Adding Equipment to the Outside of
the Vehicle
Things added to the outside of the 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 the vehicle.
Fuel
For diesel engine vehicles, 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 this 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 the
vehicle’s engine. The VIN is at the top left of the
instrument panel. SeeVehicle Identification
Number (VIN) on page 5-104.
If the vehicle has the 5.3L V8 engine (VIN Code 4) and
the N15 flexible fuel option, you can use either regular
unleaded gasoline or ethanol fuel containing up to 85%
ethanol (E85). SeeFuel E85 (85% Ethanol) on page 5-8.
For the 5.3L V8 engine (VIN Code 4) without the N15
option and 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. SeeAdditives on page 5-7for additional
information.
California Fuel
If the 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, the 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 the
vehicle might fail a smog-check test. SeeMalfunction
Indicator Lamp on page 3-34. 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 the vehicle 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 the 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:This 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 the
vehicle 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 the
vehicle’s engine. The VIN is at the top left of the
instrument panel. SeeVehicle Identification
Number (VIN) on page 5-104.
If the vehicle has the 5.3L V8 engine (VIN Code 4) and
the N15 flexible fuel option, you can use either unleaded
gasoline or ethanol fuel containing up to 85% ethanol
(E85). SeeFuel on page 5-5. For the 5.3L V8 engine
(VIN Code 4) without the N15 option and all other
gasoline 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) and the N15 flexible fuel option 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 findE85 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

Engine Oil Additives / Engine Oil
Flushes
Do not add anything to the oil. The recommended
oils with the starburst symbol that meet GM Standard
GM6094M are all you need for good performance and
engine protection.
Engine oil system flushes are not recommended and
could cause engine damage not covered by the vehicle
warranty.
Engine Oil Life System
When to Change Engine Oil
This vehicle has a computer system that lets you
know when to change the engine oil and filter. This is
based on engine revolutions and engine temperature,
and not on mileage. Based on driving conditions, the
mileage at which an oil change will be indicated can vary
considerably. For the oil life system to work properly, you
must reset the system every time the oil is changed.When the system has calculated that oil life has been
diminished, it will indicate that an oil change is necessary.
A CHANGE ENGINE OIL SOON message will come on.
SeeDIC Warnings and Messages on page 3-48. Change
the oil as soon as possible within the next 600 miles
(1 000 km). It is possible that, if you are driving under the
best conditions, the oil life system might not indicate that
an oil change is necessary for over a year. However, the
engine oil and filter must be changed at least once a year
and at this time the system must be reset. Your dealer/
retailer has trained service people who will perform this
work using genuine parts and reset the system. It is also
important to check the oil regularly and keep it at the
proper level.
If the system is ever reset accidentally, you must
change the oil at 3,000 miles (5 000 km) since the last
oil change. Remember to reset the oil life system
whenever the oil is changed.
5-18

How to Reset the Engine Oil Life
System
The Engine Oil Life System calculates when to change
the engine oil and filter based on vehicle use. Whenever
the oil is changed, reset the system so it can calculate
when the next oil change is required. If a situation occurs
where you change the oil prior to a CHANGE ENGINE
OIL SOON message being turned on, reset the system.
To reset the CHANGE ENGINE OIL SOON message:
1. Turn the ignition key to ON/RUN with the engine off.
2. Fully press and release the accelerator pedal
slowly three times within five seconds.
3. Turn the key to LOCK/OFF.
If the message comes back on when you start the
vehicle, the engine oil life system has not reset.
Repeat the procedure. If it still does not reset,
see your dealer/retailer for service.
What to Do with Used Oil
Used engine oil contains certain elements that can be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good hand
cleaner. Wash or properly dispose of clothing or rags
containing used engine oil. See the manufacturer’s
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
filter before disposal. Never dispose of oil by putting it
in the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Recycle it by taking it to a
place that collects used oil.
5-19

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