engine CHEVROLET EXPRESS CARGO VAN 2009 1.G Repair Manual

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

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

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

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