brake CHEVROLET EXPRESS CARGO VAN 2012 1.G Workshop Manual

Black plate (25,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-25
3. Unscrew the cap and wipe thedipstick with a clean rag.
4. Replace the cap and completely tighten it.
5. Then remove the cap again and look at the fluid level on the
dipstick.
The level should be at the COLD
FILL mark. If necessary, add only
enough fluid to bring the level up to
the mark.
To prevent contamination of brake
fluid, never check or fill the power
steering reservoir with the brake
master cylinder cover off.
What to Use
To determine what kind of fluid to
use, see Recommended Fluids and
Lubricants on page 11‑12. Always
use the proper fluid. Failure to use
the proper fluid can cause leaks and
damage hoses and seals.
Washer Fluid
What to Use
When the vehicle needs windshield
washer fluid, be sure to read the
manufacturer's instructions before
use. If operating the vehicle in an
area where the temperature may fall
below freezing, use a fluid that has
sufficient protection against
freezing.
Adding Washer Fluid
Open the cap with the washer
symbol on it. Add washer fluid until
the tank is full. See Engine
Compartment Overview on
page 10‑6 for reservoir location. Notice
.When using concentrated
washer fluid, follow the
manufacturer's instructions
for adding water.
.Do not mix water with
ready-to-use washer fluid.
Water can cause the solution
to freeze and damage the
washer fluid tank and other
parts of the washer system.
Also, water does not clean as
well as washer fluid.
.Fill the washer fluid tank only
three-quarters full when it is
very cold. This allows for
fluid expansion if freezing
occurs, which could damage
the tank if it is
completely full.
.Do not use engine coolant
(antifreeze) in the windshield
washer. It can damage the
windshield washer system
and paint.

Black plate (26,1)Chevrolet Express Owner Manual - 2012
10-26 Vehicle Care
Brakes
This vehicle has disc brakes.
Disc brake pads have built-in wear
indicators that make a high-pitched
warning sound when the brake pads
are worn and new pads are needed.
The sound can come and go or be
heard all the time the vehicle is
moving, except when applying the
brake pedal firmly.
{WARNING
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
a crash. When the brake wear
warning sound is heard, have the
vehicle serviced.
Notice: Continuing to drive with
worn-out brake pads could result
in costly brake repair. Some driving conditions or climates
can cause a brake squeal when the
brakes are first applied or lightly
applied. This does not mean
something is wrong with the brakes.
Properly torqued wheel nuts are
necessary to help prevent brake
pulsation. When tires are rotated,
inspect brake pads for wear and
evenly tighten wheel nuts in the
proper sequence to torque
specifications in
Capacities and
Specifications on page 12‑2.
Brake linings should always be
replaced as complete axle sets.
Brake Pedal Travel
See your dealer if the brake pedal
does not return to normal height,
or if there is a rapid increase in
pedal travel. This could be a sign
that brake service might be
required.
Brake Adjustment
Every time the brakes are applied,
with or without the vehicle moving,
the brakes adjust for wear.
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, be sure to get
new, approved replacement parts.
If this is not done, the brakes might
not work properly. For example,
installing disc brake pads that are
wrong for the vehicle, can change
the balance between the front and
rear brakes —for the worse. The
braking performance expected can
change in many other ways if the
wrong replacement brake parts
are installed.

Black plate (27,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-27
Brake Fluid
The brake master cylinder reservoir
is filled with DOT 3 brake fluid. See
Engine Compartment Overview on
page 10‑6for the location of the
reservoir.
There are only two reasons why the
brake fluid level in the reservoir
might go down:
.The brake fluid level goes down
because of normal brake lining
wear. When new linings are
installed, the fluid level goes
back up.
.A fluid leak in the brake
hydraulic system can also cause
a low fluid level. Have the brake
hydraulic system fixed, since a
leak means that sooner or later
the brakes will not work well. Do not top off the brake fluid.
Adding fluid does not correct a leak.
If fluid is added when the linings are
worn, there will be too much fluid
when new brake linings are
installed. Add or remove brake fluid,
as necessary, only when work is
done on the brake hydraulic system.
{WARNING
If too much brake fluid is added,
it can spill on the engine and/or
fuel operated heater parts,
if equipped. If the vehicle has a
diesel engine and a fuel operated
heater, see
“Fuel Operated
Heater (FOH)” in the diesel
engine supplement. The fluid will
burn if the engine is hot enough.
You or others could be burned,
and the vehicle could be
damaged. Add brake fluid only
when work is done on the brake
hydraulic system. See “Checking
Brake Fluid” in this section. Refer to the Maintenance Schedule
to determine when to check the
brake fluid. See
Maintenance
Schedule on page 11‑3.
Checking Brake Fluid
Check brake fluid by looking at the
brake fluid reservoir. See Engine
Compartment Overview on
page 10‑6.
The fluid level should be above
MIN. If it is not, have the brake
hydraulic system checked to see if
there is a leak.

Black plate (28,1)Chevrolet Express Owner Manual - 2012
10-28 Vehicle Care
After work is done on the brake
hydraulic system, make sure the
level is above the MIN but not over
the MAX mark.
What to Add
Use only new DOT 3 brake fluid
from a sealed container. See
Recommended Fluids and
Lubricants on page 11‑12.
Always clean the brake fluid
reservoir cap and the area around
the cap before removing it. This
helps keep dirt from entering the
reservoir.
{WARNING
With the wrong kind of fluid in the
brake hydraulic system, the
brakes might not work well. This
could cause a crash. Always use
the proper brake fluid.Notice
.Using the wrong fluid
can badly damage brake
hydraulic system parts. For
example, just a few drops of
mineral-based oil, such as
engine oil, in the brake
hydraulic system can
damage brake hydraulic
system parts so badly that
they will have to be replaced.
Do not let someone put in
the wrong kind of fluid.
.If brake fluid is spilled on the
vehicle's painted surfaces,
the paint finish can be
damaged. Be careful not to
spill brake fluid on the
vehicle. If you do, wash it
off immediately.
Battery
Refer to the replacement number
shown on the original battery label
when a new battery is needed. See
Engine Compartment Overview on
page 10‑6
for 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.

Black plate (33,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-33
Starter Switch Check
{WARNING
When you are doing this
inspection, the vehicle could
move suddenly. If the vehicle
moves, you or others could be
injured.
1. Before starting this check, be sure there is enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular brake.
See Parking Brake on
page 9‑34.
Do not use the accelerator
pedal, and be ready to turn off
the engine immediately if it
starts.
3. Try to start the engine in each gear. The vehicle should start
only in P (Park) or N (Neutral). If the vehicle starts in any other
position, contact your dealer
for service.Automatic Transmission
Shift Lock Control
Function Check
{WARNING
When you are doing this
inspection, the vehicle could
move suddenly. If the vehicle
moves, you or others could be
injured.
1. Before starting this check, be sure there is enough room
around the vehicle. It should be
parked on a level surface.
2. Firmly apply the parking brake. See Parking Brake on
page 9‑34.
Be ready to apply the regular
brake immediately if the vehicle
begins to move. 3. With the engine off, turn the
ignition on, but do not start the
engine. Without applying the
regular brake, try to move the
shift lever out of P (Park) with
normal effort. If the shift lever
moves out of P (Park), contact
your dealer for service.
Ignition Transmission
Lock Check
While parked, and with the parking
brake set, try to turn the ignition to
LOCK/OFF in each shift lever
position.
.The ignition should turn to
LOCK/OFF only when the shift
lever is in P (Park).
.The ignition key should come
out only in LOCK/OFF.
Contact your dealer if service is
required.

Black plate (34,1)Chevrolet Express Owner Manual - 2012
10-34 Vehicle Care
Park Brake and P (Park)
Mechanism Check
{WARNING
When you are doing this check,
the vehicle could begin to move.
You or others could be injured
and property could be damaged.
Make sure there is room in front
of the vehicle in case it begins to
roll. Be ready to apply the regular
brake at once should the vehicle
begin to move.
Park on a fairly steep hill, with the
vehicle facing downhill. Keeping
your foot on the regular brake, set
the parking brake.
.To check the parking brake's
holding ability: With the engine
running and the transmission in
N (Neutral), slowly remove foot
pressure from the regular brake
pedal. Do this until the vehicle is
held by the parking brake only.
.To check the P (Park)
mechanism's holding ability:
With the engine running, shift to
P (Park). Then release the
parking brake followed by the
regular brake.
Contact your dealer if service is
required.
Wiper Blade Replacement
Windshield wiper blades should be
inspected for wear and cracking.
See Maintenance Schedule on
page 11‑3 for more information.
Replacement blades come in
different types and are removed
in different ways. For proper type
and length, see Maintenance
Replacement Parts on page 11‑14.
Notice: Allowing the wiper blade
arm to touch the windshield when
no wiper blade is installed could
damage the windshield. Any
damage that occurs would not be
covered by your warranty. Do not
allow the wiper blade arm to
touch the windshield. 1. Lift the wiper arm away from
the windshield.
A. Wiper Arm
B. Release Lever
C. Blade Assembly
2. Push the release lever (B) to disengage the hook and push
the wiper arm (A) out of the
blade assembly (C).
3. Push the new blade assembly securely on the wiper arm until
the release lever clicks into
place.

Black plate (54,1)Chevrolet Express Owner Manual - 2012
10-54 Vehicle Care
Tire Terminology and
Definitions
Air Pressure:The amount of
air inside the tire pressing
outward on each square inch
of the tire. Air pressure is
expressed in kPa (kilopascal)
or psi (pounds per square inch).
Accessory Weight
: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
kPa (kilopascal) or psi (pounds
per square inch) before a tire
has built up heat from driving.
See Tire Pressure on
page 10‑56.
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. See Vehicle Load Limits
on page 9‑11.
GAWR FRT
:Gross Axle Weight
Rating for the front axle.
See Vehicle Load Limits on
page 9‑11.
GAWR RR
:Gross Axle Weight
Rating for the rear axle.
See Vehicle Load Limits on
page 9‑11.

Black plate (61,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-61
.Operating electronic devices or
being near facilities using radio
wave frequencies similar to the
TPMS could cause the TPMS
sensors to malfunction.
If the TPMS is not functioning
properly, it cannot detect or signal a
low tire condition. See your dealer
for service if the TPMS malfunction
light and DIC message come on
and stay on.
TPMS Sensor Matching
Process
Each TPMS sensor has a unique
identification code. The identification
code needs to be matched to a
new tire/wheel position after rotating
the vehicle’ s tires or replacing one
or more of the TPMS sensors. Also,
the TPMS sensor matching process
should be performed after replacing
a spare tire with a road tire
containing the TPMS sensor.
The malfunction light and the DIC
message should go off at the next
ignition cycle. The sensors are
matched to the tire/wheel positions, using a TPMS relearn tool, in the
following order: driver side front tire,
passenger side front tire, passenger
side rear tire, and driver side rear.
See your dealer for service or to
purchase a relearn tool.
There are two minutes to match
the first tire/wheel position, and
five minutes overall to match all
four tire/wheel positions. If it takes
longer, the matching process stops
and must be restarted.
The TPMS sensor matching
process is:
1. Set the parking brake.
2. Turn the ignition to ON/RUN with
the engine off.
3. Press the Remote Keyless Entry (RKE) transmitter's LOCK
and UNLOCK buttons at the
same time for approximately
five seconds. The horn sounds
twice to signal the receiver is
in relearn mode and TIRE
LEARNING ACTIVE message
displays on the DIC screen. If the vehicle does not have
RKE, press the Driver
Information Center (DIC) vehicle
information button until the
PRESS
VTO RELEARN TIRE
POSITIONS message displays.
The horn sounds twice to signal
the receiver is in relearn mode
and TIRE LEARNING ACTIVE
message displays on the DIC
screen.
If the vehicle does not have RKE
or DIC buttons, press the trip
odometer reset stem located on
the instrument panel cluster until
the PRESS
VTO RELEARN
TIRE POSITIONS message
displays. The horn sounds twice
to signal the receiver is in
relearn mode and TIRE
LEARNING ACTIVE message
displays on the DIC screen.
4. Start with the driver side front tire.

Black plate (65,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-65
SeeTire Inspection on page 10‑62
and Tire Rotation on page 10‑62 for
additional information.
The rubber in tires ages over time.
This also applies to the spare tire,
if the vehicle has one, even if it is
never used. Multiple conditions
including temperatures, loading
conditions, and inflation pressure
maintenance affect how fast aging
takes place. Tires will typically need
to be replaced due to wear before
they may need to be replaced
due to age. Consult the tire
manufacturer for more information
on when tires should be replaced.
Vehicle Storage
Tires age when stored normally
mounted on a parked vehicle. Park
a vehicle that will be stored for at
least a month in a cool, dry, clean
area away from direct sunlight to
slow aging. This area should be
free of grease, gasoline or other
substances that can deteriorate
rubber. Parking for an extended period can
cause flat spots on the tires that
may result in vibrations while
driving. When storing a vehicle for
at least a month, remove the tires or
raise the vehicle to reduce the
weight from the tires.
Buying New Tires
GM has developed and matched
specific tires for the vehicle.
The original equipment tires
installed were designed to meet
General Motors Tire Performance
Criteria Specification (TPC Spec)
system rating. When replacement
tires are needed, GM strongly
recommends buying tires with the
same TPC Spec rating.
GM's exclusive TPC Spec system
considers over a dozen critical
specifications that impact the
overall performance of the
vehicle, including brake system
performance, ride and handling,
traction control, and tire pressure
monitoring performance.
GM's TPC Spec number is molded
onto the tire's sidewall near the tire
size. If the tires have an all‐season
tread design, the TPC Spec number
will be followed by MS for mud and
snow. See
Tire Sidewall Labeling on
page 10‑50 for additional
information.

Black plate (67,1)Chevrolet Express Owner Manual - 2012
Vehicle Care 10-67
Vehicles that have a tire pressure
monitoring system could give an
inaccurate low‐pressure warning if
non‐TPC Spec rated tires are
installed. SeeTire Pressure Monitor
System on page 10‑58.
The Tire and Loading Information
label indicates the original
equipment tires on the vehicle.
See Vehicle Load Limits on
page 9‑11 for the label location and
more information about the Tire and
Loading Information label.Different Size Tires and
Wheels
If wheels or tires are installed that
are a different size than the original
equipment wheels and tires, vehicle
performance, including its braking,
ride and handling characteristics,
stability, and resistance to rollover
may be affected. If the vehicle has
electronic systems such as antilock
brakes, rollover airbags, traction
control, and electronic stability
control, the performance of these
systems can also be affected.
{WARNING
If different sized wheels are used,
there may not be an acceptable
level of performance and safety if
tires not recommended for those
wheels are selected. This
increases the chance of a crash
and serious injury. Only use GM
specific wheel and tire systems
developed for the vehicle, and
have them properly installed by a
GM certified technician.
See Buying New Tires on
page 10‑65 andAccessories and
Modifications on page 10‑3 for
additional information.