2009 Chevrolet Express Owners Manual

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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. See Vehicle Identiﬁcation Number (VIN) on page 5-106. 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). See Fuel 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 Speciﬁcations 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. See Additives on page 5-7 for 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. See Malfunction 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. For customers who do not use TOP TIER Detergent Gasoline regularly, one bottle of GM Fuel System Treatment PLUS, added to the fuel tank at every engine oil change, can help clean deposits from fuel injectors and intake valves. GM Fuel System Treatment PLUS is the only gasoline additive recommended by General Motors. 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. See Vehicle Identiﬁcation Number (VIN) on page 5-106. 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). See Fuel 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 under Gasoline 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 ﬁnd E85 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. 5-8 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. E85 has less energy per gallon than gasoline, so you will need to reﬁll the fuel tank more often when using E85 than when you are using gasoline. See Filling the Tank on page 5-10. Notice: Some additives are not compatible with E85 fuel and can harm the vehicle’s fuel system. Do not add anything to E85. Damage caused by additives would not be covered by the vehicle warranty. 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. Fuels in Foreign Countries If you plan on driving in another country outside the United States or Canada, the proper fuel might be hard to ﬁnd. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by the vehicle warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. 5-9 The tethered fuel cap is located behind a hinged fuel door on the driver side of the vehicle. If the vehicle has E85 fuel capability, the fuel cap will be yellow and state that E85 or gasoline can be used. See Fuel E85 (85% Ethanol) on page 5-8. To remove the fuel cap, turn it slowly counterclockwise. While refueling, hang the tethered fuel cap from the hook on the fuel door. Filling the Tank { CAUTION: Fuel vapor burns violently and a fuel ﬁre can cause bad injuries. To help avoid injuries to you and others, read and follow all the instructions on the pump island. Turn off the engine when you are refueling. Do not smoke if you are near fuel or refueling the vehicle. Do not use cellular phones. Keep sparks, ﬂames, and smoking materials away from fuel. Do not leave the fuel pump unattended when refueling the vehicle. This is against the law in some places. Do not re-enter the vehicle while pumping fuel. Keep children away from the fuel pump; never let children pump fuel. 5-10 { CAUTION: { CAUTION: Fuel can spray out on you if you open the fuel cap too quickly. If you spill fuel and then something ignites it, you could be badly burned. This spray can happen if the tank is nearly full, and is more likely in hot weather. Open the fuel cap slowly and wait for any hiss noise to stop. Then unscrew the cap all the way. Be careful not to spill fuel. Do not top off or overﬁll the tank and wait a few seconds after you have ﬁnished pumping before removing the nozzle. Clean fuel from painted surfaces as soon as possible. See Washing Your Vehicle on page 5-102. When replacing the fuel cap, turn it clockwise until it clicks. Make sure the cap is fully installed. The diagnostic system can determine if the fuel cap has been left off or improperly installed. This would allow fuel to evaporate into the atmosphere. See Malfunction Indicator Lamp on page 3-34. If a ﬁre starts while you are refueling, do not remove the nozzle. Shut off the ﬂow of fuel by shutting off the pump or by notifying the station attendant. Leave the area immediately. If you need a new fuel cap, be sure to get Notice: the right type. Your dealer/retailer can get one for you. If you get the wrong type, it may not ﬁt properly. This may cause the malfunction indicator lamp to light and may damage the fuel tank and emissions system. See Malfunction Indicator Lamp on page 3-34. 5-11 Checking Things Under the Hood { CAUTION: Things that burn can get on hot engine or fuel operated heater (FOH) parts and start a ﬁre. These include liquids like fuel, oil, coolant, brake ﬂuid, windshield washer and other ﬂuids, and plastic or rubber. You or others could be burned. Be careful not to drop or spill things that will burn onto a hot engine or fuel operated heater (FOH). Filling a Portable Fuel Container { CAUTION: Never ﬁll a portable fuel container while it is in the vehicle. Static electricity discharge from the container can ignite the fuel vapor. You can be badly burned and the vehicle damaged if this occurs. To help avoid injury to you and others: • Dispense fuel only into approved containers. • Do not ﬁll a container while it is inside a vehicle, in a vehicle’s trunk, pickup bed, or on any surface other than the ground. • Bring the ﬁll nozzle in contact with the inside of the ﬁll opening before operating the nozzle. Contact should be maintained until the ﬁlling is complete. • Do not smoke while pumping fuel. • Do not use a cellular phone while pumping fuel. 5-12 Hood Release To open the hood: 1. Pull the handle with this symbol on it. It is located in front of the driver’s side door frame near the ﬂoor. 2. Then go to the front of the vehicle and lift up the secondary hood release, which is located underneath the middle of the hood. 3. Lift the hood, release the hood prop from its retainer and put the hood prop into the slot in the hood. If your vehicle has an underhood lamp, it will automatically come on and stay on until the hood is closed. Before closing the hood, be sure all of the ﬁller caps are on properly. Then lift the hood to relieve pressure on the hood prop. Remove the hood prop from the slot in the hood and return the prop to its retainer. Let the hood down and close it ﬁrmly. 5-13 Engine Compartment Overview If your vehicle has the DURAMAX Diesel engine, see the DURAMAX Diesel manual for more information. When you lift the hood, here is what you will see: 5-14 A. Battery. See Battery on page 5-40. B. Radiator Pressure Cap. See Radiator Pressure Cap on page 5-32. C. Coolant Recovery Tank. See Cooling System on page 5-24. D. Automatic Transmission Fluid Dipstick. See “Checking the Fluid Level” under Automatic Transmission Fluid on page 5-21. E. Engine Oil Fill Cap. See “When to Add Engine Oil” under Engine Oil on page 5-15. F. Engine Oil Dipstick. See “Checking Engine Oil” under Engine Oil on page 5-15. G. Engine Air Cleaner/Filter. See Engine Air Cleaner/Filter on page 5-20. H. Power Steering Fluid Reservoir. See Power Steering Fluid on page 5-35. I. Brake Master Cylinder Reservoir. See “Brake Fluid” under Brakes on page 5-37. J. Windshield Washer Fluid Reservoir. See “Adding Washer Fluid” under Windshield Washer Fluid on page 5-36. Engine Oil For diesel engine vehicles, see “Engine Oil” in the DURAMAX® Diesel manual. Checking Engine Oil It is a good idea to check the engine oil level at each fuel ﬁll. In order to get an accurate reading, the oil must be warm and the vehicle must be on level ground. The engine oil dipstick handle is a yellow loop. See Engine Compartment Overview on page 5-14 for the location of the engine oil dipstick. 1. Turn off the engine and give the oil several minutes to drain back into the oil pan. If this is not done, the oil dipstick might not show the actual level. 2. Pull out the dipstick and clean it with a paper towel or cloth, then push it back in all the way. Remove it again, keeping the tip down, and check the level. 5-15 When to Add Engine Oil See Engine Compartment Overview on page 5-14 for the location of the engine oil ﬁll cap. If the oil is below the cross-hatched area at the tip of the dipstick, add at least one quart/liter of the recommended oil. This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities and Speciﬁcations on page 5-114. Notice: Do not add too much oil. If the engine has so much oil that the oil level gets above the cross-hatched area that shows the proper operating range, the engine could be damaged. Add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when through. 5-16 What Kind of Engine Oil to Use Look for three things: • GM6094M Use only an oil that meets GM Standard GM6094M. • SAE 5W-30 SAE 5W-30 is best for the vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. • American Petroleum Institute (API) starburst symbol Oils meeting these requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certiﬁed by the American Petroleum Institute (API). Notice: Use only engine oil identiﬁed as meeting GM Standard GM6094M and showing the American Petroleum Institute Certiﬁed For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by the vehicle warranty. 5-17 Cold Temperature Operation If in an area of extreme cold, where the temperature falls below −20°F (−29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both provide easier cold starting for the engine at extremely low temperatures. Always use an oil that meets the required speciﬁcation, GM6094M. See “What Kind of Engine Oil to Use” for more information. 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 that is needed for good performance and engine protection. Engine oil system ﬂushes are not recommended and could cause engine damage not covered by the vehicle warranty. 5-18 Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates 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 is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See DIC 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 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, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. 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 the oil is changed 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 the vehicle is started, 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 Engine Air Cleaner/Filter If your vehicle has the DURAMAX Diesel engine, see the DURAMAX Diesel manual for more information. When to Inspect the Engine Air Cleaner/Filter Inspect the air cleaner/ﬁlter at the Maintenance II intervals and replace it at the ﬁrst oil change after each 50,000 mile (80 000 km) interval. See Scheduled Maintenance on page 6-4 for more information. If you are driving in dusty/dirty conditions, inspect the ﬁlter at each engine oil change. How to Inspect the Engine Air Cleaner/Filter To inspect the air cleaner/ﬁlter, remove the ﬁlter from the vehicle and lightly shake the ﬁlter to release loose dust and dirt. If the ﬁlter remains caked with dirt, a new ﬁlter is required. Never use compressed air to clean the ﬁlter. The engine air cleaner/ﬁlter is located near the center of the engine compartment. See Engine Compartment Overview on page 5-14 for more information on location. 5-20 To inspect or replace the engine air cleaner/ﬁlter, do the following: 1. Unhook the retainer clips and remove the cover. 2. Lift the ﬁlter out of the engine air cleaner/ﬁlter housing. Care should be taken to dislodge as little dirt as possible. 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. If the air cleaner/ﬁlter is off, a backﬁre can Notice: cause a damaging engine ﬁre. And, dirt can easily get into the engine, which will damage it. Always have the air cleaner/ﬁlter 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 6-7, and be sure to use the transmission ﬂuid listed in Recommended Fluids and Lubricants on page 6-15. 5-21 How to Check Automatic Transmission Fluid Because this operation can be a little difficult, you may choose to have this done at the dealer/retailer service department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. Notice: Too much or too little ﬂuid can damage your transmission. Too much can mean that some of the ﬂuid could come out and fall on hot engine parts or exhaust system parts, starting a ﬁre. Too little ﬂuid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission ﬂuid. Wait at least 30 minutes before checking the transmission ﬂuid level if you have been driving: • When outside temperatures are above 90°F (32°C). • At high speed for quite a while. • In heavy traffic — especially in hot weather. • While pulling a trailer. To get the right reading, the ﬂuid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it is colder than 50°F (10°C), drive the vehicle in D (DRIVE) until the engine temperature gage moves and then remains steady for 10 minutes. A cold ﬂuid check can be made after the vehicle has been sitting for eight hours or more with the engine off, but this is used only as a reference. Let the engine run at idle for ﬁve minutes if outside temperatures are 50°F (10°C) or more. If it is colder than 50°F (10°C), you may have to idle the engine longer. Should the ﬂuid level be low during this cold check, you must check the ﬂuid hot before adding ﬂuid. Checking the ﬂuid hot will give you a more accurate reading of the ﬂuid level. Checking the Fluid Level Prepare your vehicle as follows: 1. Park your vehicle on a level place. Keep the engine running. 2. With the parking brake applied, place the shift lever in P (PARK). 3. With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then, position the shift lever in P (PARK). 4. Let the engine run at idle for three minutes or more. 5-22 Then, without shutting off the engine, follow these steps: The transmission dipstick is located near the center of the engine compartment and will be labeled with the graphic shown. See Engine Compartment Overview on page 5-14 for more information on location. 1. Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel. 2. Push it back in all the way, wait three seconds and then pull it back out again. 3. Check both sides of the dipstick, and read the lower level. The ﬂuid level must be in the COLD area for a cold check or in the HOT or cross-hatched area for a hot check. Be sure to keep the dipstick pointed down to get an accurate reading. 4. If the ﬂuid level is in the acceptable range, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. 5-23 How to Add Automatic Transmission Fluid Refer to the Maintenance Schedule to determine what kind of transmission ﬂuid to use. See Recommended Fluids and Lubricants on page 6-15. Using a funnel, add ﬂuid down the transmission dipstick tube only after checking the transmission ﬂuid while it is hot. A cold check is used only as a reference. If the ﬂuid level is low, add only enough of the proper ﬂuid to bring the level up to the HOT area for a hot check. It does not take much ﬂuid, generally less than one pint (0.5 L). Do not overﬁll. Notice: Use of the incorrect automatic transmission ﬂuid may damage the vehicle, and the damages may not be covered by the vehicle’s warranty. Always use the automatic transmission ﬂuid listed in Recommended Fluids and Lubricants on page 6-15. • After adding ﬂuid, recheck the ﬂuid level as described under “How to Check Automatic Transmission Fluid,” earlier in this section. • When the correct ﬂuid level is obtained, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. 5-24 Cooling System If your vehicle has a diesel engine, see “Van Models” under “Cooling System” in the DURAMAX® Diesel Supplement. The Cooling System allows the engine to maintain the correct working temperature. A. Radiator Pressure Cap B. Coolant Recovery Tank C. Engine Cooling Fan(s) { CAUTION: An electric engine cooling fan under the hood can start up even when the engine is not running and can cause injury. Keep hands, clothing, and tools away from any underhood electric fan. { CAUTION: Heater, fuel operated heater (FOH), radiator hoses, and other engine parts, can be very hot. Do not touch them. If you do, you can be burned. Do not run the engine if there is a leak. If you run the engine, it could lose all coolant. That could cause an engine ﬁre, and you could be burned. Get any leak ﬁxed before you drive the vehicle. Notice: Using coolant other than DEX-COOL may cause premature engine, heater core, radiator and fuel operated heater (FOH) corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs ﬁrst. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. Engine Coolant The cooling system in the vehicle is ﬁlled with DEX-COOL® engine coolant. This coolant is designed to remain in the vehicle for ﬁve years or 150,000 miles (240 000 km), whichever occurs ﬁrst. The following explains the cooling system and how to check and add coolant when it is low. If there is a problem with engine overheating, see Engine Overheating on page 5-32. 5-25 What to Use { CAUTION: Adding only plain water to the cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. The vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, the engine could get too hot but you would not get the overheat warning. The engine could catch ﬁre and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant. If using this mixture, nothing else needs to be added. This mixture: • Gives freezing protection down to −34°F (−37°C), outside temperature. • Gives boiling protection up to 265°F (129°C), engine temperature. • Protects against rust and corrosion. • Will not damage aluminum parts. • Helps keep the proper engine temperature. 5-26 If an improper coolant mixture is used, Notice: the engine could overheat and be badly damaged. The repair cost would not be covered by the vehicle warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core, and other parts. Notice: in the vehicle’s cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed in this manual for the cooling system. See Recommended Fluids and Lubricants on page 6-15 for more information. If extra inhibitors and/or additives are used Checking Coolant The vehicle must be on a level surface when checking the coolant level. Check to see if coolant is visible in the coolant recovery tank. If the coolant inside the coolant recovery tank is boiling, do not do anything else until it cools down. If coolant is visible but the coolant level is not at or above the COLD FILL mark, add a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant at the coolant recovery tank, but be sure the cooling system is cool before this is done. When the engine is cold, the coolant level should be at or above the COLD FILL mark. If it is not, there could be a leak in the cooling system. If the coolant is low, add the coolant or take the vehicle to a dealer/retailer for service. 5-27 How to Add Coolant to the Recovery Tank for Gasoline Engines If your vehicle has a diesel engine, see “How to Add Coolant to the Coolant Recovery Tank” under “Van Models” in the Cooling System section of the DURAMAX® Diesel Supplement for the proper coolant ﬁll procedure. { CAUTION: Notice: This vehicle has a speciﬁc coolant ﬁll procedure. Failure to follow this procedure could cause the engine to overheat and be severely damaged. If coolant is needed, add the proper DEX-COOL® coolant mixture at the coolant recovery tank. How to Add Coolant to the Radiator If your vehicle has a diesel engine, see “How to Add Coolant to the Radiator” under “Van Models” in the Cooling System section of the DURAMAX® Diesel Supplement for the proper radiator ﬁll procedure. You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine. { CAUTION: An electric engine cooling fan under the hood can start up even when the engine is not running and can cause injury. Keep hands, clothing, and tools away from any underhood electric fan. 5-28 { CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the surge tank pressure cap — even a little — they can come out at high speed. Never turn the cap when the cooling system, including the surge tank pressure cap, is hot. Wait for the cooling system and surge tank pressure cap to cool if you ever have to turn the pressure cap. If coolant is needed, add the proper mixture directly to the radiator, but be sure the cooling system is cool before this is done. 1. You can remove the radiator pressure cap when the cooling system, including the radiator pressure cap and upper radiator hose, is no longer hot. Turn the pressure cap slowly counterclockwise until it ﬁrst stops. Do not press down while turning the pressure cap. If you hear a hiss, wait for that to stop. A hiss means there is still some pressure left. 2. Then keep turning the pressure cap, but now push down as you turn it. Remove the pressure cap. 5-29 3. Fill the radiator with the proper DEX-COOL® coolant mixture, up to the base of the ﬁller neck. See Engine Coolant on page 5-25 for more information about the proper coolant mixture. 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. 5-30 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. If the pressure cap is not tightly installed, Notice: coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured. 5-31 Radiator Pressure Cap The radiator pressure cap is located near the center of the engine compartment. See Engine Compartment Overview on page 5-14 for more information on location. Notice: coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured. If the pressure cap is not tightly installed, 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. See Engine Coolant Temperature Gage on page 3-33 for more information. You may decide not to lift the hood when this warning appears, but instead get service help right away. See Roadside Assistance Program on page 7-8. 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: driven with no coolant, your vehicle can be badly damaged. The costly repairs would not be covered by the vehicle warranty. If the engine catches ﬁre because of being 5-32 If Steam Is Coming From The Engine Compartment { CAUTION: Steam from an overheated engine can burn you badly, even if you just open the hood. Stay away from the engine if you see or hear steam coming from it. Just turn it off and get everyone away from the vehicle until it cools down. Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when your engine is overheated, the liquids in it can catch ﬁre. You or others could be badly burned. Stop your engine if it overheats, and get out of the vehicle until the engine is cool. If No Steam Is Coming From The Engine Compartment If an engine overheat warning is displayed but no steam can be seen or heard, the problem may not be too serious. Sometimes the engine can get a little too hot when the vehicle: • Climbs a long hill on a hot day. • Stops after high-speed driving. • Idles for long periods in traffic. • Tows a trailer. See “Driving on Grades” under Towing a Trailer on page 4-27. If the overheat warning is displayed with no sign of steam: 1. Turn the air off. 2. Turn the heater on to the highest temperature and to the highest fan speed. Open the windows as necessary. 3. In heavy traffic, let the engine idle in N (Neutral) while stopped. If it is safe to do so, pull off the road, shift to P (Park) or N (Neutral) and let the engine idle. 5-33 If the temperature overheat gage is no longer in the overheat zone or an overheat warning no longer displays, the vehicle can be driven. Continue to drive the vehicle slow for about 10 minutes. Keep a safe vehicle distance from the car in front of you. If the warning does not come back on, continue to drive normally. If the warning continues, pull over, stop, and park the vehicle right away. If there is still no sign of steam, push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes while you are parked. If you still have the warning, turn off the engine until it cools down. You may decide not to lift the hood but to get service help right away. Engine Fan Noise Your vehicle has a clutched engine cooling fan. When the clutch is engaged, the fan spins faster to provide more air to cool the engine. In most everyday driving conditions, the fan is spinning slower and the clutch is not fully engaged. This improves fuel economy and reduces fan noise. Under heavy vehicle loading, trailer towing, and/or high outside temperatures, the fan speed increases as the clutch more fully engages, so you may hear an increase in fan noise. This is normal and should not be mistaken as the transmission slipping or making extra shifts. It is merely the cooling system functioning properly. The fan will slow down when additional cooling is not required and the clutch partially disengages. You may also hear this fan noise when you start the engine. It will go away as the fan clutch partially disengages. 5-34 Power Steering Fluid The power steering ﬂuid reservoir is located in the engine compartment on the driver’s side of the vehicle. See Engine Compartment Overview on page 5-14 for reservoir location. When to Check Power Steering Fluid It is not necessary to regularly check power steering ﬂuid unless you suspect there is a leak in the system or you hear an unusual noise. A ﬂuid loss in this system could indicate a problem. Have the system inspected and repaired. How to Check Power Steering Fluid To check the power steering ﬂuid, do the following: 1. Turn the key off and let the engine compartment cool down. 2. Wipe the cap and the top of the reservoir clean. 3. Unscrew the cap and wipe the dipstick 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 6-15. Always use the proper ﬂuid. Failure to use the proper ﬂuid can cause leaks and damage hoses and seals. 5-35 Windshield Washer Fluid What to Use When you need windshield washer ﬂuid, be sure to read the manufacturer’s instructions before use. If you will be operating your 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 5-14 for reservoir location. Notice: (cid:129) When using concentrated washer ﬂuid, follow the manufacturer’s instructions for adding water. (cid:129) Do not mix water with ready-to-use washer ﬂuid. Water can cause the solution to freeze and damage your 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. (cid:129) Do not use engine coolant (antifreeze) in your windshield washer. It can damage the vehicle’s windshield washer system and paint. 5-36 (cid:129) Brakes Brake Fluid The brake master cylinder reservoir is ﬁlled with DOT 3 brake ﬂuid. See Engine Compartment Overview on page 5-14 for 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. { CAUTION: 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 Scheduled Maintenance on page 6-4. 5-37 Checking Brake Fluid Check brake ﬂuid by looking at the brake ﬂuid reservoir. See Engine Compartment Overview on page 5-14. { CAUTION: 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: (cid:129) 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. See Washing Your Vehicle on page 5-102. The ﬂuid level should be above MIN. If it is not, have the brake hydraulic system checked to see if there is a leak. 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 6-15. Always clean the brake ﬂuid reservoir cap and the area around the cap before removing it. This helps keep dirt from entering the reservoir. 5-38 (cid:129) Brake Wear 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. { CAUTION: The brake wear warning sound means that soon the brakes will not work well. That could lead to an accident. 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 5-114. Brake linings should always be replaced as complete axle sets. Brake Pedal Travel See your dealer/retailer 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 brake stop, the brakes adjust for wear. 5-39 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. See Jump Starting on page 5-41 for 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. 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. See Engine Compartment Overview on page 5-14 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. 5-40 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. Ignoring these steps could result in costly Notice: damage to the vehicle that would not be covered by the warranty. Trying to start the vehicle by pushing or pulling it will not work, and it could damage the vehicle. 1. Check the other vehicle. It must have a 12-volt battery with a negative ground system. If the other vehicle’s system is not a 12-volt Notice: 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. 5-41 If you leave the radio or other accessories Notice: 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). 5-42 On V6 engines the remote negative (−) terminal is located on a tab attached to the engine accessory drive bracket and is marked GND (Ground). { 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 (−) or you 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. 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. 5-43 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. If the jumper cables are connected or Notice: removed in the wrong order, electrical shorting may occur and damage the vehicle. The repairs would not be covered by the vehicle 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. 5-44 Jumper Cable Removal 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 (+) Terminal To 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. See Scheduled Maintenance on page 6-4. How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface. If the level is below the bottom of the ﬁller plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the ﬁller plug hole. Use care not to overtighten the plug. 5-45 How to Check Lubricant What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Recommended Fluids and Lubricants on page 6-15. Rear Axle When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See Scheduled Maintenance on page 6-4. To get an accurate reading, the vehicle should be on a level surface. If you have the 1500 Series, the proper level is from 5/8 inch (15 mm) to 1 5/8 inch (40 mm) below the bottom of the ﬁller plug hole. The proper level for the 2500 and 3500 Series is from 0 to 1/4 (6 mm) below the bottom of the ﬁller plug hole. Add only enough ﬂuid to reach the proper level. 5-46 What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Recommended Fluids and Lubricants on page 6-15. Front Axle When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See Scheduled Maintenance on page 6-4. How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface. If the level is below the bottom of the ﬁller plug hole, you may need to add some lubricant. When the differential is cold, add enough lubricant to raise the level to 3/8 inch (10 mm) below the ﬁller plug hole. When the differential is at operating temperature (warm), add enough lubricant to raise the level to the bottom of the ﬁller plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Recommended Fluids and Lubricants on page 6-15. 5-47 Noise Control System Tampering with Noise Control System Prohibited The following information relates to compliance with federal noise emission standards for vehicles with a Gross Vehicle Weight Rating (GVWR) of more than 10,000 lbs (4 536 kg). The Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system during the life of your vehicle. The noise control system warranty is given in your warranty booklet. These standards apply only to vehicles sold in the United States. Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser or while it is in use; or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 5-48 Among those acts presumed to constitute tampering are the acts listed below. Insulation: • Removal of the noise shields or any underhood insulation. Engine: • Removal or rendering engine speed governor, if the vehicle has one, inoperative so as to allow engine speed to exceed manufacturer speciﬁcations. Fan and Drive: • Removal of fan clutch, if the vehicle has one, or rendering clutch inoperative. • Removal of the fan shroud, if the vehicle has one. Air Intake: • Removal of the air cleaner silencer. • Modiﬁcation of the air cleaner. Exhaust: • Removal of the muffler and/or resonator. • Removal of the exhaust pipes and exhaust pipe clamps. Fuel Operated Heater (FOH) — Diesel Engine: • Removal of the muffler. Bulb Replacement For the proper type of replacement bulbs, see Replacement Bulbs on page 5-53. For any bulb changing procedure not listed in this section, contact your dealer/retailer. Headlamps To remove the headlamp assembly from the vehicle and access the bulbs: 1. Open the hood. See Hood Release on page 5-13 for more information. 2. Remove the two bolts from the headlamp assembly. Halogen Bulbs { CAUTION: Halogen bulbs have pressurized gas inside and can burst if you drop or scratch the bulb. You or others could be injured. Be sure to read and follow the instructions on the bulb package. 3. Remove the two pins on the top of the headlamp assembly. To remove the pins, turn the outer pin clockwise and pull it straight up. To remove the inner pin, turn it counterclockwise and pull it straight up. 4. Lift the inboard side of the headlamp to release the inboard tab from the radiator support. 5-49 5. Lift the outboard side of the headlamp to release the outboard tab from the radiator support. 6. Lower the headlamp to allow the vertical adjustor to clear the tie bar. 7. Turn the headlamp forward and upward to remove it from the grille. 8. Turn the bulb connector counterclockwise and pull it out of the housing. 9. Without removing the headlamp assembly itself, remove the bulb socket from the back of the headlamp on the driver’s side. 10. Turn the bulb counterclockwise one quarter turn to remove it from the socket. 11. On the passenger’s side, turn the bulb clockwise one turn. 5-50 12. Install the new bulb into the socket then reinstall it into the headlamp assembly. 13. Reverse the steps to reinstall the headlamp assembly. Front Turn Signal, Sidemarker and Parking Lamps To replace the front turn signal, sidemarker and/or parking lamp bulb(s): 3. Remove the lamp from the grille. 4. Squeeze the tab on the side of the bulb socket while turning it counterclockwise. 5. Remove the bulb socket from the back of the lamp assembly. 6. Replace the bulb. 7. Turn the bulb socket clockwise to reinstall it in the lamp assembly. 1. Use a small tool to unlatch the outboard clip on the lamp. 2. Pull the lamp forward to completely unlatch the clip. Move the lamp to the outboard side to loosen the tabs. 5-51 Center High-Mounted Stoplamp (CHMSL) The Center High-Mounted Stoplamp (CHMSL) is located above the rear doors at the center of the vehicle. To replace a bulb: Taillamps To replace one of these bulbs: 1. Remove the two inboard nuts from the inside of the taillamp assembly. 1. Remove the two screws from the CHMSL assembly. 2. Remove the CHMSL assembly. 3. Turn the bulb counterclockwise one quarter turn to remove it from the socket. 4. Turn the bulb clockwise one quarter turn to install it in the socket. 5. Reinstall the CHMSL assembly and two screws. Do not block or damage the CHMSL when items are loaded on the roof of the vehicle. 5-52 2. Pull the taillamp assembly straight back to clear the studs. 3. Slide the taillamp assembly slightly upward to release the lower clip. 4. Remove the three nuts on the taillamp assembly. 5. Remove the taillamp assembly from the vehicle. 12. Push the taillamp straight forward to reengage the studs. 13. Reinstall the two inboard nuts from the inside of the taillamp assembly. Replacement Bulbs Exterior Lamp Back-up, Rear Parking, Stoplamp, and Turn Signal Lamp Center High Mounted Stop Lamp (CHMSL) Front Parking and Turn Signal Lamp Front Sidemarker Lamp Headlamps Composite High-Beam Headlamp Composite Low-Beam Headlamp Sealed Beam Headlamp Bulb Number 3157 912 3157KX 194 9005 9006GS H6054 For replacement bulbs not listed here, contact your dealer/retailer. 5-53 6. Remove the bulb socket by squeezing the tab on the side of the socket while turning it counterclockwise. 7. Turn the bulb counterclockwise to remove it. 8. Turn the bulb clockwise to install it in the socket. 9. Reinstall the bulb socket by squeezing the tab while turning it clockwise. 10. Reinstall the taillamp assembly and three nuts on the vehicle. 11. Slide the taillamp slightly downward to reengage the lower clip. Windshield Wiper Blade Replacement Windshield wiper blades should be inspected for wear and cracking. See Scheduled Maintenance on page 6-4 for more information on wiper blade inspection. Replacement blades come in different types and are removed in different ways. To remove the type with a release clip, do the following: 1. Lift the wiper arm until it locks into a vertical position. 3. The insert has two notches at one end that are locked by bottom claws of the blade assembly. At the notched end, pull the insert from the blade assembly. 4. To install the new wiper insert, slide the notched end last, into the end with two blade claws. Then slide the insert all the way through the blade claws at the opposite end. 5. Make sure that the notches are locked by the bottom claws. Make sure that all other claws are properly locked on both sides of the insert slot. 6. Put the blade assembly pivot in the wiper arm hook. Pull it up until the pivot locking tab locks in the hook slot. 7. Carefully lower the wiper arm and blade assembly into the windshield. 2. Press down on the blade assembly pivot locking tab. Pull down on the blade assembly to release it from the wiper arm hook. 5-54 Tires Your new vehicle comes with high-quality tires made by a leading tire manufacturer. If you ever have questions about your tire warranty and where to obtain service, see your vehicle Warranty booklet for details. For additional information refer to the tire manufacturer. { CAUTION: Poorly maintained and improperly used tires are dangerous. • Overloading your vehicle’s tires can cause overheating as a result of too much ﬂexing. You could have an air-out and a serious accident. See Loading the Vehicle on page 4-19. CAUTION: (Continued) CAUTION: (Continued) • Underinﬂated tires pose the same danger as overloaded tires. The resulting accident could cause serious injury. Check all tires frequently to maintain the recommended pressure. Tire pressure should be checked when your vehicle’s tires are cold. See Inﬂation - Tire Pressure on page 5-64. • Overinﬂated tires are more likely to be cut, punctured, or broken by a sudden impact — such as when you hit a pothole. Keep tires at the recommended pressure. • Worn, old tires can cause accidents. If the tire’s tread is badly worn, or if your vehicle’s tires have been damaged, replace them. 5-55 Tire Sidewall Labeling Useful information about a tire is molded into the sidewall. The following illustrations are examples of a typical P-Metric and a LT-Metric tire sidewall. Passenger (P-Metric) Tire (A) Tire Size: The tire size code is a combination of letters and numbers used to deﬁne a particular tire’s width, height, aspect ratio, construction type, and service description. See the “Tire Size” illustration later in this section for more detail. 5-56 (B) TPC Spec (Tire Performance Criteria Speciﬁcation): Original equipment tires designed to GM’s speciﬁc tire performance criteria have a TPC speciﬁcation code molded onto the sidewall. GM’s TPC speciﬁcations meet or exceed all federal safety guidelines. (C) DOT (Department of Transportation): The Department of Transportation (DOT) code indicates that the tire is in compliance with the U.S. Department of Transportation Motor Vehicle Safety Standards. (D) Tire Identiﬁcation Number (TIN): The letters and numbers following DOT code are the Tire Identiﬁcation Number (TIN). The TIN shows the manufacturer and plant code, tire size, and date the tire was manufactured. The TIN is molded onto both sides of the tire, although only one side may have the date of manufacture. (E) Tire Ply Material: The type of cord and number of plies in the sidewall and under the tread. (F) Uniform Tire Quality Grading (UTQG): Tire manufacturers are required to grade tires based on three performance factors: treadwear, traction, and temperature resistance. For more information, see Uniform Tire Quality Grading on page 5-77. (G) Maximum Cold Inﬂation Load Limit: Maximum load that can be carried and the maximum pressure needed to support that load. For information on recommended tire pressure see Inﬂation - Tire Pressure on page 5-64 and Loading the Vehicle on page 4-19. Light Truck (LT-Metric) Tire (A) Tire Size: The tire size code is a combination of letters and numbers used to deﬁne a particular tire’s width, height, aspect ratio, construction type, and service description. See the “Tire Size” illustration later in this section for more detail. (B) TPC Spec (Tire Performance Criteria Speciﬁcation): Original equipment tires designed to GM’s speciﬁc tire performance criteria have a TPC speciﬁcation code molded onto the sidewall. GM’s TPC speciﬁcations meet or exceed all federal safety guidelines. This does not apply to Goodyear LT225/75R16 G949 RSA and Goodyear LT225/75R16 G933 RSD commercial truck tires. (C) Dual Tire Maximum Load: Maximum load that can be carried and the maximum pressure needed to support that load when used in a dual conﬁguration. For information on recommended tire pressure see Inﬂation - Tire Pressure on page 5-64 and Loading the Vehicle on page 4-19. (D) DOT (Department of Transportation): The Department of Transportation (DOT) code indicates that the tire is in compliance with the U.S. Department of Transportation Motor Vehicle Safety Standards. 5-57 (E) Tire Identiﬁcation Number (TIN): The letters and numbers following DOT code are the Tire Identiﬁcation Number (TIN). The TIN shows the manufacturer and plant code, tire size, and date the tire was manufactured. The TIN is molded onto both sides of the tire, although only one side may have the date of manufacture. (F) Tire Ply Material: The type of cord and number of plies in the sidewall and under the tread. (G) Single Tire Maximum Load: Maximum load that can be carried and the maximum pressure needed to support that load when used as a single. For information on recommended tire pressure see Inﬂation - Tire Pressure on page 5-64 and Loading the Vehicle on page 4-19. Tire Size The following examples show the different parts of a tire size. Passenger (P-Metric) Tire (A) Passenger (P-Metric) Tire: The United States version of a metric tire sizing system. The letter P as the ﬁrst character in the tire size means a passenger vehicle tire engineered to standards set by the U.S. Tire and Rim Association. (B) Tire Width: The three-digit number indicates the tire section width in millimeters from sidewall to sidewall. 5-58 (C) Aspect Ratio: A two-digit number that indicates the tire height-to-width measurements. For example, if the tire size aspect ratio is 75, as shown in item C of the illustration, it would mean that the tire’s sidewall is 75 percent as high as it is wide. (D) Construction Code: A letter code is used to indicate the type of ply construction in the tire. The letter R means radial ply construction; the letter D means diagonal or bias ply construction; and the letter B means belted-bias ply construction. (E) Rim Diameter: Diameter of the wheel in inches. (F) Service Description: These characters represent the load index and speed rating of the tire. The load index represents the load carry capacity a tire is certiﬁed to carry. The speed rating is the maximum speed a tire is certiﬁed to carry a load. Light Truck (LT-Metric) Tire (A) Light Truck (LT-Metric) Tire: The United States version of a metric tire sizing system. The letters LT as the ﬁrst two characters in the tire size means a light truck tire engineered to standards set by the U.S. Tire and Rim Association. (B) Tire Width: The three-digit number indicates the tire section width in millimeters from sidewall to sidewall. (C) Aspect Ratio: A two-digit number that indicates the tire height-to-width measurements. For example, if the tire size aspect ratio is 75, as shown in item C of the light truck (LT-Metric) tire illustration, it would mean that the tire’s sidewall is 75 percent as high as it is wide. 5-59 (D) Construction Code: A letter code is used to indicate the type of ply construction in the tire. The letter R means radial ply construction; the letter D means diagonal or bias ply construction; and the letter B means belted-bias ply construction. (E) Rim Diameter: Diameter of the wheel in inches. (F) Load Range: Load Range. (G) Service Description: The service description indicates the load index and speed rating of a tire. If two numbers are given as in the example, 120/116, then this represents the load index for single versus dual wheel usage (single/dual). The speed rating is the maximum speed a tire is certiﬁed to carry a load. This does not apply to Goodyear LT225/ 75R16 G949 RSA and Goodyear LT225/75R16 G933 RSD commercial truck tires; see the dual tire and single tire maximum load and load range letter designations on the tire sidewall. 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 pounds per square inch (psi) or kilopascal (kPa). Accessory Weight: This means 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. 5-60 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 pounds per square inch (psi) or kilopascals (kPa) before a tire has built up heat from driving. See Inﬂation - Tire Pressure on page 5-64. 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 Loading the Vehicle on page 4-19. GAWR FRT: Gross Axle Weight Rating for the front axle. See Loading the Vehicle on page 4-19. GAWR RR: Gross Axle Weight Rating for the rear axle. See Loading the Vehicle on page 4-19. Intended Outboard Sidewall: The side of an asymmetrical tire, that must always face outward when mounted on a vehicle. Kilopascal (kPa): The metric unit for air pressure. Light Truck (LT-Metric) Tire: A tire used on light duty trucks and some multipurpose passenger vehicles. Load Index: An assigned number ranging from 1 to 279 that corresponds to the load carrying capacity of a tire. 5-61 Maximum Inﬂation Pressure: The maximum air pressure to which a cold tire can be inﬂated. The maximum air pressure is molded onto the sidewall. Maximum Load Rating: The load rating for a tire at the maximum permissible inﬂation pressure for that tire. Maximum Loaded Vehicle Weight: The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Normal Occupant Weight: The number of occupants a vehicle is designed to seat multiplied by 150 lbs (68 kg). See Loading the Vehicle on page 4-19. Occupant Distribution: Designated seating positions. Outward Facing Sidewall: The side of an asymmetrical tire that has a particular side that faces outward when mounted on a vehicle. The side of the tire that contains a whitewall, bears white lettering, or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same moldings on the other sidewall of the tire. Passenger (P-Metric) Tire: A tire used on passenger cars and some light duty trucks and multipurpose vehicles. Recommended Inﬂation Pressure: Vehicle manufacturer’s recommended tire inﬂation pressure as shown on the tire placard. See Inﬂation - Tire Pressure on page 5-64 and Loading the Vehicle on page 4-19. Radial Ply Tire: A pneumatic tire in which the ply cords that extend to the beads are laid at 90 degrees to the centerline of the tread. Rim: A metal support for a tire and upon which the tire beads are seated. Sidewall: The portion of a tire between the tread and the bead. Speed Rating: An alphanumeric code assigned to a tire indicating the maximum speed at which a tire can operate. Traction: The friction between the tire and the road surface. The amount of grip provided. 5-62 Tread: The portion of a tire that comes into contact with the road. Treadwear Indicators: Narrow bands, sometimes called wear bars, that show across the tread of a tire when only 1/16 inch (1.6 mm) of tread remains. See When It Is Time for New Tires on page 5-73. UTQGS (Uniform Tire Quality Grading Standards): A tire information system that provides consumers with ratings for a tire’s traction, temperature, and treadwear. Ratings are determined by tire manufacturers using government testing procedures. The ratings are molded into the sidewall of the tire. See Uniform Tire Quality Grading on page 5-77. Vehicle Capacity Weight: The number of designated seating positions multiplied by 150 lbs (68 kg) plus the rated cargo load. See Loading the Vehicle on page 4-19. Vehicle Maximum Load on the Tire: Load on an individual tire due to curb weight, accessory weight, occupant weight, and cargo weight. Vehicle Placard: A label permanently attached to a vehicle showing the vehicle’s capacity weight and the original equipment tire size and recommended inﬂation pressure. See “Tire and Loading Information Label” under Loading the Vehicle on page 4-19. 5-63 Inﬂation - Tire Pressure Tires need the correct amount of air pressure to operate effectively. Notice: Do not let anyone tell you that under-inﬂation or over-inﬂation is all right. It is not. If your tires do not have enough air (under-inﬂation), you can get the following: (cid:129) Too much ﬂexing (cid:129) Too much heat (cid:129) Tire overloading (cid:129) Premature or irregular wear (cid:129) Poor handling (cid:129) Reduced fuel economy If your tires have too much air (over-inﬂation), you can get the following: (cid:129) Unusual wear (cid:129) Poor handling (cid:129) Rough ride (cid:129) Needless damage from road hazards A vehicle speciﬁc Tire and Loading Information label is attached to your vehicle. This label shows your vehicle’s original equipment tires and the correct inﬂation pressures for your tires when they are cold. The recommended cold tire inﬂation pressure, shown on the label, is the minimum amount of air pressure needed to support your vehicle’s maximum load carrying capacity. For additional information regarding how much weight your vehicle can carry, and an example of the Tire and Loading Information label, see Loading the Vehicle on page 4-19. How you load your vehicle affects vehicle handling and ride comfort. Never load your vehicle with more weight than it was designed to carry. When to Check Check your tires once a month or more. Do not forget to check the pressure of the spare tire. See Spare Tire on page 5-98 for additional information. 5-64 How to Check Use a good quality pocket-type gage to check tire pressure. You cannot tell if your tires are properly inﬂated simply by looking at them. Radial tires may look properly inﬂated even when they are underinﬂated. Check the tire’s inﬂation pressure when the tires are cold. Cold means your vehicle has been sitting for at least three hours or driven no more than 1 mile (1.6 km). Remove the valve cap from the tire valve stem. Press the tire gage ﬁrmly onto the valve to get a pressure measurement. If the cold tire inﬂation pressure matches the recommended pressure on the Tire and Loading Information label, no further adjustment is necessary. If the pressure is low, add air until you reach the recommended amount. If you overﬁll the tire, release air by pushing on the metal stem in the center of the tire valve. Recheck the tire pressure with the tire gage. Be sure to put the valve caps back on the valve stems. They help prevent leaks by keeping out dirt and moisture. Dual Tire Operation When the vehicle is new, or whenever a wheel, wheel bolt or wheel nut is replaced, check the wheel nut torque after 100, 1,000 and 6,000 miles (160, 1 600 and 10 000 km) of driving. For proper wheel nut tightening information, see “Removing the Flat Tire and Installing the Spare Tire” later in this section, under Changing a Flat Tire on page 5-82. Also see “Wheel Nut Torque” under Capacities and Speciﬁcations on page 5-114. The outer tire on a dual wheel setup generally wears faster than the inner tire. Your tires will wear more evenly and last longer if you rotate the tires periodically. See Tire Inspection and Rotation on page 5-71. Also see Scheduled Maintenance on page 6-4. { CAUTION: If you operate your vehicle with a tire that is badly underinﬂated, the tire can overheat. An overheated tire can lose air suddenly or catch ﬁre. You or others could be injured. Be sure all tires (including the spare) are properly inﬂated. See Tires on page 5-55 and Inﬂation - Tire Pressure on page 5-64 for more information on proper tire inﬂation. 5-65 Tire Pressure Monitor System The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. The TPMS sensors monitor the air pressure in your vehicle’s tires and transmit tire pressure readings to a receiver located in the vehicle. Each tire, including the spare (if provided), should be checked monthly when cold and inﬂated to the inﬂation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inﬂation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inﬂation pressure label, you should determine the proper tire inﬂation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is signiﬁcantly under-inﬂated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inﬂate them to the proper pressure. Driving on a signiﬁcantly under-inﬂated tire causes the tire to overheat and can lead to tire failure. Under-inﬂation also reduces fuel efficiency and tire tread life, and may affect the vehicle’s handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver’s responsibility to maintain correct tire pressure, even if under-inﬂation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will ﬂash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. See Tire Pressure Monitor Operation on page 5-67 for additional information. 5-66 Federal Communications Commission (FCC) and Industry and Science Canada The Tire Pressure Monitor System (TPMS) operates on a radio frequency and complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference. 2. This device must accept any interference received, including interference that may cause undesired operation. Vehicles with TPMS operate on a radio frequency and comply with RSS-210 of Industry and Science Canada. Operation is subject to the following two conditions: 1. This device may not cause interference. 2. This device must accept any interference received, including interference that may cause undesired operation of the device. Changes or modiﬁcations to this system by other than an authorized service facility could void authorization to use this equipment. Tire Pressure Monitor Operation This vehicle may have a Tire Pressure Monitor System (TPMS). The TPMS is designed to warn the driver when a low tire pressure condition exists. TPMS sensors are mounted onto each tire and wheel assembly, excluding the spare tire and wheel assembly. The TPMS sensors monitor the air pressure in the vehicle’s tires and transmits the tire pressure readings to a receiver located in the vehicle. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. At the same time a message to check the pressure in a speciﬁc tire appears on the Driver Information Center (DIC) display. The low tire pressure warning light and the DIC warning message come on at each ignition cycle until the tires are inﬂated to the correct inﬂation pressure. If your vehicle has DIC buttons, tire pressure levels can be viewed by the driver. For additional information and details about the DIC operation and displays see DIC Operation and Displays on page 3-41 and DIC Warnings and Messages on page 3-48.

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2009 Chevrolet Express Owners Manual