2009 CHEVROLET EXPRESS CARGO VAN engine

GENERAL MOTORS, GM, the GM Emblem,
CHEVROLET, the CHEVROLET Emblem, and the
name CHEVY EXPRESS are registered trademarks of
General Motors Corporation.
This manual includes the latest information at the time it
was printed. GM reserves the right to make changes after
that time without further notice. For vehicles first sold in
Canada, substitute the name “General Motors of Canada
Limited” for Chevrolet Motor Division wherever it appears
in this manual.
This manual describes features that may or may not be
on your specific vehicle.
If the vehicle has the DURAMAX
®Diesel engine, refer
to the DURAMAX®Diesel supplement for additional
and specific information on this engine.Read this manual from beginning to end to learn about
the vehicle’s features and controls. Pictures, symbols,
and words work together to explain vehicle operation.
Keep this manual in the vehicle for quick reference.
Canadian Owners
A French language copy of this manual can be obtained
from your dealer/retailer or from:
Helm, Incorporated
P.O. Box 07130
Detroit, MI 48207
1-800-551-4123
helminc.com
Propriétaires Canadiens
On peut obtenir un exemplaire de ce guide en français
auprès de concessionnaire ou à l’adresse suivante:
Helm Incorporated
P.O. Box 07130
Detroit, MI 48207
1-800-551-4123
helminc.com
Litho in U.S.A.
Part No. 25780708 A First Printing
©2008 General Motors Corporation. All Rights Reserved.
ii

Vehicle Symbols
The vehicle has components and labels that use
symbols instead of text. Symbols are shown along with
the text describing the operation or information
relating to a specific component, control, message,
gage, or indicator.
M:This symbol is shown when you need to see your
owner manual for additional instructions or information.
*:This symbol is shown when you need to see a
service manual for additional instructions or information.
Vehicle Symbol Chart
Here are some additional symbols that may be found on
the vehicle and what they mean. For more information
on the symbol, refer to the index.
9:Airbag Readiness Light
#:Air Conditioning
!:Antilock Brake System (ABS)
g:Audio Steering Wheel Controls or OnStar®
$:Brake System Warning Light
":Charging System
I:Cruise Control
B:Engine Coolant Temperature
O:Exterior Lamps
#:Fog Lamps
.:Fuel Gage
+:Fuses
i:Headlamp High/Low-Beam Changer
j:LATCH System Child Restraints
*:Malfunction Indicator Lamp
::Oil Pressure
}:Power
/:Remote Vehicle Start
>:Safety Belt Reminders
7:Tire Pressure Monitor
_:Tow/Haul Mode
F:Traction Control
M:Windshield Washer Fluid
iv

Keys...............................................................2-2
Remote Keyless Entry (RKE) System................2-3
Remote Keyless Entry (RKE) System
Operation...................................................2-4
Doors and Locks.............................................2-6
Door Locks....................................................2-6
Power Door Locks..........................................2-6
Cargo Door Relocking.....................................2-7
Delayed Locking.............................................2-7
Programmable Automatic Door Locks................2-7
Automatic Door Lock.......................................2-8
Automatic Door Unlock....................................2-8
Rear Door Security Locks................................2-8
Lockout Protection..........................................2-9
Sliding Side Door...........................................2-9
60/40 Swing-Out Side Door............................2-10
Rear Doors..................................................2-12
Windows........................................................2-13
Manual Windows..........................................2-14
Power Windows............................................2-14
Swing-Out Windows......................................2-15
Enhanced Technology Glass..........................2-16
Sun Visors...................................................2-16Theft-Deterrent Systems..................................2-16
PASS-Key®III+ Electronic Immobilizer.............2-17
PASS-Key®III+ Electronic Immobilizer
Operation.................................................2-17
Starting and Operating Your Vehicle................2-19
New Vehicle Break-In....................................2-19
Ignition Positions..........................................2-19
Retained Accessory Power (RAP)...................2-20
Starting the Engine.......................................2-20
Engine Coolant Heater..................................2-22
Automatic Transmission Operation...................2-23
Tow/Haul Mode............................................2-25
Parking Brake..............................................2-26
Shifting Into Park..........................................2-27
Shifting Out of Park......................................2-29
Parking Over Things That Burn.......................2-29
Engine Exhaust............................................2-30
Running the Vehicle While Parked..................2-31
Mirrors...........................................................2-32
Manual Rearview Mirror.................................2-32
Outside Manual Mirrors..................................2-32
Outside Towing Mirrors..................................2-32
Outside Power Mirrors...................................2-33
Outside Convex Mirror...................................2-33
Outside Heated Mirrors..................................2-34
Storage Areas................................................2-34
Section 2 Features and Controls
2-1

PASS-Key®III+ Electronic
Immobilizer
The PASS-Key III+ system operates on a radio
frequency subject to Federal Communications
Commission (FCC) Rules and with Industry Canada.
This device 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.
This device complies with RSS-210 of Industry 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.
PASS-Key III+ uses a radio frequency transponder in
the key that matches a decoder in the vehicle.
PASS-Key®III+ Electronic
Immobilizer Operation
Your vehicle is equipped with the PASS-Key®III+
(Personalized Automotive Security System)
theft-deterrent system. PASS-Key
®III+ is a passive
theft deterrent system.
The system is automatically armed when the key is
removed from the ignition.
You do not have to manually arm or disarm the system.
The security light will come on if there is a problem
with arming or disarming the theft-deterrent system.
When the PASS-Key
®III+ system senses that someone
is using the wrong key, it shuts down the vehicle’s
starter and fuel systems. The starter will not work and
fuel will stop being delivered to the engine. Anyone
using a trial-and-error method to start the vehicle will be
discouraged because of the high number of electrical
key codes.
If the engine does not start and the security message
comes on, the key may have a damaged transponder.
Turn the ignition off and try again.
2-17

If the engine still does not start, and the key appears to
be undamaged, try another ignition key. At this time,
you may also want to check the instrument panel PASS
KEY fuse. If the engine still does not start with the
other key, your vehicle needs service. If your vehicle
does start, the first key may be faulty. See your
dealer/retailer or a locksmith who can service the
PASS-Key
®III+ to have a new key made. SeeFuses
and Circuit Breakers on page 5-105.
It is possible for the PASS-Key
®III+ decoder to learn
the transponder value of a new or replacement key.
Up to 10 keys may be programmed for the vehicle.
This procedure is for learning additional keys only.
If all the currently programmed keys are lost or do not
operate, you must see your dealer/retailer or a locksmith
who can service PASS-Key
®III+ to have keys made
and programmed to the system.
See your dealer/retailer or a locksmith who can service
PASS-Key
®III+ to get a new key blank that is cut
exactly as the ignition key that operates the system.To program the new key:
1. Verify the new key has
1stamped on it.
2. Insert the original, already programmed key into the
ignition lock cylinder and start the engine. If the
engine will not start, see your dealer/retailer
for service.
3. After the engine has started, turn the key to
LOCK/OFF and remove the key.
4. Insert the key to be programmed and turn it to
ON/RUN within 10 seconds of removing the
previous key.
The security message will turn off once the key has
been programmed. It may not be apparent that
the security message went on due to how quickly
the key is programmed.
5. Repeat Steps 1 through 4 if additional keys are to
be programmed.
If you lose or damage a PASS-Key
®III+ key, see
your dealer/retailer or a locksmith who can service
PASS-Key
®III+ to have a new key made.
Do not leave the key or device that disarms or
deactivates the theft deterrent system in the vehicle.
2-18

Starting and Operating Your
Vehicle
New Vehicle Break-In
Notice:The vehicle does not need an elaborate
break-in. But it will perform better in the long run if
you follow these guidelines:
Keep your speed at 55 mph (88 km/h) or less for
the rst 500 miles (805 km).
Do not drive at any one constant speed, fast or
slow, for the rst 500 miles (805 km). Do not
make full-throttle starts. Avoid downshifting to
brake or slow the vehicle.
Avoid making hard stops for the rst 200 miles
(322 km) or so. During this time the new brake
linings are not yet broken in. Hard stops
with new linings can mean premature wear and
earlier replacement. Follow this breaking-in
guideline every time you get new brake linings.
Do not tow a trailer during break-in. SeeTowing
a Trailer on page 4-27for the trailer towing
capabilities of the vehicle and more information.
Following break-in, engine speed and load can
be gradually increased.
Ignition Positions
The ignition switch has
four different positions.
To shift out of P (Park), the ignition must be in ON/RUN
and the regular brake pedal applied.
A (LOCK/OFF):This position locks the ignition and
transmission. You will only be able to remove the key
when the ignition is turned to LOCK/OFF.
Notice:Using a tool to force the key to turn in the
ignition could cause damage to the switch or break
the key. Use the correct key, make sure it is all the
way in, and turn it only with your hand. If the key
cannot be turned by hand, see your dealer/retailer.
2-19

B (ACC/ACCESSORY):This is the position in which
you can operate things like the radio and the windshield
wipers when the engine is off.
C (ON/RUN):This position can be used to operate the
electrical accessories and to display some instrument
panel cluster warning and indicator lights. The switch
stays in this position when the engine is running.
If you leave the key in the ACC/ACCESSORY or ON/
RUN position with the engine off, the battery could be
drained. You may not be able to start the vehicle if the
battery is allowed to drain for an extended period of time.
D (START):This is the position that starts the engine.
When the engine starts, release the key. The ignition
switch returns to ON/RUN for driving.
A warning tone will sound when the driver door is
opened, the ignition is in ACC/ACCESSORY or
LOCK/OFF and the key is in the ignition.Retained Accessory Power (RAP)
These vehicle accessories can be used for up to
10 minutes after the engine is turned off:
•Audio System
•Power Windows (if equipped)
These features will work when the ignition key is in
ON/RUN or ACC/ACCESSORY. Once the key is turned
from ON/RUN to LOCK/OFF, power to the radio will
continue to work 10 minutes or until the driver door is
opened. The power windows will continue to work for up
to 10 minutes or until any door is opened.
Starting the Engine
If the vehicle has the DURAMAX®Diesel engine, see
the DURAMAX®Diesel manual for more information.
To place the transmission in the proper gear:
Move the shift lever to P (Park) or N (Neutral). The
engine will not start in any other position. To restart
the engine when the vehicle is already moving,
use N (Neutral) only.
2-20

Starting Procedure
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as
your engine gets warm. Do not race the engine
immediately after starting it. Operate the engine and
transmission gently to allow the oil to warm up
and lubricate all moving parts.
The vehicle has a Computer-Controlled Cranking
System. This feature assists in starting the engine
and protects components. If the ignition key is turned
to the START position, and then released when the
engine begins cranking, the engine will continue
cranking for a few seconds or until the vehicle starts.
If the engine does not start and the key is held in
START for many seconds, cranking will be stopped
after 15 seconds to prevent cranking motor damage.
To prevent gear damage, this system also prevents
cranking if the engine is already running. Engine
cranking can be stopped by turning the ignition
switch to the ACC/ACCESSORY or LOCK/OFF
position.
Notice:Cranking the engine for long periods of
time, by returning the key to the START position
immediately after cranking has ended, can overheat
and damage the cranking motor, and drain the
battery. Wait at least 15 seconds between each try,
to let the cranking motor cool down.2. If the engine does not start after 5-10 seconds,
especially in very cold weather (below 0°F or−18°C),
it could be flooded with too much gasoline. Try
pushing the accelerator pedal all the way to the floor
and holding it there as you hold the key in START for
up to 15 seconds. Wait at least 15 seconds between
each try, to allow the cranking motor to cool down.
When the engine starts, let go of the key and
accelerator. If the vehicle starts briefly but then
stops again, do the same thing. This clears the extra
gasoline from the engine. Do not race the engine
immediately after starting it. Operate the engine
and transmission gently until the oil warms up and
lubricates all moving parts.
Notice:The engine is designed to work with the
electronics in the vehicle. If you add electrical parts
or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer/retailer. If you do not, the
engine might not perform properly. Any resulting
damage would not be covered by the vehicle
warranty.
2-21