2009 CHEVROLET EXPRESS CARGO VAN fuel cap

{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. SeeWashing
Your Vehicle on page 5-100.
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. SeeMalfunction Indicator Lamp
on page 3-34.
{CAUTION:
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.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer/retailer can get one
for you. If you get the wrong type, it may not t
properly. This may cause the malfunction indicator
lamp to light and may damage the fuel tank and
emissions system. SeeMalfunction Indicator Lamp
on page 3-34.
5-11

A. Battery. SeeBattery on page 5-39.
B. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-31.
C. Coolant Recovery Tank. SeeCooling System on
page 5-24.
D. Automatic Transmission Fluid Dipstick.
See “Checking the Fluid Level” underAutomatic
Transmission Fluid on page 5-21.
E. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
F. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-15.
G. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-20.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-34.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-36.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-35.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 every time you
get fuel. 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.
SeeEngine 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 you do not do this,
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

Tire Terminology and Denitions
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.
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. SeeInflation - Tire Pressure on
page 5-62.
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.
SeeLoading the Vehicle on page 4-19.
GAWR FRT
:Gross Axle Weight Rating for the
front axle. SeeLoading the Vehicle on page 4-19.
GAWR RR
:Gross Axle Weight Rating for the
rear axle. SeeLoading the Vehicle on page 4-19.
5-59

Ination - Tire Pressure
Tires need the correct amount of air pressure to
operate effectively.
Notice:Do not let anyone tell you that
under-ination or over-ination is all right.
It is not. If your tires do not have enough air
(under-ination), you can get the following:
Too much exing
Too much heat
Tire overloading
Premature or irregular wear
Poor handling
Reduced fuel economy
If your tires have too much air (over-ination),
you can get the following:
Unusual wear
Poor handling
Rough ride
Needless damage from road hazardsA 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. SeeSpare Tire on page 5-96for additional
information.
5-62

ApplicationCapacities
English Metric
Fuel Tank
Standard Tank (Passenger and Cargo) 31.0 gal 117.3 L
Standard Tank (Cab and Chassis) 33.0 gal 124.9 L
Optional Tank (Cab and Chassis)* 57.0 gal 215.7 L
* 159 inch (4 039 mm) wheelbase or 177 inch (4 496 mm) wheelbase only
Transmission Fluid
4-SPD 4L60-E 5.0 qt 4.7 L
4-SPD 4L80-E (Standard and Heavy Duty) 7.7 qt 7.3 L
Wheel Nut Torque 140 ft lb 190Y
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this
manual. Recheck fluid level after filling.
Engine Specications
Engine VIN Code Transmission Spark Plug Gap
4.3L V6 X Automatic 0.060 in (1.52 mm)
4.8L V8 C Automatic 0.040 in (1.01 mm)
5.3L V8 4 Automatic 0.040 in (1.01 mm)
6.0L V8 K Automatic 0.040 in (1.01 mm)
5-112

Maintenance Footnotes
(Gasoline Engine)
This maintenance section applies to vehicles with a
gasoline engine. For diesel engine vehicles, see
the maintenance schedule section in the DURAMAX
®
Diesel manual.
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services
be performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, kingpin bushings,
steering linkage, and rear driveline center splines.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chafing, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose, or missing parts,
signs of wear, or lack of lubrication. Inspect power
steering lines and hoses for proper hook-up, binding,
leaks, cracks, chafing, etc.(c)Visually inspect hoses and have them replaced if they
are cracked, swollen, or deteriorated. Inspect all pipes,
fittings, and clamps; replace with genuine parts as
needed. To help ensure proper operation, a pressure test
of the cooling system and pressure cap and cleaning the
outside of the radiator and air conditioning condenser is
recommended at least once a year.
(d)Inspect wiper blades for wear, cracking, or
contamination. Clean the windshield and wiper blades,
if contaminated. Replace wiper blades that are worn
or damaged. See Windshield Wiper Blade Replacement
on page 5-53 and Windshield and Wiper Blades on
page 5-102 for more information.
(e)Make sure the safety belt reminder light and safety
belt assemblies are working properly. Look for any
other loose or damaged safety belt system parts. If you
see anything that might keep a safety belt system
from doing its job, have it repaired. Have any torn or
frayed safety belts replaced. Also see Checking
the Restraint Systems on page 1-78.
(f)Lubricate all key lock cylinders, hood hinges, hood
prop rod pivot, hood latch assembly, secondary
latch, pivots, spring anchor, release pawl, rear
compartment hinges, latches, locks, fuel door hinge,
and any moving seat hardware. More frequent
lubrication may be required when exposed to a corrosive
environment. Applying silicone grease on weatherstrips
with a clean cloth will make them last longer, seal
better, and not stick or squeak.
6-8

(g)Vehicles with Gross Vehicle Weight Rating (GVWR)
above 10,000 lbs (4 536 kg) only: Inspect shields for
damage or looseness. Adjust or replace as required.
This is a Noise Emission Control Service. Applicable to
vehicles sold in the United States and recommended
for vehicles sold in Canada.
(h)Change automatic transmission fluid and filter if the
vehicle is mainly driven under one or more of these
conditions:
-In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
-In hilly or mountainous terrain.
-When doing frequent trailer towing.
-Uses such as found in taxi, police, or delivery
service.
(i)Drain, flush, and refill cooling system. This service
can be complex; you should have your dealer/retailer
perform this service. See Engine Coolant on page 5-25
for what to use. Inspect hoses. Clean radiator,
condenser, pressure cap, and filler neck. Pressure
test the cooling system and pressure cap.
(j)A fluid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired and
the fluid level checked. Add fluid if needed.(k)Inspect system. Check all fuel and vapor lines
and hoses for proper hook-up, routing, and condition.
Check that the purge valve works properly, if equipped.
Replace as needed.
(l)If driving regularly under dusty conditions, inspect the
filter at each engine oil change.
(m)Check system for interference or binding and for
damaged or missing parts. Replace parts as needed.
Replace any components that have high effort or
excessive wear. Do not lubricate accelerator or cruise
control cables.
(n)Visually inspect belt for fraying, excessive cracks, or
obvious damage. Replace belt if necessary.
(o)Check vent hose at transfer case for kinks and
proper installation. Check to be sure vent hose
is unobstructed, clear, and free of debris. During any
maintenance, if a power washer is used to clean
mud and dirt from the underbody, care should be taken
to not directly spray the transfer case output seals.
High pressure water can overcome the seals and
contaminate the transfer case fluid. Contaminated fluid
will decrease the life of the transfer case and should
be replaced.
(p)Severe Service: Change transfer case fluid if the
vehicle is mainly used for trailer towing or driven in city
traffic, wet environment, or high ambient temperatures.
6-9

Owner Checks and Services
These owner checks and services should be performed
at the intervals specified to help ensure vehicle
safety, dependability, and emission control performance.
Your dealer/retailer can assist with these checks and
services.
Be sure any necessary repairs are completed at once.
Whenever any fluids or lubricants are added to the
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-13.
At the First 100, 1,000 and
6,000 Miles (160, 1 600 and
10 000 km)
For vehicles with dual wheels, check dual wheel nut
torque. For proper torque, seeCapacities and
Specifications on page 5-111.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel fill.
Engine Oil Level Check
Notice:It is important to check the engine oil
regularly and keep it at the proper level. Failure to
keep the engine oil at the proper level can cause
damage to the engine not covered by the vehicle
warranty.
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-15.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
on page 5-25.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer fluid reservoir and add the proper fluid if
necessary.
6-10