2009 CHEVROLET EXPRESS CARGO VAN Owners Manual

What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
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.
Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine
how often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
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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.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-13.
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.
SeeScheduled 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. SeeRecommended Fluids
and Lubricants on page 6-13.
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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.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.
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Bulb Replacement
For the proper type of replacement bulbs, see
Replacement Bulbs on page 5-52.
For any bulb changing procedure not listed in this
section, contact your dealer/retailer.
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.
Headlamps
To remove the headlamp assembly from the vehicle and
access the bulbs:
1. Open the hood. SeeHood Release on page 5-13
for more information.
2. Remove the two bolts from the headlamp assembly.
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.
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4. Lift the inboard side of the headlamp to release the
inboard tab from the radiator support.
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.12. Install the new bulb into the socket then reinstall it
into the headlamp assembly.
13. Reverse the steps to reinstall the headlamp
assembly.
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Front Turn Signal, Sidemarker and
Parking Lamps
To replace the front turn signal, sidemarker and/or
parking lamp bulb(s):
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.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.
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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:
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.
Taillamps
To replace one of these bulbs:
1. Remove the two
inboard nuts from the
inside of the taillamp
assembly.
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.
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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.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 Bulb Number
Back-up, Rear Parking,
Stoplamp, and Turn Signal Lamp3157
Center High Mounted
Stop Lamp (CHMSL)912
Front Parking and Turn
Signal Lamp3157KX
Front Sidemarker Lamp 194
Headlamps
Composite High-Beam
Headlamp9005
Composite Low-Beam
Headlamp9006GS
Sealed Beam Headlamp H6054
For replacement bulbs not listed here, contact your
dealer/retailer.
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