compressed natural gas supplement guide - chevroleton compressed natural gas (cng). the general...

Black plate (1,1)Chevrolet/GMC Express/Savana CNG Compressed Natural Gas Supplement -2012

2012 Chevrolet/GMC Express/Savana CNGCompressed Natural Gas Supplement M

Instruments and Controls . . . . 4-1Warning Lights, Gauges, andIndicators . . . . . . . . . . . . . . . . . . . . 4-1

Driving and Operating . . . . . . . . 8-1Driving Information . . . . . . . . . . . . . 8-1Starting and Operating . . . . . . . . . 8-1Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Towing . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Vehicle Care . . . . . . . . . . . . . . . . . . 9-1General Information . . . . . . . . . . . . 9-1Vehicle Checks . . . . . . . . . . . . . . . . 9-2Wheels and Tires . . . . . . . . . . . . . . 9-5Jump Starting . . . . . . . . . . . . . . . . . . 9-5Towing . . . . . . . . . . . . . . . . . . . . . . . . . 9-5Appearance Care . . . . . . . . . . . . . . 9-6

Service and Maintenance . . . 10-1Maintenance Schedule . . . . . . . 10-1Maintenance Records . . . . . . . . 10-3

Technical Data . . . . . . . . . . . . . . . 11-1Vehicle Data . . . . . . . . . . . . . . . . . . 11-2

Index . . . . . . . . . . . . . . . . . . . . . i-1


ii Introduction

The names, logos, emblems,slogans, vehicle model names, andvehicle body designs appearing inthis supplement including, but notlimited to, GM, the GM logo,

CHEVROLET, the CHEVROLETEmblem, GMC, the GMC TruckEmblem, SAVANA, and EXPRESSare trademarks and/or servicemarks of General Motors LLC, itssubsidiaries, affiliates, or licensors.

This vehicle only operates onCompressed Natural Gas (CNG).It will not operate on gasoline,diesel, or Liquified PetroleumGas (LPG) fuel.

Keep this manual in the vehicle forquick reference.

Canadian Vehicle Owners

Propriétaires Canadiens

A French language copy of thismanual can be obtained from yourdealer or from:

On peut obtenir un exemplaire dece guide en français auprès duconcessionnaire ou à l'adressesuivante:

Helm, IncorporatedP.O. Box 07130Detroit, MI 48207

1-800-551-4123Numéro de poste 6438 delangue françaisewww.helminc.com

Litho in U.S.A.Part No. 2012CNGSUPL A First Printing ©2011 General Motors LLC. All Rights Reserved.


Introduction iii

Using this SupplementThis supplement containsinformation specific to the uniquecomponents of the vehicle. It doesnot explain everything you need toknow about the vehicle. Read thissupplement along with the ownermanual to learn about the vehicle'sfeatures and controls.

Index

A good place to look for what youneed is the Index in back of thissupplement. It is an alphabetical listof what is in the supplement, andthe page number where you willfind it.


iv Introduction

2 NOTES


Instruments and Controls 4-1

Instruments andControls

Warning Lights, Gauges, andIndicatorsFuel Gauge . . . . . . . . . . . . . . . . . . . 4-1Malfunction Indicator Lamp . . . 4-2

Warning Lights,Gauges, andIndicators

Fuel Gauge

The fuel gauge, when the ignition ison, indicates how much fuel is left inthe vehicle fuel tank.

An arrow on the fuel gaugeindicates the side of the vehicle thefuel door is on.

The fuel gauge has been calibratedto display full at approximately24 800 kPa (3,600 psi) and empty atapproximately 2 758 kPa (400 psi).

When the low fuel warning indicatorflashes, fill the tank as soon aspossible.

Compressed Natural Gas (CNG)quantity is affected by changes infuel temperature and fuel pressure.

See Filling the Tank on page 8‑3 formore information.


4-2 Instruments and Controls

MalfunctionIndicator LampThis vehicle has been specificallydesigned to illuminate this indicatorwhen emissions exceed acceptablelevels while operating on naturalgas fuel.

The malfunction indicator lampcomes on to indicate that there is aproblem and service is required.Malfunctions often will be indicatedby the system before any problem isapparent. This system is alsodesigned to assist the servicetechnician in correctly diagnosingany malfunction.

Notice: If the vehicle iscontinually driven with this lighton, the emission controls mightnot work as well, the vehicle fueleconomy might not be as good,and the engine might not run assmoothly. This could lead tocostly repairs that might not becovered by the vehicle warranty.

This light should come on, as acheck to show you it is working,when the ignition is on and theengine is not running.

See the owner manual for moreinformation.


Driving and Operating 8-1

Driving andOperating

Driving InformationVehicle Load Limits . . . . . . . . . . . 8-1

Starting and OperatingStarting the Engine . . . . . . . . . . . 8-1

FuelFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Filling the Tank . . . . . . . . . . . . . . . . 8-3Fuel System Leak . . . . . . . . . . . . . 8-5

TowingTrailer Towing . . . . . . . . . . . . . . . . . 8-7

Driving Information

Vehicle Load LimitsNotice: Loose items stored in thecargo area may damage the fueltank and fuel systemcomponents. Secure all items inthe cargo area to avoid shiftingand any damage to the fuel tankand fuel tank components.

Starting andOperating

Starting the EngineStarting the engine in a CNGvehicle is similar to starting agasoline engine. See “Starting theEngine” in the owner manual.

Cold Weather Starting

If the outside temperature isbelow −20°C (−4°F), the engine maybe harder to start, or may not startuntil temperatures increases.

Using the engine heater may makeit easier to start. See Engine Heaterin the owner manual for moreinformation.


8-2 Driving and Operating

High Altitude Cold Starting

An engine is harder to start in coldweather. The thinner air foundabove 1,600 m (5,000 ft) also makesthe vehicle harder to start. Theunique properties of CNGmakes it even more difficult orimpossible to start at highaltitudes if temperatures dropbelow −16°C (4°F). When startingthe vehicle in cold weather at highaltitudes:. Use the engine heater. See

Engine Heater in the ownermanual for more information.

. Turn off all electricalaccessories.

. Do not hold the ignition switch inSTART for more than15 seconds.

FuelThis vehicle is designed to operateon Compressed Natural Gas (CNG).The general marketplace fuel qualityof Compressed Natural Gas (formotor vehicles) in the state ofCalifornia shall be in compliancewith Title 13 California Code ofRegulations, Section 2292.5. Theremaining USA States and Canada,do not employ regulated fuel qualitystandards for general marketplacevehicle usage. With this, arecommended practice as outlinedby the provisions contained in SAEJ1616 “Recommended Practice forCompressed Natural Gas VehicleFuel” is intended to protect theinterior surface of the fuel containerand other vehicle fuel systemcomponents.

If a fuel is used that does not meetthese regulations/provisions, theremay be a decrease in engine powerand the emission controls can bedamaged.

The main component of CNG ismethane, a highly flammable,colorless gas. An odorant has beenadded for detection through smell.The smell is similar to that of rotteneggs. CNG used in vehicles is asimilar type gas that is delivered tohomes for domestic use. The CNGin the vehicle is stored under highpressure (maximum 24 800 kPa/3,600 psi). The CNG system in thevehicle, including the tanks andtubing, has been designed to holdgas at this pressure. It has alsobeen tested for safety. Gas shouldnever be smelled and a hissingsound should not be heard, unlessrefueling is being done. If gas issmelled or a hissing sound is heard,



at any other time, shut down thevehicle and have it serviced. It maybe possible to hear the fuel flowingwhile the engine is running ifstanding close to the pipework orvarious fuel system components(regulator, filter). This is normal andshould not be confused with ahissing sound at fittings that mayindicate a fuel leak. Follow theinstructions under Fuel System Leakon page 8‑5.

Filling the Tank

{ WARNING

CNG is flammable and highlyexplosive. You could be killed orseriously injured if leaking naturalgas is ignited. If you suspect aleak, have the vehicleimmediately inspected andrepaired by an authorized GMdealer.

The fill valve is behind a hinged fueldoor on the driver side.

There is an identifying bluediamond-shaped CNG label on theright rear cargo door. Do not removethis label. This label is necessaryfor compliance with NFPA-52regulations and insuring the vehicle.Driving without this label may violatethe laws or regulations in somestates. Replacement labels can beordered from your dealer.

Refueling Procedure

There are two methods of refueling,fast filling or slow filling. Fast fillingis normally used in fuel stations fornatural gas vehicles. It takes aboutsix to eight minutes to fill up the fueltanks. Slow filling is done with avehicle refueling appliance or atime‐fill post provided by the fleetoperator. Refueling time variesdepending upon the refuelingsystem used — consult with therefueling station attendant or systemprovider. Always observe all safetyrecommendations and operatinginstructions on the refuelingequipment. When refueling, use afuel fill nozzle that complies withANSI/CSA-NGV 1‐2006 standards.Nozzles are designed according totheir maximum fill pressure: P30(blue handle) for 20 684 kPa(3,000 psi) and P36 (yellow handle)for 24 800 kPa (3,600 psi).



The maximum fill pressure is24 800 kPa (3,600 psi). Refuel witha yellow P36 nozzle whereavailable. Using a blue P30 nozzlewill fill the tank to approximately 7/8on the fuel gauge.

{ WARNING

Attempting to fill a CNG fuelsystem that has a missing ordamaged O‐ring is dangerous.Natural gas can leak. If thenatural gas is ignited, you orothers could be injured. Replacethe O‐ring before filling the tank.

The refueling fill valve on thevehicle is located in the samelocation as was provided originallyfor gasoline refueling. Put thevehicle into P (Park) and turn off theengine prior to refueling. Removethe dust cap from the receptacle,clean off any dirt or debris on the

receptacle, and follow the refuelinginstructions on the pump orprovided by the station operator.

If fuel or vapor is heard or seenleaking from the nozzle‐fill valveconnection, stop refuelingimmediately. Dirt or other debrismay be preventing a positiveconnection. Turn off the refuelingdispenser, disconnect the nozzle,reconnect it to the fill valve, andbegin refueling again. If it continuesto leak, have an authorized dealer

inspect the sealing O‐ring in the fillvalve. It may be missing, damaged,or worn. Spare O‐rings designed foruse with CNG are included with thevehicle. See an authorized GMdealer for additional O‐rings.

To replace the fill valve O-ring:

1. Carefully remove the O-ring fromthe groove in the fill valve.A small flat-blade or pointed toolcan be used.

2. Make sure the groove is cleanand free of dirt and debris.

3. Install the new O-ring in thegroove in the fill valve. Makesure the O-ring is properlyseated in the groove.

Refueling will stop automaticallywhen the tank is full. To disconnectthe vehicle from the refuelingstation, remove the nozzle from thefill valve. A hissing sound may beheard as a small amount of naturalgas escapes. This is normal.



If dirt or other debris is adhering tothe inside of the fuel fill valve, gasmay leak out after refueling. If youneed to add more fuel, do therefueling procedure again.

Put the fill valve dust cap onsecurely and close the fuelfiller door.

Refueling Station Information

For up‐to‐date information onpublic‐access CNG station locationsand prices, and to view or add usercomments, please visit:

www.cngprices.com andwww.cngchat.com

Public and private CNG stationsmay also be found at the followingfederal government website:

http://www.afdc.energy.gov/afdc/locator/stations/

Fuel System Leak

{ WARNING

If you smell a persistent naturalgas odor or hear a continualhissing sound, there could be anatural gas leak. If the natural gasis ignited, you or others could beinjured. Do not start the engine ordrive the vehicle. Have thevehicle towed to an authorizedGM dealer for service.

A slight natural gas odor may bedetected for a few moments afterrefueling. This is normal. You shouldnot be able to smell natural gas atany other time. If you do, or if youhear a hissing sound, the fuelsystem may have a leak.

If natural gas is smelled or a hissingsound is heard:

1. Park the vehicle in a well‐ventilated area and apply theparking brake. Keep heat,sparks, and flame away. Openall the vehicle doors forventilation.

2. Turn the ignition to LOCK/OFF.



3. The manual shutoff valve is onthe inner side of the driver sideframe rail halfway between thefront and rear tires.

A label is on the outside of thevehicle above the manual shutoffvalve. Do not remove this label.

Turn the lever one‐quarter turnclockwise to turn off.

Do not drive the vehicle. The vehicleshould be towed to an authorizedGM dealer.



Towing

Trailer Towing

{ WARNING

The trailer hitch protects the CNGtank in a crash and from roadhazards. Damage may result in arupture or explosion of the CNGtank. You or others could beinjured or even killed. If the trailerhitch must be removed for anyreason, e.g, tank inspection orvehicle repair, always reinstall thetrailer hitch before operating thevehicle.

The compressed natural gas systemadds approximately 363 kg (800 lbs)of weight to the vehicle. This mustbe included when determining themaximum load and trailer towingcapacity for the vehicle as describedin the owner manual.



2 NOTES


Vehicle Care 9-1

Vehicle Care

General InformationAccessories andModifications . . . . . . . . . . . . . . . . 9-1

Vehicle Storage . . . . . . . . . . . . . . . 9-2

Vehicle ChecksDoing Your OwnService Work . . . . . . . . . . . . . . . . 9-2

Fuel System Components . . . . . 9-3

Wheels and TiresTire Changing . . . . . . . . . . . . . . . . . 9-5

Jump StartingJump Starting . . . . . . . . . . . . . . . . . 9-5

TowingTowing the Vehicle . . . . . . . . . . . . 9-5

Appearance CareExterior Care . . . . . . . . . . . . . . . . . . 9-6

General Information

Accessories andModificationsAdding accessories or makingmodifications to the vehicle,including to the CNG tank shields,could cause a malfunction ordamage and would not be coveredby the vehicle warranty. The CNGfuel tanks under the vehicle areprotected by tank shields. If thevehicle has a CNG fuel tank in thecargo area, it is covered with ashield.

{ WARNING

To help avoid damage to the CNGtanks and to reduce the risk ofexplosion, tank shields must bepresent. Do not attachaccessories, such as racks orbins to the shield. Do not drill,modify, or use the shield as awork surface, or use fire near theshield or tank.

If a CNG tank needs service orrepair, have only a qualifiedtechnician perform the work. SeeAccessories and Modifications inthe owner manual for moreinformation.


9-2 Vehicle Care

Vehicle StorageIn addition to vehicle storageprocedures outlined in the ownermanual, the following should bedone with the vehicle in the event itwill not be driven for extendedperiods of time:. The manual shutoff valve is on

the inner side of the driver sideframe rail halfway between thefront and rear tires.


Turn the lever one‐quarter turnclockwise to turn off.

. If you store the vehicle indoors,it should be parked in a well‐ventilated area. We recommendthe installation of a natural gasleak detector at the highest pointof the ceiling.

. After storing the vehicle for anextended period, and beforestarting the engine for the firsttime, open the doors and leavethem open for several minutes.This allows any natural gasvapors that may have collectedin the cargo area to dissipate.

Vehicle Checks

Doing Your OwnService Work

{ WARNING

Never try to do your own servicework on the Compressed NaturalGas (CNG) fuel system. The CNGfuel system operates under highpressure. You can be injured andthe vehicle can be damaged ifyou try to do your own servicework. Service and repair of thissystem should only be performedby a qualified dealer.


Vehicle Care 9-3

Fuel System Components

{ WARNING

Tampering with, or improperlymaintaining the high-pressure fuelsystem can cause a dangerouscondition in which serious injuryor death may result. Neverattempt to modify the fuel system,and always have fuel systemrepaired and maintained by aqualified dealer.

CNG fuel system componentsinclude fuel tanks located in thecargo area and under the vehicle,an integrated fuel pressureregulator, in-tank fuel shutoff valves,high pressure fuel lines,electronically controlled multipointfuel injectors, and other equipment.

Fuel system components complywith the appropriate safetystandards. These component partshave been designed and approvedfor use in a CNG vehicle. Nevermodify or replace any original CNGcomponents or parts with thosespecified for a gasoline-poweredvehicle. Improper parts orcomponents can damage thevehicle fuel system and affect thevehicle safety and performance.

Do not modify, tamper with,or perforate the cargo area tankshield. Damage to the fuel systemcan result.

Fuel Cutoff System

The in-tank fuel shutoff valve iscontrolled by the ignition switch.When the ignition switch is in theLOCK/OFF or ACC/ACCESSORYposition, the valve is closed,shutting off fuel flow to the engine.It opens when the ignition switch isturned to the ON/RUN position. Thisalso shuts off the high pressuresolenoid on the high pressureregulator under the vehicle.


9-4 Vehicle Care

Manual Shutoff Valve Locate the manual shutoff valve sothat it can be found quickly if it isneeded.

The manual shutoff valve is on theinner side of the driver side framerail halfway between the front andrear tires.


To turn off the valve, turn the leverone-quarter turn clockwise. Turn itcounterclockwise to turn the valveback on.

Turn off the valve if a fuel leak issuspected or the vehicle is involvedin an accident. This valve, whenturned, will stop gas flow to theengine. If the vehicle has just beenin storage and it will not start, verifythat the valve is turned to the onposition.


Vehicle Care 9-5

Wheels and Tires

Tire ChangingThis vehicle does not have a sparetire. See Towing the Vehicle onpage 9‑5.

Jump Starting

{ WARNING

If the CNG fuel system has aleak, a spark from the jumpercables could ignite the naturalgas, causing injury or death. Donot jump start the vehicle if yousmell a persistent natural gasodor or hear a continual hissingsound. Close the manual shutoffvalve, and have the vehicle towedto an authorized GM dealer forservice. See Fuel SystemComponents on page 9‑3.

See “Jump Starting” in the vehicleowner manual.

Towing

Towing the Vehicle

{ WARNING

Improperly positioned tow straps,hooks, or chains can damage theCNG fuel system and cause aleak. If leaking gas catches fire, itcould cause injury or death. Toavoid damage, the disabledvehicle should be towed with allfour wheels off the ground.Always flatbed on a car carrier.

See the owner manual for moreinformation on towing the disabledvehicle.


9-6 Vehicle Care

Appearance Care

Exterior Care

Finish Damage

{ WARNING

Heating the vehicle to above82°C (180°F) may cause thefuel pressure release device toopen and release CNG gas. Youcould be injured or the vehiclecould be damaged. Never cure apainted body repair by heating.


Service and Maintenance 10-1

Service andMaintenance

Maintenance ScheduleMaintenance Schedule . . . . . . 10-1

Maintenance RecordsNatural Gas Vehicle (CNG)Service Records . . . . . . . . . . . 10-3

MaintenanceSchedule

{ WARNING

The tank shields protect the CNGtank in a crash and from roadhazards. Removal of the shieldsmay result in tank damage thatcould result in a rupture orpossible explosion of the tank.You or others could be injured oreven killed. If you must remove atank shield for any reason, e.g.,tank inspection or vehicle repair,always reinstall the shield beforeoperating the vehicle.

{ WARNING

Keeping a CNG fuel tank inservice after the tank serviceexpiration date is dangerous andis prohibited by federal law. Thetank may no longer withstand theCNG fuel system operatingpressure. You could be severelyinjured or killed. Take the vehicleto an authorized GM dealer tohave the tank replaced.

This CNG vehicle is designed forroutine maintenance (fluids, filters,etc.) according to the originalspecifications as provided in theowner manual for gasoline fuelvehicles. See the owner manual formaintenance service intervals andfluid specifications.


10-2 Service and Maintenance

See your dealer or other qualifiedrepair facility for required serviceand maintenance. Your dealer hasthe necessary training and parts torepair the vehicle.

In addition, the CNG systemrequires the following every60 000 km (36,000 mi) or36 months, whichever occurs first:. Visual inspection of the CNG

fuel tanks by a CSAInternational‐certified inspectoror authorized GM dealer. Formore information, see yourdealer or visit:

http://www.csa‐international.org

Have the CNG fuel system andtanks inspected if the vehiclehas been involved in a collisionor fire. The fuel tanks must bereplaced 15 years aftermanufacture. The expirationdate of the fuel tanks is on alabel on the fuel tanks. Have anauthorized GM dealer replacethe fuel tanks. Do not reuse oldfuel tanks.

. Replacement of the coalescentfilter. See your dealer.



Maintenance Records

Natural Gas Vehicle (CNG) Service RecordsVehicle Identification Number (VIN)

CNG Tank Information

Location Size Capacity Serial # Exp. Date

In Front Of Rear Axle 254 mm x 1 854 mm(10 in x 73 in)

79.5 L(21.0 gal)

Behind Rear Axle(Front)

335 mm x 787mm(13 in x 31 in)

51.0 L(13.5 gal)

Behind RearAxle (Rear)

335 mm x 813mm(13 in x 32 in)

54.0 L(14.3 gal)

Interior (If Equipped) 391 mm x 991mm(15 in x 39 in)

90.0 L(23.8 gal)



CNG Fuel Tank Inspection Record

Tank Location:

Tank Serial Number: Tank Expiration Date:

Inspection Interval(Mileage or Years)

Inspection Date Inspector Inspector Initials Type of Repair

15 Years N/A N/A N/A Tank Exchanged




Tank Location:







2 NOTES


Technical Data 11-1

Technical Data

Vehicle DataCapacities andSpecifications . . . . . . . . . . . . . . 11-2


11-2 Technical Data

Vehicle Data

Capacities and Specifications

Application Capacities

Metric English

CNG Fuel Tank Capacity ¹ ² 87.4L 23.1 GGE

¹ At 24.8 MPa (3,600 psi) and 21°C (70°F).² GGE (Gasoline Gallon Equivalent)


INDEX i-1

AAccessories andModifications . . . . . . . . . . . . . . . . . . 9-1

Appearance CareExterior . . . . . . . . . . . . . . . . . . . . . . . . 9-6

BBatteryJump Starting . . . . . . . . . . . . . . . . . . 9-5

CCanadian Vehicle Owners . . . . . . . . . iiCapacities andSpecifications . . . . . . . . . . . . . . . . 11-2

CheckEngine Light . . . . . . . . . . . . . . . . . . . 4-2

CleaningExterior Care . . . . . . . . . . . . . . . . . . 9-6

DDrivingVehicle Load Limits . . . . . . . . . . . . 8-1

EEngineCheck and Service EngineSoon Light . . . . . . . . . . . . . . . . . . . 4-2

Starting . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FFlat TireChanging . . . . . . . . . . . . . . . . . . . . . . 9-5

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Filling the Tank . . . . . . . . . . . . . . . . 8-3Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

GGaugesFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

IIntroduction . . . . . . . . . . . . . . . . . . . . . . . . ii

JJump Starting . . . . . . . . . . . . . . . . . . . 9-5

LLampsMalfunction Indicator . . . . . . . . . . 4-2


i-2 INDEX

MMalfunction Indicator Lamp . . . . . 4-2

NNatural GasVehicle Service Records . . . . . .10-3

Natural Gas Vehicle (CNG)Service Records . . . . . . . . . . . . . 10-3

SServiceAccessories andModifications . . . . . . . . . . . . . . . . . 9-1

Doing Your Own Work . . . . . . . . . 9-2Engine Soon Light . . . . . . . . . . . . . 4-2

Service and MaintenanceNatural Gas Vehicle (CNG)Service Records . . . . . . . . . . . .10-3

Specifications andCapacities . . . . . . . . . . . . . . . . . . . . 11-2

Starting the Engine . . . . . . . . . . . . . 8-1StorageVehicle . . . . . . . . . . . . . . . . . . . . . . . . 9-2

SupplementUsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

TTiresChanging . . . . . . . . . . . . . . . . . . . . . . 9-5

TowingTrailer . . . . . . . . . . . . . . . . . . . . . . . . . 8-7Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 9-5

TrailerTowing . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

UUsing This Supplement . . . . . . . . . . . iii

VVehicleCanadian Owners . . . . . . . . . . . . . . . iiLoad Limits . . . . . . . . . . . . . . . . . . . . 8-1Towing . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Vehicle Storage . . . . . . . . . . . . . . . . . 9-2

compressed natural gas supplement guide - chevroleton compressed natural gas (cng). the general...

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