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Chevrolet 2000 C-Series, Owner'S Manual

The Chevrolet 2000 C-Series Owner's Manual is a comprehensive guide that provides essential information on operating and maintaining your vehicle. Easily downloadable and completely free, this manual can be found exclusively on manualshive.com, ensuring you have all the necessary instructions at your fingertips.

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7-22

(16) = Check spring

-

to

-

axle U

-

bolts and shackle 

bolts for proper torque. See the service manual for
torque sequence and specifications. When parts are
replaced, the torque must be checked and adjusted 
more often during the first 6,000 miles (10 000 km).
Check torque at 500 miles (800 km) and 2,000 miles 
(3 000 km) after first use of parts.

(17) = Check complete exhaust system and cab 
areas near the exhaust system for broken, damaged,
missing or out

-

of

-

position parts. Also inspect for 

open seams, holes, loose connections or other conditions
which could let exhaust fumes seep into the driver
compartment. Needed repairs should be made at once.
To help maintain system integrity, replace exhaust pipes
whenever a new muffler is put on.

(18) = Check all engine drive belts for cracks, fraying,
wear and proper tension. Adjust or replace as needed.

(19) = Check throttle linkage for damaged or missing
parts (including throttle return springs), interference or
binding. Fix any problems at once. Do not lubricate
accelerator and cruise control cables.

(20) = With the engine off and below normal operating
temperature, check to see that the thermostatically
controlled engine cooling fan can be rotated by hand 
on viscous

-

operated drives. Replace as needed.

(21) = Check shields and underhood insulation for
damage or looseness. Adjust or replace as needed.

(22) = Lubricate caliper housing, caliper support spring
and caliper support key.

(23) = Wheel bearing service:
D Grease type 

--

 Clean, inspect and lubricate with the

proper wheel bearing grease at designated intervals 
or when hubs are removed. See “Recommended
Fluids and Lubricants” in the Index.

D Oil

-

filled type 

--

 Some wheel bearings are 

lubricated by rear axle lubricant. When you have
oil

-

filled hubs, use lubricant identical to that used 

in your rear axle. Lubricant change intervals are the
same for front and rear axles. However, you must
maintain oil level at the OIL LEVEL mark between
change intervals. See “Recommended Fluids and
Lubricants” in the Index.

Summary of Contents for 2000 C-Series

Page 1: ......

Page 2: ...tips about the road and how to drive under different conditions 5 1 Problems on the Road This section tells you what to do if you have a problem while driving such as a flat tire or overheated engine etc 6 1 Service and Appearance Care Here the manual tells you how to keep your vehicle running properly and looking good 7 1 Maintenance Schedule This section tells you when to perform vehicle mainten...

Page 3: ...ever it appears in this manual Please keep this manual in your vehicle so it will be there if you ever need it when you re on the road If you sell the vehicle please leave this manual in it so the new owner can use it We support voluntary technician certification For Canadian Owners Who Prefer a French Language Manual Aux propriétaires canadiens Vous pouvez vous procurer un exemplaire de ce guide ...

Page 4: ...nd a number of safety cautions in this book We use a box and the word CAUTION to tell you about things that could hurt you if you were to ignore the warning CAUTION These mean there is something that could hurt you or other people In the caution area we tell you what the hazard is Then we tell you what to do to help avoid or reduce the hazard Please read these cautions If you don t you or others c...

Page 5: ...thing that can damage your vehicle Many times this damage would not be covered by your warranty and it could be costly But the notice will tell you what to do to help avoid the damage When you read other manuals you might see CAUTION and NOTICE warnings in different colors or in different words You ll also see warning labels on your vehicle They use the same words CAUTION or NOTICE ...

Page 6: ...ls have to do with your lamps MASTER LIGHTING SWITCH TURN SIGNALS PARKING LAMPS HAZARD WARNING FLASHER DAYTIME RUNNING LAMPS FOG LAMPS These symbols are on some of your controls WINDSHIELD WIPER WINDSHIELD WASHER WINDSHIELD DEFROSTER REAR WINDOW DEFOGGER VENTILATING FAN These symbols are used on warning and indicator lights ENGINE COOLANT TEMP BATTERY CHARGING SYSTEM BRAKE COOLANT ENGINE OIL PRESS...

Page 7: ...dels delivered from the factory are finished in a variety of ways by a number of companies you ll probably find other manuals in your finished vehicle These manuals are put there by the companies that have added components or equipment to the C Series model Read all these materials as well as this manual carefully to get all of the information on your vehicle ...

Page 8: ...ls 1 7 Safety Belts They re for Everyone 1 11 Here are Questions Many People Ask About Safety Belts and the Answers 1 12 How to Wear Safety Belts Properly 1 12 Driver Position 1 22 Safety Belt Use During Pregnancy 1 22 Right Passenger Position 1 23 Center Passenger Position 1 24 Children 1 27 Child Restraints 1 34 Larger Children 1 37 Safety Belt Extender 1 37 Checking Your Restraint Systems 1 37 ...

Page 9: ...fuse you or make you push a pedal when you don t want to Adjust the driver s seat only when the vehicle is not moving Bucket and Bench Seats If your vehicle has a bucket or bench seat you can adjust it with this lever located at the front of the seat Slide the lever toward the outer seat support to unlock it Slide the seat to where you want it Then release the lever and try to move the seat with y...

Page 10: ...backs forward or rearward Your seatback will move back and forth freely unless you come to a sudden stop then it will lock into place If your vehicle is parked going down a fairly steep hill the seatback may not fold without some help from you To fold the seatback forward push the seatback toward the rear of the vehicle as you lift this latch The latch must be down for the seat to work properly Be...

Page 11: ...t the seat Height Adjustment To adjust the height of a self contained seat hand pumped air seat push the seat height adjustment pump lever located on the lower outboard side down and continue pumping to raise the seat Press the lever and hold it to lower the seat To adjust the height of air sourced seats use the knob on the front left side on the seat Push the knob to inflate Pull the knob to defl...

Page 12: ...n the upper cushion on the inboard side of the driver s seat and the outboard side of the passenger s seat Seatback Adjustment To tilt the seatback turn the backrest tilt knob The knob is located on the lower cushion on the outboard side of the driver s seat and the inboard side of the passenger s seat Fore and Aft Adjustment To slide the seat forward or backward move the lever toward the passenge...

Page 13: ...plication This is only available on low back seats CAUTION If a head restraint is not installed on the seatback or stored in the vehicle properly it could be thrown about the vehicle in a crash or sudden maneuver People in the vehicle could be injured Remove the head restraints only when you need to fold the seat and be sure that the head restraints are stored securely in a safe location When the ...

Page 14: ...ur safety belt and check that your passengers belts are fastened properly too CAUTION It is extremely dangerous to ride in a cargo area inside or outside of a vehicle In a collision people riding in these areas are more likely to be seriously injured or killed Do not allow people to ride in any area of your vehicle that is not equipped with seats and safety belts Be sure everyone in your vehicle i...

Page 15: ...vive But most crashes are in between In many of them people who buckle up can survive and sometimes walk away Without belts they could have been badly hurt or killed After more than 30 years of safety belts in vehicles the facts are clear In most crashes buckling up does matter a lot Why Safety Belts Work Q Aren t safety belts for kids A Yes And they re for adult truckers and anyone else who rides...

Page 16: ...1 9 If the vehicle hits something it stops right then But nothing stops the people They keep moving Then something will stop them It could be the windshield ...

Page 17: ...ssengers were to give that big vehicle a chance to deal with the force of the impact instead of you With belts you slow down as the vehicle does You get more time to stop You stop over more distance and your strongest bones take the forces Safety belts are for everyone ...

Page 18: ...hey work with safety belts not instead of them Every air bag system ever offered for sale has required the use of safety belts Even if you re in a vehicle that has air bags you still have to buckle up to get the most protection That s true not only in frontal collisions but especially in side and other collisions Q If I m a good driver and I never drive far from home why should I wear safety belts...

Page 19: ... vehicle see the part of this manual called Children Follow those rules for everyone s protection First you ll want to know which restraint systems your vehicle has We ll start with the driver position Driver Position This part describes the driver s restraint system Lap Shoulder Belt The driver has a lap shoulder belt Here s how to wear it properly 1 Close and lock the door 2 Adjust the seat to s...

Page 20: ... plate and keep pulling until you can buckle the belt Pull up on the latch plate to make sure it is secure If the belt is pulled out all the way so that it locks press down on the button on the retractor cover to make it retract If the belt isn t long enough see Safety Belt Extender at the end of this section Make sure the release button on the buckle is positioned so you would be able to unbuckle...

Page 21: ...on B 5 To make the lap part tight on suspension type seats B pull down on the buckle end of the belt as you pull up on the shoulder belt If the shoulder belt is too tight D Pull out the belt at least 5 inches 130 mm ...

Page 22: ... like a window shade To add a little slack pull down on the shoulder belt just a little no more than 1 inch 25 mm D If it s now too loose pull it out like you did before and start again D If you move around in the vehicle and your shoulder belt becomes loose be sure to make it tight again ...

Page 23: ... you d be less likely to slide under the lap belt If you slid under it the belt would apply force at your abdomen This could cause serious or even fatal injuries The shoulder belt should go over the shoulder and across the chest These parts of the body are best able to take belt restraining forces The safety belt locks if there s a sudden stop or a crash ...

Page 24: ...t give nearly as much protection this way CAUTION You can be seriously hurt if your shoulder belt is too loose In a crash you would move forward too much which could increase injury The shoulder belt should fit against your body Don t allow more than 1 inch 25 mm of slack ...

Page 25: ...You can be seriously injured if your belt is buckled in the wrong place like this In a crash the belt would go up over your abdomen The belt forces would be there not at the pelvic bones This could cause serious internal injuries Always buckle your belt into the buckle nearest you ...

Page 26: ... be seriously injured if you wear the shoulder belt under your arm In a crash your body would move too far forward which would increase the chance of head and neck injury Also the belt would apply too much force to the ribs which aren t as strong as shoulder bones You could also severely injure internal organs like your liver or spleen ...

Page 27: ...isted across the body CAUTION You can be seriously injured by a twisted belt In a crash you wouldn t have the full width of the belt to spread impact forces If a belt is twisted make it straight so it can work properly or ask your dealer to fix it ...

Page 28: ...back out of the way For a suspension type seat if the belt is pulled out all the way so that it locks press down on the button on the retractor cover to make it retract Before you close the door be sure the belt is out of the way If you slam the door on it you can damage both the belt and your vehicle ...

Page 29: ... worn as low as possible below the rounding throughout the pregnancy The best way to protect the fetus is to protect the mother When a safety belt is worn properly it s more likely that the fetus won t be hurt in a crash For pregnant women as for anyone the key to making safety belts effective is wearing them properly Right Passenger Position The right passenger s safety belt works the same way as...

Page 30: ...e has a full bench seat or a two passenger bench seat someone can sit in the center position When you sit in a center seating position you have a lap safety belt which has no retractor To make the belt longer tilt the latch plate and pull it along the belt ...

Page 31: ...e buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to Children Everyone in a vehicle needs protection That includes infants and all children smaller than adult size Neither the distance traveled nor the age and size of the traveler changes the need for everyone to use safety restraints In fact the law in every state in the United States and in every Can...

Page 32: ... rest of its body In a frontal crash an infant in a rear facing restraint settles into the restraint so the crash forces can be distributed across the strongest part of the infant s body the back and shoulders A baby should be secured in an appropriate infant restraint This is so important that many hospitals today won t release a newborn infant to its parents unless there is an infant restraint a...

Page 33: ...rash During a crash a baby will become so heavy you can t hold it For example in a crash CAUTION Continued CAUTION Continued at only 25 mph 40 km h a 12 lb 5 5 kg baby will suddenly become a 240 lb 110 kg force on your arms The baby would be almost impossible to hold Secure the baby in an infant restraint ...

Page 34: ...en selecting a child restraint take into consideration not only the child s weight and size but also whether or not the restraint will be compatible with the motor vehicle in which it will be used An infant car bed A is a special bed made for use in a motor vehicle It s an infant restraint system designed to restrain or position a child on a continuous flat surface With an infant car bed make sure...

Page 35: ...aints are designed for infants of up to about 20 lbs 9 kg and about one year of age This type of restraint faces the rear so that the infant s head neck and body can have the support they need in a frontal crash Some infant seats come in two parts the base stays secured in the vehicle and the seat part is removable ...

Page 36: ...forward facing restraints are designed to help protect children who are from 20 to 40 lbs 9 to 18 kg and about 26 to 40 inches 66 to 102 cm in height or up to around four years of age One type a convertible restraint is designed to be used either as a rear facing infant seat or a forward facing child seat ...

Page 37: ...se instructions on the restraint itself or in a booklet or both These restraints use the belt system in your vehicle but the child also has to be secured within the restraint to help reduce the chance of personal injury The instructions that come with the infant or child restraint will show you how to do that Both the owner s manual and the child restraint instructions are important so if either o...

Page 38: ...f your child restraint has a top strap it should be anchored If you need to have an anchor installed your dealer can obtain a kit with anchor hardware and installation instructions specifically designed for this vehicle The dealer can then install the anchor for you This work will be done for you free of charge Or you may install the anchor yourself using the instructions provided in the kit ...

Page 39: ...restraint when and as the instructions say But don t use this position if the child restraint interferes with shifting gears See the earlier part about the top strap if the child restraint has one 1 Make the belt as long as possible by tilting the latch plate and pulling it along the belt 2 Put the restraint on the seat 3 Run the vehicle s safety belt through or around the restraint The child rest...

Page 40: ...h down on the child restraint If you re using a forward facing child restraint you may find it helpful to use your knee to push down on the child restraint as you tighten the belt 6 Push and pull the child restraint in different directions to be sure it is secure To remove the child restraint just unbuckle the vehicle s safety belt It will be ready to work for an adult or larger child passenger ...

Page 41: ...ty belts If you have the choice a child should sit next to a window so the child can wear a lap shoulder belt and get the additional restraint a shoulder belt can provide D Children who aren t buckled up can be thrown out in a crash D Children who aren t buckled up can strike other people who are ...

Page 42: ...er belt but the child is so small that the shoulder belt is very close to the child s face or neck A Move the child toward the center of the vehicle but be sure that the shoulder belt still is on the child s shoulder so that in a crash the child s upper body would have the restraint that belts provide If the child is so small that the shoulder belt is still very close to the child s face or neck y...

Page 43: ...t in this way in a crash the child might slide under the belt The belt s force would then be applied right on the child s abdomen That could cause serious or fatal injuries Wherever the child sits the lap portion of the belt should be worn low and snug on the hips just touching the child s thighs This applies belt force to the child s pelvic bones in a crash ...

Page 44: ...atch plates retractors and anchorages 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 Torn or frayed safety belts may not protect you in a crash They can rip apart under impact forces If a belt is torn or frayed get a new one right away Replacing Restraint System Parts Aft...

Page 45: ...haust Brake 2 18 Two Speed Rear Axle Electric Shift Control If Equipped 2 21 Automatic Transmission Operation 2 23 Manual Transmission Operation 2 24 Parking 2 30 Parking Over Things That Burn 2 30 Engine Exhaust 2 31 Running Your Engine While You re Parked Automatic Transmission 2 32 Windows 2 34 Turn Signal Multifunction Lever 2 41 Trailer Brake Hand Control Valve Option 2 42 Inter Axle Differen...

Page 46: ...en in a vehicle with the ignition key is dangerous for many reasons A child or others could be badly injured or even killed They could operate the controls or even make the vehicle move Don t leave the keys in a vehicle with children ...

Page 47: ...all locks including the ignition switch When a new vehicle is delivered the dealer removes the plugs from the keys and gives them to the first owner Each plug has a code on it that tells your dealer or a qualified locksmith how to make extra keys Keep the plugs in a safe place If you lose your keys you ll be able to have new ones made easily using this code ...

Page 48: ...Unlocked doors can be dangerous Passengers especially children can easily open the doors and fall out When a door is locked the inside handle won t open it Outsiders can easily enter through an unlocked door when you slow down or stop your vehicle This may not be so obvious You increase the chance of being thrown out of the vehicle in a crash if the doors aren t locked Wear safety belts properly l...

Page 49: ...nd close the door Theft Vehicle theft is big business especially in some cities and even commercial vehicles are no exception Although your vehicle has a number of theft deterrent features we know that nothing we put on it can make it impossible to steal However there are ways you can help Key in the Ignition If you leave your vehicle with the keys inside it s an easy target for joy riders or prof...

Page 50: ...d D Avoid making hard stops for the first 200 miles 322 km or so During this time your new brake linings aren t 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 D Use the lowest gear you can when you start a loaded vehicle in motion and when going up hills to avoid overloading the engine...

Page 51: ... system This system includes a built in temperature limiting switch to prevent internal damage to the starter If the starter motor overheats and shuts off due to over cranking the motor must cool down before the switch will reset and allow you to operate the starter It can take up to six minutes before the starter will work again Starting Your Gasoline Engine Engines start differently The 8th digi...

Page 52: ...or will disengage if after two seconds the starter pinion gear does not engage the flywheel or there is no engine rpm signal from the engine speed sensor Starting Your Engine 1 Without pushing the accelerator pedal turn your ignition key to START When the engine starts let go of the key The idle speed will go down as your engine gets warm 2 If the engine doesn t start in 10 seconds push the accele...

Page 53: ...ew miles especially in cold weather Running a cold engine at high speed can damage it Restarting the Gasoline Engine While Moving Automatic Transmission If you have to restart the engine while the vehicle is moving you ll first have to shift the automatic transmission to NEUTRAL N This safety feature prevents starting the engine when the transmission is in a drive gear Stopping the Gasoline Engine...

Page 54: ...t heater A GM Automatic Ether Injection System aids cold weather starting CaterpillarR Diesel Starter Motor Operation If your vehicle has the optional heavy duty starter it may on rare occasions not engage This condition is normal If this happens release the ignition key and reattempt to start the engine NOTICE Your diesel engine has an electric air intake heater system which reduces white smoke a...

Page 55: ...ld weather than a gasoline engine The air intake heater and use of the proper engine oil optional engine coolant heaters and optional ether injection systems help cold weather starting See the CaterpillarR Diesel Engine Operation Maintenance Manual for more information Diesel Engine Warm Up Several factors affect how quickly your diesel engine warms up These can include outside temperature engine ...

Page 56: ...re still in traffic you can restart the engine and get another 25 seconds of operation Do this only if you have to since there is a problem that can harm the engine if it isn t fixed Fast Idle System Electronically Controlled CaterpillarR Diesel and Gasoline Engines If your vehicle is equipped with an electronically controlled diesel engine it has both automatic and manual fast idle capabilities A...

Page 57: ...t pressed or the automatic transmission if equipped is in NEUTRAL N The manual fast idle feature is activated by pressing the switch on the instrument panel When the switch is pressed again or any of the previous conditions are not met manual fast idle will be deactivated Manual fast idle can be used to set any desired idle speed To set a new temporary engine idle speed 1 Make sure all of the prev...

Page 58: ... find the cause of the overheating D If you have air brakes the dual needle air pressure gage should read at least 105 psi 720 kPa for both service systems before you try to move the vehicle When air pressure is below 60 psi 420 kPa the LOW AIR light will come on and you will hear a tone alarm If the pressure doesn t build up or drops during warm up stop the engine and find the cause before you tr...

Page 59: ...the engine coolant temperature to reach 150_F 66_C before shutting off the engine Engine Coolant Heater If Equipped If your vehicle is equipped with this feature the plug in receptacle is located behind the front bumper as shown or in the component box on the driver s side of the vehicle In very cold weather 0_F 18_C or colder the engine coolant heater can help You ll get easier starting and bette...

Page 60: ...10 volt AC outlet Use a heavy duty three prong extension cord rated for at least 15 amps 4 Before starting the engine be sure to unplug the cord How long should you keep the coolant heater plugged in The answer depends on the outside temperature Above 32_F 0_C the coolant heater is not required From 32_F to 10_F 0_C to 23_C keep the coolant heater plugged in at least two hours Below 10_F 23_C keep...

Page 61: ...nd prolong the life of the foundation brake lining material When using the exhaust brake the proper gear range selection is important The exhaust brake will be most effective if the gear range selected is the lowest possible range that does not allow the engine rpm to go more than 200 rpm above rated full load rpm as shown on the Engine Information Plate Do not exceed 2900 rpm The accelerator and ...

Page 62: ...ll turn off if the anti lock brake system is activated Two Speed Rear Axle Electric Shift Control If Equipped If your vehicle is equipped with this feature you ll find a label on the ceiling above the windshield or in another place near the driver that show how to use it Be sure to follow the directions carefully Use the following directions based on the type of shift control you have Automatic Tr...

Page 63: ...n normally Manual Transmission The switch for the rear axle shift control is on the shift lever When the switch is up the rear axle is in the high range Push it down to get the low range The two speed axle should be in low when you park the vehicle You ll need to engage the transmission even move the vehicle a little to be sure the axle is in the low range Then apply the parking brake shift into N...

Page 64: ...axle from LOW to HI move the lever to the HI position disengage the clutch pause engage the clutch and then press down on the accelerator When you shift the axle down from HI to LOW you don t have to clutch Just move the lever to LOW release the accelerator and then quickly press it down again Air Suspension If Equipped Your vehicle may be equipped with the Hendrickson HAS Series single axle air s...

Page 65: ...e With some of the transmissions you will find another manual in your vehicle that goes into more detail On the ceiling in front of and above the driver or in some other place near the driver you will see a label that describes important operating facts about the automatic transmission in your vehicle Make sure you follow the instructions on this label You may have a PARK P position for your shift...

Page 66: ...ne is racing running at high speed is dangerous Unless your foot is firmly on the brake pedal your vehicle could move very rapidly You could lose control and hit people or objects Don t shift out of PARK P or NEUTRAL N while your engine is racing Automatic Transmission Third Gear Hold If Equipped If your vehicle is equipped with this feature your range selector has a 2 3 position You can t shift u...

Page 67: ...fting down to a lower gear accelerate the engine speed while in NEUTRAL to get ready for the lower gear Eaton Fuller 5 and 6 Speed Transmissions and Dana Spicer 7 Speed Transmissions These transmissions have gears that automatically synchronize when you shift up or down except FIRST 1 gear on the five speed transmission which is unsynchronized Choose the gear which will maintain the road speed you...

Page 68: ...perating your vehicle Eaton Fuller Transmission with Countershaft Brake If Equipped The countershaft brake is used when you shift from a standing start into FIRST 1 or REVERSE R You will find this feature on vehicles with gasoline engines and Eaton Fuller 9 or 10 speed transmissions See the Eaton Fuller Transmissions Driver Instructions Manual CAUTION If you skip a gear when you downshift you coul...

Page 69: ...r will have a PARK P position on the shift indicator When the PARK P position is selected with the shift lever the parking brake is automatically applied Propshaft Brake Burnish Procedure It is recommended that the propshaft mounted parking brake be burnished as part of the new vehicle break in The parking brake will work best after it has been burnished following these instructions Make 10 stops ...

Page 70: ...wn the regular brake pedal Then push the parking brake lever all the way down and shift the automatic transmission to NEUTRAL N The PARK BRAKE light will remain illuminated if the parking brake is not fully released NOTICE Driving with the parking brake on can overheat the parts in the system You may have to replace them and you could also damage other parts of your vehicle Electric Hydraulic Park...

Page 71: ...le s battery is dead or disconnected The PARK BRAKE light may flash while the parking brake is being applied or released This is normal for this system If your vehicle needs towing or the parking brake will not release the towing operator will need to disconnect the propshaft before towing your vehicle See Towing Your Vehicle in the Index Air Brake If Equipped CAUTION When the yellow SYSTEM PARK a...

Page 72: ...he parking brake by pulling the yellow SYSTEM PARK knob out 2 Hook up the trailer air system properly 3 Get into the tractor Push and hold down the regular brake pedal 4 Push in both the yellow SYSTEM PARK and the red TRAILER AIR SUPPLY knobs This will charge your trailer s air system If you have the blue TRACTOR PARKING knob pull it out to set the tractor brakes while the air system is charging A...

Page 73: ...e an emergency stop If the air pressure drops below 60 to 70 psi 413 to 482 kPa the PRIMARY BRAKE light will come on If the air pressure drops to 40 to 45 psi 275 to 309 kPa the yellow knob will automatically pop out and apply the spring brakes If you ever have a complete loss of air so that your air brakes automatically apply there is a way that the tow operator can release the parking brakes to ...

Page 74: ...sciousness and death You might have exhaust coming in if D Your exhaust system sounds strange or different D Your vehicle gets rusty underneath D Your vehicle was damaged in a collision D Your vehicle was damaged when driving over high points on the road or over road debris D Repairs weren t done correctly D Your vehicle or exhaust system had been modified improperly If you ever suspect exhaust is...

Page 75: ...etting One place this can happen is a garage Exhaust with CO can come in easily NEVER park in a garage with the engine running Another closed in place can be a blizzard See Blizzard in the Index CAUTION It can be dangerous to get out of your vehicle if the shift lever is not fully in PARK P with the parking brake firmly set Your vehicle can roll Don t leave your vehicle when the engine is running ...

Page 76: ...er steps to be sure your vehicle won t move If you re pulling a trailer see Towing a Trailer in the Index Windows Manual Windows Turn the hand crank on each door to raise or lower the window Power Windows If Equipped If you have power windows the controls are on each door The driver s door has a switch for the passenger s window as well Your power windows will not move unless the ignition switch i...

Page 77: ... The air horn works only after your air system pressure gets up to about 60 psi 415 kPa Tilt Wheel If Equipped A tilt steering wheel allows you to adjust the steering wheel before you drive You can also raise it to the highest level to give your legs more room when you enter or exit the vehicle To tilt the wheel hold the steering wheel and pull the lever Move the steering wheel to a comfortable le...

Page 78: ...turn or a lane change To signal a turn move the lever all the way up or down When the turn is finished the lever will return automatically An arrow on the instrument panel cluster will flash in the direction of the turn or lane change To signal a lane change just raise or lower the lever until the arrow starts to flash Hold it there until you complete your lane change The lever will return by itse...

Page 79: ... An arrow on the instrument panel cluster will flash in the direction of the turn when the lever is in the up or down position This system replaces the turn signal feature on the multifunction lever only All other features such as headlamp high low beam windshield wipers and washer etc remain part of the multifunction system If you have this system see Signal Stat Turn Signal and Hazard Warning Fl...

Page 80: ...teady wiping at low speed turn the band away from you to the LO position For fast wiping turn the band to HI To stop the wipers turn the band to the off symbol Low Speed Delay Wipers If Equipped You can set the wiper speed for a long or short delay between wipes This can be very useful in light rain or snow Turn the band to choose the delay time The closer to LO the shorter the delay Heavy snow or...

Page 81: ... until you turn the wiper control to the off symbol If you have the low speed delay option the wipers will clear the window and then either stop or return to your preset speed Cruise Control If Equipped If your vehicle has this feature it is located at the end of the turn signal multifunction lever With cruise control you can maintain a speed of about 30 mph 48 km h or more without keeping your fo...

Page 82: ...action can cause needless wheel spinning and you could lose control Don t use cruise control on slippery roads Setting Cruise Control CAUTION If you leave your cruise control switch on when you re not using cruise you might hit a button and go into cruise when you don t want to You could be startled and even lose control Keep the cruise control switch off until you want to use cruise control 1 Mov...

Page 83: ... the engine is restarted Increasing Speed While Using Cruise Control There are two ways to go to a higher speed D Use the accelerator pedal to get to the higher speed Press the button at the end of the lever then release the button and the accelerator pedal You ll now cruise at the higher speed D Move the cruise switch from ON to R A Hold it there until you get up to the speed you want and then re...

Page 84: ... cruise control speed you set earlier Using Cruise Control on Hills How well your cruise control will work on hills depends upon your speed load and the steepness of the hills When going up steep hills you may want to step on the accelerator pedal to maintain your speed When going downhill you may have to brake or shift to a lower gear to keep your speed down Of course applying the brake or clutch...

Page 85: ... the way if you have to Use this control only when you re driving Don t use it for parking or to hold the rig on a hill CAUTION Using the trailer brake hand control for parking or for holding the vehicle on a hill may not keep the vehicle from rolling This can happen if someone hits the valve by accident or if air pressure bleeds from the system If the vehicle rolls you or others could be injured ...

Page 86: ...er axle differential lock When you turn on this control the DIFF LOCK indicator on the instrument panel cluster will light NOTICE Activating the inter axle differential lock when the rear wheels are actually spinning freely as they might on ice or snow can cause you to lose control of the vehicle It can also damage the axles Turn on this control only when the wheels are not spinning freely Rear Ax...

Page 87: ...tivating the rear axle differential lock when the rear wheels are actually spinning freely as they might on ice or snow can cause you to lose control of the vehicle It can also damage the axle Turn on this control only when the wheels are not spinning freely Engine Air Control If Equipped If your vehicle has this control the handle is located on the instrument panel just to the right of the steeri...

Page 88: ...n NOTICE Operating this vehicle with the engine air control on when outside temperatures are above 32_F 0_C could lead to costly repairs not covered by your warranty It will also degrade fuel economy and the engine will not run smoothly Exterior Lamps Headlamps The lamp switches are on the left side of your instrument panel cluster Press the top left switch to turn on your D Parking Lamps D Marker...

Page 89: ... ignition is in OFF LOCK or ACCESSORY Daytime Running Lamps If Equipped Daytime Running Lamps DRL can make it easier for others to see the front of your vehicle during the day DRL can be helpful in many different driving conditions but they can be especially helpful in the short periods after dawn and before sunset The high and low beam headlamps will come on at reduced brightness in daylight when...

Page 90: ...is designed to pull a trailer If it has this switch you ll find it located on the upper right side of your instrument panel just above the radio If your vehicle has no radio the switch is located just above the storage area Use the switch to operate your clearance and marker lamps The marker lamps are illuminated when the indicator light is on Your headlamps switch will not operate these lamps You...

Page 91: ...d Press the tab under the mirror to reduce glare at night from headlamps behind you Outside Mirrors Adjust the outside mirror or mirrors by hand so you can just see a little of the side of your vehicle when you re sitting in the driver s seat These mirrors can fold in toward the vehicle for entering narrow garages and for clearance in an automatic car wash If your mirrors have clearance lamps they...

Page 92: ...changing lanes Heated Outside Mirrors If Equipped If your vehicle has heated mirrors you ll find this switch on the upper right side of your instrument panel area just above the radio Use it to operate your mirror heaters to defrost or defog your mirrors When you turn on the mirror heaters an indicator light in the switch will be lit to tell you that the heaters are on Once the mirrors are clear f...

Page 93: ...tte lighter in with your hand while it is heating If you do it won t be able to back away from the heating element when it s ready That can make it overheat damaging the lighter and heating element To remove the ashtray for cleaning pull up on the front of it NOTICE Don t put papers and other things that burn into your ashtray If you do cigarettes or other smoking materials could set them on fire ...

Page 94: ...d negative black outlets They have a 20 amp fuse that is common with the cigarette lighter Don t use the cigarette lighter when you re using a power jack because it may overload the circuit and blow the fuse NOTICE Whether or not your vehicle has the power outlets don t plug in FM communications gear at the ashtray area FM equipment creates high heat and over time the area could get so hot that wi...

Page 95: ...e cable that will go to the trailer to supply electrical power to the trailer s lighting system When not in use it is stored in the trailer air hose storage bracket NOTICE Starting in 1998 the center pin also known as the auxiliary circuit of the 7 pin trailer electrical connector will be wired to provide continuous power for the trailer anti lock brake systems when the ignition key is in ON or RU...

Page 96: ...2 52 The Instrument Panel Your Information System ...

Page 97: ... Mirror Switch If Equipped G Diesel Engine Exhaust Brake Switch H Marker Clearance Lamps Switch If Equipped I Audio System or Storage Area J Glove Box K Hourmeter Option L Convenience Center Fuse Panel M Air Vent Controls N Ashtray O Air Brake Controls If Equipped P Comfort Controls Q Storage Tray Cassette Player ...

Page 98: ...er Your instrument panel cluster is designed to let you know at a glance how your vehicle is running You ll know how fast you re going about how much fuel is left and many other things you ll need to drive safely and economically ...

Page 99: ...al of the old odometer then it must be But if it can t then it s set at zero and a label must be put on the driver s door to show the old mileage reading when the new odometer was installed Engine Speed Governor All gasoline engines have a electronic engine speed governor The engine governed speeds range between 3 600 and 4 000 rpm depending on model engine size and option content Engine Road Spee...

Page 100: ...Paying attention to your warning lights and gages could also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see in the details on the next few pages some warning lights come on briefly when you start the engine just to let you know they re working If you are familiar with this section you should not be alarme...

Page 101: ... their safety belts Safety Belt Reminder Tone Option When the key is turned to RUN or START a tone will sound for about eight seconds to remind people to fasten their safety belts Charging System Indicator Light CAUTION If your vehicle has an electric hydraulic parking brake do not drive if the charging system light is on If the battery drains too much the parking brake can suddenly come on and st...

Page 102: ...f the instrument panel cluster shows the charging system voltage Readings in either warning zone indicate a possible problem in the electrical system Readings in the low warning zone may occur when a large number of electrical accessories are operating in the vehicle and the engine is left at an idle for an extended period This condition is normal since the charging system may not be able to provi...

Page 103: ... on NOTICE If the DO NOT SHIFT warning light comes on while you are driving it is a warning that making a transmission range change could leave you stranded The vehicle may not continue to move if you change gears with the transmission shift control The transmission can t operate in all gears because something is wrong Leave the shift control alone and drive directly to a GM dealer for service If ...

Page 104: ...hem fixed so they will be ready to warn you if there s a problem If one or both of these warning lights stay on after you start the engine there could be a brake problem Have your brake system inspected right away If one or both of these lights come on and stay on while you are driving pull off the road and stop carefully You may notice that the pedal is harder to push Or the pedal may go closer t...

Page 105: ...one come on while you are driving you should drive only as far as the nearest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the LOW AIR warning light comes on and the warning tone sounds the vehicle can stop suddenly and without further warning This is because the parking brake will come on if the pressure falls below 40 to 45 psi 275 to 310 kPa...

Page 106: ... on as a check when the engine is first started and any time the system needs adjustment or there is a malfunction in the electric hydraulic parking brake system When the SERVICE PARK BRAKE light comes on you will also hear a warning tone If this light comes on have the system repaired immediately CAUTION If the SERVICE PARK BRAKE warning light comes on and the warning tone sounds your vehicle can...

Page 107: ...k brake system this light will come on when you start your engine and it may stay on for several seconds That s normal If the light stays on or comes on when you re driving your vehicle needs service If the PRIMARY BRAKE or LOW AIR warning light isn t on you still have brakes but you don t have the anti lock brake feature If the PRIMARY BRAKE and or LOW AIR warning light is on you don t have anti ...

Page 108: ...erpillarR Operation Maintenance Manual Low Coolant Warning Light You have a LOW COOLANT warning light If this light comes on your system is low on coolant and the engine may overheat The warning light should come on briefly as a check when you turn on the ignition When it comes on you will also hear a warning tone at five beats per second for 10 seconds See Engine Coolant in the Index and have you...

Page 109: ...he manual FAST IDLE feature is engaged For more details about this system see Fast Idle System in the Index Intake Heater Indicator Light Diesel Engines This light on the instrument panel cluster will come on when the intake heater is on and the ignition key is in ON Since the light is illuminated whenever the intake heater is activated it is normal for the light to cycle on and off as the heater ...

Page 110: ...wo things may happen First you won t notice any difference in engine performance but your tail pipe emissions may increase Second your engine may not run properly or may stall without warning If either of these things happen drive or tow your vehicle to your dealer for service This light should come on when the ignition is on but the engine is not running as a check to show you it is working If it...

Page 111: ...al If you have a diesel engine the normal operating range should be between 35 and 70 psi 240 to 480 kPa A reading in the low pressure zone may be caused by a dangerously low oil level or other problem If you have a CaterpillarR diesel engine also see your CaterpillarR Operation Maintenance Manual CAUTION Don t keep driving if the oil pressure is low If you do your engine can become so hot that it...

Page 112: ...Reduced Engine Power Warning Light If the SERVICE ENGINE SOON and REDUCED ENGINE POWER lights are on a noticeable reduction in the vehicle s performance may occur If the REDUCED ENGINE POWER light is on but there is no reduction in performance proceed to your destination The performance may be reduced the next time the vehicle is driven The vehicle may be driven at a reduced speed while the REDUCE...

Page 113: ...or on the lower portion of the instrument panel to the right of the steering wheel When your ignition is on the gage shows the temperature of the transmission oil A reading in the warning zone means you must stop driving and check into the cause One possible cause is a low oil level in the transmission NOTICE If you drive when the transmission temperature gage is in the warning zone you can badly ...

Page 114: ...rected This light may also come on if your vehicle is equipped with the optional automatic engine shutdown system and engine shutdown has begun See Engine Automatic Shutdown in the Index Fuel Gage Gasoline Engine Diesel Engine Your fuel gage will be on the right side of your instrument panel cluster if your vehicle doesn t have the optional tachometer If you have a tachometer your fuel gage is loc...

Page 115: ...arR Operation Maintenance Manual Air Pressure Gage If Equipped If your vehicle has air brakes this gage at the center of your instrument panel cluster shows the air pressure for both your front and rear brake systems If the needle on the gage indicates that the air pressure is below 60 psi 415 kPa the LOW AIR warning light will come on An alarm will also sound if this happens The yellow pointer sh...

Page 116: ... vacuum on the scale the filter should be replaced After replacing the filter reset the gage by pressing in the yellow reset pin at the bottom of the gage If you have a diesel engine also see your CaterpillarR Operation Maintenance Manual Hourmeter Gage If Equipped If your vehicle has this gage it will be to the lower left of the steering column mounted on a bracket either above or below the fuse ...

Page 117: ...about the particular systems supplied with your vehicle 3 2 Comfort Controls 3 5 Air Conditioning 3 5 Heating 3 6 Defogging 3 6 Ventilation System 3 7 Audio Systems 3 7 Setting the Clock 3 7 AM FM Stereo 3 9 Remote Cassette Tape Player If Equipped 3 10 Understanding Radio Reception 3 10 Tips About Your Audio System 3 11 Care of Your Cassette Tape Player 3 11 Fixed Mast Antenna ...

Page 118: ... setting operates the defogger Heated air comes out near the windshield Use this when fog or ice is on the windshield Temperature Lever The bottom lever lets you select the temperature of the air flowing into your vehicle Move the lever to the plus symbol for warmer air Move the lever to the minus symbol for cooler air If your engine is equipped with an engine coolant heater you can use it during ...

Page 119: ...tor Bar The bar under your system display lets you select the temperature of the air coming into the passenger area of your vehicle Press COLD for cooler air and press HOT for warmer air Release the bar when the system reaches the temperature you want The temperature is shown on the display by an arrow moving between C and H If your engine is equipped with an engine coolant heater you can use it d...

Page 120: ...button again DEFOG This setting operates the defogger Air comes out near the bottom of the windshield and at your front side windows HEATER Press the bottom of this button and heated air comes out near the floor A C Button Press the A C button to turn your air conditioner on and off The A C symbol will light on your display and air will come out of your instrument panel vents The fan will automati...

Page 121: ... air conditioner develops high system pressure it will automatically go into the MAX mode and REC will light on your display The A C system will remain in the MAX mode even if you press the MAX button until system pressure returns to a normal level Heating On cold days use HEATER with the temperature selector all the way toward H When the inside of the vehicle has reached a comfortable temperature...

Page 122: ...he cab through the air intake in the cowl by the vehicle s forward motion This air is controlled by two vent air handles under the instrument panel Air is directed through the ventilation ducts to the floor Ram air provides good airflow into the cab at normal road speeds Ventilation Tips D Keep the hood and front air inlet free of ice snow or any other obstruction such as leaves The heater and def...

Page 123: ...the UP button until the correct hour appears on the display and the DOWN button until the correct minute appears on the display If you press and hold the UP DOWN button hours or minutes will advance rapidly AM FM Stereo Playing the Radio ON OFF Press the round button to turn the radio on Press it again to turn the radio off VOLUME Slide the VOLUME lever to the right to increase volume or to the le...

Page 124: ...ons six AM and six FM Just 1 Turn the radio on 2 Press AM FM to select a band 3 Tune in the desired station 4 Press SET SET will appear on the display and will blink for about eight seconds 5 Press one of the six pushbuttons within eight seconds In the display SET will stop blinking indicating the preset is set Whenever you press that numbered button the station you set will return 6 Repeat the st...

Page 125: ...D Slide this lever to the left or right to adjust the speaker balance between the front and rear speakers The middle position balances the sound between the speakers Remote Cassette Tape Player If Equipped Your tape player is built to work best with tapes that are up to 30 to 45 minutes long on each side Tapes longer than that are so thin they may not work well in this player To load a cassette ta...

Page 126: ... come and go Tips About Your Audio System Hearing damage from loud noise is almost undetectable until it is too late Your hearing can adapt to higher volumes of sound Sound that seems normal can be loud and harmful to your hearing Take precautions by adjusting the volume control on your radio to a safe sound level before your hearing adapts to it To help avoid hearing loss or damage D Adjust the v...

Page 127: ...as the hubs of the cleaner cassette turn The recommended cleaning cassette is available through your dealership GM Part No 12344789 You may also choose a non scrubbing action wet type cleaner which uses a cassette with a fabric belt to clean the tape head This type of cleaning cassette will not eject on its own A non scrubbing action cleaner may not clean as thoroughly as the scrubbing type cleane...

Page 128: ...on driving 4 2 Defensive Driving 4 3 Drunken Driving 4 6 Control of a Vehicle 4 6 Braking 4 10 Steering 4 12 Off Road Recovery 4 12 Passing 4 14 Loss of Control 4 15 Driving at Night 4 16 Driving in Rain and on Wet Roads 4 20 City Driving 4 21 Freeway Driving 4 22 Highway Hypnosis 4 23 Hill and Mountain Roads 4 25 Winter Driving 4 29 Loading Your Vehicle 4 31 Power Take Off PTO If Equipped ...

Page 129: ...eventable of accidents Yet they are common Allow enough following distance It s the best defensive driving maneuver in both city and rural driving You never know when the vehicle in front of you is going to brake or turn suddenly Defensive driving requires that a driver concentrate on the driving task Anything that distracts from the driving task such as concentrating on a cellular telephone call ...

Page 130: ... alcohol There are good medical psychological and developmental reasons for these laws The obvious way to solve the leading highway safety problem is for people never to drink alcohol and then drive But what if people do How much is too much if the driver plans to drive It s a lot less than many might think Although it depends on each person and situation here is some general information on the pr...

Page 131: ...me other countries it s even lower The BAC limit for all commercial drivers in the United States is 0 04 percent The BAC will be over 0 10 percent after three to six drinks in one hour Of course as we ve seen it depends on how much alcohol is in the drinks and how quickly the person drinks them But the ability to drive is affected well below a BAC of 0 10 percent Research shows that the driving sk...

Page 132: ...l in a person s system can make crash injuries worse especially injuries to the brain spinal cord or heart This means that when anyone who has been drinking driver or passenger is in a crash that person s chance of being killed or permanently disabled is higher than if the person had not been drinking CAUTION Drinking and then driving is very dangerous Your reflexes perceptions attentiveness and j...

Page 133: ...g up your foot and do it That s reaction time Average reaction time is about 3 4 of a second But that s only an average It might be less with one driver and as long as two or three seconds or more with another Age physical condition alertness coordination and eyesight all play a part So do alcohol drugs and frustration But even in 3 4 of a second a vehicle moving at 60 mph 100 km h travels 66 feet...

Page 134: ...wer assist is used up it may take longer to stop and the brake pedal will be harder to push Hydraulic Brake Systems If your engine stops running or if your primary brake system stops working your vehicle has a reserve power assist system to help you slow down Just slowly and steadily apply the brake pedal until you can safely get off the road The pedal will seem harder to push down Don t pump the ...

Page 135: ...this test is going on This is normal If there s a problem with the anti lock brake system this warning light will stay on See Anti Lock Brake System Warning Light in the index Here s how anti lock works Let s say the road is wet You re driving safely Suddenly an animal jumps out in front of you You slam on the brakes Here s what happens with ABS A computer senses that wheels are slowing down If on...

Page 136: ...Remember Anti lock doesn t change the time you need to get your foot up to the brake pedal or always decrease stopping distance If you get too close to the vehicle in front of you you won t have time to apply your brakes if that vehicle suddenly slows or stops Always leave enough room up ahead to stop even though you have anti lock brakes Using Anti Lock Don t pump the brakes Just hold the brake p...

Page 137: ...same direction If you ve ever tried to steer a vehicle on wet ice you ll understand this The traction you can get in a curve depends on the condition of your tires and the road surface the angle at which the curve is banked and your speed While you re in a curve speed is the one factor you can control What should you do if this ever happens Ease up on the accelerator pedal steer the vehicle the wa...

Page 138: ...uch speed as you can from a possible collision Then steer around the problem to the left or right depending on the space available If your vehicle has anti lock brakes you don t need to release the brakes to maintain steering control An emergency like this requires close attention and a quick decision If you are holding the steering wheel at the recommended 9 and 3 o clock positions you may be abl...

Page 139: ... around the vehicle ahead then goes back into the right lane again A simple maneuver Not necessarily Passing another vehicle on a two lane highway is a potentially dangerous move since the passing vehicle occupies the same lane as oncoming traffic for several seconds A miscalculation an error in judgment or a brief surrender to frustration or anger can suddenly put the passing driver face to face ...

Page 140: ...art that more than makes up for the distance you would lose by dropping back And if something happens to cause you to cancel your pass you need only slow down and drop back again and wait for another opportunity D If other cars are lined up to pass a slow vehicle wait your turn But take care that someone isn t trying to pass you as you pull out to pass the slow vehicle D Check your mirrors and sta...

Page 141: ...ration skid too much throttle causes the driving wheels to spin A cornering skid and an acceleration skid are usually best handled by easing your foot off the accelerator pedal Of course traction is reduced when water snow ice gravel or other material is on the road For safety you ll want to slow down and adjust your driving to these conditions It is important to slow down on slippery surfaces bec...

Page 142: ...o much road ahead D In remote areas watch for animals D If you re tired pull off the road in a safe place and rest No one can see as well at night as in the daytime But as we get older these differences increase A 50 year old driver may require at least twice as much light to see the same thing at night as a 20 year old What you do in the daytime can also affect your night vision For example if yo...

Page 143: ...ract repeatedly Remember that your headlamps light up far less of a roadway when you are in a turn or curve Keep your eyes moving that way it s easier to pick out dimly lighted objects Just as your headlamps should be checked regularly for proper aim so should your eyes be examined regularly Some drivers suffer from night blindness the inability to see in dim light and aren t even aware of it Driv...

Page 144: ...equipment in good shape and keep your windshield washer tank filled with washer fluid Replace your windshield wiper inserts when they show signs of streaking or missing areas on the windshield or when strips of rubber start to separate from the inserts Driving too fast through large water puddles or even going through some vehicle washes can cause problems too The water may affect your brakes Try ...

Page 145: ...ut it can if your tires do not have much tread or if the pressure in one or more is low It can happen if a lot of water is standing on the road If you can see reflections from trees telephone poles or other vehicles and raindrops dimple the water s surface there could be hydroplaning Hydroplaning usually happens at higher speeds There just isn t a hard and fast rule about hydroplaning The best adv...

Page 146: ...e warning signs and otherwise be very cautious about trying to drive through flowing water Some Other Rainy Weather Tips D Turn on your low beam headlamps and your marker and clearance lamps if your vehicle has them not just your parking lamps to help make you more visible to others D Besides slowing down allow some extra following distance And be especially careful when you pass another vehicle A...

Page 147: ...try trip D Larger vehicles can t be driven everywhere smaller ones can There are low underpasses truck routes and other special situations Usually these are well marked so be sure to watch for the signs D Try to use the freeways that rim and crisscross most large cities You ll save time and energy See the next part Freeway Driving D Treat a green light as a warning signal A traffic light is there ...

Page 148: ... ramp that leads to the freeway If you have a clear view of the freeway as you drive along the entrance ramp you should begin to check traffic Try to determine where you expect to blend with the flow Try to merge into the gap at close to the prevailing speed Switch on your turn signal check your mirrors and try to blend smoothly with the traffic flow Once you are on the freeway adjust your speed t...

Page 149: ...ain falling asleep at the wheel Call it highway hypnosis lack of awareness or whatever When you drive the vehicle for a long distance there is something about an easy stretch of road with the same scenery along with the hum of the tires on the road the drone of the engine and the rush of the wind against the vehicle that can make you sleepy Don t let it happen to you If it does your vehicle can le...

Page 150: ...stem and transmission These parts can work hard on mountain roads D Know how to go down hills The most important thing to know is this let your engine do some of the slowing down Shift to a lower gear when you go down a steep or long hill CAUTION If you don t shift down your brakes could get so hot that they wouldn t work well You would then have poor braking or even none going down a hill You cou...

Page 151: ...lp cool your engine and transmission and you can climb the hill better D Stay in your own lane when driving on two lane roads in hills or mountains Don t swing wide or cut across the center of the road Drive at speeds that let you stay in your own lane D As you go over the top of a hill be alert There could be something in your lane like a stalled car or an accident D You may see highway signs on ...

Page 152: ...and reflective warning triangles And if you will be driving under severe conditions include a small bag of sand a piece of old carpet or a couple of burlap bags to help provide traction Be sure you properly secure these items in your vehicle Driving on Snow or Ice Most of the time those places where your tires meet the road probably have good traction However if there is snow or ice between your t...

Page 153: ...k the fragile traction If you accelerate too fast the drive wheels will spin and polish the surface under the tires even more D Allow distance on any slippery road D Watch for slippery spots The road might be fine until you hit a spot that s covered with ice On an otherwise clear road ice patches may appear in shaded areas where the sun can t reach around clumps of trees behind buildings or under ...

Page 154: ...mmon help and keep yourself and your passengers safe D Turn on your hazard flashers D Tie a red cloth to your mirror arm to alert police that you ve been stopped by the snow D Put on extra clothing or wrap a blanket around you If you have no blankets or extra clothing make body insulators from newspapers burlap bags rags floor mats anything you can wrap around yourself or tuck under your clothing ...

Page 155: ...e it go a little faster than just idle That is push the accelerator slightly This uses less fuel for the heat that you get and it keeps the battery or batteries charged You will need a well charged battery or batteries to restart the vehicle and possibly for signaling later on with your headlamps Let the heater run for a while If you have a diesel engine you may have to run it at a higher speed to...

Page 156: ...Certification Tire label is provided by the final manufacturer and should be on the door or door jamb It also tells you the maximum weights for the front and rear axles called Gross Axle Weight Rating GAWR To find out the actual loads on your front and rear axles you need to go to a weigh station and weigh your vehicle Your dealer can help you with this Be sure to spread out your load equally on b...

Page 157: ...l because of overloading If you put things inside your vehicle like suitcases tools packages or anything else they will go as fast as the vehicle goes If you have to stop or turn quickly or if there is a crash they ll keep going CAUTION Things you put inside your vehicle can strike and injure people in a sudden stop or turn or in a crash D Put things in the cargo area of your vehicle Try to spread...

Page 158: ...enabled Do not hold the brake or clutch pedal down 4 The PTO Enable and cruise control if equipped switch must be in ON prior to enabling the PTO operation Three rpm settings are controlled by the multifunctional stalk lever A OFF ON ON position has a base engine idle of 1 400 rpm B With optional cruise control RESUME ACCEL has a base engine idle of 1 800 rpm SET COAST has a base engine idle of 1 ...

Page 159: ...by 25 rpm C Without the optional cruise control PTO UP increases by 25 rpm PTO DOWN decreases by 25 rpm To engage a PTO with Mobile Variable 1 The PTO Enable and cruise control if equipped switch must be in ON 2 Press the accelerator pedal to the desired engine speed 3 Engine speed is controlled by the multifunctional stalk lever A OFF ON ON position holds engine speed selected by the accelerator ...

Page 160: ...d 5 2 Hazard Warning Flashers 5 4 Other Warning Devices 5 5 Jump Starting 5 10 Towing Your Vehicle 5 18 Engine Overheating 5 20 Cooling System Gasoline Engines 5 27 Cooling System Diesel Engine 5 33 Engine Fan Noise 5 33 If a Tire Goes Flat 5 34 Changing a Flat Tire 5 37 If You re Stuck In Sand Mud Ice or Snow ...

Page 161: ...on and off The hazard flasher switch is located on the steering column Press the button in to make your front and rear turn signal lamps flash on and off Your hazard warning flashers work no matter what position your key is in and even if the key isn t in To turn off the flashers pull out on the collar When the hazard warning flashers are on your turn signals won t work ...

Page 162: ...t to the switch will also flash Push it back in to turn off the flashers The turn signal lamps won t flash if you re braking This switch works no matter what position the key is in and even if the key isn t in the ignition When the hazard warning flashers are on your turn signals won t work Signal Stat Turn Signal and Hazard Warning Flasher If Equipped If you have this system it lets you warn othe...

Page 163: ... turn signal lever either up or down Then move the signal lever back to the center position When the hazard warning flashers are on your turn signals won t work Other Warning Devices If you carry reflective triangles you can set one up at the side of the road behind your vehicle in the recommended manner per FMCSR Federal Motor Carrier Safety Regulation Section 392 22 to warn others ...

Page 164: ...ctricity to burn you If you don t follow these steps exactly some or all of these things can hurt you NOTICE Ignoring these steps could result in costly damage to your vehicle that wouldn t be covered by your warranty The ACDelcoR battery in your vehicle has a built in hydrometer Do not charge test or jump start the battery if the hydrometer looks clear or light yellow Replace the battery when the...

Page 165: ...ry that s closest to the starter this will reduce electrical resistance CAUTION If your vehicle has air conditioning the auxiliary electric fan under the hood can start up even when the engine is not running and can injure you Keep hands clothing and tools away from any underhood electric fan 2 Get the vehicles close enough so the jumper cables can reach but be sure the vehicles aren t touching ea...

Page 166: ...d be present Battery fluid contains acid that can burn you Don t 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 5 Check that the jumper cables don t 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 ...

Page 167: ...ive terminal of the good battery 8 Now connect the black negative cable to the good battery s negative terminal Don t let the other end touch anything until the next step The other end of the negative cable doesn t go to the dead battery It goes to a heavy unpainted metal part on the engine or some other well grounded part of the vehicle with the dead battery ...

Page 168: ...art the vehicle with the good battery and run the engine for one to two minutes If your vehicle has the high idle option use it 11 Try to start the vehicle with the dead battery If it won t start after a few tries it probably needs service 12 Remove the cables in reverse order to prevent electrical shorting Take care that they don t touch each other or any other metal A Heavy Unpainted Metal Engin...

Page 169: ... safety chains when towing it CAUTION D Working on air brakes without first using the release studs to compress the springs can lead to injury Never work on the air brake chambers without first using the release studs to compress the brake springs D When the brake springs are manually compressed you will have no brakes Release your air operated parking brakes manually only to tow the vehicle Never...

Page 170: ...r vehicle uses dragfoilers be sure to have the dragfoiler to cab mounting bracket bolts tightened after your vehicle has been towed Here are specific towing instructions Towing Your Vehicle From the Front Front Wheels Off the Ground Before Towing Block the rear wheels of the disabled vehicle On vehicles with air brakes release the emergency brake system by compressing the brake chamber springs as ...

Page 171: ...ift Chain C Front Axle 3 Place a 6 x 6 x 5i hardwood beam underneath and slightly behind the front spring shackle brackets 4 Connect lift chains to the tow bar and raise the tow bar until lift chain slack has been taken up and the hardwood beam is fully seated against the spring shackle brackets as shown A Shackle Bracket B Tow Bar C Lift Chain D Hardwood Beam 5 Raise the vehicle to the required h...

Page 172: ...h and slightly behind the front spring shackle brackets as previously shown 3 Connect the lift chains to the tow bar and take up the slack in the chains until the tow bar is within 4 of the front bumper facing Place a 2 x 12 x 40 hardwood board with rubber pads against the front bumper and secure as shown A Rubber Pad B Hardwood Board C Shackle Bracket D Lift Chain E Hardwood Beam F Bumper G Tow B...

Page 173: ...f the ground Remove the rearward propshaft Tandem Drive Rear Axle Both Axles on the Ground Due to Type of Suspension or Attached Load Disconnect the propshaft at the forward tandem axle Secure the propshaft to the frame or crossmember If there is damage or suspected damage to the axle s remove all axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objec...

Page 174: ...ft Disconnect the propshaft at the rear axle forward axle on tandem axle models Secure the propshaft to the frame or crossmember If there is damage or suspected damage to the axle s remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects After Towing Block the rear wheels and install axle and propshafts Check for proper phasing of universa...

Page 175: ... pressure from both systems the parking brakes may have applied The tow operator can release the brakes manually by using the following steps Then your vehicle can be towed with all wheels or just the rear wheels on the ground 1 Block the wheels of the vehicle 2 Remove the release stud and nut from the side of the brake chamber Some chambers have studs which are visible at all times ...

Page 176: ...kwise several turns to release the brakes Follow the same procedure to release the other brake 7 At the repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from an external air supply or the vehicle s air system 8 Turn the stud nut counterclockwise several turns Remove the stud from the chamber 9 Put the stud into the side of the chamber and replace the rubbe...

Page 177: ...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...

Page 178: ... shift to NEUTRAL N otherwise shift to the highest gear while driving DRIVE D for automatic transmissions 4 If climbing a hill downshift to raise engine and fan speeds If you no longer have the overheat warning you can drive Just to be safe drive slower for about 10 minutes If the warning doesn t come back on you can drive normally If the warning continues pull over stop and park your vehicle righ...

Page 179: ...ine Engines When you decide it s safe to lift the hood here s what you ll see Specialty Hood A Coolant Recovery Tank B Radiator Pressure Cap C Engine Fan Sloped Hood A Engine Fan B Coolant Recovery Tank C Radiator Pressure Cap ...

Page 180: ... If the coolant inside the coolant recovery tank is boiling don t do anything else until it cools down Specialty Hood When the engine is cold the coolant level should be above the HOT LEVEL mark on the vehicle with the specialty hood or at or above the COLD LEVEL mark on the vehicle with the sloped hood Sloped Hood If it isn t you may have a leak in the radiator hoses heater hoses radiator water p...

Page 181: ...lant it is important that you use only DEX COOLR silicate free coolant If coolant other than DEX COOL is added to the system premature engine heater core or radiator corrosion may result In addition the engine coolant will require change sooner at 30 000 miles 50 000 km or 24 months whichever occurs first Damage caused by the use of coolant other than DEX COOLR is not covered by your new vehicle w...

Page 182: ...water to your cooling system can be dangerous Plain water or some other liquid like alcohol can boil before the proper coolant mixture will Your vehicle s coolant warning system is set for the proper coolant mixture With plain water or the wrong mixture your engine could get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50...

Page 183: ...e If the overheat warning continues there s one more thing you can try You can add the proper coolant mixture directly to the radiator but be sure the cooling system is cool before you do it 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 radiator pressure cap even a little they can come out at high speed Neve...

Page 184: ...until it first stops Don t 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 3 Fill the radiator with the proper DEX COOLR coolant mixture up to the base of the filler neck See Engine Coolant in the Index for more information ...

Page 185: ...n feel the upper radiator hose getting hot Watch out for the engine cooling fan s 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 COOLR coolant mixture through the filler neck until the level reaches the base of the filler neck 8 Then reinstall the pressure cap At any time during this procedure if coolant begins to flow...

Page 186: ...nder the hood can start up even when the engine is not running and can injure you Keep hands clothing and tools away from any underhood electric fan If the coolant inside the coolant surge tank is boiling don t do anything else until it cools down The coolant level should be at COLD ADD or higher If it isn t you may have a leak in the radiator hoses heater hoses radiator water pump or somewhere el...

Page 187: ...ant to the Coolant Surge Tank If you haven t found a problem yet but the coolant level isn t at the COLD ADD mark or higher add a 50 50 mixture of clean drinkable water and coolant at the coolant surge tank but be sure the cooling system including the coolant surge tank pressure cap is cool before you do it See the CaterpillarR Diesel Engine Operation Maintenance Manual for the proper engine coola...

Page 188: ...e the proper coolant mixture will Your vehicle s coolant warning system is set for the proper coolant mixture With plain water or the wrong mixture your engine could get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and coolant ...

Page 189: ...ll burn if the engine parts are hot enough Don t spill coolant on a hot engine 1 You can remove the coolant surge tank pressure cap when the cooling system including the coolant surge tank pressure cap and upper radiator hose is no longer hot Turn the pressure cap slowly counterclockwise until it first stops Don t press down while turning the pressure cap If you hear a hiss wait for that to stop A...

Page 190: ...5 31 2 Then keep turning the cap but now push down as you turn it Remove the pressure cap 3 Then fill the coolant surge tank with the proper coolant mixture up to the COLD FULL mark ...

Page 191: ...e getting hot Watch out for the engine fan By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixture to the coolant surge tank until the level reaches the COLD FULL mark 5 Then replace the pressure cap Be sure the arrows on the pressure cap line up like this ...

Page 192: ...ages If a Tire Goes Flat It s unusual for a tire to blow out while you re driving especially if you maintain your tires properly If air goes out of a tire it s much more likely to leak out slowly But if you should ever have a blowout here are a few tips about what to expect and what to do If a front tire fails the flat tire will create a drag that pulls the vehicle toward that side Take your foot ...

Page 193: ...look at the wheel See if it looks like another wheel on the vehicle If so go on to the next step If it doesn t or even if you can t be sure stop and get expert help CAUTION Tire rim assemblies can explode If you work on a pressurized tire mounted on a damaged wheel the assembly can expand with explosive force without warning You and others nearby can be badly injured Don t work around a tire that ...

Page 194: ...s where the wheel attaches to the vehicle In an emergency you can use a cloth or a paper towel to do this but be sure to use a scraper or wire brush later if you need to to get all the rust or dirt off D If the lock ring and side rings seem to be seated properly or if the wheel doesn t have these let the air out of the tire You can do this by taking out the valve core D If the flat or damaged tire...

Page 195: ...u add air to your tires You ll need an accurate truck tire pressure gage Stand to one side and add the air Be sure you don t go over the top inflation pressure for the tire CAUTION Incorrect wheel nuts or improperly tightened wheel nuts can cause the wheel to become loose and even come off This could lead to an accident Be sure to use the correct wheel nuts If you have to replace them be sure to g...

Page 196: ... parts of your vehicle as well as the tires If you spin the wheels too fast while shifting your transmission back and forth you can destroy your transmission Rocking Your Vehicle To Get It Out First turn your steering wheel left and right That will clear the area around your front wheels Then shift back and forth between REVERSE R and a forward gear or with a manual transmission between FIRST 1 or...

Page 197: ...ne Oil CaterpillarR Diesel Engines 6 18 Engine Air Cleaner Filter 6 19 Automatic Transmission Fluid 6 19 Manual Transmission Fluid 6 20 Rear Axle 6 21 Rear Axle Shift Motor Option 6 21 Engine Coolant Gasoline Engine 6 26 Engine Coolant CaterpillarR Diesel Engine 6 26 Radiator Pressure Cap Gasoline Engines 6 27 Surge Tank Pressure Cap Diesel Engines 6 27 Power Steering Fluid 6 29 Windshield Washer ...

Page 198: ...an To order the proper service manual see Service and Owner Publications in the Index You should keep a record with all parts receipts and list the mileage and the date of any service work you perform See Maintenance Record in the Index CAUTION You can be injured and your vehicle could be damaged if you try to do service work on a vehicle without knowing enough about it D Be sure you have sufficie...

Page 199: ...overned speed of the vehicle without getting the necessary information from your dealer CAUTION Continued CAUTION Continued Winter Fronts Grille Covers or Obstructions Winter fronts grille covers or other add on equipment causing obstructions in front or behind the fan should not be used on this vehicle They may increase the stress on the fan as the blades pass over the covered areas If this cause...

Page 200: ...rive If it s bad enough it can damage your engine If you re using fuel rated at 87 octane or higher and you hear heavy knocking your engine needs service But don t worry if you hear a little pinging noise when you re accelerating or driving up a hill That s normal and you don t have to buy a higher octane fuel to get rid of pinging It s the heavy constant knock that means you have a problem Some g...

Page 201: ...ontains methanol Don t use it It can corrode metal parts in your fuel system and also damage plastic and rubber parts That damage wouldn t be covered under your warranty Diesel Fuel Requirements and Fuel System Diesel Engine Fuel See your CaterpillarR Diesel Engine Operation Maintenance Manual for information concerning fuel usage Water in Fuel Sometimes water can be pumped into your fuel tank alo...

Page 202: ... if the diesel engine vehicle will not be used for a time Fuels in Foreign Countries Gasoline Engines If you plan on driving in another country outside the United States or Canada the proper fuel may 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 wouldn t be covered by your warranty To check on ...

Page 203: ...es Don t smoke if you re near gasoline or diesel fuel or if you re refueling your vehicle Keep sparks flames and smoking materials away from gasoline or diesel fuel The fuel cap can be on either or both sides of your vehicle depending on option content To take off the cap turn it slowly to the left counterclockwise ...

Page 204: ...em might be damaged If you have dual tanks fill the driver s side first The fuel gage will give better readings this way Your gage will show the average level of both tanks combined Filling a Portable Fuel Container CAUTION Never fill a portable fuel container while it is in your vehicle Static electricity discharge from the container can ignite the gasoline vapor You can be badly burned and your ...

Page 205: ...d To tilt the hood forward pull out on each of the hood latches If the hood is equipped with hood access panels make sure the panel latches are locked down before lifting the hood open Then take the hand holds and pull the hood forward ...

Page 206: ...the cables will support it If your vehicle has the optional hood access panels you can easily get to one side of the engine or the other as you need to Pull out on the top of each hood latch Then push the latch down and swing the bottom out ...

Page 207: ... Be careful not to drop or spill things that will burn onto a hot engine Before closing the hood or access panels be sure all the filler caps are on properly Noise Control System 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 ...

Page 208: ...nt of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Insulation D Removal of the noise shields or any underhood insulation Engine D Removal or rendering engine speed governor if equipped inoperative so as to allow engine speed to exceed manufacturer specifications Fan and Drive D Removal of fan clutch if equ...

Page 209: ... on level ground The engine oil dipstick is located on the passenger s side of the engine compartment Turn off the engine and give the oil several minutes to drain back into the oil pan If you don t the oil dipstick might not show the actual level 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...

Page 210: ...e in the proper operating range Push the dipstick all the way back in when you re through What Kind of Engine Oil to Use Oils recommended for your vehicle can be identified by looking for the starburst symbol This symbol indicates that the oil has been certified by the American Petroleum Institute API Do not use any oil which does not carry this starburst symbol If you change your own oil be sure ...

Page 211: ...h the American Petroleum Institute Certified For Gasoline Engines starburst symbol Failure to use the recommended oil can result in engine damage not covered by your warranty GM GoodwrenchR oil meets all the requirements for your vehicle If you are in an area where the temperature falls below 20_F 29_C consider using either an SAE 5W 30 synthetic oil or an SAE 0W 30 oil Both will provide easier co...

Page 212: ...t whenever the oil is changed How to Reset the Change Oil Light To reset the CHANGE OIL light turn the ignition key to RUN with the engine off Fully press and release the accelerator pedal three times within 10 seconds If the CHANGE OIL light flashes for five seconds the system is reset If the light does not display for five seconds you will need to reset the system again What to Do with Used Oil ...

Page 213: ...r appears in the sight glass it s time to service the air filter After the air filter is properly serviced the indicator can be reset by pushing the button on top of the indicator to reset it Engine Air Filter Restriction Indicator Diesel Engines Your engine has an indicator that lets you know when the air filter is dirty and needs to be serviced It is located in the air intake tube below the air ...

Page 214: ...gine backfires If it isn t there and the engine backfires you could be burned Don t drive with it off and be careful working on the engine with the air cleaner filter off NOTICE Gasoline Engines Only If the air cleaner filter is off a backfire can cause a damaging engine fire And dirt can easily get into your engine which will damage it Always have the air cleaner filter in place when you re drivi...

Page 215: ...ransmission fluid Automatic Transmission External Filter Your automatic transmission spin on type filter requires periodic replacement It is mounted just behind the radiator on the outside of the passenger s side frame rail Consult the Allison Automatic Transmission Operator s Manual that came with the vehicle for proper change intervals Automatic Transmission External Filter With Service Trans Fi...

Page 216: ...eading if you check your transmission fluid Rear 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 Services in the Maintenance Schedule How to Check Lubricant If the level is below the bottom of the filler plug hole you ll need to add some lubricant Add enough lubricant to raise th...

Page 217: ...t kind of lubricant to use Engine Coolant Gasoline Engine The cooling system in your vehicle is filled with DEX COOLR engine coolant This coolant is designed to remain in your vehicle for 5 years or 150 000 miles 240 000 km whichever occurs first if you add only DEX COOLR extended life coolant The following explains your cooling system and how to add coolant when it is low If you have a problem wi...

Page 218: ...ixture of one half clean drinkable water and one half DEX COOLR coolant which won t damage aluminum parts If you use this coolant mixture you don t need to add anything else CAUTION Adding only plain water to your cooling system can be dangerous Plain water or some other liquid like alcohol can boil before the proper coolant mixture will Your vehicle s coolant warning system is set for the proper ...

Page 219: ... can freeze and crack the engine radiator heater core and other parts If you have to add coolant more than four times a year have your dealer check your cooling system NOTICE If you use the proper coolant you don t have to add extra inhibitors or additives which claim to improve the system These can be harmful Checking Coolant Coolant Recovery Tank Gasoline Engines Specialty Hood ...

Page 220: ...rge Tank CaterpillarR Diesel Engines When your engine is cold the coolant level should be at the COLD level or a little higher on the coolant recovery tank with the gasoline engine or at the COLD FULL mark visible through the surge tank with the diesel engine ...

Page 221: ...ng the radiator pressure cap on a gasoline engine or the surge tank cap on a diesel engine when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly With the coolant recovery system you will almost never have to add coolant at the radiator Never turn the radiator pressure cap or the surge tank pressure cap even a little when the engine and radiator ar...

Page 222: ...terpillar diesel engine see the CaterpillarR Diesel Engine Operation Maintenance Manual provided with your vehicle to find out what to add also when and how to service your cooling system Radiator Pressure Cap Gasoline Engines The radiator pressure cap must be tightly installed with the arrows on the cap lined up with the top of the overflow tube This will prevent coolant loss and possible engine ...

Page 223: ...ng Be sure the arrows on the cap line up with the top tube of the coolant surge tank Power Steering Fluid See your Maintenance Schedule for when to check your power steering fluid How To Check Power Steering Fluid Check your power steering fluid only when the engine is warm If the engine isn t warm you probably won t get an accurate reading Vehicles with diesel engines have a sight glass If you ca...

Page 224: ...teering fluid or making a complete fluid change always use the proper fluid Failure to use the proper fluid can cause leaks and damage hoses and seals If your power steering fluid level is low this can cause the PRIMARY BRAKE or AUX BRAKE warning lights to come on If either light remains on after you have added power steering fluid to the proper level then shut off the engine for 10 seconds This s...

Page 225: ...l NOTICE D When using concentrated washer fluid follow the manufacturer s instructions for adding water D Don t 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 doesn t clean as well as washer fluid D Fill your washer fluid tank only three quarters full when it s very cold This allows f...

Page 226: ...ed and your vehicle could be damaged Checking Brake Fluid Apply the brake pedal several times with the ignition off Then clean one of the reservoir caps and the area around the cap and remove it The fluid level should be even with the bottom ring of the filler opening If it s low add enough fluid to fill the reservoir to the proper level What to Add Use the proper fluid listed in your Maintenance ...

Page 227: ...vehicle If you do wash it off immediately See Appearance Care in the Index Four Wheel Disc Brakes Hydraulic Only Your vehicle has four wheel disc brakes Some driving conditions or climates may cause a brake squeal when the brakes are first applied or lightly applied This does not mean something is wrong with your brakes Brake linings should always be replaced as complete axle sets Four Wheel and S...

Page 228: ...l system pressure To be sure you re at full pressure check your air pressure gage It should read at least 100 psi 692 kPa Moisture Ejector Option If you have air brakes with a moisture ejector the valve automatically ejects moisture from the reserve tank when the air compressor cycles Air Dryer Option If your vehicle has air brakes it may have an air dryer This collects and removes dirt moisture o...

Page 229: ...hol injector helps prevent moisture in the air brake system from freezing Use it only in cold weather 32_F 0_C or below To turn it on in cold weather turn the valve so that the word ON is on top When the temperature is above freezing turn the valve to OFF Use only methyl alcohol in this system During the cold weather season you may find that you need to check this bottle once a week ...

Page 230: ... may no longer work properly For example if someone puts in brake linings that are wrong for your vehicle the balance between your front and rear brakes can change for the worse The braking performance you ve come to expect can change in many other ways if someone puts in the wrong replacement brake parts Electric Hydraulic Parking Brake Fluid If you have an electric hydraulic parking brake a good...

Page 231: ...Free Travel If you have a manual transmission your clutch will need adjustment when pedal free travel gets down to about 1 1 4 inch 32 mm as measured at the clutch pedal pad You should have 1 1 2 to 2 inches 38 to 51 mm of clutch pedal free travel Your Maintenance Schedule has more on this If your clutch ever needs service be sure to use only genuine GM clutch replacement parts Chassis Lubrication...

Page 232: ...6 36 Single Axle Models ...

Page 233: ...and Hinges Apply chassis lubricant 6 Slack Adjuster n One fitting 7 Brake Cam Roller Pins at interface of pin and shoe n Apply engine oil 8 Front Steering Knuckles One fitting each side lower bushing hand operated grease gun only Hand pack upper bearing 9 Front Wheel Bearings Hand pack or lubricate 10 Steering Tie Rod Ends One fitting each end 11 Spring Slip Pads Multi Leaf Only Apply chassis lubr...

Page 234: ...e with GM Part No 1051344 Wheel Bearing Lubricant Two fittings each joint 1610 Series and larger lubricate with GM Part No 1051344 Wheel Bearing Lubricant 19 Rear Wheel Bearing Hand pack or lubricate 20 Rear Axle Fill to level of filler plug 21 Parking Brake Clevis Pin Apply chassis lubricant 22 Master Cylinder Fill to 1 4 6 mm below opening 23 Parking Brake Lever Pivot Apply chassis lubricant App...

Page 235: ...ricate with GM Part No 1051344 Wheel Bearing Lubricant 4 Brake Shoe Roller Pins Apply engine oil at pin to shoe joint only 5 Rear Spring Pin One fitting each side 6 Wheel Bearings Hand pack or lubricate 7 Rear Axles Fill to level of filler plug 8 Propshaft Slip Joint Two fittings each side Lubricate with GM Part No 1051344 Wheel Bearing Lubricant ...

Page 236: ...e battery This will help keep your battery from running down If your vehicle has more than one battery be sure to remove the negative battery cable from each battery CAUTION Batteries have acid that can burn you and gas that can explode You can be badly hurt if you aren t careful See Jump Starting in the Index for tips on working around a battery without getting hurt When you are ready to use the ...

Page 237: ...der Part B Owner Checks and Services for more information Replacement blades come in different types and are removed in different ways Here s how to remove the Sheppard s Hook type 1 Pull the windshield wiper arm away from the windshield 2 Push the release lever and slide the wiper assembly toward the driver s side of the vehicle 3 Install a new blade by reversing Steps 1 and 2 ...

Page 238: ...mm bolts on top and the single 8 mm bolt at the top front Then pull the cover toward you and lift it off You can then remove the front cover if you need to by removing the two 8 mm bolts and pulling it off When you re through be sure to put the front cover on before you put on the top cover Fuel Filter Gasoline Engines The steel fuel filter is located inside the component box at the rear See your ...

Page 239: ...ly open the drain valve at the bottom of the filter See Engine Oil in the Index for proper disposal procedures Secondary Fuel Filter and Water Separator Heater Option If you have a CaterpillarR diesel engine you may have this spin on filter and fuel separator heater It is mounted on the driver s side of the engine It has a metal drain bowl at the bottom Occasionally check the bowl for any water or...

Page 240: ...f the cylinder and the top of the valve before you take out the cylinder 4 Check the inside of the valve for any foreign matter Clean the valve as necessary 5 Cover the valve to protect it from dirt and take out the cylinder 6 Install a new gasket whenever you take out the cylinder Use only one gasket and spread a light film of clean oil on it before installation 7 Put in the new cylinder Turn it ...

Page 241: ...b check the glass again after driving a short distance It takes a while for the oil to flow through the system and you may find that you have to add a little more to fill it to the proper level Air Conditioning System Every now and then have your dealership check your air conditioning system to be sure it has not lost any cooling ability If you think the system is not working properly have your GM...

Page 242: ...y a sudden impact such as when you hit a pothole Keep tires at the recommended pressure D Worn old tires can cause accidents If your tread is badly worn or if your tires have been damaged replace them Inflation Tire Pressure The Certification Tire label which is on the driver s door shows the correct inflation pressures for your tires when they re cold Cold means your vehicle has been sitting for ...

Page 243: ...g Be sure you don t exceed these limits Dual Tire Operation When the vehicle is new or whenever a wheel wheel bolt or wheel nut is replaced check the wheel nut torque as indicated Your vehicle has hub piloted wheels Tighten the wheel stud nuts to the specified torque values at 100 miles 160 km 500 miles 800 km and 1 000 miles 1 600 km and then every 1 000 miles 1 600 km thereafter For proper torqu...

Page 244: ...cation of the damage CAUTION Mixing tires could cause you to lose control while driving If you mix tires of different types like radial and bias belted tires the vehicle may not handle properly and you could have a crash Be sure to use the same type of tires all around When you replace tires make sure they are the same size load range speed rating and construction type bias bias belted or radial a...

Page 245: ...ction to be sure they are This section lets you know how often to check the tightness of the wheel nuts on your vehicle and how tight they must be First use these pictures to decide what kind of wheels you have Hub Piloted Type 8 Hole Hub Piloted Type 10 Hole Then follow the steps below for the wheels you have CAUTION Never use oil or grease on studs or nuts If you do the nuts might come loose You...

Page 246: ...ter rear tire and rim assembly so that its valve stem is exactly opposite the valve stem on the inner tire and rim assembly 3 Put on the wheel nuts 4 Finger tighten the nuts 5 Oil the surfaces between the nuts and washers as shown Do not oil the studs or the threads of the nut 6 Tighten the nuts to 400 lb ft 542 N m if an eight hole stud or 480 lb ft 650 N m if a 10 hole stud use the following dia...

Page 247: ...eel or on the parts to which it is fastened can make the wheel nuts become loose after a time The wheel could come off and cause an accident When you change a wheel remove any rust or dirt from the places where the wheel attaches to the vehicle In an emergency you can use a cloth or paper towel to do this but be sure to use a scraper or wire brush later if you need to to get all the rust or dirt o...

Page 248: ...try to stop the leaking Get a new wheel of the proper type CAUTION Without the correct wheel you may not be able to stop properly and you could have other problems like a tire air out You could have a collision If you don t go to your dealer to get a new wheel be sure you get the correct one Each new wheel should match the original wheel in load carrying capacity inflation pressure capacity diamet...

Page 249: ...w GM original equipment wheel Appearance Care Remember cleaning products can be hazardous Some are toxic Others can burst into flame if you strike a match or get them on a hot part of the vehicle Some are dangerous if you breathe their fumes in a closed space When you use anything from a container to clean your vehicle be sure to follow the manufacturer s warnings and instructions And always open ...

Page 250: ...Appearance Care and Materials in the Index Here are some cleaning tips D Always read the instructions on the cleaner label D Clean up stains as soon as you can before they set D Carefully scrape off any excess stain D Use a clean cloth or sponge and change to a clean area often A soft brush may be used if stains are stubborn D If a ring forms on fabric after spot cleaning clean the entire area imm...

Page 251: ...lingers after cleaning vomit or urine treat the area with a water baking soda solution 1 teaspoon 5 ml of baking soda to 1 cup 250 ml of lukewarm water 4 Let dry Stains caused by candy ice cream mayonnaise chili sauce and unknown stains can be removed as follows 1 Carefully scrape off excess stain 2 First clean with cool water and allow to dry completely 3 If a stain remains follow instructions fo...

Page 252: ...e finish Care of Safety Belts Keep belts clean and dry CAUTION Do not bleach or dye safety belts If you do it may severely weaken them In a crash they might not be able to provide adequate protection Clean safety belts only with mild soap and lukewarm water Cleaning Glass Surfaces Glass should be cleaned often GM Glass Cleaner or a liquid household glass cleaner will remove normal tobacco smoke an...

Page 253: ...oth at least every six months During very cold damp weather more frequent application may be required See Recommended Fluids and Lubricants in the Index Cleaning the Outside of Your Vehicle The paint finish on your vehicle provides beauty depth of color gloss retention and durability Washing Your Vehicle The best way to preserve your vehicle s finish is to keep it clean by washing it often with lu...

Page 254: ...ther salts ice melting agents road oil and tar tree sap bird droppings chemicals from industrial chimneys etc can damage your vehicle s finish if they remain on painted surfaces Wash the vehicle as soon as possible If necessary use non abrasive cleaners that are marked safe for painted surfaces to remove foreign matter Exterior painted surfaces are subject to aging weather and chemical fallout tha...

Page 255: ...wheel and buff off immediately after application Don t take your vehicle through an automatic vehicle wash that has silicon carbide tire cleaning brushes These brushes can also damage the surface of these wheels Cleaning Tires To clean your tires use a stiff brush with a tire cleaner NOTICE When applying a tire dressing always take care to wipe off any overspray or splash from all painted surfaces...

Page 256: ...he underbody with plain water Clean any areas where mud and other debris can collect Dirt packed in closed areas of the frame should be loosened before being flushed Your dealer or an underbody vehicle washing system can do this for you Chemical Paint Spotting Some weather and atmospheric conditions can create a chemical fallout Airborne pollutants can fall upon and attack painted surfaces on your...

Page 257: ... plastic rubber and vinyl 1052925 16 oz 0 473 L Multi Purpose Interior Cleaner Cleans carpets seats interior trim door panels and floor mats 1052929 16 oz 0 473 L Wheel Cleaner Spray on and rinse with water 1052930 8 oz 0 237 L Capture Dry Spot Remover Attracts absorbs and removes soils on fabric 12345721 2 5 sq ft Synthetic Chamois Shines vehicle without scratching 12345725 12 oz 0 354 L Silicone...

Page 258: ...nts is on your Certification Tire label Here is what each one means TRUCK SERVICE A vehicle made to carry property or special equipment It is made for uniform frame loading That includes using the vehicle to pull a full trailer TRUCK TRACTOR A vehicle made to draw other vehicles It s made to carry part of the load of the trailer It is made for point frame loading usually for a semi trailer fifth w...

Page 259: ...D a list of all production options and special equipment Be sure that this label is not removed from the vehicle Electrical System Add On Electrical Equipment NOTICE Don t add anything electrical to your vehicle unless you check with your dealer first Some electrical equipment can damage your vehicle and the damage wouldn t be covered by your warranty Some add on electrical equipment can keep othe...

Page 260: ...link with one of the same size and insulation type Fusible link insulation is a special purpose high temperature material The hydraulic brake booster motor feed circuit and starter relay circuit are protected by a fusible link Vehicles with a diesel engine have a fusible link for the intake heater feed circuit Power Windows and Other Power Options Circuit breakers in the fuse panel protect the pow...

Page 261: ...to place If you ever have a problem on the road and don t have a spare circuit breaker you can borrow one of the correct value Just pick some feature of your vehicle that you can get along without like the radio or cigarette lighter and use its circuit breaker if it is of the value you need Remember to replace the circuit breaker as soon as you can These circuit breakers are non cycling do not rep...

Page 262: ...Power Window Relay Transmission Temperature Gage STOP Stoplamps Stoplamp Relay WASH WIPE Windshield Wipers Washer Accessory Relay DOME PNL Dome Lamp Radio Lighting Relay Instrument Panel Lights A C Controller Headlamp Seatbelt Module Engine Control Module Gasoline Engines BLOWER Blower Motor A C A C Clutch Compressor A C Controller A C Clutch Relay TRN HAZ Turn Lamps Hazard Lamps CHAS Exhaust Brak...

Page 263: ... LP Roof Marker Lamps Trailer Marker Lamps Marker Lamp Relay CIG AUX Cigarette Lighter Auxiliary Power Jacks AUX I Auxiliary Wiring Ignition Name Circuits Protected IGN RLY VIM Vehicle Interface Module Diesel Engines Mass Air Flow Engine Control Module Electronic Throttle Control Gasoline Engines WDO Power Windows ENG3 Ignition Coils Fuel Injectors Odd Bank Gasoline Engines CRNK Starter Relay Ethe...

Page 264: ...e rear To access the maxi fuse block gently squeeze both sides of the cover to unlatch the tabs at the top Then unsnap both attachments at the bottom and remove the cover Power is fed through these fuses to devices such as the headlamp switch ignition switch feed circuits and the auxiliary brake pump hydraulic brake vehicles Be sure to replace maxi fuses with maxi fuses of the same rating Do not u...

Page 265: ...kers Protected INT EXT LIGHTS Parking Lamps Dome Panel Lights HEAD LAMP Headlamps Daytime Running Lamps AUX WRG Auxiliary Park Brake IGN SW1 Ignition Switch Wash Wipe Crank Radio HYD PUMP Hydraulic Brake Brake Pump Motor HYD ABS Hydraulic ABS PWR WDO LCKS Window Door Locks PARK BRK Parking Brake Motor BLOWER HORN Blower Horn Cigarette Lighter Auxiliary FUEL ENGINE Ignition Coils Fuel Injectors Gas...

Page 266: ... part listed here isn t the same as the part in your vehicle when it was built or if you have any questions please contact your GM Truck dealer Engine Identification and Data Engine RPO LG5 LP4 L21 Engine Type 7 2L L6 7 4L V8 Fuel System HEUI SPFI Firing Order 1 5 3 6 2 4 1 8 4 3 6 5 7 2 Wheel Nut Torque Refer to Tightening the Wheel Nuts in this section for wheel nut torque information Cooling Sy...

Page 267: ... content Extending the recommended oil change interval requires the use of an infrared oil analysis program which shows the condition of the oil and its additives For more information consult your GM Truck dealer who is an authorized CaterpillarR engine dealer Fuel Tank Capacity Model Gallons Liters Standard 50 189 0 Optional 35 132 5 Optional 60 227 1 Optional 70 264 0 Optional 100 378 0 Two 35 g...

Page 268: ...0 19 0 MT643 for oil pan filter change 13 0 24 5 MT653 for oil pan filter change 36 0 17 0 Add two pints one liter when changing spin on filter Rear Axle Lubricant Capacity Single Speed Axle Lubricant Pints Liters 15040S 21 0 10 1 19060S 28 0 12 8 21060D 28 0 14 7 21060S 28 0 14 7 22060S 28 0 14 7 22080S 40 0 20 3 23080S 40 0 20 3 23431 40 0 20 3 23105S 48 0 22 7 26085P 41 0 19 5 26105S 48 0 22 7 ...

Page 269: ...front 34 0 16 1 RT402 rear 34 0 16 1 Above capacities volumes are approximate Air Conditioning Refrigerant Capacity Refrigerant 2 5 lbs 1 134 kg This capacity volume is approximate Normal Maintenance Replacement Parts Allison Transmission External Filters Engine AC Part Number 7 2L PF897 7 4L PF897 Air Compressor Filter Air Compressor GM Part Number Bendix Tu Flo 550 13 2 CFM 2467368 ...

Page 270: ...PF 932 PCV Valve AC Type CV 774C Air Cleaner Donaldson P522606 Donaldson P533355 Fuel Filter AC TP 915 Primary AC Type GF 481 Pressure Caps RC 54 GM Part No 15997145 Optional Davco K28 D350921 spin on type filter located in component box Optional Cold Weather KUK Racor B6484GM spin on type located in component box Optional Davco heated fuel water separator mounted on the side of the diesel engine ...

Page 271: ...icle Your vehicle needs these services to retain its safety dependability and emission control performance 7 2 Introduction 7 4 Part A Scheduled Maintenance Services 7 5 Scheduled Maintenance 7 26 Part B Owner Checks and Services 7 31 Part C Recommended Fluids and Lubricants 7 34 Part D Maintenance Record ...

Page 272: ...nt Improper vehicle maintenance can even affect the quality of the air we breathe Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle To help protect our environment and to keep your vehicle in good condition please maintain your vehicle properly Maintenance Requirements Maintenance intervals checks inspections and recommended fluids and lubrican...

Page 273: ...r tools and equipment for the job If you have any doubt have a qualified technician do the work Ifyouwanttogettheserviceinformation see Serviceand Owner Publications in the Index Part B Owner Checks and Services tells you what should be checked and when It also explains what you can easily do to help keep your vehicle in good condition Part C Recommended Fluids and Lubricants lists some recommende...

Page 274: ... needs you ll know that GM trained and supported service people will perform the work using genuine GM parts The proper fluids and lubricants to use are listed in Part C Make sure whoever services your vehicle uses these All parts should be replaced and all necessary repairs done before you or anyone else drives the vehicle This schedule is for vehicles that D carry passengers and cargo within rec...

Page 275: ... will indicate that a change is necessary The Footnotes at the end of this Maintenance Schedule further explain maintenance services If the vehicle has a CaterpillarR diesel engine see the CaterpillarR Diesel Engine Operation Maintenance Manual for supplemental engine maintenance information 100 Miles 160 km j Wheel stud nut service 45 500 Miles 800 km j Wheel stud nut service 45 1 000 Miles 1 600...

Page 276: ...onths whichever occurs first 1 2 6 12 000 Miles 20 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 j Hydr...

Page 277: ...ths whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Inspect door hinge pins and bushings and replace as necessary Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic brake caliper service or every 6 months whichever occurs first 2...

Page 278: ...irst 18 j Clutch pedal free travel service 10 j Throttle linkage service 19 j Thermostatically controlled engine cooling fan service 4 20 j Shields and underhood insulation service 4 5 21 j Air intake system service or every 24 months whichever occurs first 4 5 24 j Evaporative Control System service if equipped or every 24 months whichever occurs first 3 26 j Rear axle air shift motor service 11 ...

Page 279: ... whichever occurs first 39 j Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic parking brake service or every 6 months whichever occurs first 8 j Clutch pedal free travel service 10 j Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 33 000 Miles ...

Page 280: ... leaks or every month or every 300 hours whichever occurs first j Clean air brake application valve or every 3 months or every 300 hours whichever occurs first lubricate linkage 39 000 Miles 65 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 42 000 Miles 70 000 km ...

Page 281: ... 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Lubricate door hinge pins and rollers with engine oil j Wheel bearing grease type service or every 24 months whichever occurs first and whenever hubs are removed 23 j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic parking brake service or every 6 months whi...

Page 282: ...3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Inspect door hinge pins and bushings and replace if necessary Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic brake caliper service or ...

Page 283: ...gine oil j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic parking brake service or every 6 months whichever occurs first 8 j Engine drive belts service or every 12 months whichever occurs first 18 j Clutch pedal free travel service 10 j Throttle linkage service 19 j Thermostatically controlled engine cooling fan service 4 20 j Shields a...

Page 284: ...fluid levels or every 3 months whichever occurs first 1 2 6 72 000 Miles 120 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Inspect door hinge pins and bushings and replace as necessary Lu...

Page 285: ...heck air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first j Clean air brake application valve or every 3 months or every 300 hours whichever occurs first lubricate linkage j Air brake chamber service or every 2 months whichever occurs first 41 j Trailer brake hand control valve service or every 3 months or 900 hours whichever occurs first 42 ...

Page 286: ...bearings service Eaton Axle oil filled orevery24months whicheveroccursfirst 23 47 84 000 Miles 140 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Lubricate door hinge pins and rollers with...

Page 287: ...e 16 j Exhaust system service or every 6 months whichever occurs first 3 4 17 j Air brake service or every 6 months whichever occurs first 39 j Inspect door hinge pins and bushings and replace as necessary Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 j Hydraulic brake service or every 6 months whichever occurs first 7 j Hydraulic brake caliper service or ever...

Page 288: ...s first 18 j Clutch pedal free travel service 10 j Throttle linkage service 19 j Thermostatically controlled engine cooling fan service 4 20 j Shields and underhood insulation service 4 5 21 j Air intake system service or every 24 months whichever occurs first 4 5 24 j Evaporative Control System Service if equipped orevery24months whicheveroccursfirst 3 26 j Rear axle air shift motor service 11 j ...

Page 289: ...4 150 000 Miles 240 000 km j Cooling system service or every 60 months since last service whichever occurs first 3 35 200 000 Miles 320 000 km j Remove disassemble clean and inspect the air brake trailer supply valve or every 2 years or 7 200 hours whichever occurs first 250 000 Miles 400 000 km j Wheel bearings service Eaton Axle oil filled orevery36months whicheveroccursfirst 23 48 j Rear axle s...

Page 290: ...ly 7 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 Check brake pedal for excessive free play or travel or every 6 months whichever occurs first and have serviced if needed Check brakes more often if driving habits and conditions result in frequent braking 8 Inspect hydraulic parking brake drum and...

Page 291: ...cross shaft and clutch pedal springs Lubricate suspension axle and steering linkage more often when operating under dusty or muddy conditions and in excessive off road use 13 Check steering system D Look for damaged loose or missing parts Also look for parts showing signs of wear or lack of lubrication Replace parts as needed Also check steering gear mounting bolts pitman arm nut gear housing uppe...

Page 292: ...ts including throttle return springs interference or binding Fix any problems at once Do not lubricate accelerator and cruise control cables 20 With the engine off and below normal operating temperature check to see that the thermostatically controlled engine cooling fan can be rotated by hand on viscous operated drives Replace as needed 21 Check shields and underhood insulation for damage or loos...

Page 293: ... the fuel tank fuel cap and fuel lines for damage which could cause leakage Inspect fuel cap and gasket for any damage Check fuel cap gasket for even filler neck imprint Replace parts as needed 31 Check EGR system as described in the service manual See Service and Owner Publications in the Index 32 Inspect Electronic Vacuum Regulator Valve EVRV filter for excessive contamination or plugging If nee...

Page 294: ... The spring brake section of the rear brake diaphragms are non serviceable D Replace the air compressor filter element mounted on the air compressor For remote air compressor intake service refer to air cleaner filter replacement 40 Clean and lubricate air brake automatic slack adjuster Check pushrod travel and auto adjustment operation Have serviced if needed 41 Air brake chamber service Check op...

Page 295: ... km after each time the wheel is removed See Tightening the Wheel Nuts in the Index 47 Service is required now if you operate under any of these Short Trip City conditions D Most trips are less than 5 to 10 miles 8 to 16 km This is particularly important when outside temperatures are below freezing D Most trips are through dusty areas D You frequently tow a trailer D The vehicle is operated at or ...

Page 296: ...per oil if necessary See Engine Oil in the Index for further details Engine Coolant Level Check Check the engine coolant level and add DEX COOLR coolant mixture if necessary See Engine Coolant in the Index for further details Windshield Washer Fluid Level Check Check the windshield washer fluid level in the windshield washer tank and add the proper fluid if necessary See Windshield Washer Fluid in...

Page 297: ...door weatherstrips and rubber cab bumpers should also be lubricated Part C tells you what to use More frequent lubrication may be required when exposed to a corrosive environment Parking Brake Check Park on a fairly steep hill and hold the vehicle with the parking brake only This checks holding ability Starter Switch Check CAUTION When you are doing this check the vehicle could move suddenly If it...

Page 298: ...essure and check system for leaks Any of these conditions could indicate the need for brake system inspection and or service Engine Cooling System Service Inspect the hoses and have them replaced if they are cracked swollen or deteriorated Inspect all pipes fittings and clamps replace as needed Clean the outside of the radiator and air conditioning condenser To help ensure proper operation a press...

Page 299: ...backup lamps and hazard warning flashers Have headlamp aim checked at once if beams seem improperly aimed Glass Mirrors Lamps and or Reflectors Condition Check Look for broken scratched dirty or damaged glass mirrors lamps or reflectors that could reduce the view or visibility or cause injury Replace clean or repair promptly Door Latches Check Check that doors close latch and lock tightly Check fo...

Page 300: ... frame should be loosened before being flushed Engine Cover Check Check that the cab s engine cover and seal if equipped are not torn or damaged Be sure that the cover is bolted down firmly to the floor At Least Once a Year Key Lock Cylinders Service Lubricate the key lock cylinders with the lubricant specified in Part C Underbody Flushing Service At least every spring use plain water to flush any...

Page 301: ...R Operation Maintenance Manual for Engine Oil recommendations USAGE FLUID LUBRICANT Engine Coolant GM Gasoline Engine 50 50 mixture of clean drinkable water and use only GM GoodwrenchR DEX COOLR or HavolineR DEX COOLR Coolant See Engine Coolant in the Index Engine Coolant Caterpillar Diesel Engine See the CaterpillarR Operation Maintenance Manual for Engine Coolant recommendations Hydraulic Brake ...

Page 302: ...stem Alcohol Evaporator Commercial grade of Methyl Alcohol as specified in GM 6015 M USAGE FLUID LUBRICANT Power Steering System GM Power Steering Fluid GM Part No 1052884 1 pint 1050017 1 quart or equivalent Manual Transmission Synthetic Manual Transmission Fluid GM Part No 12345724 is the recommended lubricant to use Automatic Transmission See the Allison Transmission Operator s Manual for corre...

Page 303: ...um Duty Trucks GM Part No 12345841 or equivalent Rear Axle Shift Motor Lubricant Refrigerant Oil GM Part No 5416939 USAGE FLUID LUBRICANT Propshafts and Splines Wheel Bearing Lubricant meeting requirements of NLGI 2 Category GC or GC LB GM Part No 1051344 or equivalent Cab Door Hinges and Latches Multi Purpose Lubricant SuperlubeR GM Part No 12346241 or equivalent Weatherstrip Conditioning Dielect...

Page 304: ...he maintenance record charts provided here Any additional information from Owner Checks and Services can be added on the following record pages Also you should retain all maintenance receipts Your owner information portfolio is a convenient place to store them Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED ...

Page 305: ...7 35 Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED ...

Page 306: ...7 36 Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED ...

Page 307: ...ort any safety defects 8 2 Customer Satisfaction Procedure 8 3 Customer Assistance for Text Telephone TTY Users 8 3 Customer Assistance Offices 8 5 Roadside Assistance 8 5 Warranty Information 8 6 Reporting Safety Defects to the United States Government 8 6 Reporting Safety Defects to the Canadian Government 8 7 Reporting Safety Defects to General Motors 8 7 Ordering Owner Publications in Canada ...

Page 308: ...STEP ONE Discuss your concern with a member of dealership management Normally concerns can be quickly resolved at that level If the matter has already been reviewed with the sales service or parts manager contact the owner of the dealership or the general manager STEP TWO If after contacting a member of dealership management it appears your concern cannot be resolved by the dealership without furt...

Page 309: ...oncern Customer Assistance for Text Telephone TTY Users To assist customers who are deaf hard of hearing or speech impaired and who use Text Telephones TTYs Chevrolet has TTY equipment available at its Customer Assistance Center Any TTY user can communicate with Chevrolet by dialing 1 800 833 CHEV 1 800 833 2438 TTY users in Canada can dial 1 800 263 3830 Customer Assistance Offices Chevrolet enco...

Page 310: ...Customer Communication Centre 169 007 1908 Colonel Sam Drive Oshawa Ontario L1H 8P7 Telephone 905 644 4112 Fax 905 644 4866 Caribbean Numbers 1 800 496 9992 English Puerto Rico 1 800 496 9993 Spanish Puerto Rico 1 800 751 4135 English Dominican Republic 1 800 751 4136 Spanish Dominican Republic 1 800 496 9994 U S Virgin Islands 1 800 389 0009 Bahamas 1 800 534 0122 Bermuda Barbados Antigua B V I I...

Page 311: ...vices can also be arranged for situations such as retrieving locked in keys changing a tire or delivering gasoline at a charge to the owner We also provide dealer information at no charge such as location of the nearest authorized medium duty GM Truck dealer and their hours of operation Roadside Assistance is available 24 hours a day 7 days a week 365 days a year including weekends and holidays Sh...

Page 312: ...nnot become involved in individual problems between you your dealer or General Motors To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in the Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the hotline REPORTING SAFETY DEFECTS TO THE ...

Page 313: ...er P O Box 436008 Pontiac MI 48343 6008 In Canada please call us at 1 800 263 3777 English or 1 800 263 7854 French Or write General Motors of Canada Limited Customer Communication Centre 163 005 1908 Colonel Sam Drive Oshawa Ontario L1H 8P7 Ordering Owner Publications in Canada Owner s manuals are available for purchase for all current and past model General Motors vehicles The toll free telephon...

Page 314: ...n about the vehicle The owner s manual will include the Maintenance Schedule for all models In Portfolio Includes a Portfolio Owner s Manual and Warranty Booklet RETAIL SELL PRICE 20 00 Without Portfolio Owner s Manual only RETAIL SELL PRICE 15 00 CURRENT PAST MODEL ORDER FORMS Service Publications are available for current and past model GM vehicles To request an order form please specify year an...

Page 315: ... 00 2000 50 00 2000 20 00 2000 15 00 TOTAL MATERIAL Michigan Purchasers U S Order Processing 6 00 Canadian Postage GRAND TOTAL add 6 sales tax See Note Below GM CHE ORD99 Prices are subject to change without notice and without incurring obligation Allow ample time for delivery Note to Canadian Customers All listed prices are quoted in U S funds Canadian residents are to make checks payable in U S ...

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