Chevrolet 2005 T-Series Owner'S Manual Download Page 187

Page: 187 / 288

Item Number

Item

Remarks

Brake Camshaft***

Brake Caliper Rails$

One fitting each (apply sparingly).

For caliper rails, apply Aero Shell #5 Lubricant.

Steering Column Slip Joint**

One fitting.

Steering Drag Link Ends

One fitting each end.

Steering Column U-Joints

One fitting each joint.

Pivot Points and Hinges

Apply chassis lubricant.

Slack Adjuster***

One fitting.

Brake Cam Roller Pins***

Apply engine oil.

Front Steering Knuckles

One fitting each side, lower bushing.

(Hand-operated grease gun only.)

Hand-pack upper bearing.

Front Wheel Bearings*

Hand-pack or lubricate.

Steering Tie Rod Ends

One fitting each end.

Spring Slip Pads** (Multi-leaf Only)

Apply chassis lubricant.

Clutch Release Bearing**

Cup or fitting.

Battery Terminal (except “ST” type)

Keep coated with petroleum jelly.

Parking Brake Bell Crank**, $

One fitting.

Transmission*

Fill to level of filler plug.

5-39

Summary of Contents for 2005 T-Series

Page 1: ...ing the Road and Your Vehicle 4 2 Towing 4 31 Service and Appearance Care 5 1 Service 5 3 Fuel 5 5 Checking Things Under the Hood 5 14 Rear Axle 5 47 Cab Tilting 5 48 Noise Control System 5 55 Windshield Wiper Blade Replacement 5 56 Other Service Items 5 57 Tires 5 59 Appearance Care 5 68 Vehicle Identification 5 77 Electrical System 5 77 Capacities and Specifications 5 85 Normal Maintenance Repla...

Page 2: ...t is needed while you are on the road If the vehicle is sold leave this manual in the vehicle How to Use This Manual Many people read the owner manual from beginning to end when they first receive their new vehicle If this is done it can help you learn about the features and controls for the vehicle Pictures and words work together in the owner manual to explain things Index A good place to quickl...

Page 3: ...ION 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 do not you or others could be hurt You will also find a circle with a slash through it in this book This safety symbol means Do Not Do Not do this or Do Not let this happen iii ...

Page 4: ...o warning labels on the vehicle They use the same words CAUTION or NOTICE Vehicle Symbols The vehicle has components and labels that use symbols instead of text Symbols are shown along with the text describing the operation or information relating to a specific component control message gage or indicator If you need help figuring out a specific name of a component gage or indicator reference the f...

Page 5: ...These are some examples of symbols that may be found on the vehicle v ...

Page 6: ... NOTES vi ...

Page 7: ...egnancy 1 15 Right Passenger Position 1 16 Center Passenger Position 1 16 Safety Belt Extender 1 17 Child Restraints 1 18 Older Children 1 18 Infants and Young Children 1 20 Child Restraint Systems 1 24 Top Strap 1 27 Securing a Child Restraint in a Center Seat Position 1 27 Restraint System Check 1 29 Checking Your Restraint Systems 1 29 Replacing Restraint System Parts After a Crash 1 29 Section...

Page 8: ... Then release the lever and try to move the seat with your body to make sure the seat is locked into place To adjust the lower seat cushion forward or backward pull up on lever B and slide the cushion to where you want it Then release the lever 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...

Page 9: ...the vehicle is not moving Center Seat Your vehicle may have a center seat To fold the seatback down pull the lever located on the right side of the seat Then lower the seatback forward and push down firmly to lock in position A storage compartment is located on the rear of the seatback for use when the seatback is in the fully lowered position Push the lever on the right side of the seat and pull ...

Page 10: ...ed or killed In the same crash you might not be if you are buckled up Always fasten your 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 vehic...

Page 11: ...ve 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 are for adult truckers and anyone else who rides ...

Page 12: ...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 1 6 ...

Page 13: ...gers 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 1 7 ...

Page 14: ...ers can be hurt Being a good driver does not protect you from things beyond your control such as bad drivers Most accidents occur within 25 miles 40 km of home And the greatest number of serious injuries and deaths occur at speeds of less than 40 mph 65 km h Safety belts are for everyone How to Wear Safety Belts Properly This part is only for people of adult size Be aware that there are special th...

Page 15: ... let the belt go back slightly to unlock it Then pull the belt across you more slowly There is a clip on the lap portion of the lap shoulder belt Make sure this clip is not too close to the latch plate when you wear your safety belt so you can make the belt snug 4 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure If the belt is not long enoug...

Page 16: ... pelvic bones And you would 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 is a sudden stop or crash or if you pull the belt...

Page 17: ...oo loose It will not 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 1 11 ...

Page 18: ...an 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 1 12 ...

Page 19: ...eriously 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 are not as strong as shoulder bones You could also severely injure internal organs like your liver or spleen 1 13 ...

Page 20: ... across the body CAUTION You can be seriously injured by a twisted belt In a crash you would not 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 1 14 ...

Page 21: ...t women Like all occupants they are more likely to be seriously injured if they do not wear safety belts A pregnant woman should wear a lap shoulder belt and the lap portion should be 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 is more likely that the fetus will not be hurt in ...

Page 22: ...See Driver Position on page 1 9 Center Passenger Position Lap Belt If your vehicle has a center 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 1 16 ...

Page 23: ...the vehicle s safety belt will fasten around you you should use it But if a safety belt is not long enough your dealer will order you an extender It is free When you go in to order it take the heaviest coat you will wear so the extender will be long enough for you To help avoid personal injury do not let someone else use it and use it only for the seat it is made to fit The extender has been desig...

Page 24: ...ossible an older child should wear a lap shoulder belt and get the additional restraint a shoulder belt can provide The shoulder belt should not cross the face or neck The lap belt should fit snugly below the hips just touching the top of the thighs It should never be worn over the abdomen which could cause severe or even fatal internal injuries in a crash In a crash children who are not buckled u...

Page 25: ...elt 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 you m...

Page 26: ...child s pelvic bones in a crash Infants and Young Children Everyone in a vehicle needs protection This includes infants and all other children 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 Canadian province says children up to some age must be restrained whil...

Page 27: ... until a crash During a crash a baby will become so heavy it is not possible to hold it CAUTION Continued CAUTION Continued For example in a crash at only 25 mph 40 km h a 12 lb 5 5 kg baby will suddenly become a 240 lb 110 kg force on a person s arms A baby should be secured in an appropriate restraint 1 21 ...

Page 28: ...t will have a label saying that it meets federal motor vehicle safety standards The restraint manufacturer s instructions that come with the restraint state the weight and height limitations for a particular child restraint In addition there are many kinds of restraints available for children with special needs CAUTION Newborn infants need complete support including support for the head and neck T...

Page 29: ...cause serious or fatal injuries Young children always should be secured in appropriate child restraints We know securing a child can present real problems in a medium duty vehicle like yours The only place where you can properly secure a child restraint is the center seating position the place that has the lap belt only But your vehicle may not have a center seating position Or even if you have on...

Page 30: ... or position a child on a continuous flat surface Make sure that the infant s head rests toward the center of the vehicle A rear facing infant seat B provides restraint with the seating surface against the back of the infant The harness system holds the infant in place and in a crash acts to keep the infant positioned in the restraint 1 24 ...

Page 31: ...ces such as T shaped or shelf like shields A booster seat F G is a child restraint designed to improve the fit of the vehicle s safety belt system Some booster seats have a shoulder belt positioner and some high back booster seats have a five point harness A booster seat can also help a child to see out the window 1 25 ...

Page 32: ...t the child s body A shelf or armrest type shield has straps that are attached to a wide shelf like shield that swings up or to the side When choosing a child restraint be sure the child restraint is designed to be used in a vehicle If it is it will have a label saying that it meets federal motor vehicle safety standards Then follow the instructions for the restraint You may find these instruction...

Page 33: ...strap cannot be properly anchored Securing a Child Restraint in a Center Seat Position If your vehicle has a center seat you can secure a child restraint here You will be using the lap belt Be sure to follow the instructions that came with the child restraint Secure the child in the child restraint when and as the instructions say But do not use this position if the child restraint interferes with...

Page 34: ... be able to unbuckle the safety belt quickly if you ever had to 5 To tighten the belt pull its free end while you push down on the child restraint If you are 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 chil...

Page 35: ...e the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or even death in a crash To help make sure your restraint systems are working properly after a crash have them inspected and any necessary replacements made as soon as possible If you have had a crash do you need new belts After a very minor collision nothing ...

Page 36: ... NOTES 1 30 ...

Page 37: ...ift Control 2 14 Automatic Transmission Operation 2 14 Automatic Transmission Third Gear Hold 2 16 Manual Transmission Operation 2 16 Parking 2 18 Hydraulic Brakes Parking Brake Operation 2 18 Propshaft Brake Burnish Procedure 2 18 Parking Brake 2 19 Air Brake 2 20 Air Suspension 2 22 Parking Over Things That Burn 2 23 Engine Exhaust 2 23 Running Your Engine While You Are Parked 2 24 Mirrors 2 25 ...

Page 38: ... leave the keys in a vehicle with children One key operates all locks including the ignition switch The key has a code on it that tells your dealer or a qualified locksmith how to make extra keys Record and keep the key code in a safe place If you lose your key you ll be able to have a new one made easily using this code Notice If you ever lock your keys in your vehicle you may have to damage the ...

Page 39: ...ocked vehicles may be unable to get out A child can be overcome by extreme heat and can suffer permanent injuries or even death from heat stroke Always lock your vehicle whenever you leave it Outsiders can easily enter through an unlocked door when you slow down or stop your vehicle Locking your doors can help prevent this from happening A manual door lock is located above each door handle To lock...

Page 40: ...senger power window switches are located on each door Push the switch down to lower the passenger power window and pull the switch up to raise it The driver s door also has a LOCK button When the LOCK button is pressed down the passenger s window will not operate with either switch Push LOCK again to return the passenger s power window to normal operation The lock button does not affect the driver...

Page 41: ...cleaned To open this window pull out on the latch at the rear of the window and swing the window open When closing the window push firmly at the latch to close completely CAUTION Never open the passenger side door glass with the ignition on You can be injured if the window linkage moves Open this glass only with the ignition off 2 5 ...

Page 42: ...n 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 Use the lowest gear you can when you start a loaded vehicle in motion and when going up hills to avoid overloading the engine Check and adjust engine and transmission fluid levels often and be sure tires are properly inflated for the load you are c...

Page 43: ...y turn the ignition key to START When the engine starts let go of the key Notice Holding your key in START for longer than 15 seconds at a time will cause your battery to be drained much sooner And the excessive heat can damage your starter motor Notice If the wait to start indicator stays on after starting your vehicle your vehicle may not run properly Have your vehicle serviced right away 3 If t...

Page 44: ...gine oil pressure is detected you will also hear a tone alarm The alarm and the light will remain on until the condition is fixed If the engine temperature or oil pressure condition worsens the tone alarm will increase in frequency If the system senses low engine oil coolant the alarm and the low coolant warning light will come on See Low Coolant Warning Light on page 3 31 for more information The...

Page 45: ...strictor valve located in the exhaust stream The valve closes to provide back pressure to the engine for the purpose of warming the engine quickly The exhaust restrictor operates while the engine is running while the vehicle is not moving while the accelerator brake and clutch pedals are not pressed on a manual transmission vehicle while idling or driving in cold temperatures when the shift lever ...

Page 46: ... system check If the light comes on and then goes off and you know your batteries are charged but your engine still will not start your vehicle needs service If the light does not come on when the engine is cold your vehicle needs service If your batteries do not have enough charge to start your engine see Battery on page 5 41 Battery for more information Be sure you have the right oil for your en...

Page 47: ...re information If you have air brakes the dual needle air pressure gage should read at least 115 psi 790 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 See Brake System Warning Light on page 3 27 for more information If the pressure does not build up or drops during warm up stop...

Page 48: ...f the engine coolant heater when the temperature is at or above 0 F 18 as noted on the cord To Use the Engine Coolant Heater 1 Turn off the engine 2 Find the cord on the drivers side in the engine compartment 3 Plug it into a normal grounded 110 volt AC outlet CAUTION Plugging the cord into an ungrounded outlet could cause an electrical shock Also the wrong kind of extension cord could overheat an...

Page 49: ... See Exhaust Brake Indicator Light on page 3 35 for more information 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 exceed 2550 rpm If you have an automatic transmission and press this button the transmission will downshift to a factory d...

Page 50: ...rmally On the highway with the rear axle in low range and the transmission in top gear you may shift the rear axle to high range by raising the switch and releasing the accelerator momentarily Reapply the accelerator after you shift Under light load conditions first shift the rear axle into the high range with the vehicle at a standstill and then operate the transmission normally Automatic Transmi...

Page 51: ...ld lose control and hit people or objects Do not shift into a drive gear while your engine is running at high speed Overdrive Defeat If your vehicle has this feature you can select to limit the transmission to fourth gear This may be useful when operating at a higher Gross Vehicle Weight GVW or where operating conditions do not require fifth gear The overdrive defeat button is located in the instr...

Page 52: ...tch and listen for an engine speed drop of about 100 rpm At this point the clutch is engaging so you should increase the engine speed and fully engage the clutch Notice If you increase the engine speed before the clutch is fully engaged you could damage your transmission Always allow the clutch to fully engage before increasing engine speed Six Speed Transmission The transmission has gears that au...

Page 53: ...peed match When downshifting accelerate the engine until the engine rpm and road speed match Then quickly disengage the clutch and move the shift lever to the next gear position and engage the clutch Clutch Brake Vehicles with Non Synchronized Transmission A clutch brake is used to stop transmission input shaft rotation so that FIRST 1 or REVERSE R gear selection can be initiated when the vehicle ...

Page 54: ...ydraulic Brakes Parking Brake Operation If your vehicle has hydraulic brakes it has a parking brake lever The lever is located in the center console Your vehicle may also be equipped with an automatic transmission which has a center console shift lever This lever will have a PARK P position on the shift indicator Even when PARK P is selected be sure to apply the parking brake firmly so the vehicle...

Page 55: ...dure on page 2 18 for more information If your parking brake does not hold the vehicle when applied see your dealer to adjust your parking brake properly To release the parking brake first push down the regular brake pedal Then while pressing in the release button push the parking brake lever all the way down and shift the transmission to NEUTRAL The park brake light will stay on if the parking br...

Page 56: ...cles have two air brake controls They look like this CAUTION When the yellow PARKING BRAKE and the red TRAILER AIR SUPPLY knobs are both pushed in your rig will be free to move It could strike someone or something When both of these knobs are pushed in hold the regular brake pedal down to keep your rig from moving To charge a trailer s air brake system do the following 1 Move your vehicle into the...

Page 57: ...of these controls while you are driving unless you have to make an emergency stop If the air pressure drops below 60 to 70 psi 413 to 482 kPa the primary brake light and warning buzzer will come on If the air pressure drops to 35 to 45 psi 241 to 310 kPa the red trailer air supply knob will automatically pop out and apply the spring brakes on the trailer If the air pressure drops to 35 to 45 psi 2...

Page 58: ...ies single axle air suspension you may have this control The air suspension dump control allows the operator to lower the deck height approximately 4 5 inches 11 5 cm from the normal frame height The switch to deflate and inflate the air suspension is located in the instrument panel Press the bottom of the switch to deflate the air suspension and lower the deck height Press the top of the switch t...

Page 59: ...nconsciousness and death You might have exhaust coming in if Your exhaust system sounds strange or different Your vehicle gets rusty underneath Your vehicle was damaged in a collision Your vehicle was damaged when driving over high points on the road or over road debris Repairs were not done correctly Your vehicle or exhaust system had been modified improperly If you ever suspect exhaust is coming...

Page 60: ... in a garage with the engine running Another closed in place can be a blizzard See Winter Driving on page 4 24 CAUTION It can be dangerous to get out of your vehicle if the automatic transmission shift lever is not fully in PARK P with the parking brake firmly set Your vehicle can roll Do not leave your vehicle when the engine is running unless you have to If you have left the engine running the v...

Page 61: ...ally are If you cut too sharply into the right or left lane you could hit a vehicle Check your regular outside mirrors or your inside mirror if you have one before changing lanes The vehicle may have convex mirrors that are curved which allows more to be seen from the driver s seat A convex mirror can make things look farther away than they really are Outside Heated Mirrors If the vehicle has this...

Page 62: ...driver s and passenger s seats To open push down on the inner button and lift the compartment doors all the way up to lock in position Be sure the doors are securely closed before moving the vehicle Center Seat Storage A storage compartment is located behind the seatback in the center seat 2 26 ...

Page 63: ...he handle located on the passenger side to fold the seat all the way forward To open squeeze both sides of the latch Center Console Storage Area There are additional storage areas for small items in the center console to the right of the driver s seat 2 27 ...

Page 64: ... NOTES 2 28 ...

Page 65: ...3 16 Ashtrays and Cigarette Lighter 3 17 Climate Controls 3 17 Climate Control System 3 17 Outlet Adjustment 3 19 Passenger Compartment Air Filter 3 20 Warning Lights Gages and Indicators 3 21 Instrument Panel Cluster 3 22 Speedometer and Odometer 3 23 Trip Odometer 3 23 Tachometer 3 23 Engine Speed Limiter 3 23 Safety Belt Reminder Light 3 24 Safety Belt Reminder Tone 3 24 Airbag Readiness Light ...

Page 66: ...rake Indicator Light 3 35 Differential Lock Indicator Light 3 35 Reduced Engine Power Light 3 36 Highbeam On Light 3 36 Daytime Running Lamps DRL Indicator Light 3 37 Check Gages Warning Light 3 37 Fuel Gage 3 38 Water in Fuel Warning Light 3 38 Air Pressure Gage 3 39 Hourmeter Gage 3 39 Audio System s 3 40 Setting the Time 3 40 AM FM Radio 3 41 Radio with Cassette 3 44 Radio Reception 3 48 Care o...

Page 67: ... NOTES 3 3 ...

Page 68: ...Instrument Panel Overview 3 4 ...

Page 69: ... on page 2 13 I High Idle Button See Manual High Idle System under Starting Your Diesel Engine on page 2 7 J Heated Mirror Switch See Outside Heated Mirrors on page 2 25 K Front Panel Release See Lifting the Front Panel on page 5 54 L Tilt Steering Column See Tilt Wheel on page 3 6 M Horn See Horn on page 3 6 N Air Brake Controls If Equipped See Air Brake on page 2 20 O Audio System See Audio Syst...

Page 70: ... what position your key is in and even if the key isn t in When the hazard warning flashers are on your turn signals won t work The hazard warning flashers will not flash if the brakes are applied Other Warning Devices If you carry reflective triangles you can set them up at the side of the road about 300 feet 100 m behind your vehicle Horn Sound the horn by firmly pressing the pad in the center o...

Page 71: ... way down Turn Signal Multifunction Lever The multifunction lever located on the left side of the steering column includes the following Turn and Lane Change Signals See Turn and Lane Change Signals on page 3 8 Headlamp High Beam Low Beam Changer See Headlamp High Low Beam Changer on page 3 8 Flash to pass See Flash to Pass on page 3 8 Headlamps See Headlamps on page 3 13 Cruise Control if equippe...

Page 72: ...turn check for burned out bulbs and a blown fuse See Fuses and Circuit Breakers on page 5 78 Headlamp High Low Beam Changer 3 Headlamp High Low Beam Changer To change the headlamps from low to high beam push the multifunction lever toward the instrument panel To return to low beam headlamps pull the multifunction lever toward you Then release it While the high beams are on this indicator light on ...

Page 73: ...er the delay will be LO Low Turn the knob to this setting to operate the windshield wipers at a low speed HI High Turn the knob to this setting to operate the windshield wipers at a high speed Be sure to clear ice and snow from the wiper blades before using them If they are frozen to the windshield carefully loosen or thaw them If your blades do become worn or damaged get new blades or blade inser...

Page 74: ...or more without keeping your foot on the accelerator Cruise control does not work at speeds below about 25 mph 40 km h If you have an automatic transmission and you apply your brakes the cruise control will shut off If you have a manual transmission and you apply your brakes or push the clutch pedal the cruise control will shut off CAUTION Cruise control can be dangerous where you cannot drive saf...

Page 75: ... set the cruise control speed RESUME Move the band to this position to resume the set speed CAUTION If you leave your cruise control on when you are not using cruise you might hit a button and go into cruise when you do not want to You could be startled and even lose control Keep the cruise control switch off until you want to use cruise control 1 Press the AUTO CRUISE button to turn the cruise co...

Page 76: ... accelerator pedal You will now cruise at the higher speed Turn the band on the multifunction lever to the RESUME position Hold it there until you get up to the speed you want and then release it To increase your speed in very small amounts turn the band on the multifunction lever to the RESUME position and release it Each time you do this your vehicle will go about 1 mph 1 6 km h faster Reducing ...

Page 77: ... Memory When you turn off the ignition your cruise control set speed memory is erased Headlamps The multifunction lever operates the exterior lamps O Exterior Lamps Turn the band on the multifunction lever with this symbol to operate the exterior lamps The exterior lamp band has three positions OFF Turn the band to this position to turn off all lamps except the daytime running lamps DRL Parking La...

Page 78: ...fore sunset Fully functional daytime running lamps are required on all vehicles first sold in Canada The DRL system will make your headlamps come on at reduced brightness when the following conditions are met The ignition is on The headlamp band is in the OFF position The parking brake is released When the DRL are on only your low beam headlamps will be on The exterior lamps and instrument panel w...

Page 79: ...l Brightness If your vehicle has this feature the knob is located on the lower right of the instrument panel Turn the knob counterclockwise to brighten the instrument panel lights or clockwise to dim them Dome Lamps The dome lamp switch can be set to three different positions DOOR OFF and ON When the switch is set to DOOR the dome lamp will come on only when the driver s door is open If the switch...

Page 80: ...icle to learn more about this switch or see your dealer for more information Auxiliary Power Jacks If your vehicle has these power jacks you will find them in the console to the right of the driver s seat These jacks provide 12 volt power so you can operate things such as a citizen s band CB radio or a cellular phone You will see positive red and negative black outlets They are protected by a 15 a...

Page 81: ...t go When it s ready it will pop back out by itself Notice Holding a cigarette lighter in while it is heating will not allow the lighter to back away from the heating element when it is hot Damage from overheating may occur to the lighter or heating element or a fuse could be blown Do not hold a cigarette lighter in while it is heating Do not use anything other than the cigarette lighter in the he...

Page 82: ...This mode can also be used to keep outside air odors and dust from entering your vehicle A C Air Conditioning If your vehicle has this feature you can use your air conditioner by selecting one of the mode buttons selecting a fan speed and pressing the A C button On hot days open the windows to let hot inside air escape then close them This helps to reduce the time it takes for your vehicle to cool...

Page 83: ... this button to direct most of the air to the windshield and the side window outlets with some air directed to the floor outlets In this mode the system will automatically turn off recirculation and run the air conditioning compressor unless the outside temperature is at or below freezing Recirculation cannot be selected while in the defrost mode Outlet Adjustment The air outlets are located in th...

Page 84: ... compartment air filter can be accessed from the outside of the vehicle on the front passenger side It is concealed by the front access panel Pull the latch inside the cab on the driver s side of the vehicle to open the front access panel To inspect and clean the passenger compartment air filter use the following steps 1 Pull the tab located at the bottom of the screen 2 Pull the tab and remove th...

Page 85: ...ages 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 alarmed when this happens Gages can indicate when there may be or is a problem with one of your vehicle s functions Often gages and warning lights work together to let you know when there s a problem with your vehicle When one of the warnin...

Page 86: ...luster is designed to let you know at a glance how your vehicle is running You ll know how fast your going about how much fuel is left and many other things you ll need to drive safely and economically United States version shown Canada similar 3 22 ...

Page 87: ...e reset button located to the right of the trip odometer to toggle between the trip odometer and the regular odometer Holding the reset button for two seconds while the engine is running and the trip odometer is displayed will reset it To display the odometer reading with the ignition off press the reset button The hourmeter gage is accessed through the trip odometer for more information see Hourm...

Page 88: ...ight will also come on and stay on for several seconds Safety Belt Reminder Tone If your vehicle has this feature when you turn your key to ON or START a tone will sound for several seconds to remind people to fasten their safety belts Airbag Readiness Light There is an airbag readiness light on the instrument panel which shows the airbag symbol The system checks the airbag s electrical system for...

Page 89: ...ere is a problem Charging System Light The charging system light may be located in the instrument panel cluster or with the auxiliary warning lights in the center of the instrument panel It should come on briefly when you turn on the ignition before the engine is running as a check to show that it is working If it stays on or comes on while you are driving have your vehicle checked right away You ...

Page 90: ... Light If your vehicle has an Allison automatic transmission certain transmission malfunctions will turn this light on This light is located with the auxiliary warning lights in the center of the instrument panel If this light comes on while you are driving do not use the transmission shift control or you may lose forward gears The computer for the transmission senses a problem and chooses a gear ...

Page 91: ... or air brakes Each system has different warning lights Hydraulic Brake System Warning Lights Vehicles with hydraulic brake systems have two brake system warning lights on the instrument panel If the BRAKE system warning light comes on it means that the fluid level in the master cylinder reservoir is low or there is another problem with your hydraulic brakes When it comes on you will also hear a w...

Page 92: ...loor It may take longer to stop If the BRAKE light is still on have the vehicle towed for service See Towing Your Vehicle on page 4 31 See Hydraulic Brake Systems under Braking on page 4 5 for further information Parking Brake Warning Light This light will also come on when you set the parking brake The light will stay on if your parking brake does not release fully Air Brake System Warning Light ...

Page 93: ...sounds stop as soon as you can You will not know how quickly the system is losing pressure so be aware that the parking brake may come on suddenly Anti Lock Brake System Warning Light This light should come on briefly when you start the engine if it does not have your vehicle fixed immediately If the light stays on or comes on when you re driving your vehicle needs service If the BRAKE or LOW AIR ...

Page 94: ...ave the system repaired immediately If an anti lock brake system equipped trailer is not connected this light is not functional Engine Coolant Temperature Gage This gage shows the engine coolant temperature If the gage pointer moves into the red area your engine coolant might have overheated and your engine may be too hot You should pull off the road stop your vehicle and turn off the engine as so...

Page 95: ...serviced as soon as you can This light may also come on if your vehicle is equipped with the automatic engine shutdown system and engine shutdown has begun Wait to Start Indicator This indicator in the center of the instrument panel will come on when the glow plug is on and the ignition key is in ON or START Wait until the indicator turns off before turning the ignition key to START When the tempe...

Page 96: ...light on after awhile your emission controls may not work as well your fuel economy may not be as good and your engine may not run as smoothly This could lead to costly repairs that may not be covered by your warranty Oil Pressure Gage The engine oil pressure gage on the lower right portion of your instrument panel cluster shows engine oil pressure in psi pounds per square inch or in kPa kilopasca...

Page 97: ...or changing engine oil Low Oil Level Light This light should come on as a check when you start your engine If the light fails to come on have it repaired as soon as possible so you will be aware when the oil level is low If this light comes on and stays on it means your engine is low on oil You need to check the oil level right away See Engine Oil on page 5 14 for further information Notice Lack o...

Page 98: ...r additional information on when to change engine oil for DURAMAX diesel engines see Engine Oil on page 5 14 To reset the change engine oil light see Engine Oil on page 5 14 Engine Overspeed Warning Light If your vehicle has this light it will come on if your engine is operating at too many revolutions per minute rpm It will also come on for a moment as a check when you start your engine If it com...

Page 99: ...ight will come on and stay on whenever the diesel engine exhaust brake or exhaust restrictor is active For more information see Diesel Engine Exhaust Brake on page 2 13 Differential Lock Indicator Light If your vehicle has this feature this light is located in the center of the instrument panel The light is on when the inter axle differential lock system is in use The light will come on momentaril...

Page 100: ... destination The performance may be reduced the next time the vehicle is driven The vehicle may be driven at a slower speed while the reduced engine power light is on but acceleration and speed may be limited Anytime the check engine light stays on the vehicle should be taken to an authorized GM dealer as soon as possible for service Highbeam On Light This light will illuminate when the headlamp h...

Page 101: ...minder to turn on your headlamps Check Gages Warning Light This light will come on as you re starting the engine just as a check If it ever comes on and stays on while you are driving however it means that either your engine coolant temperature gage or your engine oil pressure gage may be showing a reading in the warning zone When the check gages light comes on you will also hear a warning tone Th...

Page 102: ...e are four concerns of some operators None of these shows a problem with your fuel gage The gage moves a little when you turn a corner or speed up The gage doesn t go back to empty when you turn off the ignition At the gas station the pump shuts off before the gage reads full It takes a little more or less fuel to fill up than the gage indicated Water in Fuel Warning Light If your vehicle is equip...

Page 103: ... need to apply your brakes Hourmeter Gage To access the engine hourmeter gage press the trip odometer button three times The instrument panel cluster displays the accumulated engine run time hours using the reconfigurable odometer display The engine run time hours displays only when the ignition is in the LOCK or ACC Accessory position and the trip reset switch is pressed for about four seconds Wh...

Page 104: ...out which audio system is in your vehicle find out what your audio system can do and how to operate all of its controls Setting the Time AM FM Radio Press and hold the DISP button Press the up tuning button until the correct hour appears on the display Press the down tuning arrow until the correct minute appears on the display The time can be set with the ignition on or off See Using the Alarm und...

Page 105: ...second or longer The radio will seek to the next or previous station The radio will only seek stations with a strong signal that are in the selected band t Scan Press this button to scan radio stations The radio will go to a station play for a few seconds then go on to the next station Press this button again to stop scanning The radio will only scan stations with a strong signal that are in the s...

Page 106: ... numbered pushbutton is pressed the station that was set will return Setting the Tone Bass Treble TONE To adjust the bass turn the control ring behind the ON VOL knob counterclockwise To adjust the treble turn the control ring behind the ON VOL knob clockwise If a station is weak or noisy decrease the treble Adjusting the Speakers Balance Fade BAL Balance To adjust the balance between the right an...

Page 107: ... the same time every day 6 To turn the alarm off press the alarm button 7 To deactivate the alarm press the alarm button To check the time of the alarm press the DISP button Using the Wake Up Timer The wake up timer can be used to turn the radio on at a specific time without the key in the ignition 1 Press the DISP button until the alarm symbol appears on the display 2 Press the alarm button while...

Page 108: ...r a second or longer The radio will seek to the next or previous station The radio will only seek stations with a strong signal that are in the selected band t Scan Press this button to scan radio stations The radio will go to a station play for a few seconds then go on to the next station Press this button again to stop scanning The radio will only scan stations with a strong signal that are in t...

Page 109: ... numbered pushbutton is pressed the station that was set will return Setting the Tone Bass Treble TONE To adjust the bass turn the control ring behind the ON VOL knob counterclockwise To adjust the treble turn the control ring behind the ON VOL knob clockwise If a station is weak or noisy decrease the treble Adjusting the Speakers Balance Fade BAL Balance To adjust the balance between the right an...

Page 110: ... the same time every day 6 To turn the alarm off press the alarm button 7 To deactivate the alarm press the alarm button To check the time of the alarm press the DISP button Using the Wake Up Timer The wake up timer can be used to turn the radio on at a specific time without the key in the ignition 1 Press the DISP button until the alarm symbol appears on the display 2 Press the alarm button while...

Page 111: ...rd Reverse Press either arrow to either fast forward or reverse the tape depending on the direction of the tape as indicated on the display To stop fast forwarding or reversing press the other arrow PROG Program Press both arrows at the same time to play the other side of the tape An arrow will appear on the display to show the tape playing direction AM FM Press this button to switch between playi...

Page 112: ...n sound quality try a known good cassette to see if the tape or the tape player is at fault If this other cassette has no improvement in sound quality clean the tape player For best results use a scrubbing action non abrasive cleaning cassette with pads which scrub the tape head as the hubs of the cleaner cassette turn The recommended cleaning cassette is available through your dealer A non scrubb...

Page 113: ...ing 4 10 Off Road Recovery 4 12 Passing 4 12 Loss of Control 4 14 Driving at Night 4 15 Driving in Rain and on Wet Roads 4 16 City Driving 4 19 Freeway Driving 4 20 Highway Hypnosis 4 21 Hill and Mountain Roads 4 22 Winter Driving 4 24 If You Are Stuck In Sand Mud Ice or Snow 4 28 Rocking Your Vehicle to Get It Out 4 28 Tow Hooks 4 29 Loading Your Vehicle 4 29 Towing 4 31 Towing Your Vehicle 4 31 ...

Page 114: ... driving task Anything that distracts from the driving task such as concentrating on a cellular telephone call reading or reaching for something on the floor makes proper defensive driving more difficult and can even cause a collision with resulting injury Ask a passenger to help do things like this or pull off the road in a safe place to do them yourself These simple defensive driving techniques ...

Page 115: ...drinking depends upon four things The amount of alcohol consumed The drinker s body weight The amount of food that is consumed before and during drinking The length of time it has taken the drinker to consume the alcohol According to the American Medical Association a 180 lb 82 kg person who drinks three 12 ounce 355 ml bottles of beer in an hour will end up with a BAC of about 0 06 percent The pe...

Page 116: ...els above 0 05 percent Statistics show that the chance of being in a collision increases sharply for drivers who have a BAC of 0 05 percent or above A driver with a BAC level of 0 06 percent has doubled his or her chance of having a collision At a BAC level of 0 10 percent the chance of this driver having a collision is 12 times greater at a level of 0 15 percent the chance is 25 times greater The...

Page 117: ...e First you have to decide to push on the brake pedal That is perception time Then you have to bring up your foot and do it That is reaction time Average reaction time is about three fourths of a second But that is 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 d...

Page 118: ... you can safely get off the road The pedal will seem harder to push down Do not pump the pedal the system will not work well or at all that way You may find that the steering wheel seems hard to turn when you are turning and braking at the same time Also the primary brake warning light may come on and the warning tone may sound This is normal because the main hydraulic brake system and power steer...

Page 119: ...the wheels is about to stop rolling the computer will separately work the brakes at each wheel The anti lock system can change the brake pressure faster than any driver could The computer is programmed to make the most of available tire and road conditions This can help you steer around the obstacle while braking hard As you brake your computer keeps receiving updates on wheel speed and controls b...

Page 120: ... time In many emergencies steering can help you more than even the very best braking Trailer Brake Hand Control Valve If your vehicle has this control it is mounted on the console to the right of the driver s seat This control lets you apply the trailer brakes without applying the tractor brakes You can apply the trailer brakes a little or apply them all the way if you have to Use this control onl...

Page 121: ...is on the TCS is off and will not limit wheel spin Adjust your driving accordingly The light in the top of the TCS button will come on if the TCS is turned off by pressing the TCS on off button The light may also come on if a problem has been detected in either the traction control system or the anti lock brake system The traction control system automatically comes on whenever you start your vehic...

Page 122: ... condition of your tires and the road surface the angle at which the curve is banked and your speed While you are in a curve speed is the one factor you can control Suppose you are steering through a sharp curve Then you suddenly accelerate Both control systems steering and acceleration have to do their work where the tires meet the road Adding the sudden acceleration can demand too much of those ...

Page 123: ...hese First apply your brakes See Braking on page 4 5 It is better to remove as much speed as you can from a possible collision Then steer around the problem to the left or right depending on the space available 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 can turn it a full 180 degrees ve...

Page 124: ...und 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 with...

Page 125: ... start 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 If other cars are lined up to pass a slow vehicle wait your turn But take care that someone is not trying to pass you as you pull out to pass the slow vehicle Check your mirrors and sta...

Page 126: ...is system or if the system is off then an acceleration skid is also 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 will want to slow down and adjust your driving to these conditions It is important to slow down on slippery surfaces because stopping distance will be longer and vehicl...

Page 127: ...oad ahead In remote areas watch for animals If you are 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 you spend the...

Page 128: ...eatedly 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 is 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 are not even aware of it Driving in...

Page 129: ...in a quick stop and may cause pulling to one side You could lose control of the vehicle CAUTION Continued CAUTION Continued After driving through a large puddle of water or a vehicle wash apply your brake pedal lightly until your brakes work normally Hydroplaning Hydroplaning is dangerous So much water can build up under your tires that they can actually ride on the water This can happen if the ro...

Page 130: ...can be carried away As little as six inches of flowing water can carry away a smaller vehicle If this happens you and other vehicle occupants could drown Do not ignore police warning signs and otherwise be very cautious about trying to drive through flowing water Some Other Rainy Weather Tips Turn on your low beam headlamps and your marker and clearance lamps if your vehicle has them not just your...

Page 131: ... trip Larger vehicles cannot 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 Try to use the freeways that rim and crisscross most large cities You will save time and energy See Freeway Driving on page 4 20 Treat a green light as a warning signal A traffic light is there because...

Page 132: ...ine 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 to the posted limit or to the prevailing rate if it is slower Stay in the right lane unless you want to pass On some freeways larger vehicles are not allowed...

Page 133: ...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 Do not let it happen to you If it does your vehicle can leave the road in less than a second and you could crash and be injured What can you do about highway hypnosis First be aware that it can happen Then here...

Page 134: ...nd transmission These parts can work hard on mountain roads 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 do not shift down your brakes could get so hot that they would not work well You would then have poor braking or even none going down a hill You could cra...

Page 135: ...cool your engine and transmission and you can climb the hill better Stay in your own lane when driving on two lane roads in hills or mountains Do not swing wide or cut across the center of the road Drive at speeds that let you stay in your own lane 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 You may see highway signs on mountain...

Page 136: ...cloth 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 ...

Page 137: ...wn and adjust your driving to the road conditions Under certain conditions you may want to turn the traction control system off such as when driving through deep snow and loose gravel to help maintain vehicle motion at lower speeds See Traction Control System TCS on page 4 9 If you do not have a traction system accelerate gently Try not to break the fragile traction If you accelerate too fast the ...

Page 138: ...of you brake before you are on it Try not to brake while you are actually on the ice and avoid sudden steering maneuvers If You Are Caught in a Blizzard If you are stopped by heavy snow you could be in a serious situation You should probably stay with your vehicle unless you know for sure that you are near help and you can hike through the snow Here are some things to do to summon help and keep yo...

Page 139: ...t 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 ge...

Page 140: ...oo 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 If your vehicle has traction control you should turn the traction control system off See Traction Control System TCS on page 4 9 Then shift back and forth between REVERSE R and a ...

Page 141: ...in or cable snapping back Notice Never use tow hooks to tow the vehicle Your vehicle could be damaged and it would not be covered by warranty Loading Your Vehicle There is a vehicle specific GVW Rating label on your vehicle that shows how much weight it may properly carry It also shows the size of your original tires and the inflation pressures needed to obtain the gross weight capacity of your ve...

Page 142: ... life of your vehicle Using heavier suspension components to get added durability might not change your weight ratings Ask your dealer to help you load your vehicle the right way Notice Overloading your vehicle may cause damage Repairs would not be covered by your warranty Do not overload your vehicle If you put things inside your vehicle like suitcases tools packages or anything else they will go...

Page 143: ...ually compressed you will have no brakes Release your air operated parking brakes manually only to tow the vehicle Never drive the vehicle with the brakes released Consult your dealer or a professional towing service if you need to have your vehicle towed They can provide the right equipment and know how to tow it without damage See Roadside Assistance Program on page 7 6 Before you do anything tu...

Page 144: ...nt the possibility of the emergency brake being applied during towing On vehicles with hydraulic brakes release the parking brake fully by moving the lever to the fully released position Towing the Vehicle with the Front Bumper Removed 1 Remove the front bumper 2 Connect and lock the lift chains to the front axle outside of the spring anchor plates as shown 3 Connect the lift chains to the tow bar...

Page 145: ...tween the towing vehicle and the disabled vehicle Before Towing Block the wheels of the disabled vehicle On vehicles with air brakes release the emergency brake system by compressing the brake chamber springs as outlined in this section This is to prevent the possibility of the emergency brake being applied during towing On vehicles with hydraulic brakes release the parking brake fully by moving t...

Page 146: ...re disconnecting from the towing vehicle 3 Check and fill the rear axle with oil as required Releasing Air Operated Parking Brakes If your vehicle has air brakes you could have a special towing problem If your vehicle has to be towed because of a complete loss of air pressure from both systems the parking brakes will have automatically engaged The tow operator can release the brakes manually by us...

Page 147: ... brakes Follow the same procedure to release the other brake or brakes 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 Replace the stud and washer and tighten the nut into the side of the chamber 10 Replace...

Page 148: ...xt to the trailer wiring harness for use with a trailer The eight wire harness contains the following trailer circuits Yellow Left Stop Turn Signal Dark Green Right Stop Turn Signal Brown Taillamps White Ground Light Green Back up Lamps Light Blue CHMSL Red Battery Feed Dark Blue Trailer Brake Power Take Off PTO Your vehicle may be equipped with power take off PTO The PTO switch is located on the ...

Page 149: ...ic Clutch 5 23 Engine Coolant 5 24 Coolant Surge Tank Pressure Cap 5 26 Engine Overheating 5 27 Cooling System 5 29 Power Steering Fluid 5 32 Windshield Washer Fluid 5 33 Brakes 5 34 Battery 5 41 Jump Starting 5 42 Rear Axle 5 47 Rear Axle Shift Motor 5 48 Cab Tilting 5 48 Before You Tilt the Cab 5 48 Tilting the Cab 5 49 Lowering the Cab 5 52 Lifting the Front Panel 5 54 Noise Control System 5 55...

Page 150: ...ish Care 5 73 Windshield and Wiper Blades 5 73 Aluminum Wheels 5 74 Tires 5 74 Sheet Metal Damage 5 74 Finish Damage 5 75 Underbody Maintenance 5 75 Chemical Paint Spotting 5 75 Vehicle Care Appearance Materials 5 76 Vehicle Identification 5 77 Vehicle Identification Number VIN 5 77 Electrical System 5 77 Add On Electrical Equipment 5 77 Headlamp Wiring 5 77 Windshield Wiper Fuses 5 78 Fusible Lin...

Page 151: ...want to keep your GM vehicle all GM Genuine GM parts have one of these marks California Proposition 65 Warning Most motor vehicles including this one contain and or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Engine exhaust many parts and systems including some inside the vehicle many fluids and some component wear by products contai...

Page 152: ...ement parts and tools before you attempt any vehicle maintenance task Be sure to use the proper nuts bolts and other fasteners English and metric fasteners can be easily confused If you use the wrong fasteners parts can later break or fall off You could be hurt Two Safety Cautions about Engine Fan Breakage CAUTION Changing the Fan Drive Ratio or Engine Governed Speed If you change the fan drive ra...

Page 153: ...al could damage your fuel system and engine Your warranty would not cover this damage And Diesel fuel that has been mixed with engine oil or automatic transmission fluid could damage your engine and emission controls Aftermarket diesel fuel additives are not tested by General Motors Some additives particularly those which contain alcohol or water emulsifiers may damage your fuel system If you beli...

Page 154: ...ers Association EMA has identified properties of an improved diesel fuel for better engine performance and durability Diesel fuels corresponding to the EMA Recommended Guideline on Premium Diesel Fuel FQP 1A could provide better starting less noise and better vehicle performance If there are questions about the fuel you are using contact your fuel supplier Diesel fuel may foam when you fill your t...

Page 155: ...d performance excessive smoke and unpleasant odor At a minimum the diesel fuel you use should meet specifications CAN CGSB 3 517 2000 Low Sulfur Diesel in Canada In addition the Engine Manufacturers Association EMA has identified properties of an improved diesel fuel for better engine performance and durability FQP 1A Diesel fuels corresponding to the EMA description could provide better starting ...

Page 156: ...your fuel system may still need to be cleaned Your dealer can advise you of the appropriate solution If your fuel tank needs to be purged to remove water see your dealer or a qualified technician Improper purging can damage your fuel system Sometimes water can be pumped into your fuel tank along with your diesel fuel This can happen if a service station does not regularly inspect and clean its fue...

Page 157: ...and a large amount of water was possibly pumped into the fuel tank Fuel tank purging is required See your dealer for assistance Notice If you drive when this warning indicator is on you can damage your fuel injection system and your engine If the indicator comes on right after you refuel it means water was pumped into your fuel tank Turn off your engine immediately Then have the water drained at o...

Page 158: ...iming procedure See Fuel Priming following 10 Start your engine and check that there are no leaks If the water in fuel light comes on again after driving a short distance or if the engine runs rough or stalls a large amount of water has probably been pumped into the fuel tank The fuel tank should be purged Fuel Priming In order for the diesel engine fuel system to work properly the fuel lines must...

Page 159: ...nce becomes firm This may take from 20 to 100 times depending upon fuel tank location 7 Turn the fuel filter breather valve screw 2 left counterclockwise several turns to open the breather valve 8 Use the palm of your hand to repeatedly press and release the plunger 1 at the top of the fuel filter priming pump until fuel begins to seep from the breather valve 9 Tighten the fuel filter breather scr...

Page 160: ... seconds at a time until your engine starts If the engine tries to run but does not run smoothly increase the rpm a little using the accelerator pedal This will help force air through the system Filling Your Tank CAUTION Fuel vapor burns violently and a fuel fire can cause bad injuries To help avoid injuries to you and others read and follow all the instructions on the pump island Turn off your en...

Page 161: ...el cap turn it to the right clockwise until it is tight CAUTION If a fire starts while you are refueling do not remove the nozzle Shut off the flow of fuel by shutting off the pump or by notifying the station attendant Leave the area immediately Notice If you need a new fuel cap be sure to get the right type Your dealer can get one for you If you get the wrong type it may not fit properly This may...

Page 162: ...ce other than the ground Bring the fill nozzle in contact with the inside of the fill opening before operating the nozzle Contact should be maintained until the filling is complete Do not smoke while pumping gasoline Checking Things Under the Hood Engine Oil Checking Engine Oil It is a good idea to check your engine oil level every time you get fuel The engine oil dipstick is located behind the ca...

Page 163: ...per towel or a cloth then push it back in all the way 3 Remove the dipstick again keeping the tip down and check the oil level When to Add Engine Oil If the oil is at or below the lower hole at the tip of the dipstick then you will need to add at least one quart of oil But you must use the right kind This section explains what kind of oil to use For engine oil crankcase capacity see Capacities and...

Page 164: ... API designations such as API CI 4 SL These letters show American Petroleum Institute API levels of quality Notice If you use oil that does not have this designation CH 4 you can cause engine damage not covered by your warranty Notice Use only engine oils that have one of these designations CI 4 or CH 4 for the DURAMAX diesel engine Failure to use the recommended oils can result in engine damage n...

Page 165: ... the oil has been certified by the American Petroleum Institute You should look for this on the oil container and use only those oils that display this logo GM Goodwrench oil of the recommended viscosity grades meets all the requirements for your vehicle Engine Oil Additives Do not add anything to your oil The recommended oils with the API service symbol are all you will need for good performance ...

Page 166: ...m must be reset Your dealer has GM trained service people who will perform this work using genuine GM parts and reset the system It is also important to check your oil regularly and keep it at the proper level If the system is ever reset accidentally you must change your oil at 3 000 miles 5 000 km or 150 hours of engine operation whichever occurs first since your last oil change Remember to reset...

Page 167: ... oil products Used oil can be a threat to the environment If you change your own oil be sure to drain all the oil from the filter before disposal Never dispose of oil by putting it in the trash pouring it on the ground into sewers or into streams or bodies of water Instead recycle it by taking it to a place that collects used oil If you have a problem properly disposing of your used oil ask your d...

Page 168: ...0 000 km If you are driving in dusty dirty conditions inspect the filter at each engine oil change How to Inspect the Engine Air Cleaner Filter Locate the filter change indicator if equipped When the change indicator turns black or is in the red orange change zone replace the filter and reset the indicator To inspect the air cleaner filter remove the filter from the vehicle and lightly shake the f...

Page 169: ...ne with the air cleaner filter off can cause you or others to be burned The air cleaner not only cleans the air it helps to stop flame if the engine backfires If it is not there and the engine backfires you could be burned Do not drive with it off and be careful working on the engine with the air cleaner filter off Notice If the air cleaner filter is off a backfire can cause a damaging engine fire...

Page 170: ...t checked is when the engine oil is checked Refer to the Maintenance Schedule to find out when to check and change your manual transmission fluid See Scheduled Maintenance on page 6 5 How to Check and What to Use Check the fluid level only when your engine is off the vehicle is parked on a level place and the transmission is cool enough for you to rest your fingers on the transmission case To chec...

Page 171: ... a leak in the system Adding fluid will not correct a leak A fluid loss in this system could indicate a problem Have the system inspected and repaired When to Check and What to Use The hydraulic clutch fluid reservoir is located behind the front panel on the driver s side of the vehicle Refer to the Maintenance Schedule to determine how often you should check the fluid level in your clutch master ...

Page 172: ...engine heater core or radiator corrosion In addition the engine coolant may require changing sooner at 30 000 miles 50 000 km or 24 months whichever occurs first Any repairs would not be covered by your warranty Always use DEX COOL silicate free coolant in your vehicle What to Use Use a mixture of one half clean drinkable water and one half DEX COOL coolant which will not damage aluminum parts If ...

Page 173: ...Coolant The coolant surge tank pressure cap can be accessed without tilting the cab It is located behind the cab on the driver s side of the vehicle CAUTION Turning the surge tank pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle ...

Page 174: ...h Do not spill coolant on a hot engine When replacing the pressure cap make sure it is hand tight Coolant Surge Tank Pressure Cap The surge tank pressure cap is located behind the cab on the driver s side of the vehicle Notice Your vehicle s surge tank pressure cap is designed for use with medium duty cooling systems only If the surge tank pressure cap is not tightly installed coolant loss and pos...

Page 175: ... overheated engine can burn you badly even if you just open the hood Stay away from the 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 bur...

Page 176: ...road shift to PARK P or NEUTRAL and let the engine idle 2 Turn on your heater to full hot at the highest fan speed and open the windows as necessary 3 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 does not come back on you can drive normally If the warning continu...

Page 177: ...ot touch them If you do you can be burned Do not run the engine if there is a leak If you run the engine it could lose all coolant That could cause an engine fire and you could be burned Get any leak fixed before you drive the vehicle If there seems to be no leak start the engine again The engine cooling fan speed should increase when idle speed is doubled by pushing the accelerator pedal down If ...

Page 178: ...ed Never turn the cap when the cooling system including the coolant surge tank pressure cap is hot Wait for the cooling system and coolant surge tank pressure cap to cool if you ever have to turn the pressure cap CAUTION Adding only plain water to your cooling system can be dangerous Plain water or some other liquid such as alcohol can boil before the proper coolant mixture will Your vehicle s coo...

Page 179: ...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 left about one full turn 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 slowly and remove it 3 Fill the coolant surge tank with the proper mixture ...

Page 180: ...above the COLD FULL mark 5 Then replace the pressure cap Be sure the pressure cap is hand tight and fully seated Power Steering Fluid See Scheduled Maintenance on page 6 5 to determine 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 is not warm you probably will not get an accurate reading If the f...

Page 181: ...d be sure to read the manufacturer s instructions before use If you will be operating your vehicle in an area where the temperature may fall below freezing use a fluid that has sufficient protection against freezing Adding Washer Fluid Open the cap with the washer symbol on it Add washer fluid until the tank is full The reservoir is located behind the front panel on the driver s side of the vehicl...

Page 182: ...d Brake fluid could spill on the hot engine and it can catch fire You could be burned and your vehicle could be damaged See Checking Brake Fluid in this section 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 i...

Page 183: ...ps of mineral based oil such as engine oil in your brake system can damage brake system parts so badly that they will have to be replaced Do not let someone put in the wrong kind of fluid and do not use DOT 5 silicone brake fluid If you spill brake fluid on your vehicle s painted surfaces the paint finish can be damaged Be careful not to spill brake fluid on your vehicle If you do wash it off imme...

Page 184: ...linings wear down and you need new ones put in be sure you get new approved GM replacement parts If you do not your brakes 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 have come to expect can change in many other ways if someone puts in the...

Page 185: ...me rail Your dryer is a Bendix Westinghouse model that has a filter that you need to change at intervals See Scheduled Maintenance on page 6 5 for more about servicing this filter Electric Air Compressor Your vehicle may have an electric air compressor This compressor is used to run options that require pressurized air such as air horn air seat exhaust restrictor or an exhaust brake The air compre...

Page 186: ...Chassis Lubrication 5 38 ...

Page 187: ...Slack Adjuster One fitting 7 Brake Cam Roller Pins 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 lubricant 12 Clutch Release Bearing Cup or fitting 13 Battery Terminal exc...

Page 188: ...ies and larger lubricate with GM Part No 1051344 Wheel Bearing Lubricant 18 Rear Wheel Bearings Hand pack or lubricate 19 Rear Axle Fill to level of filler plug 20 Parking Brake Clevis Pin Apply chassis lubricant 21 Master Cylinder Fill 1 4 inch 6 mm below opening 22 Parking Brake Lever Pivot Apply chassis lubricant 23 Clutch Release Cross Shaft One fitting each Refer to Maintenance Schedule Appli...

Page 189: ...ter handling Vehicle Storage If you are not going to drive your vehicle for 25 days or more remove the black negative cable from the 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 are...

Page 190: ...em is not a 12 volt system with a negative ground both vehicles can be damaged Only use vehicles with 12 volt systems with negative grounds to jump start your vehicle In diesel engine vehicles with two batteries or more you may not be able to get enough power from a single battery in another vehicle to start your diesel engine especially in cold weather If your vehicle has more than one battery us...

Page 191: ...u will not see the batteries of your vehicle under the hood They are located in a frame mounted battery box on the passenger s side of the vehicle CAUTION Using a match near a battery can cause battery gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You do not need to add water to the ACDelco...

Page 192: ... Negative will go to a heavy unpainted metal engine part or to a remote negative terminal if the vehicle has one Do not connect positive to negative or you will get a short that would damage the battery and maybe other parts too And do not connect the negative cable to the negative terminal on the dead battery because this can cause sparks 6 Connect the red positive cable to the positive terminal ...

Page 193: ...inal on the vehicle with the dead battery 9 Connect the other end of the negative cable at least 18 inches 45 cm away from the dead battery but not near engine parts that move The electrical connection is just as good there and the chance of sparks getting back to the battery is much less 10 Now start the vehicle with the good batteries and run the engine for a while If your vehicle has the high i...

Page 194: ...te Negative Terminal B Good Battery or Remote Positive and Remote Negative Terminals C Dead Battery or Remote Positive Terminal To disconnect the jumper cables from both vehicles do the following 1 Disconnect the black negative cable from the vehicle that had the dead batteries 2 Disconnect the black negative cable from the vehicle with the good batteries 3 Disconnect the red positive cable from t...

Page 195: ...ving your vehicle through deep puddles or standing water If you must drive through water that is higher than the front or rear axle see your dealer immediately afterward to have the condition of the axle lubricant checked How to Check Lubricant To get an accurate reading the vehicle should be on a level surface If the level is below the bottom of the filler plug hole located on the rear axle you l...

Page 196: ...nance Schedule to determine what kind of lubricant to use See Part C Recommended Fluids and Lubricants on page 6 28 Cab Tilting Before You Tilt the Cab Most fluids and lubricants requiring regular checking can be accessed at the back of the cab If you need to gain access to components under the cab follow this entire procedure carefully Find a level place to tilt the cab Secure all loose articles ...

Page 197: ...e cab do the following 1 Locate the lever pin at the rear of the cab on the passenger s side 2 Turn the lever pin so that the tab is aligned with the slot Remove the lever pin 3 Move the primary tilt lever all the way down 5 49 ...

Page 198: ...4 Pull the secondary latch lever to release the hook from the catch at the back of the cab 5 Using the handle located at the bottom of the cab at the back tilt the cab forward 5 50 ...

Page 199: ...position could fall causing serious injury To ensure that the cab is securely locked in position and will not move the safety lock pin A must always be inserted into the cab support B when the cab is in the tilted position CAUTION Things that burn can get on hot engine parts and start a fire These include liquids like fuel oil coolant brake fluid windshield washer and other fluids and plastic or r...

Page 200: ...d follow the instructions below carefully Before lowering the cab be sure all filler caps ar on properly 1 Remove the safety lock pin from the cab support by turning it and pulling it out 2 Squeeze the lever on the cap support to release the detent 5 52 ...

Page 201: ...down 4 Push the primary tilt lever upward fully to lock the cab to the chassis 5 Reinstall the pin and turn it to keep the primary tilt lever from moving downward CAUTION An unsecured cab could move suddenly causing an accident or an injury Be sure the tilt cab is properly secured to the chassis before moving the vehicle 5 53 ...

Page 202: ...the bottom of the instrument panel and pull it toward you See Instrument Panel Overview on page 3 4 for more information on location of the release catch 2 Then go to the front of the vehicle and lift the panel at the center Use the prop rod to hold the panel open 3 To close the front panel remove the prop rod close the panel and push firmly on both sides to ensure that the panel is fully closed 5...

Page 203: ...repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below ...

Page 204: ... Year on page 6 24 for more information Replacement blades come in different types and are removed in different ways Here s how to remove the Shephard 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 5 56 ...

Page 205: ...Scheduled Maintenance on page 6 5 for recommended service intervals Primary Fuel Filter and Water Separator Your vehicle may have this spin on filter It is located on the driver s side frame rail It has a clear plastic drain bowl at the bottom Check the drain bowl occasionally for any water or particles To drain the water or to replace the element follow the water draining and element replacement ...

Page 206: ...the front or rear axle water may enter the axle housing and cause the axle lubricant to break down This could damage the gears inside Avoid driving your vehicle through deep water You should avoid driving your vehicle through deep puddles or standing water If you must drive through water that is higher than the front or rear axle see your dealer immediately afterward to have the condition of the a...

Page 207: ...ee your GM Warranty booklet for details For additional information refer to the tire manufacturer s booklet included with your vehicle s Owner s Manual CAUTION Poorly maintained and improperly used tires are dangerous Overloading your tires can cause overheating as a result of too much friction You could have an air out and a serious accident See Loading Your Vehicle on page 4 29 Underinflated tir...

Page 208: ...uch air over inflation you can get the following Unusual wear Poor handling Rough ride Needless damage from road hazards When to Check Check your tires once a month or more Also check the tire pressure of the spare tire if equipped How to Check Use a good quality pocket type gage to check tire pressure You can t tell if your tires are properly inflated simply by looking at them Radial tires may lo...

Page 209: ...properly inflated See Tires on page 5 59 and Inflation Tire Pressure on page 5 60 for more information on proper tire inflation When It Is Time for New Tires Replace your tires when the tread depth is down to 1 8 of an inch 3 2 mm for the front tires or 1 16 of an inch 1 6 mm for a rear tire Also you need a new tire if You can see cord or fabric showing through the tire s rubber The tread or sidew...

Page 210: ...nt abnormal tire wear If you notice unusual tire wear or your vehicle is pulling one way or the other the alignment may need to be reset If you notice your vehicle vibrating when driving on a smooth road your wheels may need to be balanced Tightening the Wheel Nuts CAUTION Wheel nuts that are not tight can work loose If all the nuts on a wheel come off the wheel can come off the vehicle causing a ...

Page 211: ...ht hand threads 1 With intermittent pilot pads position a pad at 12 o clock to center the wheel and reduce run out 2 Put the tire and rim assembly on the axle hub Install the outer 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 Hub Piloted Type 8 Hole Hub Piloted Type 10 Hole ...

Page 212: ...e nuts to 400 lb ft 542 Y if an 8 hole stud or 480 lb ft 650 Y if a 10 hole stud using the following diagrams CAUTION Never use oil or grease on studs or the threads of the wheel nuts If you do the wheel nuts might come loose and the wheel could fall off causing a crash 8 Hole 10 Hole Front 10 Hole Rear 5 64 ...

Page 213: ...s hubs wheel nuts or wheels be sure to use GM original equipment parts CAUTION Rust or dirt on a wheel or on the parts to which it is fastened can make wheel nuts become loose after a time The wheel could come off and cause a crash When you change a wheel remove any rust or dirt from places where the wheel attaches to the vehicle In an emergency you can use a cloth or a paper towel to do this but ...

Page 214: ...e other thing to try to stop the leaking Get a new wheel or 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 pressur...

Page 215: ...ly Steer to maintain lane position and then gently brake to a stop well out of the traffic lane A rear blowout particularly on a curve acts much like a skid and may require the same correction you d use in a skid In any rear blowout remove your foot from the accelerator pedal Get the vehicle under control by steering the way you want the vehicle to go It may be very bumpy and noisy but you can sti...

Page 216: ... off the wheel and checked for damage So if you re stopped somewhere by a flat or damaged tire or wheel you should get expert help See Roadside Assistance Program on page 7 6 Appearance Care Cleaning products can be hazardous Some are toxic Other cleaning products can burst into flames if a match is struck near them or if they get on a hot part of the vehicle Some are dangerous if their fumes are ...

Page 217: ...clean area often A soft brush may be used if stains are stubborn To avoid forming a ring on fabric after spot cleaning clean the entire area immediately or it will set Most stains can be removed with club soda water To clean use the following instructions 1 For liquids blot with a clean soft white cloth For solids remove as much as possible and then vacuum or brush 2 Apply club soda water to a cle...

Page 218: ... white cloth 7 If the cleaner leaves a ring effect follow up with the club soda water instructions given earlier in this section Special Fabric Cleaning Problems Stains caused by such things as catsup black coffee egg fruit fruit juice milk soft drinks vomit urine and blood can be removed using the club soda water instructions given earlier in this section If an odor lingers after cleaning vomit o...

Page 219: ... see through the windshield under certain conditions Interior Plastic Components Use only a mild soap and water solution on a soft cloth or sponge Commercial cleaners may affect the surface finish Glass Surfaces Glass should be cleaned often GM Glass Cleaner or a liquid household glass cleaner will remove normal tobacco smoke and dust films on interior glass See Vehicle Care Appearance Materials o...

Page 220: ... retention and durability The best way to preserve the vehicle s finish is to keep it clean by washing it often with lukewarm or cold water Do not wash the vehicle in the direct rays of the sun Use a car washing soap Do not use strong soaps or chemical detergents Be sure to rinse the vehicle well removing all soap residue completely GM approved cleaning products can be obtained from your dealer Se...

Page 221: ...the vehicle garaged or covered whenever possible Protecting Exterior Bright Metal Parts Bright metal parts should be cleaned regularly to keep their luster Washing with water is all that is usually needed However chrome polish on chrome or stainless steel trim can be used if necessary Use special care with aluminum trim To avoid damaging protective trim never use auto or chrome polish steam or cau...

Page 222: ...olish on aluminum wheels Notice If you drive your vehicle through an automatic car wash that has silicone carbide tire cleaning brushes you could damage the aluminum or chrome plated wheels The repairs would not be covered by your warranty Never drive a vehicle equipped with aluminum or chrome plated wheels through an automatic car wash that uses silicone carbide tire cleaning brushes Do not take ...

Page 223: ...osion protection At least every spring flush these materials from the underbody with plain water Clean any areas where mud and debris can collect Dirt packed in close areas of the frame should be loosened before being flushed Your GM dealer or an underbody car washing system can do this for you Chemical Paint Spotting Some weather and atmospheric conditions can create a chemical fallout Airborne p...

Page 224: ...d wire wheel covers Finish Enhancer Removes dust fingerprints and surface contaminants Spray on wipe off Vehicle Care Appearance Materials cont d Description Usage Swirl Remover Polish Removes swirl marks fine scratches and other light surface contamination Cleaner Wax Removes light scratches and protects finish Foaming Tire Shine Low Gloss Cleans shines and protects in one easy step no wiping nec...

Page 225: ...de This code will help you identify your engine specifications and replacement parts 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 other components from working as...

Page 226: ...s burned beyond recognition consult your GM dealer for the proper size Replace a fusible link with one of the same size and insulation type Fusible link insulation is a special purpose high temperature material Power Windows and Other Power Options Circuit breakers in the fuse panel protect the power windows and other power accessories When the current load is too heavy the circuit breaker opens T...

Page 227: ...ar of the cover into the slots on the instrument panel and lower the cover down to snap into place If you ever have a problem on the road and don t have a spare fuse 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 fuse if it is the value you need Remember to replace the fuse as soon as you...

Page 228: ...5 80 ...

Page 229: ...ial Lock Air Dryer Moisture Ejection Heater Electric Air Compressor Power Take Off 10 Ignition Power 11 Left Trailer Turn Lamp Fuses Usage 12 Auxiliary Ignition ON 13 Auxiliary Battery Direct 14 Driver s Side Headlamp 15 Passenger s Side Headlamp 16 Headlamp 17 Heated Fuel 18 Meter Transmission Control Module 19 Identification Lamp Marker Lamp Tail Lamp Lighted Mirror Illumination Lamp 20 Cool Con...

Page 230: ...les Do not use maxi fuses of higher amperage than those indicated on the maxi fuse block Fuses Usage ST TURN HAZ Stoplamp Turn Signals Hazard Warning Flashers IGN SW 3 Air Conditioner Axle Chassis INT EXT LIGHTS Parking Lamps Dome Lamp Instrument Panel Lights HEAD LAMP Headlamps Daytime Running Lamps AUX WRG Auxiliary Parking Brake IGN SW 1 Ignition Switch Washer Wiper Crank Radio HYD PUMP Hydraul...

Page 231: ...e A Relay Block A B Relay Block B C Relay Block C Relay Block A Usage 1 Power Window 2 Power Main 3 High Beam 4 Lighting 5 Lighting Low High 6 Trailer Turn Signal Left Headlamp 7 Tail Lamp 8 Marker Lamp 9 Trailer Turn Signal Right Headlamp Relay Block A 5 83 ...

Page 232: ...nition 1 6 Ignition 2 7 Auxiliary 8 Horn 9 Ignition 3 10 Dome Lamp 11 Exhaust Brake 12 Power Take Off Control Relay Block C Usage 1 Parking Brake Daytime Running Lamps Off 2 Daytime Running Lamps On 3 Not Used 4 Parking Lamps Daytime Running Lamps 5 Fuel Filter Heated Fuel 6 Stop Lamp Relay Block B Relay Block C 5 84 ...

Page 233: ...ith Filter 23 8 quarts 22 5 L Additional oil is required with auxiliary oil filter systems Make sure to add enough extra oil to fill the auxiliary oil filter system For vehicles equipped with LUBERFINER 750 C add 14 quarts 13 2 L Fuel Tank Standard Optional Optional 50 0 gallons 75 0 gallons 100 0 gallons 189 3 L 283 9 L 378 5 L Two 50 gallon 189 L tanks Not applicable to vehicles with 128 inch or...

Page 234: ...s MD 3060 P MD 3560 P 35 0 pints 52 0 pints 13 5 L 24 6 L Add 2 pints 1 L when changing spin on or remote filter See the Allison Automatic Transmission Operator s Manual for fluid check and maintenance information Transmission Fluid Manual FS5406 FS6406 RT8709B RT8908LL 18 4 pints 25 1 pints 29 1 pints 8 7 L 11 8 L 13 8 L All capacities are approximate When adding be sure to fill to the approximat...

Page 235: ...3 6 2 4 Normal Maintenance Replacement Parts Part Part Number Oil Filter GM Part No 94392475 Engine Air Cleaner Filter Donaldson P533930 Fuel Filter Racor NWB B32002 Primary Secondary Fuel Filter GM Part No 94392474 engine mounted Pressure Caps GM Part No 15997145 5 87 ...

Page 236: ... NOTES 5 88 ...

Page 237: ...uled Maintenance Services 6 4 Using Your Maintenance Schedule 6 4 Scheduled Maintenance Supplements 6 4 Scheduled Maintenance 6 5 Part B Owner Checks and Services 6 23 At Each Fuel Fill 6 23 At Least Twice a Year 6 24 At Least Once a Year 6 27 Part C Recommended Fluids and Lubricants 6 28 Part D Maintenance Record 6 30 Section 6 Maintenance Schedule 6 1 ...

Page 238: ...e necessary to keep your vehicle in good working condition Any damage caused by failure to follow scheduled maintenance may not be covered by warranty Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition but also helps the environment Improper vehicle maintenance can even affect the quality of the air we breathe Improper fluid le...

Page 239: ...uired know how and the proper tools and equipment for the job If you have any doubt have a qualified technician do the work If you want to purchase service information see Service Publications Ordering Information on page 7 7 Part B Owner Checks and Services tells you what should be checked and when It also explains what you can easily do to keep your vehicle in good condition Part C Recommended F...

Page 240: ...t tells you the maintenance services you should have done and when to schedule them When you go to your dealer for your service needs you will 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 rep...

Page 241: ... 13 Hydraulic brake service or every 6 months whichever occurs first 6 30 Parking brake service or every 6 months whichever occurs first 7 Air brake service or every 6 months whichever occurs first 26 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 27 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs fi...

Page 242: ... 6 months whichever occurs first 2 3 15 Wheels and tires service 13 Hydraulic brake service or every 6 months whichever occurs first 6 30 Parking brake service or every 6 months whichever occurs first 7 Air brake service or every 6 months whichever occurs first 26 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 27 Check air brake relay valve operation and check...

Page 243: ...ccurs first 26 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 27 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber service or every 2 months whichever occurs first 28 ...

Page 244: ... 7 Air brake service or every 6 months whichever occurs first 26 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 27 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber se...

Page 245: ...000 Miles 72 000 km Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 5 19 for more information An Emission Control Service See footnote Check fluid levels or every 3 months whichever occurs first 1 5 Replace fuel filter or...

Page 246: ...er occurs first 28 Air brake system valve service or every 3 months or every 900 hours whichever occurs first 31 Thermostatically controlled engine cooling fan service 3 17 Shields and underhood insulation service 3 4 18 Rear axle air shift motor service 9 Air intake system service or every 24 months whichever occurs first 3 4 20 Air compressor dry element pleated paper air strainer service or eve...

Page 247: ...ice or every 2 months whichever occurs first 28 60 000 Miles 96 000 km Vehicles Without Oil Life System Only Change engine oil and filter or every 12 months whichever occurs first 2 Vehicles With Oil Life System Only Check Oil Life System If engine oil and filter are changed reset system See Engine Oil Life System on page 5 18 2 8 Inspect engine air cleaner filter change indicator If necessary rep...

Page 248: ... 3 4 18 Air compressor dry element pleated paper air strainer service or every 2 months or every 800 hours whichever occurs first 67 500 Miles 108 000 km Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubrication service or every 6 months whichever occurs first 10 Cooling system service Clean the cooling system filler cap with clean water clean the core pressure test the c...

Page 249: ...rs of engine operation whichever occurs first If engine oil and filter are changed reset system See Engine Oil Life System on page 5 18 2 8 75 000 Miles 120 000 km Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 5 19 for ...

Page 250: ...r air strainer service or every 2 months or every 800 hours whichever occurs first 82 500 Miles 132 000 km Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubrication service or every 6 months whichever occurs first 10 Wheels and tires service 13 Hydraulic brake service or every 6 months whichever occurs first 6 30 Parking brake service or every 6 months whichever occurs fi...

Page 251: ... filter or every 750 hours of engine operation whichever occurs first Chassis lubrication service or every 6 months whichever occurs first 10 Cooling system service Clean the cooling system filler cap with clean water clean the core pressure test the cap and the system for proper pressure capability and inspect condition of cooling and heater hoses and clamps Replace hoses if cracked swollen or da...

Page 252: ...t motor service 9 Air intake system service or every 24 months whichever occurs first 3 4 20 Air compressor dry element pleated paper air strainer service or every 2 months or every 800 hours whichever occurs first 96 000 Miles 152 000 km Vehicles Without Engine Oil Life System Only Change engine oil and filter or every 12 months or every 600 hours of engine operation whichever occurs first 2 Vehi...

Page 253: ...r every 48 months whichever occurs first Trailer brake hand control valve service or every 12 months or every 3 600 hours whichever occurs first 29 150 000 Miles 240 000 km Cooling system service or every 60 months since last service whichever occurs first 2 23 Inspect engine drive belt replace as necessary 200 000 Miles 320 000 km Remove disassemble clean and inspect the air brake trailer supply ...

Page 254: ...hook up binding leaks cracks chafing etc Inspect disc brake pads for wear and rotors for surface condition Inspect caliper assemblies 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 7 Inspect parking brake drum and linings for wear or cracks a...

Page 255: ... in excessive off road use Frequently power washed vehicles will require more frequent lubrication 11 Check steering system Look for damaged loose or missing parts Inspect the steering linkage relay rod and tie rod ends for looseness or lack of lubricant 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 g...

Page 256: ...sulation for damage or looseness Adjust or replace as needed 19 Wheel bearing service Grease type Clean inspect and lubricate with the proper wheel bearing grease at designated intervals or when hubs are removed See Part C Recommended Fluids and Lubricants on page 6 28 Oil filled type Some wheel bearings are lubricated by rear axle lubricant When you have oil filled hubs use lubricant identical to...

Page 257: ...ng Replace air dryer cartridge only if excessive oil or moisture is present A small amount of oil in the system is normal and should not be considered as a reason to replace the cartridge Test air lines for leaks tighten as needed Replace compressor filter Inspect air parking brake chamber for leaks and damage Inspect lines and hoses for leaks cracks chafing etc Also check all attachments for tigh...

Page 258: ...nd follower 30 Tighten the wheel stud nuts to the specified torque values at 100 miles 160 km Thereafter tighten them 1 000 miles 1 600 km after each time the wheel is removed See Tightening the Wheel Nuts on page 5 62 31 Inspect and clean any accumulated dirt gravel or other foreign objects from the valves and valve boots as needed Using light oil lubricate brake pedal to brake application valve ...

Page 259: ...Fill It is important for you or a service station attendant to perform these underhood checks at each fuel fill Engine Oil Level Check Check the engine oil level and add the proper oil if necessary See Engine Oil on page 5 14 for further details Engine Coolant Level Check Check the engine coolant level and add DEX COOL coolant mixture if necessary See Engine Coolant on page 5 24 for further detail...

Page 260: ...brication Silicone grease on weatherstrips will make them last longer seal better and not stick or squeak Apply silicone grease with a clean cloth During very cold damp weather more frequent application may be required Part C tells you what to use Body Lubrication Service Lubricate all exposed surfaces such as door checks door lock bolts lock strike plates door hinge bushings latches and dovetail ...

Page 261: ...ire wear or steering wheel position An inspection or service is needed when the steering wheel is harder to turn or has too much free play or if there are strange sounds when turning or parking Brake System Check Be alert to illumination of the low air warning lamp or for the tone alarm or changes in braking action such as repeated pulling to one side unusual sounds when braking or increased brake...

Page 262: ... latch by attempting to move the seat after latching Lamps Check Check panel lighting warning lights indicator lights and interior lamps On the outside check license plate lamps sidemarker lamps reflectors or lights on outside mirrors headlamps parking lamps identification and clearance lamps taillamps brake lamps turn signals backup lamps and hazard warning flashers Have headlamp aim checked at o...

Page 263: ...d and other debris can collect Sediment packed in closed areas of the 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 clamped 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 Underbo...

Page 264: ...Coolant See Engine Coolant on page 5 24 Hydraulic Brake System Delco Supreme 11 Brake Fluid or equivalent DOT 3 brake fluid Usage Fluid Lubricant Hydraulic Clutch System Hydraulic Clutch Fluid GM Part No U S 12345347 in Canada 10953517 or equivalent DOT 3 brake fluid Windshield Washer Solvent GM Optikleen Washer Solvent Clutch Bearing Lubricant Clutch Bearing Lubricant GM Part No 12378484 or equiv...

Page 265: ...rucks GM Part No U S 12345841 in Canada 10953512 Rear Axle and Rear Hubs SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part No U S 12345841 in Canada 10953512 Usage Fluid Lubricant Rear Axle Shift Motor Lubricant Refrigerant Oil GM Part No U S 5416939 in Canada 10953496 Propshafts and Splines Wheel bearing lubricant meeting requirements of NLGI 2 Category GC or GC LB GM Part No U S...

Page 266: ...rmed record the date odometer reading and who performed the service and any additional information from Owner Checks and Services on the following record pages Also you should retain all maintenance receipts Date Miles km Or Hours Serviced By Maintenance Record 6 30 ...

Page 267: ...Date Miles km Or Hours Serviced By Maintenance Record 6 31 ...

Page 268: ...Date Miles km Or Hours Serviced By Maintenance Record 6 32 ...

Page 269: ... Mobility Reimbursement Program 7 5 Roadside Assistance Program 7 6 Canadian Roadside Assistance 7 6 Reporting Safety Defects 7 6 Reporting Safety Defects to the United States Government 7 6 Reporting Safety Defects to the Canadian Government 7 7 Reporting Safety Defects to General Motors 7 7 Service Publications Ordering Information 7 7 Section 7 Customer Assistance and Information 7 1 ...

Page 270: ...nce Center at 1 800 862 4389 We encourage you to call the toll free number in order to give your inquiry prompt attention Please have the following information available to give the Customer Assistance Representative Vehicle Identification Number VIN This is available from the vehicle registration or title or the plate at the top left of the instrument panel and visible through the windshield Deal...

Page 271: ...A 22203 1838 Telephone 1 800 955 5100 This program is available in all 50 states and the District of Columbia Eligibility is limited by vehicle age mileage and other factors General Motors reserves the right to change eligibility limitations and or discontinue its participation in this program Online Owner Center The Owner Center is a resource for your GM ownership needs Specific vehicle informati...

Page 272: ...d be addressed to the GM Medium Duty Truck Customer Assistance Center United States Customer Assistance GM Medium Duty Truck Customer Assistance Center P O Box 44947 Detroit MI 48244 1 800 TO CHEVY 1 800 862 4389 1 800 833 2438 For Text Telephone devices TTYs Fax Number 313 381 0022 From Puerto Rico 1 800 496 9992 English 1 800 496 9993 Spanish Fax Number 313 381 0022 From U S Virgin Islands 1 800...

Page 273: ...s program available to qualified applicants can reimburse you up to 1 000 toward eligible aftermarket driver s or passenger s adaptive equipment you may require for your vehicle such as hand controls and wheelchair scooter lifts The offer is available for a limited period of time from the date of vehicle purchase lease For more details or to determine your vehicle s eligibility visit gmmobility co...

Page 274: ...or contact your dealer Canadian Roadside Assistance Vehicles purchased in Canada have an extensive roadside assistance program accessible from anywhere in Canada or the United States Please refer to the Warranty and Owner Assistance Information book Reporting Safety Defects Reporting Safety Defects to the United States Government If you believe that your vehicle has a defect which could cause a cr...

Page 275: ... of Canada Limited Customer Communication Centre 163 005 1908 Colonel Sam Drive Oshawa Ontario L1H 8P7 Service Publications Ordering Information Service Manuals Service Manuals have the diagnosis and repair information on engines transmission axle suspension brakes electrical steering body etc Transmission Transaxle Transfer Case Unit Repair Manual This manual provides information on unit repair s...

Page 276: ...ations are available for current and past model GM vehicles To request an order form please specify year and model name of the vehicle ORDER TOLL FREE 1 800 551 4123 Monday Friday 8 00 AM 6 00 PM Eastern Time For Credit Card Orders Only VISA MasterCard Discover visit Helm Inc on the World Wide Web at www helminc com Or you can write to Helm Incorporated P O Box 07130 Detroit MI 48207 Prices are su...

Page 277: ...Carpet 5 69 Finish Care 5 73 Finish Damage 5 75 Glass Surfaces 5 71 Appearance Care cont Instrument Panel 5 71 Interior Plastic Components 5 71 Sheet Metal Damage 5 74 Tires 5 74 Underbody Maintenance 5 75 Vehicle Care Appearance Materials 5 76 Vinyl 5 71 Washing Your Vehicle 5 72 Weatherstrips 5 72 Windshield and Wiper Blades 5 73 Ashtrays 3 17 Audio System s 3 40 AM FM Radio 3 41 Care of Your Ca...

Page 278: ...5 Braking in Emergencies 4 8 Break In New Vehicle 2 6 Bucket Seats 1 2 C Cab Tilting Before You Tilt the Cab 5 48 Lifting the Front Panel 5 54 Lowering the Cab 5 52 Tilting the Cab 5 49 Capacities and Specifications 5 85 Carbon Monoxide 2 23 4 24 Care of Safety Belts 5 72 Your Cassette Tape Player 3 48 Center Console Storage Area 2 27 Center Passenger Position Safety Belts 1 16 Center Seat 1 3 Cha...

Page 279: ...ystem 3 17 Air Filter Passenger Compartment 3 20 Outlet Adjustment 3 19 Clutch Hydraulic 5 23 Control of a Vehicle 4 5 Coolant Engine Temperature Gage 3 30 Heater Engine 2 12 Low Warning Light 3 31 Surge Tank Pressure Cap 5 26 Cooling System 5 29 Cruise Control Lever 3 10 Customer Assistance Information Customer Assistance for Text Telephone TTY Users 7 4 Customer Assistance Offices 7 4 Customer S...

Page 280: ...s 4 29 Winter 4 24 Dual Tire Operation 5 61 E Electrical System Add On Equipment 5 77 Fuses and Circuit Breakers 5 78 Fusible Links 5 78 Headlamp Wiring 5 77 Instrument Panel Fuse Block 5 79 Maxi Fuse Block 5 82 Power Windows and Other Power Options 5 78 Relay Center 5 83 Windshield Wiper Fuses 5 78 Engine Air Cleaner Filter 5 19 Battery 5 41 Change Engine Oil Light 3 34 Check and Service Engine S...

Page 281: ...ing a Portable Fuel Container 5 14 Filling Your Tank 5 12 Filter 5 57 Gage 3 38 Primary Filter and Water Separator 5 57 Fuel cont Running Out of Fuel 5 12 Very Cold Weather Operation 5 7 Water in Fuel 5 8 Water in Warning Light 3 38 What Fuel to Use 5 6 Fuses Fuses and Circuit Breakers 5 78 Instrument Panel Fuse Block 5 79 Maxi Fuse Block 5 82 Relay Center 5 83 Windshield Wiper 5 78 G Gage Air Pre...

Page 282: ... Hill and Mountain Roads 4 22 Horn 3 6 Hourmeter Gage 3 39 How to Use This Manual ii How to Wear Safety Belts Properly 1 8 Hydraulic Brake Systems 4 6 Hydraulic Brakes 2 18 Hydraulic Clutch 5 23 I Ignition Positions 2 6 Infants and Young Children Restraints 1 20 Inflation Tire Pressure 5 60 Instrument Panel Brightness 3 15 Cluster 3 22 Overview 3 4 J Jacks Auxiliary Power 3 16 Jump Starting 5 42 K...

Page 283: ...24 Safety Belt Reminder Tone 3 24 Service Transmission Warning 3 26 Light cont Trailer Anti Lock Brake System Warning 3 30 Wait to Start Indicator 3 31 Water in Fuel Warning 3 38 Locks Door 2 3 Loss of Control 4 14 Low Coolant Warning Light 3 31 M Maintenance Normal Replacement Parts 5 87 Maintenance Schedule At Each Fuel Fill 6 23 At Least Once a Year 6 27 At Least Twice a Year 6 24 How This Sect...

Page 284: ...hildren Restraints 1 18 Online Owner Center 7 3 Other Service Items Front Wheel Bearings with Oil Filled Hubs 5 58 Fuel Filter 5 57 Primary Fuel Filter and Water Separator 5 57 Other Warning Devices 3 6 Outlet Adjustment 3 19 Outside Convex Mirrors 2 25 Heated Mirrors 2 25 Manual Mirrors 2 25 Overspeed Warning Light 3 34 P Parking 2 18 Air Brake 2 20 Brake 2 19 Hydraulic Brakes 2 18 Over Things Th...

Page 285: ...nhibit Warning Indicator 3 27 Rear Axle 5 47 Shift Motor 5 48 Two Speed Electric Shift Control 2 14 Rear Reading Lamps 3 16 Reduced Engine Power Light 3 36 Reporting Safety Defects Canadian Government 7 7 General Motors 7 7 United States Government 7 6 Restraint System Check Checking Your Restraint Systems 1 29 Replacing Restraint System Parts After a Crash 1 29 Restraint Systems Checking 1 29 Rep...

Page 286: ...e Supplements 6 4 Seats Bucket Seats 1 2 Center Seat 1 3 Securing a Child Restraint Center Seat Position 1 27 Service 5 3 Doing Your Own Work 5 4 Engine Soon Light 3 32 Publications Ordering Information 7 7 Transmission Warning Light 3 26 Two Safety Cautions about Engine Fan Breakage 5 4 Setting the Time 3 40 Sheet Metal Damage 5 74 Side Door Glass 2 5 Signals Turn and Lane Change 3 8 Specificatio...

Page 287: ...our Vehicle 4 31 Traction Control System TCS 4 9 Trailer Connections 4 36 Trailer Brake Hand Control Valve 4 8 Transmission Fluid Automatic 5 22 Fluid Manual 5 22 Service Warning Light 3 26 Transmission Operation Automatic 2 14 Transmission Operation Manual 2 16 Trip Odometer 3 23 Turn and Lane Change Signals 3 8 Turn Signal Multifunction Lever 3 7 Two Speed Rear Axle Electric Shift Control 2 14 U...

Page 288: ...t Fuel to Use 5 6 Wheels Alignment and Tire Balance 5 62 Front Bearings with Oil Filled Hubs 5 58 Loading 5 60 Replacement 5 66 Tightening the Wheel Nuts 5 62 Windows 2 4 Manual 2 4 Passenger Side Door Glass 2 5 Power 2 4 Windshield Wiper Blades Cleaning 5 73 Windshield Washer 3 10 Fluid 5 33 Windshield Wiper Blade Replacement 5 56 Fuses 5 78 Windshield Wipers 3 9 Winter Driving 4 24 Y Your Vehicl...

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Chevrolet 2005 T-Series, Owner'S Manual

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Summary of Contents for 2005 T-Series

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