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Chevrolet 2007 Kodiak, Owner'S Manual

The Chevrolet 2007 Kodiak is a reliable heavy-duty truck designed for commercial use. Ensure optimal performance and maintenance by downloading the free Owner's Manual from manualshive.com. This comprehensive manual provides detailed instructions and key insights to safely operate and maintain the Chevy Kodiak.

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Secondary Fuel Filter and
Water Separator/Heater
(Caterpillar

®

Diesel)

If you have a
Caterpillar

®

diesel

engine, you may also
have this spin-on
filter and fuel
separator/heater. It will
be mounted in the
engine compartment on
the driver’s side of
the vehicle.

It has a metal drain bowl at the bottom.
Occasionally, check the bowl for any water
or particles.

To check or drain the bowl, do the following:

•

Shut off the engine.

•

Push up on the spring loaded drain valve until
clear fuel is flowing from the valve.

The particles or water will drain out first. See

Engine Oil (Caterpillar

®

Diesel Engine) on

page 268

or

Engine Oil (Gasoline Engine) on

page 268

or

Engine Oil (DURAMAX

®

/Isuzu Diesel

Engine) on page 272

for proper disposal

procedures.

Automatic Ether Injection System
(Caterpillar

®

Diesel)

If you have a Caterpillar

®

diesel engine, you
may have this feature.
The ether cylinder is
located in the engine
compartment on the
driver’s side of the
vehicle.

318

Summary of Contents for 2007 Kodiak

Page 1: ...and Operating Your Vehicle 95 Mirrors 133 Storage Areas 135 Instrument Panel 137 Instrument Panel Overview 140 Climate Controls 157 Warning Lights Gages and Indicators 161 Audio System s 184 Driving Your Vehicle 205 Your Driving the Road and Your Vehicle 206 Towing 241 Service and Appearance Care 245 Service 248 Fuel 251 Checking Things Under the Hood 266 Rear Axle 311 2007 Chevrolet Kodiak Owner ...

Page 2: ...ce Items 317 Tires 321 Appearance Care 331 Vehicle Identification 340 Electrical System 340 Capacities and Specifications 347 Normal Maintenance Replacement Parts 352 Maintenance Schedule 359 Maintenance Schedule 360 Customer Assistance Information 403 Customer Assistance and Information 404 Reporting Safety Defects 414 Index 417 2 ...

Page 3: ...s manual describes features that may be available in this model but your vehicle may not have all of them For example more than one entertainment system may be offered or your vehicle may have been ordered without a front passenger or rear seats Keep this manual in the vehicle so it will be there if it is needed while you are on the road If the vehicle is sold leave this manual in the vehicle Cana...

Page 4: ...anual and the page number where it can be found Safety Warnings and Symbols There are a number of safety cautions in this book We use a box and the word CAUTION to tell about things that could hurt you if you were to ignore the warning CAUTION These mean there is something that could hurt you or other people In the caution area we tell you what the hazard is Then we tell you what to do to help avo...

Page 5: ...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 6: ...These are some examples of symbols that may be found on the vehicle 6 ...

Page 7: ...r Position 37 Rear Outside Passenger Positions Crew Cab 38 Safety Belt Extender 41 Child Restraints 42 Older Children 42 Infants and Young Children 45 Child Restraint Systems 49 Where to Put the Restraint Regular Cab Models 54 Where to Put the Restraint Crew Cab Models 55 Lower Anchors and Tethers for Children LATCH 57 Securing a Child Restraint in a Rear Outside Seat Position Crew Cab Models 58 S...

Page 8: ...ag Restrain 73 What Will You See After an Airbag Inflates 74 Airbag Off Switch 76 Servicing Your Airbag Equipped Vehicle 80 Adding Equipment to Your Airbag Equipped Vehicle 81 Restraint System Check 82 Checking the Restraint Systems 82 Replacing Restraint System Parts After a Crash 83 Section 1 Seats and Restraint Systems 8 ...

Page 9: ...ing The sudden movement could startle and confuse you or make you push a pedal when you do not want to Adjust the driver s seat only when the vehicle is not moving You can adjust the seat forward or rearward with the bar located under the front of the seat cushion Lift the bar to unlock the seat Slide the seat to where you want it and release the bar Try to move the seat with your body to be sure ...

Page 10: ...he knob counterclockwise Seatback Adjustment CAUTION You can lose control of the vehicle if you try to adjust a manual driver s seat while the vehicle is moving The sudden movement could startle and confuse you or make you push a pedal when you do not want to Adjust the driver s seat only when the vehicle is not moving CAUTION If the seatback is not locked it could move forward in a sudden stop or...

Page 11: ...ack to the desired position then release the lever to lock the seatback in place 3 Push and pull on the seatback to make sure it is locked To return the seatback to an upright position do the following 1 Lift the lever fully without applying pressure to the seatback and the seatback will return to the upright position 2 Push and pull on the seatback to make sure it is locked 11 ...

Page 12: ...d go into it receiving neck or other injuries The lap belt cannot do its job either In a crash the belt could go up over your abdomen The belt forces would be there not at your pelvic bones This could cause serious internal injuries For proper protection when the vehicle is in motion have the seatback upright Then sit well back in the seat and wear your safety belt properly Do not have a seatback ...

Page 13: ...5 Air Suspension Seats Your vehicle may have a low back or high back air suspension seat There are several ways to adjust the seat Fore and Aft Adjustment If your vehicle has this lever it is located underneath the front of the driver s seat To slide the seat forward or rearward move the lever toward the outboard side of the seat The seat will lock in at 1 2 inch 1 5 cm increments 13 ...

Page 14: ...ed under the front of the seat cushion Lift the bar to unlock the seat Slide the seat to where you want it and release the bar Try to move the seat with your body to be sure the seat is locked in place Height Adjustment Seat Height Adjustment Lever 14 ...

Page 15: ...h it is located below the front of the seat cushion on the inboard side of the seat Push the left side of the switch to inflate Push the right side of the switch to deflate Your seat cushion may also be able to be raised or lowered If your vehicle has this feature the seat cushion height adjustment handle is located underneath the front of the seat To adjust the height of the cushion lift the hand...

Page 16: ...stment If your vehicle has a lumbar adjustment knob it is located on the inboard side of the driver s seatback or on the outboard side of the passenger s seatback Lumbar Adjustment Knob Lumbar Adjustment Switch 16 ...

Page 17: ... lumbar adjustment switch it is located below the front of the seat cushion on the outboard side of the seat For more support to your lower back push the right side of the switch To decrease the amount of lumbar support press the left side of the switch Seatback Adjustment Your vehicle has one of the following seatback adjustment levers Lever Located On Outboard Side 17 ...

Page 18: ...eatback in place 3 Push and pull on the seatback to make sure it is locked To return the seatback to an upright position do the following 1 Lift the lever fully without applying pressure to the seatback and the seatback will return to the upright position 2 Push and pull on the seatback to make sure it is locked Lever Located On Inboard Side 18 ...

Page 19: ... up over your abdomen The belt forces would be there not at your pelvic bones This could cause serious internal injuries For proper protection when the vehicle is in motion have the seatback upright Then sit well back in the seat and wear your safety belt properly Chugger Snubber Lock Out Feature If your vehicle has this feature the handle is located on the outboard side of the driver s and passen...

Page 20: ...nbuckle the safety belts and return them to their normal stowed position before folding a rear seat The rear bench seat on the crew cab can be folded down to provide more cargo space To fold down the seatback pull this nylon strap located on the rear of the seat while pulling the seatback down To raise a seatback pull the nylon strap while raising the seatback until it locks upright CAUTION If the...

Page 21: ...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 22: ...urvive 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 40 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 ri...

Page 23: ...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 23 ...

Page 24: ...s were to give that big vehicle a chance to deal with the force of the impact instead of you With safety 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 24 ...

Page 25: ... system ever offered for sale has required the use of safety belts Even if you are in a vehicle that has airbags you still have to buckle up to get the most protection That is true not only in frontal collisions but especially in side and other collisions Q If I am a good driver and I never drive far from home why should I wear safety belts A You may be an excellent driver but if you are in an acc...

Page 26: ...n First you will want to know which restraint systems your vehicle has We will start with the driver position Driver Position Lap Shoulder Belt The driver has a lap shoulder belt Here is how to wear it properly 1 Close and lock the door 2 Adjust the seat so you can sit up straight To see how see Seats in the Index 3 Pick up the latch plate and pull the belt across you Do not let it get twisted The...

Page 27: ...le the safety belt quickly if you ever had to 5 Move the shoulder belt height adjuster to the height that is right for you Improper shoulder belt height adjustment could reduce the effectiveness of the safety belt in a crash See Shoulder Belt Height Adjustment on page 35 6 To make the lap part tight pull up on the shoulder belt It may be necessary to pull stitching on the safety belt through the l...

Page 28: ...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 28 ...

Page 29: ...too 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 29 ...

Page 30: ...rotection this way CAUTION You can be seriously hurt if your lap belt is too loose In a crash you could slide under the lap belt and apply force at your abdomen This could cause serious or even fatal injuries The lap belt should be worn low and snug on the hips just touching the thighs 30 ...

Page 31: ...can be seriously injured if your belt is buckled in the wrong place like this In a crash the belt would go up over your abdomen The belt forces would be there not at the pelvic bones This could cause serious internal injuries Always buckle your belt into the buckle nearest you 31 ...

Page 32: ...jured if your belt goes over an armrest like this The belt would be much too high In a crash you can slide under the belt The belt force would then be applied at the abdomen not at the pelvic bones and that could cause serious or fatal injuries Be sure the belt goes under the armrests 32 ...

Page 33: ...seriously injured if you wear the shoulder belt under your arm In a crash your body would move too far forward which would increase the chance of head and neck injury Also the belt would apply too much force to the ribs which are not as strong as shoulder bones You could also severely injure internal organs like your liver or spleen 33 ...

Page 34: ...d 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 34 ...

Page 35: ...o that the shoulder portion of the belt is centered on your shoulder The belt should be away from your face and neck but not falling off your shoulder Improper shoulder belt height adjustment could reduce the effectiveness of the safety belt in a crash To move it down press in at the top of the arrows and move the height adjuster to the desired position You can move the height adjuster up just by ...

Page 36: ...ly it is more likely that the fetus will not be hurt in a crash For pregnant women as for anyone the key to making safety belts effective is wearing them properly Right Front Passenger Position To learn how to wear the right front passenger s safety belt properly see Driver Position on page 26 The right front passenger s safety belt works the same way as the driver s safety belt If your vehicle ha...

Page 37: ...elt which has no retractor To make the belt longer tilt the latch plate and pull it along the belt To make the belt shorter pull its free end as shown until the belt is snug Buckle position and release it the same way as the lap part of a lap shoulder belt If the belt is not long enough see Safety Belt Extender on page 41 Make sure the release button on the buckle is positioned so you would be abl...

Page 38: ...an be thrown out of the vehicle in a crash And they can strike others in the vehicle who are wearing safety belts Lap Shoulder Belt The positions next to the windows have lap shoulder belts Here is how to wear one properly 1 Pick up the latch plate and pull the belt across you Do not let it get twisted The shoulder belt may lock if you pull the belt across you very quickly If this happens let the ...

Page 39: ...out all the way it will lock If it does let it go back all the way and start again If the belt is not long enough see Safety Belt Extender on page 41 Make sure the release button on the buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to 3 To make the lap part tight pull up on the shoulder part 39 ...

Page 40: ...uld 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 a crash or if you pull the belt very quickly out of the retractor Each position next to the windows has a shoulder belt height adjuster See Shoulder Belt Height Adjustment on page 35 CAUTION You can be seriously hurt if your shoulder...

Page 41: ...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 designed for adults Never use it for securing child seats To wear it just attach it to the regular safety belt For more information see the instruction sheet that...

Page 42: ...tional 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 According to accident statistics children are safer when properly restrained in the rear seating positions than ...

Page 43: ...lt 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 mi...

Page 44: ... this way in a crash the child might slide under the belt The belt s force would then be applied right on the child s abdomen That could cause serious or fatal injuries Wherever the child sits the lap portion of the belt should be worn low and snug on the hips just touching the child s thighs This applies belt force to the child s pelvic bones in a crash 44 ...

Page 45: ...st be restrained while in a vehicle CAUTION Children can be seriously injured or strangled if a shoulder belt is wrapped around their neck and the safety belt continues to tighten Never leave children unattended in a vehicle and never allow children to play with the safety belts Every time infants and young children ride in vehicles they should have the protection provided by appropriate restraint...

Page 46: ...does not weigh much until a crash During a crash a baby will become so heavy it is not possible to hold it 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 46 ...

Page 47: ...ed or killed Airbags plus lap shoulder belts offer protection for adults and older children but not for young children and infants Neither the vehicle s safety belt system nor its airbag system is designed for them Young children and infants need the protection that a child restraint system can provide 47 ...

Page 48: ...nt 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 ...

Page 49: ...uld be secured in appropriate child restraints We know securing a child can present real problems in a medium duty vehicle like yours If your vehicle is a regular cab model with an air suspension seat in the right front passenger s position there is no place in your vehicle to secure a child restraint The only answer is to have smaller children make the trip in another vehicle where they can get t...

Page 50: ... of the infant The harness system holds the infant in place and in a crash acts to keep the infant positioned in the restraint A forward facing child seat C E provides restraint for the child s body with the harness and also sometimes with surfaces such as T shaped or shelf like shields 50 ...

Page 51: ...raint system is a permanent part of the motor vehicle An add on child restraint system is a portable one which is purchased by the vehicle s owner To help reduce injuries an add on child restraint must be secured in the vehicle With built in or add on child restraints the child has to be secured within the child restraint When choosing an add on child restraint be sure the child restraint is desig...

Page 52: ...ed in vehicle seats by lap belts or the lap belt portion of a lap shoulder belt A child can be endangered in a crash if the child restraint is not properly secured in the vehicle When securing an add on child restraint refer to the instructions that come with the restraint which may be on the restraint itself or in a booklet or both and to this manual The child restraint instructions are important...

Page 53: ...s that are attached to a flat pad which rests low against 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 CAUTION A child can be seriously injured or killed in a crash if the child is not properly secured in the child restraint Make sure the child is properly secured following the instructions that came with tha...

Page 54: ... restraint must be secured properly in the right front passenger s seat If your vehicle has airbags and you need to secure a child restraint in the right front passenger s seat there is a switch on the instrument panel that you can use to turn off the passenger s airbag See Airbag Off Switch on page 76 and Securing a Child Restraint in the Right Front Seat Position on page 63 for more on this incl...

Page 55: ...ve around in a collision or sudden stop and injure people in the vehicle even when no child is in it Where to Put the Restraint Crew Cab Models Accident statistics show that children are safer if they are restrained in the rear rather than the front seat We recommend that child restraints be secured in a rear seat position including an infant riding in a rear facing infant seat a child riding in a...

Page 56: ... in the right front seat position CAUTION Continued CAUTION Continued Even though the airbag off switch is designed to turn off the passenger s airbag no system is fail safe and no one can guarantee that an airbag will not deploy under some unusual circumstance even though it is turned off We recommend that rear facing child restraints be secured in the rear seat even if the airbag is off If you n...

Page 57: ...lision or sudden stop and injure people in the vehicle even when no child is in it Lower Anchors and Tethers for Children LATCH Some child restraints have a LATCH system As part of the LATCH system your child restraint may have lower attachments and or a top tether The LATCH system can help hold the child restraint in place during driving or in a crash Some vehicles have lower and or top tether an...

Page 58: ...or securing a child restraint using the vehicle s safety belts Securing a Child Restraint in a Rear Outside Seat Position Crew Cab Models There are no top tether anchors in the rear outside seat positions Do not secure a child seat in these positions if a national or local law requires that the top tether be anchored or if the instructions that come with the child restraint say that the top tether...

Page 59: ... belt Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly if you ever had to 4 Pull the rest of the shoulder belt all the way out of the retractor to set the lock 59 ...

Page 60: ...e freely again and be ready to work for an adult or larger child passenger Securing a Child Restraint in the Center Rear Seat Position Crew Cab or Center Front Position There are no top tether anchors in these positions Do not secure a child seat in these positions if a national or local law requires that the top tether be anchored or if the instructions that come with the child restraint say that...

Page 61: ... your vehicle has one You may secure a forward facing child restraint in the right front passenger static seat but before you do always move the front passenger seat as far back as it will go It is better to secure the child restraint in a rear seat 1 Make the belt as long as possible by tilting the latch plate and pulling it along the belt 2 Put the child restraint on the seat 3 Run the vehicle s...

Page 62: ...wn 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 child restraint just unbuckle the vehicle s safety belt It will be ready to work for an adult or large child passenger 62 ...

Page 63: ...s position if a national or local law requires that the top tether be anchored or if the instructions that come with the child restraint say that the top tether must be anchored See Lower Anchors and Tethers for Children LATCH on page 57 if your child restraint has a top tether If your vehicle has a right front passenger s airbag there is a switch on the instrument panel that you can use to turn o...

Page 64: ...vehicle unless the passenger s airbag has been turned off CAUTION Continued CAUTION Continued Even though the airbag off switch is designed to turn off the passenger s frontal airbag no system is fail safe and no one can guarantee that an airbag will not deploy under some unusual circumstance even though it is turned off We recommend that rear facing child restraints be transported in vehicles wit...

Page 65: ...n this including important safety information You will be using the lap shoulder 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 1 If your vehicle has a right front passenger s airbag see Airbag Off Switch on page 76 If your vehicle has a right front passenger s airbag and your child restraint is fo...

Page 66: ... belt Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly if you ever had to 5 Pull the rest of the shoulder belt all the way out of the retractor to set the lock 66 ...

Page 67: ... child passenger If you were using a child restraint in a vehicle equipped with a right front passenger s airbag turn on the right front passenger s airbag when you remove the child restraint from the vehicle unless the person who will be sitting there is a member of a passenger airbag risk group See Airbag Off Switch on page 76 CAUTION If the right front passenger s airbag is turned off for a per...

Page 68: ...ontal airbags are designed to help reduce the risk of injury from the force of an inflating airbag But these airbags must inflate very quickly to do their job and comply with federal regulations Here are the most important things to know about the airbag system CAUTION You can be severely injured or killed in a crash if you are not wearing your safety belt even if you have airbags Wearing your saf...

Page 69: ...gs The driver should sit as far back as possible while still maintaining control of the vehicle If your vehicle has an airbag for the right front passenger please read this CAUTION Anyone who is up against or very close to any airbag when it inflates can be seriously injured or killed Airbags plus lap shoulder belts offer the best protection for adults but not for young children and infants Neithe...

Page 70: ... airbag symbol The system checks the airbag electrical system for malfunctions The light tells you if there is an electrical problem See Airbag Readiness Light on page 165 for more information Where Are the Airbags The driver s airbag is in the middle of the steering wheel 70 ...

Page 71: ... an airbag the bag might not inflate properly or it might force the object into that person causing severe injury or even death The path of an inflating airbag must be kept clear Do not put anything between an occupant and an airbag and do not attach or put anything on the steering wheel hub or on or near any other airbag covering 71 ...

Page 72: ... can vary however with specific vehicle design so that it can be somewhat above or below this range Frontal airbags may inflate at different crash speeds For example If the vehicle hits a stationary object the airbags could inflate at a different crash speed than if the vehicle hits a moving object If the vehicle hits an object that deforms the airbags could inflate at a different crash speed than...

Page 73: ...de the steering wheel and in the instrument panel in front of the right front passenger How Does an Airbag Restrain In moderate to severe frontal or near frontal collisions even belted occupants can contact the steering wheel or the instrument panel The airbag supplements the protection provided by safety belts Airbags distribute the force of the impact more evenly over the occupant s upper body s...

Page 74: ... the deflated airbags Airbag inflation does not prevent the driver from seeing out of the windshield or being able to steer the vehicle nor does it prevent people from leaving the vehicle CAUTION When an airbag inflates there may be dust in the air This dust could cause breathing problems for people with a history of asthma or other breathing trouble To avoid this everyone in the vehicle should ge...

Page 75: ...bag system will not be there to help protect you in another crash A new system will include airbag modules and possibly other parts The service manual for your vehicle covers the need to replace other parts Your vehicle has a crash sensing and diagnostic module which records information after a crash See Vehicle Data Collection and Event Data Recorders on page 409 Let only qualified technicians wo...

Page 76: ...ember of a passenger risk group identified by the national government as follows Infant An infant less than 1 year old must ride in the front seat because My vehicle has no rear seat My vehicle has a rear seat too small to accommodate a rear facing infant seat or The infant has a medical condition which according to the infant s physician makes it necessary for the infant to ride in the front seat...

Page 77: ...according to the child s physician makes it necessary for the child to ride in the front seat so that the driver can constantly monitor the child s condition Medical Condition A passenger has a medical condition which according to his or her physician Causes the passenger airbag to pose a special risk for the passenger and Makes the potential harm from the passenger airbag in a crash greater than ...

Page 78: ...here Do not turn off the passenger s airbag unless the person sitting there is in a risk group To turn off the right front passenger s airbag insert your ignition key into the switch push in and move the switch to the off position The airbag off light will come on to let you know that the right front passenger s airbag is off The light will stay on to remind you that the airbag is off The right fr...

Page 79: ... national government has identified as a member of a passenger airbag risk group sit in the right front passenger s position for example do not secure a rear facing child restraint in the right front passenger s seat until you have your vehicle serviced See Airbag Readiness Light on page 165 for additional information To turn the right front passenger s airbag on insert your ignition key into the ...

Page 80: ...ystem To purchase a service manual see Service Publications Ordering Information on page 415 CAUTION For up to 10 seconds after the ignition is turned off and the battery is disconnected an airbag can still inflate during improper service You can be injured if you are close to an airbag when it inflates Avoid yellow connectors They are probably part of the airbag system Be sure to follow proper se...

Page 81: ... modify your vehicle The phone numbers and addresses for Customer Assistance are in Step Two of the Customer Satisfaction Procedure on page 404 Q Because I have a disability I have to get my vehicle modified How can I find out whether this will affect my airbag system A Changing or moving any parts of the front seats safety belts the airbag sensing and diagnostic module steering wheel the instrume...

Page 82: ... Torn or frayed safety belts may not protect you in a crash They can rip apart under impact forces If a belt is torn or frayed get a new one right away Also look for any opened or broken airbag covers and have them repaired or replaced The airbag system does not need regular maintenance Notice If you damage the covering for the driver s or the right front passenger s airbag the airbag may not work...

Page 83: ...ible If you have had a crash do you need new belts After a very minor collision nothing may be necessary But if the belts were stretched as they would be if worn during a more severe crash then you need new parts If belts are cut or damaged replace them Collision damage also may mean you will need to have safety belt or seat parts repaired or replaced New parts and repairs may be necessary even if...

Page 84: ... NOTES 84 ...

Page 85: ...rating 109 Engine Coolant Heater 111 Diesel Engine Exhaust Brake 112 Two Speed Rear Axle Electric Shift Control 113 Air Shift Control Automatic Transmission 114 Automatic Transmission Operation 115 Manual Transmission Operation 116 Power Take Off PTO 118 Four Wheel Drive 119 Parking 125 Parking Brake With Hydraulic Brakes 125 Parking Brake with Air Brakes 126 Parking Brake Burnish Procedure 128 Ai...

Page 86: ...th the ignition key is dangerous for many reasons They could operate the power windows or other controls or even make the vehicle move The children or others could be badly injured or even killed Do not leave the keys in a vehicle with children 86 ...

Page 87: ... Federal Communications Commission FCC Rules and with Industry Canada This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause interference 2 This device must accept any interference received including interference that may cause undesired operation of the device This device complies with RSS 210 of Industry Canada Operatio...

Page 88: ...ssary See Battery Replacement under Remote Keyless Entry RKE System Operation on page 88 If you are still having trouble see your dealer or a qualified technician for service Remote Keyless Entry RKE System Operation If your vehicle has this feature you can lock and unlock your doors from about 3 feet 1 m up to 30 feet 9 m away using the remote keyless entry transmitter supplied with your vehicle ...

Page 89: ...mum of four transmitters matched to it Battery Replacement Under normal use the battery in your remote keyless entry transmitter should last about two years You can tell the battery is weak if the transmitter won t work at the normal range in any location If you have to get close to your vehicle before the transmitter works it s probably time to change the battery Notice When replacing the battery...

Page 90: ...is system The transmitter does not send the same signal twice to the receiver The receiver will not respond to a signal it has been sent previously This prevents anyone from recording and playing back the signal from the transmitter To resynchronize your transmitter stand close to your vehicle and simultaneously press and hold the LOCK and UNLOCK buttons on the transmitter for at least five second...

Page 91: ...ontinued Young children who get into unlocked 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 There are several wa...

Page 92: ...door down To unlock the door slide the manual lever up Power Door Locks If your vehicle has power door locks press the bottom of the power door lock switch to lock all the doors at once To unlock all the doors at once press the top of the power door lock switch When a door is locked the inside door handle will not work 92 ...

Page 93: ...s They can be overcome by the extreme heat and suffer permanent injuries or even death from heat stroke Never leave a child a helpless adult or a pet alone in a vehicle especially with the windows closed in warm or hot weather Manual Windows Turn the hand crank on each door to raise or lower the window 93 ...

Page 94: ...initiate the express down feature Press the top of the switch to stop the window from lowering Window Lockout Crew Cab o Window Lockout The driver s window switches include a lockout feature This prevents the passenger s from operating their windows The driver can still operate all windows with the lockout on Press the button to turn the lockout feature on and off Sliding Rear Window To open the s...

Page 95: ...he first 500 miles 805 km Do not make full throttle starts Avoid making hard stops for the first 200 miles 322 km or so During this time your new brake linings are not yet broken in Hard stops with new linings can mean premature wear and earlier replacement Follow this breaking in guideline every time you get new brake linings Use the lowest gear you can when you start a loaded vehicle in motion a...

Page 96: ...heel and transmission It is a theft deterrent feature You will only be able to remove your key when the ignition is turned to LOCK C OFF This position lets you turn off the engine but still turn the steering wheel It does not lock the steering wheel like LOCK Use OFF if you must have your vehicle in motion while the engine is off D RUN This is the position for driving The battery could be drained ...

Page 97: ...ystem If the starter motor overheats and shuts off due to over cranking the motor must cool down before it will reset and allow starter operation It can take up to six minutes before the starter will work again Starting the Gasoline Engine The 8th digit of your Vehicle Identification Number VIN shows the code letter for your engine Use this number to verify the type of engine in your vehicle See V...

Page 98: ...dle speed will go down as your engine gets warm 2 If the engine does not start in 10 seconds push the accelerator pedal all the way down and crank the engine for five more seconds unless it starts sooner 3 If your engine still will not start or starts but then stops it could be flooded with too much gasoline Wait 15 seconds to let the starter motor cool down Do Steps 1 through 3 again When the eng...

Page 99: ...et your engine idle for a few seconds before turning it off after you have finished driving your vehicle If you shift to NEUTRAL N or PARK P set the parking brake If your vehicle has a two speed axle put the range selector in low To be sure the axle has shifted into low engage the clutch and transmission the vehicle may move slightly when you do this While your engine is idling and before you turn...

Page 100: ...sion Shift to PARK P only when your vehicle is stopped Manual Transmission Move your shift lever to NEUTRAL and hold the clutch pedal to the floor while starting the engine Your vehicle will not start if the clutch pedal is not all the way down that is a safety feature Starting Your Engine 1 Turn your ignition key to RUN Observe the wait to start light See Wait to Start Indicator on page 174 This ...

Page 101: ... up Your engine will sound louder when it is cold Notice If you are not in an idling vehicle and the engine overheats you would not be there to see the overheated engine indication This could damage your vehicle Do not let your engine run when you are not in your vehicle Cold Weather Starting If your vehicle has the 6 6L DURAMAX Diesel Engine and the Isuzu 6H Diesel Engine the following notice app...

Page 102: ...r See Engine Coolant Heater on page 111 See What Fuel to Use on page 253 for information on what fuel to use in cold weather Cold Weather Starting Caterpillar Diesel Because the diesel engine uses compression ignition it is harder to start in cold weather than a gasoline engine The air intake heater and use of the proper engine oil optional engine coolant heaters and optional ether injection syste...

Page 103: ...smission adds heat to the cooling system through the heat exchanger in the radiator Because of this vehicles equipped with automatic transmissions are often able to retain engine coolant heat better than manual transmission vehicles See your Caterpillar Operation Maintenance manual for additional diesel engine warm up information If Your Diesel Engine Will Not Start If you have run out of fuel see...

Page 104: ...e which could cause serious personal injury Engine Alarm and Automatic Shutdown Your check gages warning light will come on if the system senses high engine temperature or low engine oil pressure If high engine temperature or low engine oil pressure is detected you will also hear a tone alarm at two beats per second The alarm and the light will remain on until the condition is fixed If the engine ...

Page 105: ...damage the vehicle Have your vehicle repaired as soon as possible Ambulance Fire and Rescue Packages Your check gages warning light will come on if the system senses high engine temperature or low engine oil pressure If high engine temperature or low engine oil pressure is detected you will also hear a tone alarm at two beats per second The alarm and the light will remain on until the condition is...

Page 106: ...t be pressed for vehicles with gasoline engines If the vehicle has manual transmission the clutch pedal is not pressed or if the vehicle has the automatic transmission it is in NEUTRAL N or PARK P The manual high idle feature is activated by pressing the switch on the instrument panel When the switch is pressed again or any of the previous conditions are not met manual high idle will be deactivate...

Page 107: ...the preset operating temperature This will help decrease engine warm up time On vehicles that have the Caterpillar diesel engine you may have an exhaust restrictor that will operate in High Idle mode The exhaust brake switch must be on for this feature to operate See Diesel Engine Exhaust Brake on page 112 for more information Idle speed will then return to normal under any of the following condit...

Page 108: ...ng the engine coolant temperature faster For all engines this feature is already turned on The automatic quick warm up on the DURAMAX engine can be turned off and on by doing the following procedure 1 Turn the ignition to RUN with the vehicle off 2 Press the accelerator pedal to the floor and hold it while quickly pressing and fully releasing the brake pedal three times in less than eight seconds ...

Page 109: ...re still met Engine Checks Before Operating When you have started your engine let it run for 20 to 30 seconds before you put a load on the engine But do not leave the vehicle while the engine is running Avoid unnecessary idling of diesel engine equipped vehicles If the engine idles too long the temperature of the engine coolant will fall below the normal operating range Low engine operating temper...

Page 110: ...ve idle If the light does not go out or comes back on during normal engine operation have the charging system checked right away This light tells you if the generator is not charging it does not reflect the condition of the battery See Charging System Light on page 167 for more information The voltmeter charge indicator gage tells you the condition of your battery s charge The gage should be in th...

Page 111: ...tlet could cause an electrical shock Also the wrong kind of extension cord could overheat and cause a fire You could be seriously injured Plug the cord into a properly grounded three prong 110 volt AC outlet If the cord will not reach use a heavy duty three prong extension cord rated for at least 15 amps 4 Before starting the engine be sure to unplug and store the cord as it was before to keep it ...

Page 112: ...xhaust brake will be most effective if the gear range selected is the lowest possible range that does not allow the engine rpm to go more than 200 rpm above rated full load rpm If you have a Caterpillar Diesel Engine do not exceed 2900 rpm If you have a Isuzu 6H Diesel engine do not exceed 2550 rpm If you have a DURAMAX 6600 Diesel Engine do not exceed 3600 rpm If your vehicle has an Allison 1000 ...

Page 113: ...range The two speed axle control should be in the up position or low range when you park the vehicle You will need to engage the transmission and move the vehicle a little to assure the axle is in the low range Then apply the parking brake shift into NEUTRAL and shut off the engine Also always start the vehicle in motion with the two speed axle in the low range To shift up from low to high do the ...

Page 114: ...ft into PARK P apply the parking brake and shut off the engine To shift up from low to high range while driving press the bottom of the rear axle shift control switch as you are releasing the accelerator pedal After the shift has occurred apply the accelerator as desired To shift from high to low range while driving press the top of the rear axle shift control switch as you release the accelerator...

Page 115: ...AL N or PARK P to a drive gear All vehicles equipped with automatic transmissions can be started in PARK P if equipped or in NEUTRAL N See the Allison Transmission Operator s Manual in your vehicle for more information about this CAUTION It can be dangerous to get out of your vehicle without the parking brake firmly set Your vehicle can roll If you have left the engine running the vehicle can move...

Page 116: ...the engine speed at idle Then start to engage the clutch 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 It is important not to increase the engine speed sooner or before the clutch begins its engagement If you do you can cause damage to your vehicle Double Clutching You must use the doubl...

Page 117: ... to double clutch if required Eaton Fuller Nine and Ten Speed Non Synchronized Manual Transmissions If your vehicle has one of these transmissions the engine rpm and road speed must match when upshifting and downshifting The label above the windshield will tell you the operating basics you need to know The following are driving tips Always choose an initial starting gear suitable for the load and ...

Page 118: ...ing light pressure to the shift lever This will provide for a smooth shift into either FIRST 1 or REVERSE R gear Notice Using the clutch brake for shifting into any gear other than FIRST 1 or REVERSE R may cause premature wear of the clutch brake and make gear shift effort more difficult Do not use the clutch brake for shifting after engaging FIRST 1 or REVERSE R Power Take Off PTO If your vehicle...

Page 119: ...onditions Notice Driving on clean dry pavement in four wheel drive for an extended period of time can cause premature wear on your vehicle s powertrain Do not drive on clean dry pavement in four wheel drive for extended periods of time Locking Hubs Turn the dial of the hublock A from the Free position to the Lock position to lock the front axle Turn the dial of the hublock A from the Lock position...

Page 120: ...r case cannot make a requested shift it returns to the last chosen setting Recommended Transfer Case Settings Driving Conditions Transfer Case Settings 2 m 4 m 4 n N Normal YES Severe YES Extreme YES Vehicle in Tow YES See Towing Your Vehicle on page 241 for further information 2m Two Wheel High This setting is for driving in most street and highway situations The transfer case does not drive the ...

Page 121: ...to PARK P and make sure the transfer case is in a drive gear Notice If your vehicle has an Allison transmission and you try to put the transmission in PARK P while the transfer case is in Four Wheel Low the transmission might not go into PARK P and could damage your vehicle When parking your vehicle make sure the transfer case is in Two Wheel High or Four Wheel High NEUTRAL Shift the vehicle s tra...

Page 122: ...ission into gear Be sure to lock the front hubs Notice Shifting the transmission into gear before the Four Wheel Drive Low indicator light has stopped flashing could damage the transfer case To help avoid damaging your vehicle always wait for the Four Wheel Drive Low indicator light to stop flashing before shifting the transmission into gear If you turn the knob to Four Wheel Low while your vehicl...

Page 123: ...or light to stop flashing before shifting the transmission into gear If the knob is turned to Four Wheel High or Two Wheel High while your vehicle is in gear and or moving the Four Wheel High or Two Wheel high indicator light flashes for 30 seconds It will not complete the shift unless your vehicle is moving less than 3 mph 5 km h with the transmission in NEUTRAL N Shifting Into NEUTRAL Before shi...

Page 124: ... parking brake on can overheat the brake system and cause premature wear or damage to brake system parts Verify that the parking brake is fully released and the brake warning light is off before driving 6 Release the parking brake 7 Start the engine and shift the transmission lever to the desired position Excessively shifting the transfer case into or out of the different modes can cause the trans...

Page 125: ... need to move the vehicle in gear just a little 2 Hold the regular brake pedal down with your right foot 3 Apply the parking brake 4 Shift the transmission to NEUTRAL for manual transmission or PARK P for automatic transmission Parking Brake With Hydraulic Brakes If your vehicle has hydraulic brakes it has either a parking brake foot pedal or hand lever If you have the parking brake foot pedal it ...

Page 126: ...brake hold the regular brake pedal down Pull the brake release handle located just above the parking brake pedal to release the parking brake To release the hand lever parking brake hold the regular brake pedal down and push down on the handle until it stops If the ignition is on when the parking brake is released the brake system warning light will go off Parking Brake with Air Brakes If your veh...

Page 127: ...r s air brake system do the following 1 Move your vehicle into the proper position 2 Apply the parking brake by pulling the yellow parking brake knob out 3 Hook up the trailer air system properly 4 Get into the vehicle 5 Push and hold down the regular brake pedal 6 Push in both the yellow parking brake and the red trailer air supply knobs This will charge your trailer s air system After a few minu...

Page 128: ...g brakes on the trailer If the air pressure drops to 35 to 45 psi 241 to 310 kPa the yellow park brake knob will automatically pop out and apply the spring brakes on the truck or tractor If you ever have a complete loss of air so that your air brakes automatically apply there is a way that the tow operator can release the parking brakes to tow the vehicle See Towing Your Vehicle on page 241 Parkin...

Page 129: ...613 3 kg 21 000 lb 9 525 4 kg and 23 000 lb 10 432 6 kg capacities Rear Air Suspension Dump Control If your vehicle is equipped with the Hendrickson HAS Series 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 suspen...

Page 130: ...Parking Over Things That Burn CAUTION Things that can burn could touch hot exhaust parts under your vehicle and ignite Do not park over papers leaves dry grass or other things that can burn 130 ...

Page 131: ... vehicle gets rusty underneath Your vehicle was damaged in a collision CAUTION Continued CAUTION Continued 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 has been modified improperly If you ever suspect exhaust is coming into your vehicle Drive it only with all the windows down to blow out any CO...

Page 132: ... a garage with the engine running Another closed in place can be a blizzard See Winter Driving on page 231 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 vehic...

Page 133: ...icle from a comfortable driving position All mirrors can be folded in to enter narrow passageways Outside Power Mirrors If you have outside power mirrors they can be adjusted from the inside of the vehicle The control for this feature is located on the driver s door Select the mirror you want to move by turning the switch clockwise to adjust the passenger s side mirror or counterclockwise to adjus...

Page 134: ...driver s side and the passenger s side They are curved to allow 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 your vehicle has this feature your outside rearview mirrors can be defrosted The switch for this feature is located in the instrument panel switchbank Press the bottom of the switch to turn the outsid...

Page 135: ...th sides of the vehicle Center Console Storage Area Your vehicle may have a center console compartment if you have the bucket or suspension seats The back of your center bench seat may also fold forward to reveal a console compartment The release strap for the center console is located between the center seat and passenger s seat To expose the storage compartment pull the strap to release the seat...

Page 136: ... NOTES 136 ...

Page 137: ...sory Power Outlet s 156 Ashtray s and Cigarette Lighter 157 Climate Controls 157 Climate Control System 157 Outlet Adjustment 160 Rear Heating System 161 Warning Lights Gages and Indicators 161 Instrument Panel Cluster 162 Speedometer and Odometer 163 Trip Odometer 163 Tachometer 163 Engine Speed Limiter 164 Safety Belt Reminder Light 164 Safety Belt Reminder Tone 164 Airbag Readiness Light 165 Ai...

Page 138: ...r Light 179 Highbeam On Light 179 Daytime Running Lamps DRL Indicator Light 179 Low Washer Fluid Warning Light 180 Check Gages Warning Light 180 Fuel Gage 181 Water in Fuel Warning Light 182 Air Filter Restriction Indicator 182 Air Pressure Gage 183 Hourmeter Gage 183 Audio System s 184 Setting the Time 185 AM FM Radio 186 Radio with Cassette 189 Radio with CD 195 Theft Deterrent Feature Non RDS R...

Page 139: ... NOTES 139 ...

Page 140: ...Instrument Panel Overview Automatic Transmission Shown 140 ...

Page 141: ...pped See Air Filter Restriction Indicator on page 182 F Auxiliary Gages See Warning Lights Gages and Indicators on page 161 G Exterior Lamp Control See Exterior Lamps on page 150 H Turn Signal Multifunction Lever See Turn Signal Multifunction Lever on page 143 I Hazard Warning Flashers Button See Hazard Warning Flashers on page 142 J Audio System s See Audio System s on page 184 K Climate Controls...

Page 142: ...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 pushing the center of the steering wheel If you have the optional air horn it is controlled by a cord that you will find up above and to the left of the driver The harder you pull on the cord the louder the air horn will sound The air h...

Page 143: ...heel in place Turn Signal Multifunction Lever The 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 144 Headlamp High Low Beam Changer See Headlamp High Low Beam Changer on page 144 Windshield Wipers See Windshield Wipers on page 145 Windshield Washer See Windshield Washer on page 146 Cruise Control Op...

Page 144: ...til you complete your lane change The lever will return by itself when you release it As you signal a turn or a lane change if the arrows don t flash but just stay on check the turn signal flasher and circuit breaker See Fuses and Circuit Breakers on page 341 If a bulb is burned out replace it to help avoid an accident If the arrows don t go on at all when you signal a turn check the circuit break...

Page 145: ... band toward you to the first solid band below the delay settings For high speed wiping turn the band farther to the last solid band below the delay settings To stop the wipers move the band to off 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 ...

Page 146: ...her until the windshield is warmed Otherwise the washer fluid can form ice on the windshield blocking your vision Cruise Control If your vehicle has this feature it is located at the end of the multifunction lever T Set Pressing in this button at the end of the lever sets the cruise control speed 9 Off Moving the switch to this position turns off the cruise control R On Moving the switch to this p...

Page 147: ...winding roads or in heavy traffic Cruise control can be dangerous on slippery roads On such roads fast changes in tire traction can cause excessive wheel slip and you could lose control Do not use cruise control on slippery roads Setting Cruise Control 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 cou...

Page 148: ...g Cruise Control There are two ways to go to a higher speed Use the accelerator pedal to get to the higher speed Press the button at the end of the lever then release the button and the accelerator pedal You ll now cruise at the higher speed Move the cruise switch from on to resume accelerate Hold it there until you get up to the speed you want and then release the switch To increase your speed in...

Page 149: ...takes you out of cruise control Many drivers find this to be too much trouble and don t use cruise control on steep hills If your vehicle is equipped with the exhaust brake option and the exhaust brake is turned on the exhaust brake may come on and try to slow down the vehicle to the set cruise control speed if the vehicle has accelerated past the set cruise control speed while going downhill Endi...

Page 150: ...ps Turning the control to this position turns on the headlamps together with the previously listed lamps and lights You can switch your headlamps from low to high beam by pulling the turn signal multifunction lever toward you Pull the lever toward you again to return to low beam A circuit breaker protects your headlamps If you have an electrical overload your headlamps will flicker on and off Have...

Page 151: ...lamp control is off and the parking brake is released When the DRL are on only your headlamps will be on The taillamps sidemarker and other lamps won t be on Your instrument panel won t be lit up either When it begins to get dark your DRL indicator light is a reminder to turn the headlamps on The other lamps that come on with your headlamps will also come on When you turn the headlamps off the reg...

Page 152: ...ps will come back on Instrument Panel Brightness This feature controls the brightness of the instrument panel lights The thumbwheel for this feature is located to the right of the exterior lamp control Turn the thumbwheel up to brighten the lights When the thumbwheel is moved to the first position the radio display and transmission selection display will go to full intensity The instrument panel c...

Page 153: ...sed You can use the dome override button to set the dome lamps to automatically come on when a door is open or to remain off The dome override button is located below the exterior lamp control If the dome override button is pushed in the dome lamps will not come on Use this feature when you want to leave your door s open for an extended period of time and do not want to run the battery down If the...

Page 154: ...t your vehicle with the lights on for about 20 seconds after the door is closed or the ignition is cycled Reading Lamps If your vehicle has reading lamps press the button next to the lamp to turn the lamp on or off Instrument Panel Switchbank Vehicles Without Four Wheel Drive 154 ...

Page 155: ...itch See Power Take Off PTO on page 118 h Rear Air Suspension Dump Control Switch Air Suspension on page 129 k Rear Axle Shift Control Switch See Air Shift Control Automatic Transmission on page 114 q Exhaust Brake Switch See Diesel Engine Exhaust Brake on page 112 l Differential Lock Control Switch See Rear Axle Differential Lock Control on page 215 c Airbag On Off Switch See Airbag Off Switch on...

Page 156: ...not be compatible with the accessory power outlet and could result in blown vehicle or adapter fuses If you experience a problem see your dealer for additional information on accessory power outlets Notice Adding any electrical equipment to your vehicle may damage it or keep other components from working as they should The repairs would not be covered by your warranty Do not use equipment exceedin...

Page 157: ...l 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 Climate Controls Climate Control System With these systems you can control the heating co...

Page 158: ...efogging and Defrosting later in this section 9 Fan Turn the left knob clockwise or counterclockwise to increase or decrease the fan speed To increase airflow turn the knob clockwise To decrease airflow turn it counterclockwise To turn the fan off turn the mode knob on the far right counterclockwise to the off position Temperature Knob Turn the middle knob located clockwise or counterclockwise to ...

Page 159: ... mode to clear the windows of fog or moisture and warm the passengers Use the defrost mode to remove fog or frost from the windshield more quickly For best results clear all snow and ice from the windshield before defrosting Turn the mode knob on the right of the climate control panel to select the defog or defrost mode Defog With this setting the outside air comes out of both the floor and defros...

Page 160: ...ch a temporary vehicle license tape a decal or anything similar to the defogger grid Outlet Adjustment Your vehicle has air outlets on the instrument panel that allow you to adjust the direction and amount of airflow inside the vehicle Move the lever on the outlet up or down to direct the airflow Increase or reduce the amount of airflow by opening and closing the louvers The outlets can be moved s...

Page 161: ...warning lights and gages could also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see in the details on the next few pages some warning lights come on briefly when you start the engine just to let you know they are working If you are familiar with this section you should not be alarmed when this happens Gage...

Page 162: ...you know at a glance how your vehicle is running You will know how fast you are going about how much fuel is left and many other things you will need to drive safely and economically United States Isuzu 6H Diesel Engine shown Canada 6 6L Diesel and Gasoline Engine similar 162 ...

Page 163: ... 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 Hourmeter Ga...

Page 164: ...though some tire sizes and tread patterns may limit maximum speed to 55 to 65 mph 86 to 105 km h You may have a label on the headliner of your vehicle with more information on your engine road speed governor See your GM dealer for assistance with programming your engine limited speed Safety Belt Reminder Light When the key is turned to RUN or START a light will come on for several seconds to remin...

Page 165: ...o out This means the system is ready If the airbag readiness light stays on after you start the vehicle or comes on when you are driving your airbag system may not work properly Have your vehicle serviced right away The airbag readiness light should flash for a few seconds when you turn the ignition key to RUN or START If the light doesn t come on then have it fixed so it will be ready to warn you...

Page 166: ...important safety information CAUTION If the right front passenger s airbag is turned off for a person who is not in a risk group identified by the national government that person will not have the extra protection of an airbag In a crash the airbag will not be able to inflate and help protect the person sitting there Do not turn off the passenger s airbag unless the person sitting there is in a ri...

Page 167: ...5 for more on this including important safety information 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 ...

Page 168: ...s allow the charging system to create maximum power You can only drive a short time on the battery Be sure to shut off the radio the fan or any unnecessary accessories and have the system serviced Service Transmission Warning 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 ...

Page 169: ...hicle has an Allison 3000 3500 series automatic transmission the current gear selected on the pushbutton display will flash The flashing bar or gear selection indicates that transmission range shifts may not occur For detailed information on shift inhibit limitations see the Allison Automatic Transmission Operator s Manual in your vehicle for further information Brake System Warning Light Your veh...

Page 170: ...ghts should come on briefly every time you start your engine If they do not come on then have them fixed so they will be ready to warn you if there is a problem If one or both of these warning lights stay on after you start the engine there could be a brake problem Have your brake system inspected right away If one or both of these lights come on while you are driving pull off the road and stop ca...

Page 171: ...g light comes on while you are driving you should drive only as far as the nearest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the air brake system warning light comes on and the warning tone sounds the vehicle can stop suddenly and without further warning This is because the parking brake will come on if the pressure falls below 35 to 45 psi ...

Page 172: ...e 212 for more information The anti lock brake system warning light should come on briefly when you turn the ignition key to ON If the light does not come on then have it fixed so it will be ready to warn you if there is a problem Trailer Anti Lock Brake System Warning Light This light is located above the climate controls in the center of the instrument panel If your vehicle is connected to a tra...

Page 173: ...ing light If this light comes on your system is low on coolant and the engine may overheat The warning light should come on briefly as a check when you turn on the ignition When it comes on you will also hear a warning tone at several beats per second for 10 seconds See Engine Coolant Gas and DURAMAX Isuzu Engines on page 284 or Engine Coolant Caterpillar Diesel Engines on page 287 and have your v...

Page 174: ...ight comes on or flashes while you are driving two things may happen First you will not notice any difference in engine performance but your tail pipe emissions may increase Second your engine may not run properly or may stall without warning If either of these things happen drive or tow your vehicle to your dealer for service This light should come on when the ignition is on but the engine is not...

Page 175: ...5 and 70 psi 240 to 480 kPa A reading in the low pressure zone may be caused by a dangerously low oil level or other problem If you have a Caterpillar diesel engine also see your Caterpillar Operation Maintenance Manual CAUTION Do not keep driving if the oil pressure is low If you do your engine can become so hot that it catches fire You or others could be burned Check your oil as soon as possible...

Page 176: ...r engine is low on oil You need to check the oil level right away See Engine Oil Caterpillar Diesel Engine on page 268 or Engine Oil Gasoline Engine on page 268 or Engine Oil DURAMAX Isuzu Diesel Engine on page 272 for further information Notice Lack of proper engine oil maintenance may damage the engine The repairs would not be covered by your warranty Always follow the maintenance schedule in th...

Page 177: ...X Diesel on page 278 or Engine Oil Life System Caterpillar Diesel Engine on page 279 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 comes on when you re driving reduce your engine speed immediately Engine Shutdown Warning Li...

Page 178: ... that would not be covered by your warranty Do not drive your vehicle while the transmission temperature gage reading is above normal See your dealer for service Exhaust Brake Indicator Light If your vehicle is equipped with an exhaust brake you will have this light located above the climate controls in the center of the instrument panel The exhaust brake indicator light will come on and stay on w...

Page 179: ...e 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 dealer as soon as possible for service Highbeam On Light This light comes on when the high beam headlamps are in use See ...

Page 180: ...is light comes on and stays on while you are driving 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 The tone and the light will stay activated until the problem is corrected This light may also come on if your vehicle is equipped with the op...

Page 181: ...s the reading on the gage is the total fuel left in both tanks Here 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 does not 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 ...

Page 182: ... Air Filter Restriction Indicator If your vehicle has this feature the gage is located above the switchbank in the center of the instrument panel It monitors the engine air filter As the filter gets dirty the yellow indicator will begin to rise When it reaches 25 inches of vacuum on the scale the filter should be replaced After replacing the filter reset the gage by pressing in the yellow reset bu...

Page 183: ...showing between the systems Don t drive until both pointers are showing at least 120 psi 827 kPa so you ll have enough air if you 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 displa...

Page 184: ... vehicle is parked set up your audio system by presetting your favorite radio stations setting the tone and adjusting the speakers Then when driving conditions permit you can tune to your favorite stations using the presets and steering wheel controls if the vehicle has them CAUTION This system provides you with a far greater access to audio stations and song listings Giving extended attention to ...

Page 185: ...ded it is very important to do it properly Added sound equipment may interfere with the operation of your vehicle s engine radio or other systems and even damage them Your vehicle s systems may interfere with the operation of sound equipment that has been added Notice The chime signals related to safety belts parking brake and other functions of your vehicle operate through the radio entertainment...

Page 186: ... Press the right or the left arrow to go to the next or to the previous station and stay there To scan stations press and hold either SEEK arrow for two seconds until a beep sounds The radio goes to a station plays for a few seconds then goes to the next station Press either SEEK arrow again to stop scanning To scan preset stations press and hold either SEEK arrow for more than four seconds until ...

Page 187: ...UDIO until BAS bass or TRE treble displays Then press and hold the up or the down arrow to increase or to decrease the tone If a station is weak or has static decrease the treble To adjust bass or treble to the middle position select BAS bass or TRE treble Then press and hold AUDIO for more than two seconds until a beep sounds B balance and a zero or T treble and a zero displays To adjust both ton...

Page 188: ...lays To adjust both tone controls and both speaker controls to the middle position first exit out of audio mode by pressing another button causing the radio to perform that function or wait five seconds for the display to return to time of day Then press and hold AUDIO for more than two seconds until a beep sounds CEN center displays Fade might not be available if the vehicle is a regular cab mode...

Page 189: ... to the next or to the previous station and stay there To scan stations press and hold one of the SEEK arrows for two seconds until you hear a beep The radio goes to a station plays for a few seconds and flashes the station frequency then goes to the next station Press one of the SEEK arrows again to stop scanning To scan preset stations press and hold one of the SEEK arrows for more than four sec...

Page 190: ...t bass and treble press and release AUDIO until BAS bass or TRE treble appears on the display Then press and hold the up or the down arrow to increase or to decrease If a station is weak or has static decrease the treble To adjust bass or treble to the middle position select BAS or TRE Then press and hold AUDIO for more than two seconds until you hear a beep B and a zero or T and a zero appears on...

Page 191: ... display Then press and hold AUDIO for more than two seconds until you hear a beep CEN center appears on the display Fade may not be available if the vehicle is a regular cab model Radio Messages CAL Calibration The audio system has been calibrated for your vehicle from the factory If CAL appears on the display it means that the radio has not been configured properly for your vehicle and must be r...

Page 192: ...ust have at least three seconds of silence between each selection for previous to work Press this pushbutton to go to the previous selection on the tape if the current selection has been playing for less than three seconds If pressed when the current selection has been playing from three to 13 seconds it goes to the beginning of the previous selection or the beginning of the current selection depe...

Page 193: ...r repeat to work Press and release this pushbutton to hear a selection over again RPT appears on the display Press this pushbutton again to turn off repeated play OFF appears on the display oSEEK p The tape must have at least three seconds of silence between each selection for seek to work The left arrow is the same as the PREV pushbutton and the right arrow is the same as the NEXT pushbutton If e...

Page 194: ...If any error occurs repeatedly or if an error cannot be corrected contact your dealer If the radio displays an error message write it down and provide it to your dealer when reporting the problem CD Adapter Kits It is possible to use a portable CD player adapter kit with the cassette tape player after deactivating the tight loose tape sensor feature on the tape player To deactivate this feature us...

Page 195: ...p Press the right or the left arrow to go to the next or to the previous station and stay there To scan stations press and hold either SEEK arrow for two seconds until you hear a beep The radio goes to a station plays for a few seconds then goes to the next station Press either SEEK arrow again to stop scanning To scan preset stations press and hold either SEEK arrow for more than four seconds unt...

Page 196: ...AS bass or TRE treble appears on the display Then press and hold the up or the down arrow to increase or to decrease If a station is weak or has static decrease the treble To adjust bass or treble to the middle position select BAS or TRE Then press and hold the AUDIO button for more than two seconds until you hear a beep B and a zero or T and a zero appears on the display To adjust both tone contr...

Page 197: ...ears on the display To adjust both tone controls and both speaker controls to the middle position first end out of audio mode by pressing another button causing the radio to perform that function or by waiting five seconds for the display to return to the time of day Then press and hold the AUDIO button for more than two seconds until you hear a beep CEN appears on the display Fade may not be avai...

Page 198: ...mber appears on the display The CD player can play the smaller 3 inch 8 cm single CDs with an adapter ring Full size CDs and the smaller CDs are loaded in the same manner If playing a CD R the sound quality may be reduced due to CD R quality the method of recording the quality of the music that has been recorded and the way the CD R has been handled There may be an increase in skipping difficulty ...

Page 199: ...ressed more than once the player continues moving backward through the CD 2 NEXT Press this pushbutton to go to the next track The track number appears on the display If this pushbutton is held or pressed more than once the player continues moving forward through the CD 3 REV Reverse Press and hold this pushbutton to reverse quickly within a track Release this pushbutton to play the passage The el...

Page 200: ... activated with either the ignition or radio off CDs may be loaded with the ignition and radio off if this button is pressed first CD Messages If the CD comes out it could be for one of the following reasons It is very hot When the temperature returns to normal the CD should play You are driving on a very rough road When the road becomes smoother the CD should play The CD is dirty scratched wet or...

Page 201: ...plugged into the accessory power outlet If there is interference or static unplug the item from the accessory power outlet AM The range for most AM stations is greater than for FM especially at night The longer range can cause station frequencies to interfere with each other For better radio reception most AM radio stations will boost the power levels during the day and then reduce these levels du...

Page 202: ...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 The cut tape detecti...

Page 203: ...ys make sure the cassette tape is in good condition before the tape player is serviced Care of Your CDs Handle CDs carefully Store them in their original cases or other protective cases and away from direct sunlight and dust The CD player scans the bottom surface of the disc If the surface of a CD is damaged such as cracked broken or scratched the CD will not play properly or not at all If the sur...

Page 204: ...er turn Chime Level Adjustment The radio is used to adjust the vehicle s chime level To change the volume level of the chime press and hold pushbutton 6 with the ignition on and the radio power off The volume level will change from the normal level to loud and HI will appear on the radio display To change back to the default or normal setting press and hold pushbutton 6 again The volume level will...

Page 205: ...m TCS 216 Steering 217 Off Road Recovery 219 Passing 220 Loss of Control 221 Driving at Night 223 Driving in Rain and on Wet Roads 224 City Driving 227 Freeway Driving 228 Highway Hypnosis 229 Hill and Mountain Roads 230 Winter Driving 231 If Your Vehicle is Stuck in Sand Mud Ice or Snow 236 Rocking Your Vehicle to Get It Out 236 Tow Hooks 237 Loading Your Vehicle 238 Adding a Snow Plow or Similar...

Page 206: ... pedestrians or other drivers are going to be careless and make mistakes Anticipate what they might do and be ready Rear end collisions are about the most preventable of accidents Yet they are common Allow enough following distance Defensive driving requires that a driver concentrate on the driving task Anything that distracts from the driving task makes proper defensive driving more difficult and...

Page 207: ...ates nearly half the adult population choose never to drink alcohol so they never drive after drinking For persons under 21 it is against the law in every U S state to drink alcohol There are good medical psychological and developmental reasons for these laws The obvious way to eliminate the leading highway safety problem is for people never to drink alcohol and then drive But what if people do Ho...

Page 208: ... drinking will have a somewhat lower BAC level There is a gender difference too Women generally have a lower relative percentage of body water than men Since alcohol is carried in body water this means that a woman generally will reach a higher BAC level than a man of her same body weight will when each has the same number of drinks The law in most U S states and throughout Canada sets the legal l...

Page 209: ...t answer What if there is an emergency a need to take sudden action as when a child darts into the street A person with even a moderate BAC might not be able to react quickly enough to avoid the collision There is something else about drinking and driving that many people do not know Medical research shows that alcohol in a person s system can make crash injuries worse especially injuries to the b...

Page 210: ...ot 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 do alcohol drugs and frustration But even in three fourths of a second a vehicle moving at 60 mph 100 km h trave...

Page 211: ... assist is used up it may take longer to stop and the brake pedal will be harder to push Hydraulic Brake Systems If your engine stops running or if your primary brake system stops working your vehicle has a reserve power assist system to help you slow down Just slowly and steadily apply the brake pedal until you can safely get off the road The pedal will seem harder to push down Do not pump the pe...

Page 212: ...this test is going on This is normal If there is a problem with ABS this warning light will stay on See Anti Lock Brake System Warning Light on page 172 Let us say the road is wet and you are driving safely Suddenly an animal jumps out in front of you You slam on the brakes and continue braking Here is what happens with ABS A computer senses that wheels are slowing down If one of the wheels is abo...

Page 213: ... or always decrease stopping distance If you get too close to the vehicle in front of you you will not have time to apply your brakes if that vehicle suddenly slows or stops Always leave enough room up ahead to stop even though you have ABS Using ABS Do not pump the brakes Just hold the brake pedal down firmly and let anti lock work for you You may feel the brakes pulsate or you may hear air exhau...

Page 214: ...you have to Use this control only when you are driving Do not use it for parking or to hold the rig on a hill CAUTION Using the trailer brake hand control for parking or for holding the vehicle on a hill may not keep the vehicle from rolling This can happen if someone hits the valve by accident or if air pressure bleeds from the system If the vehicle rolls you or others could be injured To park th...

Page 215: ...ly to both rear wheels Let up on the accelerator before you turn on your rear axle differential lock Notice Turning on the inter axle differential lock while the rear wheels are spinning freely as they might on snow or ice can damage the axle s Turn on this control only while the wheels are not spinning freely Interaxle Differential Lock This switch is located on the center instrument panel You wi...

Page 216: ...s of these conditions include a hard acceleration in a turn an abrupt upshift or downshift of the transmission or driving on rough roads When the light in the top of the TCS button 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 o...

Page 217: ...akes the power steering and main hydraulic brake system both use the power steering pump See Braking on page 210 Steering Tips Driving on Curves It is important to take curves at a reasonable speed A lot of the driver lost control accidents mentioned on the news happen on curves Here is why Experienced driver or beginner each of us is subject to the same laws of physics when driving on curves The ...

Page 218: ...ower If you need to reduce your speed as you approach a curve do it before you enter the curve while your front wheels are straight ahead Try to adjust your speed so you can drive through the curve Maintain a reasonable steady speed Wait to accelerate until you are out of the curve and then accelerate gently into the straightaway Steering in Emergencies There are times when steering can be more ef...

Page 219: ...od reason to practice defensive driving at all times and wear safety belts properly Off Road Recovery You may find that your right wheels have dropped off the edge of a road onto the shoulder while you are driving If the level of the shoulder is only slightly below the pavement recovery should be fairly easy Ease off the accelerator and then if there is nothing in the way steer so that your vehicl...

Page 220: ...ahead than you would with a passenger car Drive ahead Look down the road to the sides and to crossroads for situations that might affect your passing patterns If you have any doubt whatsoever about making a successful pass wait for a better time Watch for traffic signs pavement markings and lines If you can see a sign up ahead that might indicate a turn or an intersection delay your pass A broken ...

Page 221: ...e to see its front in your vehicle s passenger side outside mirror activate the right lane change signal and move back into the right lane Remember that if your vehicle s right outside mirror is convex the vehicle you just passed may seem to be further away from you than it really is Try not to pass more than one vehicle at a time on two lane roads Reconsider before passing the next vehicle Do not...

Page 222: ... 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 vehicle control more limited While driving on a surface with reduced traction try your best to avoid sudden steering acceleration or braking including red...

Page 223: ...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 day in bright sunshine you are wise to wear sunglasses Your eyes will have less trouble adjusting to night But if you are driv...

Page 224: ...jects Just as the 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 Rain and on Wet Roads Rain and wet roads can mean driving trouble On a wet road you cannot stop accelerate or turn as well because your tire to road traction is not as good...

Page 225: ...rakes work normally Driving too fast through large water puddles or even going through some vehicle washes can cause problems too The water may affect your brakes Try to avoid puddles But if you cannot try to slow down before you hit them 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 road is wet en...

Page 226: ... 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 you...

Page 227: ...y 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 228 Treat a green light as a warning signal A traffic light is there because...

Page 228: ... that leads to the freeway If you have a clear view of the freeway as you drive along the entrance ramp you should begin to check traffic Try to determine where you expect to blend with the flow Try to merge into the gap at close to the prevailing speed Switch on your turn signal check your mirrors and try to blend smoothly with the traffic flow Once you are on the freeway adjust your speed to the...

Page 229: ...n falling asleep at the wheel Call it highway hypnosis lack of awareness or whatever When you drive the vehicle for a long distance there is something about an easy stretch of road with the same scenery along with the hum of the tires on the road the drone of the engine and the rush of the wind against the vehicle that can make you sleepy Do not let it happen to you If it does your vehicle can lea...

Page 230: ...t 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 crash Shift down to let your engine assist your brakes on a steep downhill slope CAUTION Coasting downhill in NEUTRAL N or with the ignition off is dangerous Your brakes will have to do all the work of slowing down They could get so hot that they would not wor...

Page 231: ...nter 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 mountains that warn of special problems Examples are long grades passing or no passing zones a falling rocks area winding roads and special truck lanes Be alert to these and take appropriat...

Page 232: ...e the tires meet the road probably have good traction However if there is snow or ice between the tires and the road you can have a very slippery situation You will have a lot less traction or grip and will need to be very careful What is the worst time for this Wet ice Very cold snow or ice can be slick and hard to drive on But wet ice can be even more trouble because it may offer the least tract...

Page 233: ...ake very gently too If you do have ABS see Anti Lock Brake System ABS on page 212 ABS improves your vehicle s stability when you make a hard stop on a slippery road Whether you have ABS or not you will want to begin stopping sooner than you would on dry pavement Without ABS if you feel your vehicle begin to slide let up on the brakes a little Push the brake pedal down steadily to get the most trac...

Page 234: ... help and keep yourself and your passengers safe Turn on your hazard flashers Tie a red cloth to your mirror arm to alert police that you have been stopped by the snow Put on extra clothing or wrap a blanket around you If you do not have blankets or extra clothing make body insulators from newspapers burlap bags rags floor mats anything you can wrap around yourself or tuck under your clothing to k...

Page 235: ...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 236: ...ack and forth you can destroy the transmission Rocking Your Vehicle to Get It Out First turn the steering wheel left and right That will clear the area around the front wheels If you have a four wheel drive vehicle shift into 4HI See Four Wheel Drive on page 119 If your vehicle has traction control you should turn the traction control system off See Traction Control System TCS on page 216 Then shi...

Page 237: ...could be injured from the chain 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 If your vehicle has tow hooks the hooks are at the front and on some models the rear of the vehicle You may need to use them if you are stuck off road and need to be pulled to some place where you can continue driving 237 ...

Page 238: ... the maximum weight for the front and rear axles called the Gross Axle Weight Rating GAWR To find out the actual loads on your front and rear axles go to a weigh station and weigh your vehicle Your dealer can help you with this Be sure to spread out your load equally on both sides of the center line Never exceed the GVWR for your vehicle or the GAWR for either the front or rear axle And if you do ...

Page 239: ... as the vehicle goes If you have to stop or turn quickly or if there is a crash they keep going CAUTION Things you put inside your vehicle can strike and injure people in a sudden stop or turn or in a crash Put things in the cargo area of your vehicle Try to spread the weight evenly Never stack heavier things like suitcases inside the vehicle so that some of them are above the tops of the seats Do...

Page 240: ... certain front mounted equipment such as a snow plow it may be possible to load the front axle to the front gross axle weight rating GAWR but not have enough weight on the rear axle to have proper braking performance If your brakes can not work properly you could have a crash To help your brakes work properly when a snow plow is installed always follow the snow plow manufacturer or installer s rec...

Page 241: ...roblem 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 using the following steps Then your vehicle can be towed with all wheels or only the rear wheels on the ground 1 Block the wheels of the vehicle 2 Remove the release stud and nut from the side of t...

Page 242: ... 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 243: ...ps Light Blue CHMSL Red Battery Feed Dark Blue Trailer Brake Trailer Connections C7 C8 Models Only If your vehicle has these trailer connections they are located at the rear of the cab for a tractor and at the rear of the chassis when towing a trailer There will be an air connection and an electrical connection Be sure that the couplings to the trailer are made correctly Air Connections If you are...

Page 244: ... NOTES 244 ...

Page 245: ...le Fuel Container 266 Checking Things Under the Hood 266 Hood Latches 267 Engine Oil Caterpillar Diesel Engine 268 Engine Oil Gasoline Engine 268 Engine Oil DURAMAX Isuzu Diesel Engine 272 Engine Oil Life System Gasoline Engine 276 Engine Oil Life System DURAMAX Diesel 278 Engine Oil Life System Caterpillar Diesel Engine 279 Engine Air Cleaner Filter 280 Automatic Transmission Fluid 282 Manual Tra...

Page 246: ... Blade Replacement 316 Other Service Items 317 Fuel Filter 317 Primary Fuel Filter and Water Separator 317 Secondary Fuel Filter and Water Separator Heater Caterpillar Diesel 318 Automatic Ether Injection System Caterpillar Diesel 318 Front Wheel Bearings with Oil Filled Hubs 319 Air Conditioning System 320 Tires 321 Inflation Tire Pressure 322 Wheel Loading 323 Dual Tire Operation 323 When It Is ...

Page 247: ...amage 338 Underbody Maintenance 338 Chemical Paint Spotting 338 Vehicle Identification 340 Vehicle Identification Number VIN 340 Service Parts Identification Label 340 Electrical System 340 Add On Electrical Equipment 340 Headlamp Wiring 341 Windshield Wiper Fuses 341 Fusible Links 341 Power Windows and Other Power Options 341 Fuses and Circuit Breakers 341 Instrument Panel Fuse Block 342 Underhoo...

Page 248: ...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 249: ...rong fasteners parts can later break or fall off You could be hurt If you want to do some of your own service work you will want to use the proper service manual It tells you much more about how to service your vehicle than this manual can To order the proper service manual see Service Publications Ordering Information on page 415 Your vehicle has an airbag system Before attempting to do your own ...

Page 250: ... vehicle Do not change the fan drive ratio or increase the governed speed of the vehicle without getting the necessary information from your dealer CAUTION Continued CAUTION Continued Winter Fronts Grille Covers or Obstructions Winter Fronts grille covers or other add on equipment causing obstructions in front or behind the fan should not be used on this vehicle If this causes the fan to eventuall...

Page 251: ...rating is less than 87 you may notice an audible knocking noise when you drive commonly referred to as spark knock If this occurs use a gasoline rated at 87 octane or higher as soon as possible If you are using gasoline rated at 87 octane or higher and you hear heavy knocking your engine needs service Gasoline Specifications At a minimum gasoline should meet ASTM specification D 4814 in the United...

Page 252: ...n your area General Motors recommends that you use these gasolines if they comply with the specifications described earlier However E85 85 ethanol and other fuels containing more than 10 ethanol must not be used in vehicles that were not designed for those fuels Notice Your vehicle was not designed for fuel that contains methanol Do not use fuel containing methanol It can corrode metal parts in yo...

Page 253: ... run out of fuel Running Out of Fuel on page 262 tells you how to restart your engine What Fuel to Use In the United States for best results use No 2 D diesel fuel year round above and below freezing conditions as oil companies blend No 2 D fuel to address climate differences No 1 D diesel fuel may be used in very cold temperatures when it stays below 0 F or 18 C however it will produce a power an...

Page 254: ...meet the latest version of ASTM specification D 6751 Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to your fuel system and engine Higher concentration i e greater than B5 biodiesel containing fuels or the use of unmodified bio oils blended into diesel fuel at any concentration is not recommended and could damage your ...

Page 255: ...sociation 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 less noise and better vehicle performance If there are questions about the fuel you are using contact your fuel supplier If your vehicle has the 6 6L engine it is acceptable to use diesel fuel containi...

Page 256: ...Notice If there is water in your diesel fuel and the weather is warm or humid fungus and bacteria can grow in the fuel They can damage your fuel system A diesel fuel biocide can be used to sterilize your fuel system However 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 q...

Page 257: ...g 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 once To drain water do the following 1 Stop and park the vehicle in a safe place Tur...

Page 258: ...draining the water from the fuel filter air may enter the fuel system If air has entered the fuel system the fuel system will need to be primed If the water in fuel light comes on again after driving a short distance or 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 If your vehicle has a Caterpillar di...

Page 259: ...m is primed and the air is removed Priming the 6 6L DURAMAX Diesel Engine If your vehicle is equipped with the 6 6L DURAMAX diesel engine it has a priming pump which is part of the engine mounted fuel filter The vent valve and the fuel filter primer pump are located on top of the fuel filter housing The priming pump is hand operated and is designed to bring fuel to the engine to eliminate any air ...

Page 260: ...Let the pump return upward between pushes 7 Operate the priming pump until a small amount of fuel seeps from the vent valve When you see the fuel the filter is now full of fuel and the system should be primed 8 Close the vent valve 9 Clean any fuel which accumulated on the fuel filter 10 Start the engine and let it idle for a few minutes 11 Check the filter for leaks 260 ...

Page 261: ...r resistance becomes firm This may take from 20 to 100 times depending upon fuel tank location 7 Turn the fuel filter breather valve screw 2 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...

Page 262: ...ou are parked on a slope you may need to add up to 5 gallons 18 9 liters of fuel 2 Follow the fuel priming procedure earlier in this section to prime the fuel filter 3 Close the air bleed valve 4 Turn the ignition key to START for 10 to 15 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 ...

Page 263: ...he fuel filters are located in the engine compartment on the driver s side of the vehicle and on the driver s side frame rail in front of the fuel tank 1 Apply the parking brake 2 Unplug the water sensor wire connected to the fuel filter and unscrew the filter element 3 Remove the filter element If there is any dirt on the filter sealing surface clean it off Remove and reuse the water sensor float...

Page 264: ...company that does business in the country where you will be driving Filling the Tank CAUTION Fuel vapor is highly flammable It burns violently and that can cause very bad injuries Do not smoke if you are near fuel or refueling your vehicle Keep sparks flames and smoking materials away from fuel The fuel cap can be on either or both sides of your vehicle depending on option content To take off the ...

Page 265: ...is may cause your malfunction indicator lamp to light and may damage your fuel tank and emissions system See Malfunction Indicator Lamp on page 174 If you have dual tanks fill the driver s side tank or forward tank first The fuel gage will give better readings this way Your gage will show the total fuel left in both tanks If your vehicle is a C4 C5 model and you have dual tanks the engine must be ...

Page 266: ...cle in a vehicle s trunk pickup bed or on any surface 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 CAUTION Things that burn can get on hot engine parts and start a fire These include liquids like fuel...

Page 267: ...Hood Latches To tilt the hood forward pull back and up on each of the hood latches located above the wheel wells on both sides of the vehicle Then take the hand hold and pull the hood forward 267 ...

Page 268: ...tion Maintenance Manual for information on oil quality and viscosities as well as the temperature range chart Engine Oil Gasoline Engine If the low oil light appears on the instrument cluster it means you need to check the engine oil level right away For more information see Low Oil Level Light on page 176 You should check the engine oil level regularly this is an added reminder 268 ...

Page 269: ...Pull out the dipstick and clean it with a paper towel or cloth then push it back in all the way Remove it again keeping the tip down and check the level When to Add Engine Oil If the oil is below the cross hatched area at the tip of the dipstick you will need to add at least one quart liter of oil But you must use the right kind This section explains what kind of oil to use For engine oil crankcas...

Page 270: ...ugh oil to put the level somewhere in the proper operating range in the cross hatched area Push the dipstick all the way back in when you are through What Kind of Engine Oil to Use Look for two things GM6094M Your vehicle s engine requires oil meeting GM Standard GM6094M You should look for and use only an oil that meets GM Standard GM6094M 270 ...

Page 271: ...ntainer Notice Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol Failure to use the recommended oil can result in engine damage not covered by your warranty GM Goodwrench oil meets all the requirements for your vehicle If you are in an area of extreme cold where the temperature falls below 20 F...

Page 272: ...gine is at normal operating temperature and the oil is warm turn off the engine and allow at least five minutes for the oil to drain back into the oil pan If you do not do this the oil dipstick might not show the actual level If the engine has not been run long enough to bring it up to normal operating temperature and the oil is cool turn off the engine and allow 30 minutes for the oil to drain ba...

Page 273: ...uzu 6H engine you will need to add at least one quart liter 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 Specifications on page 347 Notice Do not add too much oil If the engine has so much oil that the oil level gets above the cross hatched area for the 6 6L V8 LLY engine or above the upper hole that shows...

Page 274: ...k for these two things CJ 4 or CI 4 Oils designated as API CJ 4 or CI 4 are recommended for your vehicle The CJ 4 or CI 4 designations may appear either alone together or in combination with other API designations such as API CJ 4 SM These letters show American Petroleum Institute API levels of quality Notice Use only engine oils that have one of these designations CJ 4 or CI 4 for the diesel engi...

Page 275: ...d for use at high temperatures above 100 F 38 C These numbers on the oil container show its viscosity or thickness Do not use other viscosity oils such as SAE 10W 40 or SAE 20W 50 This doughnut shaped logo symbol is used on most oil containers to help you select the correct oil It means that the oil has been certified by the American Petroleum Institute You should look for this on the oil containe...

Page 276: ...hen to change the engine oil and filter This is based on engine revolutions and engine temperature and not on mileage Based on driving conditions the mileage at which an oil change will be indicated can vary considerably For the oil life system to work properly you must reset the system every time the oil is changed When the system has calculated that oil life has been diminished it will indicate ...

Page 277: ...ing 3 Turn the key to OFF If the change engine oil light comes back on when you start your vehicle the engine oil life system has not reset Repeat the procedure What to Do with Used Oil Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer Do not let used oil stay on your skin for very long Clean your skin and nails with soap and water or a good ...

Page 278: ...re driving under the best conditions the oil life system may not indicate that an oil change is necessary for over a year However your engine oil and filter must be changed at least once a year and at this time the system 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 an...

Page 279: ...gine oil See the manufacturer s warnings about the use and disposal of 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 oi...

Page 280: ...Filter The engine air cleaner filter is located in the center of the engine compartment When to Inspect the Engine Air Cleaner Filter If your vehicle has an air cleaner filter change indicator inspect the indicator at every oil change and replace the filter when the indicator tells you to For vehicles without a change indicator inspect the air cleaner filter at every oil change and replace the fil...

Page 281: ...e 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 And dirt can easily get into your engine which will damage it Always have the air cleaner filter in place when you are driving Hood Inlet Seal If your vehicle is being used in heavy snow conditions or for snow plowing there is a possibility of snow and...

Page 282: ...matic transmission fluid level is when the engine oil is checked See your Allison Automatic Transmission Operator s Manual to find out when to change your transmission fluid and filters How to Check and What to Use The Allison Automatic Transmission Operator s Manual that came with the vehicle shows how to check the automatic transmission fluid and what fluid to use Automatic Transmission External...

Page 283: ...he bottom of the fill opening On heavy duty transmissions an inch of oil level equals about one gallon of fluid 3 If the fluid level is good reinstall the plug and be sure it is fully seated If the fluid level is low add more fluid as described in the next steps Refer to the Maintenance Schedule to determine what kind of fluid to use See Part C Recommended Fluids and Lubricants on page 397 How to ...

Page 284: ...ing on page 288 A 50 50 mixture of clean drinkable water and DEX COOL coolant will Give freezing protection down to 34 F 37 C Give boiling protection up to 265 F 129 C Protect against rust and corrosion Help keep the proper engine temperature Let the warning lights and gages work as they should Notice Using coolant other than DEX COOL may cause premature engine heater core or radiator corrosion In...

Page 285: ...ngine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If you use an improper coolant mixture your engine could overheat and be badly damaged The repair cost would not be covered by your warranty Too much water in the mixture can freeze and crack the engine radiator heater core and other parts If you have to add coolant mor...

Page 286: ...k 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 must be parked on a level surface When your engine is cold the coolant level should be at the FULL COLD mark or higher 286 ...

Page 287: ...AUTION You can be burned if you spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if the engine parts are hot enough Do not spill coolant on a hot engine When replacing the pressure cap make sure it is hand tight and fully seated Engine Coolant Caterpillar Diesel Engines If your vehicle has a Caterpillar diesel engine see the Caterpillar Diesel Engine Operation Ma...

Page 288: ...Your vehicle also has a check gages warning light on the instrument panel See Check Gages Warning Light on page 180 for more information If Steam Is Coming From Your Engine CAUTION Steam from an 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 ...

Page 289: ...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 290: ...gine Operation and Maintenance Manual provided with your vehicle If the coolant inside the coolant surge tank is boiling do not do anything else until it cools down The vehicle should be parked on a level surface The coolant level should be at the FULL COLD mark or higher If it is not you may have a leak at the pressure cap or in the radiator hoses heater hoses radiator water pump or somewhere els...

Page 291: ...than DEX COOL may cause premature engine heater core or radiator corrosion In addition the engine coolant could 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 How to Add Coolant to the Coolant Surge Tank If you have not found a problem yet check to see ...

Page 292: ...o 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 coolant warning system is set for the proper coolant mixture With plain water or the wrong mixture your engine could get too hot but you would not get the overheat warning Your engine could ca...

Page 293: ...ge 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 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 to...

Page 294: ...cooling fan When the clutch is engaged the fan spins faster to provide more air to cool the engine In most everyday driving conditions the clutch is not fully engaged This improves fuel economy and reduces fan noise Under heavy vehicle loading trailer towing and or high outside temperatures the fan speed increases when the clutch engages So you may hear an increase in fan noise This is normal and ...

Page 295: ...ake or service brakes soon warning lights to come on In addition the steering effort and emergency brake distance could increase If either light remains on after you have added power steering fluid to the proper level then shut off the engine for 10 seconds This should reset the brake warning lights If one or both lights stay on see Hydraulic Brake System Warning Lights under Brake System Warning ...

Page 296: ...e engine compartment on the driver s side of the vehicle Notice When using concentrated washer fluid follow the manufacturer s instructions for adding water Do not mix water with ready to use washer fluid Water can cause the solution to freeze and damage your washer fluid tank and other parts of the washer system Also water does not clean as well as washer fluid Fill your washer fluid tank only th...

Page 297: ...d 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 The brake fluid reservoir is in the engine compartment on the driver side of the vehicle Clean one of the reservoir caps and the area around the cap and remove it The fluid...

Page 298: ...is could cause a crash Always use the proper brake fluid Notice Using the wrong fluid can badly damage brake system parts For example just a few drops of mineral based oil such as engine oil in the 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 flui...

Page 299: ...al height or if there is a rapid increase in pedal travel This could be a sign that brake service is needed Brake Adjustment Every time you make a brake stop the brakes adjust for wear Brake Adjustment on Air Braked Vehicles Your vehicle has automatic slack adjusters Every time you make a brake stop the brakes automatically adjust for wear Slack adjusters should never be manually adjusted to corre...

Page 300: ... are two ways to do this One is automatic through the air brake vehicle s air dryer with integral automatic moisture ejector that purges air from the system through a self contained reservoir The other way to drain moisture from the air brake system is to manually activate drain valves at each reservoir Drain the air reservoirs occasionally to be sure the air dryer is working properly Drain the ai...

Page 301: ... on a weekly basis Clutch Pedal Free Travel If you have a V8 engine and a manual transmission the clutch will need adjustment when pedal free travel gets down to about 1 4 inch 6 mm as measured at the clutch pedal pad You should have 1 1 2 to 2 inches 38 to 51 mm of clutch pedal free travel If the clutch ever needs service be sure to use only GM clutch replacement parts Chassis Lubrication Your Ma...

Page 302: ...Single Axle Models Item Number Item Remarks 1 Brake Camshaft One fitting each apply sparingly 2 Steering Column Slip Joint One fitting 3 Steering Drag Link Ends One fitting each end 302 ...

Page 303: ... Apply chassis lubricant 12 Clutch Release Bearing Cup or fitting 13 Battery Terminal except ST type Keep coated with petroleum jelly 14 Transmission Fill to level of filler plug 15 Propshaft U Joints Lubricate with GM Part No 1051344 Wheel Bearing Lubricant 16 Parking Brake Clevis Pin Apply chassis lubricant 17 Parking Brake Lever Pivot Apply chassis lubricant 18 Clutch Release Cross Shaft Master...

Page 304: ...o shoe joint only 5 Rear Spring Pin One fitting each side Battery Your vehicle has one or more maintenance free batteries When it is time for a new battery be sure it has the replacement number shown on the original battery s label We recommend an ACDelco replacement battery Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of Cali...

Page 305: ... 305 for tips on working around a battery without getting hurt When you are ready to use the vehicle again refer to the engine starting procedure in the Index Jump Starting If your vehicle s battery or batteries has run down you may want to use another vehicle and some jumper cables to start your vehicle Be sure to use the following steps to do it safely CAUTION Batteries can hurt you They can be ...

Page 306: ...s will reduce electrical resistance 2 Get the vehicles close enough so the jumper cables can reach but be sure the vehicles are not touching each other If they are it could cause a ground connection you do not want You would not be able to start your vehicle and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on bo...

Page 307: ... or the passenger s side of the vehicle You will not need to access your battery or batteries for jump starting The remote positive terminal is for that purpose 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 ...

Page 308: ...will go to positive or to a remote positive terminal if the vehicle has one 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 ...

Page 309: ...s to a heavy unpainted metal engine part or to the remote negative terminal 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 ...

Page 310: ...minal 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 battery 2 Disconnect the black negative cable from the vehicle with the good battery 3 Disconnect the red positive cable from the vehicle with the...

Page 311: ...iving 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 ...

Page 312: ...dd enough fluid to raise the level to the bottom of the filler plug hole then replace the plug What to Use Refer to your Maintenance Schedule to determine what kind of lubricant to use See Part C Recommended Fluids and Lubricants on page 397 Four Wheel Drive Transfer Case When to Check Lubricant It is not necessary to regularly check transfer case fluid unless you suspect there is a leak or you he...

Page 313: ... Fluids and Lubricants on page 397 Front Axle When to Check Lubricant It is not necessary to regularly check front axle fluid unless you suspect there is a leak or you hear an unusual noise A fluid loss could indicate a problem Have it inspected and repaired Notice If you drive your vehicle through deep water that is higher than the front or rear axle water may enter the axle housing and cause the...

Page 314: ... page 397 Noise Control System Tampering with Noise Control System Prohibited The following information relates to compliance with federal noise emission standards for vehicles with a Gross Vehicle Weight Rating GVWR of more than 10 000 lbs 4 536 kg The Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system dur...

Page 315: ...hose acts presumed to constitute tampering are the acts listed below Insulation Removal of the noise shields or any underhood insulation Engine Removal or rendering engine speed governor if the vehicle has one inoperative so as to allow engine speed to exceed manufacturer specifications Fan and Drive Removal of fan clutch if the vehicle has one or rendering clutch inoperative Removal of the fan sh...

Page 316: ...wice a Year on page 392 for more information Replacement blades come in different types and are removed in different ways Here s how to remove the wiper blade 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 2 316 ...

Page 317: ... in the engine compartment on the driver s side of the vehicle or along the driver s side frame rail See Fuel Filter Replacement earlier in this section for further information Also see Scheduled Maintenance on page 363 for recommended service intervals Primary Fuel Filter and Water Separator If you have a diesel engine you may have this spin on filter It is located on the driver s side frame rail...

Page 318: ...the bowl do the following Shut off the engine Push up on the spring loaded drain valve until clear fuel is flowing from the valve The particles or water will drain out first See Engine Oil Caterpillar Diesel Engine on page 268 or Engine Oil Gasoline Engine on page 268 or Engine Oil DURAMAX Isuzu Diesel Engine on page 272 for proper disposal procedures Automatic Ether Injection System Caterpillar D...

Page 319: ...on 7 Put in the new cylinder Turn it clockwise until it just starts to contact the gasket 8 Tighten the cylinder another half turn 180 degrees Don t over tighten 9 Retighten the cylinder clamp Front Wheel Bearings with Oil Filled Hubs Notice If you drive your vehicle through deep water that is higher than the front or rear axle water may enter the axle housing and cause the axle lubricant to break...

Page 320: ...that you ll see on the glass Refer to your Maintenance Schedule for the proper oil to use When you fill the hub check the glass again after driving a short distance It takes a while for the oil to flow through the system and you may find that you have to add a little more to fill it to the proper level Be sure not to overfill the hub Air Conditioning System Every now and then have your dealership ...

Page 321: ... an air out and a serious accident See Loading Your Vehicle on page 238 CAUTION Continued CAUTION Continued Underinflated tires pose the same danger as overloaded tires The resulting accident could cause serious injury Check all tires frequently to maintain the recommended pressure Tire pressure should be checked when your vehicle s tires are cold See Inflation Tire Pressure on page 322 Overinflat...

Page 322: ...ture or irregular wear Poor handling Reduced fuel economy If your tires have too much 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 your vehicle has one How to Check Use a good quality pocket type gage to check tire pressure Yo...

Page 323: ...henever a wheel wheel bolt or wheel nut is removed or serviced repeat the 100 miles 160 km and then 1 000 mile 1 600 km wheel nut tightness check See Tightening the Wheel Nuts on page 325 for wheel nut tightening information and proper torque values CAUTION If you operate your vehicle with a tire that is badly underinflated the tire can overheat An overheated tire can lose air suddenly or catch fi...

Page 324: ... all around When you replace tires make sure they are the same size load range speed rating and construction type bias bias belted or radial as your original tires If your vehicle has four wheel drive the axle differentials propshafts and transfer case may be damaged if tires of different sizes brands or tread types are installed on the front and rear axles That damage would not be covered under y...

Page 325: ...ey must be First use these pictures to decide what kind of wheels you have Then refer to the following steps for the wheels you have Hub Piloted Wheels 8 Hole or 10 Hole The studs and nuts used with these wheels have right 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...

Page 326: ...l the surfaces B between the nuts C and washers A Do not oil the studs or the threads of the nut 6 Tighten the 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 8 Hole 10 Hole Front 10 Hole Rear 326 ...

Page 327: ... larger or distorted in any way Inspect hubs and CAUTION Continued CAUTION Continued hub piloted wheels for damage Because of loose running wheels piloting pad damage may occur and require replacement of the entire hub for proper centering of the wheels When replacing studs 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...

Page 328: ...e wheel If the wheel leaks air replace it Your dealer will know the kind of wheel you need Each new wheel should have the same load carrying capacity diameter width offset and be mounted the same way as the one it replaces If you need to replace any of your wheels wheel bolts or wheel nuts replace them only with new GM original equipment parts This way you will be sure to have the right wheel whee...

Page 329: ...hange the Gross Axle Weight Rating GAWR or the Gross Vehicle Weight Rating GVWR of your vehicle See Loading Your Vehicle on page 238 for more information Notice The wrong wheel can cause trouble in bearing life brake cooling speedometer odometer calibration headlamp aim bumper height vehicle ground clearance stopping distance and tire clearance to the body and chassis You could also have other pro...

Page 330: ...a skid and may require the same correction you would 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 still steer Gently brake to a stop well off the road if possible If a tire goes flat avoid further tire and wheel damage by driving slowly to a level...

Page 331: ...mage So if you are stopped somewhere by a flat or damaged tire or wheel you should get expert help See Roadside Assistance Program on page 408 Appearance Care Cleaning the Inside of Your Vehicle Your vehicle s interior will continue to look its best if it is cleaned often Although not always visible dust and dirt can accumulate on your upholstery Dirt can damage carpet fabric leather and plastic s...

Page 332: ...st may be removed from small buttons and knobs using a small brush with soft bristles Your dealer has a product for cleaning your vehicle s glass Should it become necessary you can also obtain a product from your dealer to remove odors from your vehicle s upholstery Do not clean your vehicle using the following cleaners or techniques Never use a knife or any other sharp object to remove a soil fro...

Page 333: ...th with water or club soda 2 Wring the cloth to remove excess moisture 3 Start on the outside edge of the soil and gently rub toward the center Continue cleaning using a clean area of the cloth each time it becomes soiled 4 Continue to gently rub the soiled area until the cleaning cloth remains clean 5 If the soil is not completely removed use a mild soap solution and repeat the cleaning process t...

Page 334: ... alter the appearance by increasing the gloss in a non uniform manner Some commercial products may increase gloss on your instrument panel The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions Care of Safety Belts Keep belts clean and dry CAUTION Do not bleach or dye safety belts If you do it may sev...

Page 335: ...tton towel to avoid surface scratches and water spotting High pressure car washes may cause water to enter the vehicle Cleaning Exterior Lamps Lenses Use only lukewarm or cold water a soft cloth and a car washing soap to clean exterior lamps and lenses Follow instructions under Washing Your Vehicle on page 335 Finish Care Occasional waxing or mild polishing of your vehicle by hand may be necessary...

Page 336: ...er you may use chrome polish on chrome or stainless steel trim if necessary Use special care with aluminum trim To avoid damaging protective trim never use auto or chrome polish steam or caustic soap to clean aluminum A coating of wax rubbed to high polish is recommended for all bright metal parts Windshield and Wiper Blades If the windshield is not clear after using the windshield washer or if th...

Page 337: ... them because you could damage the surface Do not use chrome polish on aluminum wheels Notice Using chrome polish on aluminum wheels could damage the wheels The repairs would not be covered by your warranty Use chrome polish on chrome wheels only Use chrome polish only on chrome plated wheels but avoid any painted surface of the wheel and buff off immediately after application Tires To clean the t...

Page 338: ...sion 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 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 pollu...

Page 339: ...vers Finish Enhancer Removes dust fingerprints and surface contaminants Spray on wipe off Swirl Remover Polish Removes swirl marks fine scratches and other light surface contamination Vehicle Care Appearance Materials cont d Description Usage Cleaner Wax Removes light scratches and protects finish Foaming Tire Shine Low Gloss Cleans shines and protects in one easy step no wiping necessary Wash Wax...

Page 340: ...s engine specifications and replacement parts Service Parts Identification Label You will find this label in a location determined by the body manufacturer It is very helpful if you ever need to order parts On this label you will find the following VIN Model designation Paint information Production options and special equipment Do not remove this label from the vehicle Electrical System Add On Ele...

Page 341: ...tion is burned beyond recognition consult your 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 Some examples of circuits with fusible links are the hydraulic brake booster motor feed circuit the generator output circuit and the intake heater feed circuit in vehicles with a diesel ...

Page 342: ...ssenger s side of the vehicle Be sure to replace fuses with fuses of the same rating Do not use fuses of higher amperage than those indicated on the fuse block Fuse Usage 1 Stoplamps 2 Center High Mounted Stoplamp 3 Parking Lamps Fuse Usage 4 Powertrain Control Module 5 Auxiliary Wiring 6 Heater Air Conditioning 342 ...

Page 343: ...Brake 19 Accessory Power 20 Ignition 4 21 Sidemarker Lamps 22 Turn Signal Backup Lamps 23 Transmission Fuse Usage 24 Hydraulics Air Brake A Spare B Spare Fuse Usage Blank Not Used BRK Brake Warning Lamp RT PRK Passenger s Side Parking Lamps Blank Not Used Blank Not Used LT PARK Driver s Side Parking Lamps RT REAR TRN STOP Passenger s Side Rear Turn Signal Stoplamp LT REAR TRN STOP Driver s Side Re...

Page 344: ...nal Blank Not Used Blank Not Used Blank Not Used Underhood Fuse Block When a circuit goes out the problem could be in either the primary or secondary underhood fuse blocks These blocks use blade type fuses Both underhood fuse blocks are located in the engine compartment on the passenger s side of the vehicle To access the fuse blocks gently squeeze both sides of the cover to unlatch the tabs at th...

Page 345: ...FUEL Heated Fuel BLANK Not Used BLANK Not Used 02A Emissions A C COMP Air Conditioning Compressor ABS 1 Anti lock Brake System 1 ABS 2 Anti lock Brake System 2 ABS 3 Anti lock Brake System 3 ENGINE Engine E A PUMP Electronic Automatic Pump HORN Horn NOTE 2 L18 Fuel LG4 Powertrain Control Valve LG5 Electronic Control Module Primary Underhood Fuse Block 345 ...

Page 346: ...N A Ignition Relay PTO ECU Power Take Off Engine Control Unit Diesel 7 8L LG4 REVERSE Reverse Relay NEUTRAL START Neutral Start LG4 Allison Automatic Transmission Series 3000 3500 Fuse Usage IGN 1 Ignition 1 IGN 4 Ignition 4 IGN 3 Ignition 3 BATT HAZ Battery Hazard Warning Flashers HEADLAMP Headlamps LIGHTING Interior Exterior Lamps HVAC Climate Control System NOTE C4 C5 Electric Brake C6 C7 C8 Br...

Page 347: ...ur dealer for more information Cooling System C4 C5 Models 6 6L Automatic Transmission 27 3 qt 25 8 L 8 1L Automatic Transmission 29 8 qt 28 2 L 8 1L Manual Transmission 30 1 qt 28 5 L Cooling System C6 C7 C8 Automatic Transmission 7 2L Engine hp 207 230 31 4 qt 29 7 L 7 2L Engine hp 250 300 31 2 qt 29 5 L Isuzu 6H Engine hp 200 215 33 7 qt 31 9 L Isuzu 6H Engine hp 230 275 33 3 qt 31 5 L 8 1L Eng...

Page 348: ... 4 qt 33 5 L 8 1L 225 295 hp Engine 33 3 qt 31 5 L 8 1L with A C and Increased Cooling 34 9 qt 33 0 L Engine Oil with Filter 6 6L 14 6 qt 13 8 L 7 2L 30 0 qt 28 4 L Isuzu 6H1 23 8 qt 22 5 L 8 1L 10 0 qt 9 4 L Check fill level on the oil indicator after initial fill to make sure it is actually full Oil level may vary depending on vehicle option content 1 Additional oil is required with auxiliary oi...

Page 349: ... 40 gal 151 4 L Optional Mid Mounted 60 gal 227 1 L Optional Mid Mounted 80 gal 302 8 L One 25 gallon 94 6 L tank and one 15 gallon 56 8 L tank Fuel Capacity C6 C7 C8 Models Optional 35 gal 132 4 L Standard 50 gal 189 2 L Optional 50 gal 189 2 L Optional1 Dual Tanks 70 gal 264 8 L Optional2 Dual Tanks 75 gal 283 8 L Optional3 Dual Tanks 100 gal 378 5 L 1 Two 35 gallon 132 4 L tanks 2 One 25 gallon...

Page 350: ... 51 0 pt 24 1 L 26105S HPA 51 0 pt 24 1 L S110 HD2 and S130 HD1 15 0 pt 7 1 L Rear Axle Tandem DS344 front HPI 34 0 pt 16 1 L DS344 rear HPI 31 0 pt 14 7 L DS404 HPE DS404P HPJ front rear unit 32 0 pt 15 1 L RSH44 front rear unit HP3 29 0 pt 13 7 L Rear Axle Two Speed 19060T HPL 22060T HPH 38 0 pt 18 0 L 21060T H15 38 0 pt 18 0 L 23082T H25 44 0 pt 20 8 L 26080T GJ4 44 0 pt 20 8 L Transfer Case Fo...

Page 351: ...s 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 ES052 7 ES066 7 22 0 pt 10 4 L FS5205A 12 5 pt 5 9 L FSO8406 FS6305A FS6305B FS6406 FS5406A 19 5 pt 9 2 L FS4205A FS4205B 11 5 pt 5 4 L RT6609 12 0 pt 5 7 L RT8709 26 0 pt 12 3 L RT8908LL 28 0 pt 13 2 L All capacities are approx...

Page 352: ... name part number or specification can be obtained from your dealer Part GM Part Number ACDelco Part Number Air Compressor Filter Haldex compressor 8 1L Engine Only 88915425 A507CF Engine Air Cleaner Filter 6 6L 8 1L C4 C5 Models 88937527 A2032C 7 2L Isuzu 6H C6 C7 C8 Models with Standard Air Cleaner 88937525 A2031C 7 2L Isuzu 6H C6 C7 C8 Models with Heavy Duty Air Cleaner 889375251 A2031C 8 1L C6...

Page 353: ... Filter 6 6L 97385488 TP1298A 7 2L 1R 0751 Isuzu 6H 94392474 8 1L NG6 NK1 21998364 8 1L All others S3202 Power Steering Fluid Filter 88892858 Secondary Fuel Filter 6 6L 7 2L 25014274 TP915D 7 2L KUK 88983117 TP1519 7 2L NWB 15618921 Isuzu 6H 25014274 TP915D Isuzu 6H KUK 88983117 TP1519 8 1L K28 and standard U Haul 25014476 TP1247 353 ...

Page 354: ...lter GM Part No 88937548 AC Delco No A2035C for C6 C7 C8 Models Fits inside standard size filter GM Part No 88937525 AC Delco No A2031C listed previously Racor part number Caterpillar part number See the Allison Transmission Operator s Manual in your vehicle for external filter part numbers and information 354 ...

Page 355: ...Engine Drive Belt Routing Air conditioning compressor A Dual Generators B Air conditioning compressor A Air brake compressor B 8 1L V8 Engine C4 C5 8 1L V8 Engine C6 C7 C8 355 ...

Page 356: ...Dual Generators A Air conditioning compressor A 6 6L V8 DURAMAX Diesel Engine Isuzu 6H Diesel Engine 356 ...

Page 357: ...Air conditioning compressor A 7 2L V6 Caterpillar Diesel Engine 357 ...

Page 358: ... NOTES 358 ...

Page 359: ...cheduled Maintenance Services 362 Using the Maintenance Schedule 362 Scheduled Maintenance Supplements 363 Scheduled Maintenance 363 Part B Owner Checks and Services 391 At Each Fuel Fill 391 At Least Twice a Year 392 At Least Once a Year 396 Part C Recommended Fluids and Lubricants 397 Part D Maintenance Record 400 Section 6 Maintenance Schedule 359 ...

Page 360: ...ps 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 levels or the wrong tire inflation can increase the level of emissions from your vehicle To help protect our environment and to keep your vehicle in good condition be sure to maintain your vehicle properly How This Section is...

Page 361: ... Information on page 415 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 Fluids and Lubricants lists some recommended products necessary to help keep your vehicle properly maintained These products or their equivalents should be used whether you do the work yourself or have ...

Page 362: ... your vehicle in good condition see your dealer This part 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 ...

Page 363: ...r those intervals for the life of this vehicle Gasoline engine vehicles and some DURAMAX diesel and Isuzu 6H diesel engine vehicles have a computer that lets you know when to change the engine oil This is not based on mileage but on engine operation and engine temperature When the computer has calculated that the oil needs changing the Engine Oil Life System will indicate that a change is necessar...

Page 364: ...ack adjuster service or every 500 hours whichever occurs first 33 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 34 12 000 Miles 20 000 km Isuzu 6H Diese...

Page 365: ...inspect filter at every engine oil change See Engine Air Cleaner Filter on page 280 for more information Diesel Engine 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 280 for more information DURAMAX Isuzu Diesel Only Rep...

Page 366: ...d filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubrication service or every 6 months whichever occurs first 11 Inspect door hinge pins and bushings and replace as necessary Cooling system service Clean the cooling system filter cap with clean water clean the core pressure test the cap and the...

Page 367: ...rs first 3 4 23 Evaporative Control System service if equipped or every 24 months whichever occurs first 2 24 Rear axle air shift motor service 10 24 000 Miles 40 000 km Isuzu 6H Diesel 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 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life sy...

Page 368: ...il change See Engine Air Cleaner Filter on page 280 for more information Diesel Engine 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 280 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 ho...

Page 369: ...s service or every 12 months whichever occurs first 17 Thermostatically controlled engine cooling fan service 3 19 Shields and underhood insulation service 3 4 20 Gasoline Engine Air compressor remote mounted air filter dry element pleated paper air strainer service or every 6 months or every 1800 hours whichever occurs first 36 000 Miles 55 000 km Isuzu 6H Diesel Without Engine Oil Life System On...

Page 370: ...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 34 45 000 Miles 72 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 6 6L DURAMAX Diese...

Page 371: ...acked swollen or damaged Inspect door hinge pins and bushings and replace as necessary Steering system service 12 Front and rear suspension service 13 Spring to axle U bolts and shackle bolts service 15 Exhaust system service or every 6 months whichever occurs first 2 3 16 Wheels and tires service 14 Hydraulic brake service or every 6 months whichever occurs first 6 36 Parking brake service or eve...

Page 372: ...iner service or every 6 months or every 1800 hours whichever occurs first 48 000 Miles 75 000 km Isuzu 6H Diesel 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 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life system or every 12 months or every 600 hours of engine operation whichever ...

Page 373: ...y 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 34 60 000 Miles 96 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system ...

Page 374: ...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 280 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 hours of engine operation whichever occurs first Chassis lubrication service or every 6 months whichever occurs first 11 Replace fuel filter s or every 1...

Page 375: ...r filter dry element pleated paper air strainer service or every 6 months or every 1800 hours whichever occurs first 67 500 Miles 108 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubrication service or every 6 months w...

Page 376: ...er occurs first 2 24 72 000 Miles 115 000 km Isuzu 6H Diesel 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 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life system or every 12 months or every 600 hours of engine operation whichever occurs first If engine oil and filter are changed re...

Page 377: ...e Air Cleaner Filter on page 280 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 hours of engine operation whichever occurs first Steering system service 12 Front and rear suspension service 13 Spring to axle U bolts and shackle bolts service 15 Exhaust system service or every 6 months whichever occurs first 2 3 16 Wheels and tires service 14 Hydraulic brake service...

Page 378: ...ee Engine Oil Gasoline Engine in the Index 2 8 Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubrication service or every 6 months whichever occurs first 11 Wheels and tires service 14 Hydraulic brake service or every 6 months whichever occurs first 6 36 Parking brake service or every 6 months whichever occurs first 21 Air brake service or every 6 months whichever occurs ...

Page 379: ...filter or every 12 months or every 750 hours of engine operation whichever occurs first 2 6 6L DURAMAX Diesel With Engine Oil Life System Only Check oil life system If engine oil and filter are changed reset system See Engine Oil DURAMAX Isuzu Diesel in the Index 2 9 Check fluid levels or every 3 months whichever occurs first 1 5 Gasoline Engine Replace engine air cleaner filter See Engine Air Cle...

Page 380: ...ery 6 months whichever occurs first 6 36 Parking brake service or every 6 months whichever occurs first 21 Air brake service or every 6 months whichever occurs first 32 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 33 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application ...

Page 381: ... and filter are changed reset system See Engine Oil DURAMAX Isuzu Diesel in the Index 2 7 Lubricate U joints or every 6 months whichever occurs first 97 500 Miles 156 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 Check fluid levels or every 3 months whichever occurs first 1 5 Chassis lubric...

Page 382: ... service 30 Rear axle service Eaton Rockwell Spicer axles or every 12 months whichever occurs first 30 Exhaust brake service if equipped Check for excessive spindle free play and smooth operation Lubricate ball joint cap Inspect air compressor discharge port or every 6 months or every 1 800 hours whichever occurs first Manual transmission ZF 6 speed only fluid replacement or every 48 months whiche...

Page 383: ...Spicer axles or every 12 months whichever occurs first 30 Remove disassemble clean and inspect the air brake air dryer or every 3 years or 10 800 hours whichever occurs first Replace desiccant Footnotes The U S Environmental Protection Agency or the California Air Resources Board has determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall...

Page 384: ...vel 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 This vehicle has the Engine Oil Life System This system will show you when to change the engine oil and filter usually between 3 000 miles 5 000 km and 12 000 miles 20 000 km since your last oil change Under severe conditions the indicator m...

Page 385: ...tem This system will show you when to change the engine oil and filter usually between 3 000 miles 5 000 km and 15 000 miles 24 000 km since your last oil change Under severe conditions the indicator may come on before 3 000 miles 5 000 km Never drive your 6 6L diesel engine vehicle more than 15 000 miles 24 000 km or 12 months or 750 engine hours without an oil and filter change Remember to reset...

Page 386: ...dal shaft clutch cross shaft clutch pedal springs and clutch cable bushing at transmission Lubricate suspension axle and steering linkage more often when operating under dusty or muddy conditions and in excessive off road use Frequently power washed vehicles will require more frequent lubrication 12 Check steering system Look for damaged loose or missing parts Inspect the steering linkage relay ro...

Page 387: ...omplete exhaust system and cab areas near the exhaust system for broken damaged missing or out of position parts Also inspect for open seams holes loose connections or other conditions which could let exhaust fumes seep into the driver compartment Needed repairs should be made at once To help maintain system integrity replace exhaust pipes whenever a new muffler is put on 17 Check all gasoline eng...

Page 388: ...ets are seated properly and all hose connections fasteners and other components are tight Tighten connections and fasteners or replace parts as required 24 Evaporative Control System Service if equipped Check all fuel and vapor lines and hoses for proper connections and correct routing or every 24 months whichever occurs first Replace parts as needed 25 Replace spark plugs Inspect wires for damage...

Page 389: ...oller bearing 32 Air brake service Inspect brake lines and hoses for proper hook up binding leaks cracks chafing etc Inspect drum brake linings for wear or cracks Inspect other brake parts at each wheel including drums and wheel speed sensor wiring 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 dri...

Page 390: ...lubricate air brake automatic slack adjuster Check pushrod travel and auto adjustment operation Have serviced if needed 34 Air brake chamber service Check operation mounting clamps and air lines and check for leaks 35 Trailer brake hand control valve service Check operation lubricate cam and follower 36 Tighten the wheel stud nuts to the specified torque values at 100 miles 160 km Thereafter tight...

Page 391: ...rform 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 Caterpillar Diesel Engine on page 268 or Engine Oil Gasoline Engine on page 268 or Engine Oil DURAMAX Isuzu Diesel Engine on page 272 Engine Coolant Level Check Check the engine coolant level and add DEX COOL coolant mixture if necessary See Engine Coo...

Page 392: ...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 393: ...ly when the clutch pedal is all the way down Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen Steering Check Be alert for any changes in steering action abnormal front tire 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 o...

Page 394: ... are signs the system may be leaking Have it checked and or repaired at once Refer to Engine Exhaust on page 131 and Running the Engine While Parked on page 132 Windshield Wipers and Washers Check Check operation and condition of the wiper blades Check the flow of the washer spray Defroster Check Move the control to the defrost symbol and the fan to HI or the high symbol Then check the airflow fro...

Page 395: ...maged glass mirrors lamps or reflectors that could reduce the view or visibility or cause injury Replace clean or repair promptly Door Latches Check Check that doors close latch and lock tightly Check for broken damaged or missing parts that might prevent tight latching Hood Latches Check Check that the hood closes firmly Check for broken damaged loose or missing parts that might prevent tight lat...

Page 396: ...e 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 Underbody Flushing Service At least every spring use plain water to flush any cor...

Page 397: ...il in the Index Usage Fluid Lubricant Engine Oil DURAMAX Isuzu Diesel Engines Engine oil with the letters CJ 4 or CI 4 is best for your vehicle The CJ 4 or CI 4 designation may appear either alone or in combination with other API designations such as API CJ 4 SM These letters show American Petroleum Institute levels of quality To determine the preferred viscosity for your vehicle s diesel engine s...

Page 398: ...alent NLGI 3 consistency Exhaust Brake Ball Joint Cap Lubricant High Temperature Grease GM Part No U S 1051344 in Canada 903037 or NLGI 3 consistency Usage Fluid Lubricant Power Steering System DEXRON VI Automatic Transmission Fluid Manual Transmission Synthetic Manual Transmission Fluid GM Part No U S 12345724 in Canada 10953510 Automatic Transmission See the Allison Transmission Operator s Manua...

Page 399: ...512 Rear Axle and Rear Hubs SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part No U S 89021675 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 1051344 in Canada 993037 Cab Door Hinges and...

Page 400: ...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 400 ...

Page 401: ...Date Miles km Or Hours Serviced By Maintenance Record 401 ...

Page 402: ...Date Miles km Or Hours Serviced By Maintenance Record 402 ...

Page 403: ...7 Roadside Assistance Program 408 Vehicle Data Collection and Event Data Recorders 409 Collision Damage Repair 410 Reporting Safety Defects 414 Reporting Safety Defects to the United States Government 414 Reporting Safety Defects to the Canadian Government 414 Reporting Safety Defects to General Motors 415 Service Publications Ordering Information 415 Section 7 Customer Assistance Information 403 ...

Page 404: ...tacting a member of dealership management it appears your concern cannot be resolved by the dealership without further help contact the GM Medium Duty Truck Customer Assistance Center at 1 800 862 4389 In Canada contact GM of Canada Customer Communication Centre in Oshawa by calling 1 800 263 3777 English or 1 800 263 7854 French We encourage you to call the toll free number in order to give your ...

Page 405: ...le Limited Warranty Although you may be required to resort to this informal dispute resolution program prior to filing a court action use of the program is free of charge and your case will generally be heard within 40 days If you do not agree with the decision given in your case you may reject it and proceed with any other venue for relief available to you You may contact the BBB Auto Line Progra...

Page 406: ... or e mail refer to the addresses below United States Customer Assistance GM Medium Duty Truck Customer Assistance Center P O Box 44947 Detroit MI 48244 www Chevrolet com 1 800 TO CHEVY 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 1 800 496 9994 Fax Numb...

Page 407: ...This program available to qualified applicants can reimburse you up to 1 000 of the cost of eligible aftermarket adaptive equipment required for your vehicle such as hand controls or a wheelchair scooter lift The offer is available for a very limited period of time from the date of vehicle purchase lease For more details or to determine your vehicle s eligibility visit gmmobility com or call the G...

Page 408: ...tion at no charge such as location of the nearest authorized medium duty GM Truck dealer and their hours of operation Roadside Assistance is available 24 hours a day 7 days a week 365 days a year Should you have any questions about Roadside Assistance call the GM Medium Duty Truck Roadside Assistance Center or contact your dealer Canadian Roadside Assistance In Canada Medium Duty trucks are not el...

Page 409: ...cle may record information about the condition of the vehicle and how it was operated such as data related to engine speed brake application throttle position vehicle speed safety belt usage airbag readiness airbag performance and the severity of a collision This information has been used to improve vehicle crash performance and may be used to improve crash performance of future vehicles and drivi...

Page 410: ... compromised in subsequent collisions Collision Parts Genuine GM Collision parts are new parts made with the same materials and construction methods as the parts with which your vehicle was originally built Genuine GM Collision parts are your best choice to assure that your vehicle s designed appearance durability and safety are preserved The use of Genuine GM parts can help maintain your GM New V...

Page 411: ...g Your Vehicle Protect your investment in your GM vehicle with comprehensive and collision insurance coverage There are significant differences in the quality of coverage afforded by various insurance policy terms Many insurance policies provide reduced protection to your GM vehicle by limiting compensation for damage repairs by using aftermarket collision parts Some insurance companies will not s...

Page 412: ...ce Program on page 408 for more information If your vehicle cannot be driven know where the towing service will be taking it Get a card from the tow truck operator or write down the driver s name the service s name and the phone number Remove any valuables from your vehicle before it is towed away Make sure this includes your insurance information and registration if you keep these items in your v...

Page 413: ...take your vehicle there or have it towed there Specify to the facility that any required replacement collision parts be original equipment parts either new Genuine GM parts or recycled original GM parts Remember recycled parts will not be covered by your GM vehicle warranty Insurance pays the bill for the repair but you must live with the repair Depending on your policy limits your insurance compa...

Page 414: ...n individual problems between you your dealer or General Motors To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington D C 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Reporting Safety Defects to the Canad...

Page 415: ...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 service procedures adjustments and specifications for GM transmissions transaxles and transfer cases Service Bulletins Service Bulletins give technical service information needed to knowledgeably service Gene...

Page 416: ...l Service Bulletins and Manuals 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 Detro...

Page 417: ... 73 Servicing Your Airbag Equipped Vehicle 80 Airbag System cont What Makes an Airbag Inflate 73 What Will You See After an Airbag Inflates 74 When Should an Airbag Inflate 72 Where Are the Airbags 70 AM FM Radio 186 Antenna Fixed Mast 204 Anti Lock Brake System ABS 212 Anti Lock Brake System Warning Light 172 Anti Lock Brakes Trailer System Warning Light 172 Appearance Care Aluminum or Chrome Pla...

Page 418: ...r Injection System 318 Automatic Transmission Fluid 282 Operation 115 Axle Two Speed Rear Axle Electric Shift Control 113 B Battery 304 Bench Seat Split 13 Brake Anti Lock Brake System ABS 212 Diesel Engine Exhaust 112 Emergencies 213 Exhaust Indicator Light 178 Hydraulic Systems 211 Parking 125 126 System Warning Light 169 Trailer Hand Control Valve 214 Brakes 297 Parking Brake Burnish Procedure ...

Page 419: ...n Crew Cab or Center Front Position 60 Securing a Child Restraint in the Right Front Seat Position 63 Where to Put the Restraint 54 55 Chime Level Adjustment 204 Cigarette Lighter 157 Cleaning Aluminum or Chrome Plated Wheels 337 Exterior Lamps Lenses 335 Fabric Carpet 333 Finish Care 335 Inside of Your Vehicle 331 Instrument Panel Vinyl and Other Plastic Surfaces 334 Tires 337 Underbody Maintenan...

Page 420: ...Running Lamps 151 Daytime Running Lamps Indicator Light 179 Defensive Driving 206 Diesel Engine Engine Alarm and Automatic Shutdown 104 Exhaust Brake 112 Exhaust Restrictor 108 Diesel Engine cont Fuel 253 High Idle System 106 Starting 100 Differential Lock Control Rear Axle 215 Differential Lock Indicator Light 178 Doing Your Own Service Work 249 Dome Lamps 153 Door Locks 91 Power Door Locks 92 Dr...

Page 421: ...erature Gage 173 Diesel Engine Exhaust Brake 112 Drive Belt Routing 355 Exhaust 131 Exhaust Restrictor 108 Fan Breakage 250 Engine cont Fan Noise 294 High Idle System 106 Oil 268 272 Oil Life System 276 278 279 Overheating 288 Overspeed Warning Light 177 Reduced Power Light 179 Shutdown Warning Light 177 Speed Limiter 164 Starter Over Crank Protection 97 Starting Your Diesel 100 Starting Your Gaso...

Page 422: ...ary Filter and Water Separator 317 Running Out of Fuel 262 Secondary Filter and Water Separator Heater 318 Very Cold Weather Operation 256 Water in Fuel 256 Fuel cont Water in Warning Light 182 What Fuel to Use 253 Fuses Fuses and Circuit Breakers 341 Instrument Panel Fuse Block 342 Underhood Fuse Block 344 Windshield Wiper 341 G Gage Air Pressure 183 Check Gages Warning Light 180 Engine Coolant T...

Page 423: ...l and Mountain Roads 230 Hood Checking Things Under 266 Latches 267 Horn 142 Hourmeter Gage 183 How to Use This Manual 4 How to Wear Safety Belts Properly 26 Hydraulic Brake Systems 211 I Ignition Positions 96 Infants and Young Children Restraints 45 Inflation Tire Pressure 322 Instrument Panel Overview 140 Switchbank 154 Instrument Panel I P Brightness 152 Cluster 162 J Jump Starting 305 K Keyles...

Page 424: ...l Level 176 Low Washer Fluid Warning 180 Malfunction Indicator 174 Light cont Range Inhibit Warning Indicator 169 Reduced Engine Power 179 Safety Belt Reminder 164 Safety Belt Reminder Tone 164 Service Transmission Warning 168 Trailer Anti Lock Brake System Warning 172 Wait to Start Indicator 174 Water in Fuel Warning 182 Lighting Entry 154 Loading Your Vehicle 238 Locks Door 91 Power Door 92 Loss...

Page 425: ...s 93 Marker Lamps 152 Mirrors Manual Rearview Mirror 133 Outside Convex Mirrors 134 Outside Heated Mirrors 134 Outside Manual Mirrors 133 Outside Power Mirrors 133 N New Vehicle Break In 95 Noise Control System Tampering 314 Normal Maintenance Replacement Parts 352 O Odometer 163 Odometer Trip 163 Off Road Recovery 219 Oil Change Engine Oil Light 176 Engine 268 272 Low Oil Level Light 176 Pressure...

Page 426: ... Things That Burn 130 Part A Scheduled Maintenance Services 362 Part B Owner Checks and Services 391 Part C Recommended Fluids and Lubricants 397 Part D Maintenance Record 400 Passing 220 Power Accessory Outlet s 156 Door Locks 92 Electrical System 341 Reduced Engine Light 179 Steering Fluid 295 Windows 94 Power Take Off PTO 118 Q Questions and Answers About Safety Belts 25 R Radios 184 AM FM Radi...

Page 427: ...estraint System Parts After a Crash 83 Right Front Passenger Position Safety Belts 36 Roadside Assistance Program 408 Rocking Your Vehicle to Get it Out 236 Routing Engine Drive Belt 355 Running Out of Fuel 262 Running the Engine While Parked 132 S Safety Belt Reminder Light 164 Reminder Tone 164 Safety Belts Care of 334 Center Passenger Position 37 Driver Position 26 How to Wear Safety Belts Prop...

Page 428: ...e 337 Shoulder Belt Height Adjuster 35 Signals Turn and Lane Change 144 Sliding Rear Windows 94 Snow Plow 240 Specifications Capacities 347 Speedometer 163 Split Bench Seat 13 Starting Your Diesel Engine 100 Starting Your Gasoline Engine 97 Steering 217 Steering Wheel Tilt Wheel 142 Storage Areas 135 Center Console Storage Area 135 Stuck in Sand Mud Ice or Snow 236 Sun Visors 95 Suspension Air 129...

Page 429: ...e Gage 178 Transmission Operation Automatic 115 Transmission Operation Manual 116 Trip Odometer 163 Turn and Lane Change Signals 144 Turn Signal Multifunction Lever 143 Two Speed Rear Axle Electric Shift Control 113 U Understanding Radio Reception 201 V Vehicle Control 210 Damage Warnings 5 Loading 238 Symbols 5 Vehicle Data Collection and Event Data Recorders 409 Vehicle Identification Number VIN...

Page 430: ... Warning Light 182 What Fuel to Use 253 Wheels Alignment and Tire Balance 324 Front Bearings with Oil Filled Hubs 319 Loading 323 Replacement 328 Tightening the Wheel Nuts 325 Where to Put the Restraint 54 55 Windows 93 Manual 93 Power 94 Sliding Rear 94 Windshield Washer 146 Washer Fluid 296 Wiper Blade Replacement 316 Wiper Blades Cleaning 336 Wiper Fuses 341 Wipers 145 Winter Driving 231 Y Your...

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