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Chevrolet GMC 2002, Owner'S Manual Supplement, Page: 63 / 65

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Chevrolet GMC 2002 Owner'S Manual Supplement Download Page 63

6-34

Surge Tank Pressure Cap

The surge tank pressure 
cap must be tightly installed
with the arrows on the cap
lined up with the top tube 
of the coolant surge tank.

See “Engine Compartment Overview” in the Index for
more information on location.

NOTICE:

Your surge tank pressure cap is a unique 
15 psi (105 kPa) pressure

-

type cap for use 

with surge tank cooling systems only. It must 
be tightly installed to prevent coolant loss and
possible engine damage from overheating. 
Be sure the arrows on the cap line up with the 
top tube of the coolant surge tank.

Summary of Contents for GMC 2002

Page 1: ......

Page 2: ...This section explains how to start and operate your vehicle 5 1 Problems on the Road This section tells what to do if you have a problem while driving such as an overheated engine etc 6 1 Service and...

Page 3: ...l includes the latest information at the time it was printed We reserve the right to make changes in the product after that time without notice For Canadian Owners Who Prefer a French Language Manual...

Page 4: ...if you have a problem Use this section along with the information in Section 2 of your owner s manual 2 2 Starting Your Diesel Engine 2 4 Engine Coolant Heater If Equipped 2 6 Instrument Panel Cluster...

Page 5: ...dal to the floor while starting the engine Your vehicle won t start if the clutch pedal is not all the way down that s a safety feature Starting Your Engine 1 Turn your ignition key to RUN Observe the...

Page 6: ...be there to see the coolant temperature gage This could damage your vehicle Don t let your engine run when you re not in your vehicle Cold Weather Starting Diesel Engine The following tips will help...

Page 7: ...ur engine see Battery in the owner s manual Be sure you have the right oil for your engine and that you ve changed the oil at the proper times If you use the wrong oil your engine may be harder to sta...

Page 8: ...to a properly grounded three prong 110 volt AC outlet If the cord won t 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...

Page 9: ...2 6 Instrument Panel Cluster 3500HD model United States version shown Canada similar...

Page 10: ...Canada similar Your instrument panel cluster is designed to let you know at a glance how your vehicle is running You ll know how fast you re going about how much fuel you have and many other things y...

Page 11: ...trip odometer can tell you how far your vehicle has been driven since you last set the trip odometer to zero To reset the trip odometer fully press the reset button located near the trip odometer read...

Page 12: ...Gages can indicate when there may be or is a problem with one of your vehicle s functions Often gages and warning lights work together to let you know when there s a problem with your vehicle When one...

Page 13: ...sist your service technician in correctly diagnosing any malfunction NOTICE If you keep driving your vehicle with this light on after a while your emission controls may not work as well your fuel econ...

Page 14: ...e vehicle Your dealer has the proper test equipment and diagnostic tools to fix any mechanical or electrical problems that may have developed Emissions Inspection and Maintenance Programs Some state p...

Page 15: ...onic accelerator As a check to show you it s working this light comes on for a few seconds after the ignition is turned on Normally it will not come back on unless the ignition has been off for 30 sec...

Page 16: ...s functioning properly and tells you when the engine is ready to be started For more details see Starting Your Diesel Engine in the Index Fuel Gage 3500HD Full Size Van The fuel gage when the ignition...

Page 17: ...ated the tank was half full but it actually took a little more or less than half the tank s capacity to fill the tank D The gage moves a little when you turn a corner or speed up D The gage doesn t go...

Page 18: ...ems that can occur on the road Use this section along with the information in Section 5 of your owner s manual 5 2 Engine Overheating 5 2 If Steam Is Coming From Your Engine 5 3 If No Steam Is Coming...

Page 19: ...turn it off and get everyone away from the vehicle until it cools down Wait until there is no sign of steam or coolant before you open the hood If you keep driving when your engine is overheated the...

Page 20: ...t the highest fan speed and open the window as necessary 3 If you re in a traffic jam shift to NEUTRAL N otherwise shift to the highest gear while driving D DRIVE D Full Size Van models or D AUTOMATIC...

Page 21: ...the hood here s what you ll see 3500HD Models A Coolant Surge Tank B Engine Cooling Fan Full Size Van Models A Coolant Surge Tank B Engine Cooling Fan s If the coolant inside the coolant surge tank i...

Page 22: ...stem CAUTION Heater and radiator hoses and other engine parts can be very hot Don t touch them If you do you can be burned Don t run the engine if there is a leak If you run the engine it could lose a...

Page 23: ...w vehicle warranty How to Add Coolant to the Coolant Surge Tank NOTICE The diesel engine has a specific coolant fill procedure Failure to follow this procedure could cause your engine to overheat and...

Page 24: ...burn you badly They are under pressure and if you turn the coolant surge tank pressure cap even a little they can come out at high speed Never turn the cap when the cooling system including the coola...

Page 25: ...d get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOLR coolant NOTICE In cold...

Page 26: ...2 Turn the pressure cap slowly counterclockwise left until it first stops Don t press down while turning the pressure cap If you hear a hiss wait for that to stop A hiss means there is still some pres...

Page 27: ...coolant on a hot engine 4 Fill with the proper mixture Add coolant until you see a steady stream of coolant coming from the bleed valve 5 Close the bleed valve 6 Rinse or wipe the spilled coolant from...

Page 28: ...the upper radiator hose getting hot Watch out for the engine cooling fan s By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixtur...

Page 29: ...5 12 3500HD Models Full Size Van Models 9 Then replace the pressure cap Be sure the arrows on the pressure cap line up like this...

Page 30: ...ant levels There is also technical information about your vehicle Use this section along with the information in Section 6 of your owner s manual 6 2 Diesel Fuel Requirements and Fuel System 6 15 Fill...

Page 31: ...e police or other officials Diesel Engine Fuel NOTICE Diesel fuel or fuel additives not recommended in this manual could damage your fuel system and engine Your warranty wouldn t cover this damage And...

Page 32: ...rers Association EMA has identified properties of an improved diesel fuel for better engine performance and durability Diesel fuels corresponding to the EMA Recommended Guideline on Premium Diesel Fue...

Page 33: ...specifications CAN CGSB 3 517 93 Low Sulfur Diesel in Canada In addition the Engine Manufacturers Association EMA has identified properties of an improved diesel fuel for better engine performance an...

Page 34: ...t gets contaminated fuel from its suppliers If this happens a WATER IN FUEL light will come on If it does the water must be drained Your dealer can show you how to do this It also should come on brief...

Page 35: ...nes Move the vehicle to a warm location to thaw out Problem Recommended Action S At temperatures below freezing Full Size Van Drain fuel filter immediately If no water can be drained water may be froz...

Page 36: ...odels 4 With the engine off open the water drain valve two to three turns The valve is located to the left of the engine oil fill cap when standing in front of the vehicle 5 Start the engine and allow...

Page 37: ...e is off for the following step If the engine is running diesel fuel could spray out of the drain cap With the engine off open the drain cap one or two turns If no liquid comes out your vehicle needs...

Page 38: ...nd you think that you ve run out of fuel do this 3500HD Models Full Size Van Models First open the fuel filter air bleed valve Briefly crank the engine and have someone watch the bleed valve If air co...

Page 39: ...starter motor could damage it Keep doing this until you can just see some clear fuel at the air bleed valve If during this step the engine starts turn the ignition off and close the valve before rest...

Page 40: ...See Engine Compartment Overview in the Index for more information on location 1 Apply the parking brake 2 Take off the fuel cap This releases vacuum or pressure in the tank 3 Unscrew and remove the ri...

Page 41: ...n key to START for 10 to15 seconds Wait one minute for your starter to cool Do this until you can see clear fuel coming from the air bleed valve If no liquid comes out your vehicle needs service 9 Clo...

Page 42: ...sen and remove the ring nut from the top of the filter head 7 Pull the element straight down and remove any dirt from the element sealing surface 8 Unscrew the water drain valve assembly from the orig...

Page 43: ...d when the ring nut snaps into the locked position 13 Connect the water sensor electrical connector to the water sensor on the bottom of the filter Be sure the connector boot is sealed to the bottom o...

Page 44: ...ck on turn it to the right clockwise until you hear a clicking sound Make sure you fully install the fuel cap If you need a new fuel cap be sure to get the right type Your dealer can get one for you I...

Page 45: ...aner Filter Restriction Indicator E Crankcase Depression Regulator Valve CDRV F Automatic Transmission Dipstick If Equipped G Water Drain Valve H Engine Oil Fill Cap I Fuel Filter Under Engine Cover J...

Page 46: ...ollowing A Battery B Surge Tank Pressure Cap C Automatic Transmission Dipstick D Engine Oil Dipstick E Engine Oil Fill Cap F Engine Cooling Fan G Engine Air Cleaner Filter H Power Steering Fluid Reser...

Page 47: ...e 3500HD is located on the driver s side of the engine compartment The engine oil dipstick on the full size van is located at the center of the engine compartment See Engine Compartment Overview in th...

Page 48: ...e capacity see Capacities and Specifications in the Index NOTICE Don t add too much oil If your engine has so much oil that the oil level gets above the proper operating range your engine could be dam...

Page 49: ...best for your vehicle However you can use SAE 10W 30 if it s going to be colder than 32_F 0_C before your next oil change When it s very cold below 0_F 18_C you should use SAE 10W 30 to improve cold...

Page 50: ...trips are less than 5 miles 8 km This is particularly important when outside temperatures are below freezing D Most trips include extensive idling such as frequent driving in stop and go traffic D Yo...

Page 51: ...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...

Page 52: ...eck the indicator If the area inside the clear section of the indicator is green no air filter service is required When the area inside the indicator is orange and CHANGE AIR FILTER appears the filter...

Page 53: ...and the filter into the air cleaner housing Make sure that the duct fits properly into the housing Align the tab on the duct with the notch on the filter housing 5 Install the cover and fasten the tw...

Page 54: ...r remove the three air cleaner assembly bolts 2 Then loosen the screw on the air intake hose clamp 3 Remove the air cleaner assembly from the vehicle 4 Slide the engine air cleaner filter assembly out...

Page 55: ...fluid level if you have been driving D When outside temperatures are above 90_F 32_C D At high speed for quite a while D In heavy traffic especially in hot weather D While pulling a trailer To get the...

Page 56: ...g brake applied place the shift lever in PARK P D With your foot on the brake pedal move the shift lever through each gear range pausing for about three seconds in each range Then position the shift l...

Page 57: ...r s side For full size van models this dipstick is located near the center of the engine compartment See Engine Compartment Overview in the Index for more information on location 1 Flip the handle up...

Page 58: ...uid only after checking the transmission fluid while it is hot A cold check is used only as a reference If the fluid level is low add only enough of the proper fluid to bring the level up to the HOT a...

Page 59: ...OOLR coolant will D Give freezing protection down to 34_F 37_C D Give boiling protection up to 265_F 129_C D Protect against rust and corrosion D Help keep the proper engine temperature D Let the warn...

Page 60: ...engine could get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOLR coolant NO...

Page 61: ...ed on the passenger s side at the rear corner of the engine compartment 3500HD Full Size Van On full size van models the coolant surge tank is located near the center of the engine compartment See Eng...

Page 62: ...rk for full size van models United States Canada If the light comes on and stays on it means you re low on engine coolant Adding Coolant If you need more coolant add the proper DEX COOLR coolant mixtu...

Page 63: ...Compartment Overview in the Index for more information on location NOTICE Your surge tank pressure cap is a unique 15 psi 105 kPa pressure type cap for use with surge tank cooling systems only It mus...

Page 64: ...els only 2 3500HD and Full Size Van Models All quantities are approximate After refill the level MUST be checked as outlined under Engine Cooling System in Section 5 Engine Oil Capacity Engine VIN Eng...

Page 65: ...er TP1263 Surge Tank Cap RC33 For operation in extremely dirty or dusty environments use A1236C for full size van models ACDelcoR part number 3500HD Engine 6 5L VIN F Oil Filter PF1218 Air Cleaner A13...

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