Chevrolet kodiak 2004 Owner'S Manual Download Page 306

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Rear Axle Lubricant Capacity (cont’d)

Application

Capacities

English

Metric

DSH44 (front)

32.0 pints

15.1 liters

RSH44 (rear)

31.0 pints

14.7 liters

DS404, DS404P (front)

32.0 pints

15.1 liters

RS404 (rear)

31.0 pints

14.7 liters

Normal Maintenance Replacement Parts

Allison Transmission

External Filters

See the Allison Transmission

Operator’s Manual in your vehicle for external filter part numbers and information.

Part

Number

Bendix Tu-Flo 550 (13.2 CFM)

2467368

5-100

Summary of Contents for kodiak 2004

Page 1: ...ing Your Vehicle 4 1 Your Driving the Road and Your Vehicle 4 2 Towing 4 31 Service and Appearance Care 5 1 Service 5 3 Fuel 5 6 Checking Things Under the Hood 5 18 Rear Axle 5 61 Noise Control System...

Page 2: ...anual in it so the new owner can use it Litho in U S A Part No C2401 A First Edition Copyright General Motors Corporation 07 14 03 All Rights Reserved Canadian Owners You can obtain a French language...

Page 3: ...CAUTION These mean there is something that could hurt you or other people In the caution area we tell you what the hazard is Then we tell you what to do to help avoid or reduce the hazard Please read...

Page 4: ...bels on your vehicle They use the same words CAUTION or NOTICE Vehicle Symbols Your vehicle has components and labels that use symbols instead of text Symbols used on your vehicle are shown along with...

Page 5: ...These are some examples of symbols you may find on your vehicle v...

Page 6: ...8V064 C4E042 C5E042 C6E042 C7E042 C8E042 C8E064 Since C series models delivered from the factory are finished in a variety of ways by a number of companies you will probably find other manuals in your...

Page 7: ...Models 1 35 Where to Put the Restraint Crew Cab Models 1 37 Top Strap 1 38 Securing a Child Restraint in a Rear Outside Seat Position Crew Cab Models 1 39 Securing a Child Restraint in the Center Rear...

Page 8: ...when you don t want to Adjust the driver s seat only when the vehicle is not moving If your vehicle has bucket seats you can adjust them forward or rearward with the lever located at the front of the...

Page 9: ...ard side of the driver s seat and on the outboard side of the passenger s seat To get more support in the lumbar area of your back turn the lumbar adjustment knob clockwise To decrease the amount of l...

Page 10: ...crash That could cause injury to the person sitting there Always press rearward on the seatback to be sure it is locked Reclining Seatbacks If your vehicle has standard non suspension bucket seats you...

Page 11: ...because it won t be against your body Instead it will be in front of you In a crash you could go into it receiving neck or other injuries The lap belt can t do its job either In a crash the belt coul...

Page 12: ...ension seat height adjustment lever is located on the front inboard side of the seat To adjust the height of the air suspension seat pull the lever up to inflate Push the lever down to deflate The sea...

Page 13: ...crew cab can be folded down to provide more cargo space CAUTION A safety belt that is improperly routed not properly attached or twisted won t provide the protection needed in a crash The person weari...

Page 14: ...an t wear a safety belt properly If you are in a crash and you re not wearing a safety belt your injuries can be much worse You can hit things inside the vehicle or be ejected from it You can be serio...

Page 15: ...so serious that even buckled up a person wouldn t survive 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 b...

Page 16: ...If the vehicle hits something it stops right then But nothing stops the people They keep moving Then something will stop them It could be the windshield 1 10...

Page 17: ...rs were to give that big vehicle a chance to deal with the force of the impact instead of you With belts you slow down as the vehicle does You get more time to stop You stop over more distance and you...

Page 18: ...belts not instead of them Every air bag system ever offered for sale has required the use of safety belts Even if you re in a vehicle that has air bags you still have to buckle up to get the most pro...

Page 19: ...ildren on page 1 27 or Infants and Young Children on page 1 29 Follow those rules for everyone s protection First you ll want to know which restraint systems your vehicle has We ll start with the driv...

Page 20: ...buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to The lap part of the belt should be worn low and snug on the hips just touching the thighs In a crash th...

Page 21: ...shoulder The belt should be away from your face and neck but not falling off your shoulder To move it down push in at the top of the arrows and move the height adjuster to the desired position You ca...

Page 22: ...oo loose It won t give nearly as much protection this way CAUTION You can be seriously hurt if your shoulder belt is too loose In a crash you would move forward too much which could increase injury Th...

Page 23: ...n 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 se...

Page 24: ...red 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...

Page 25: ...riously 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...

Page 26: ...across the body CAUTION You can be seriously injured by a twisted belt In a crash you wouldn t have the full width of the belt to spread impact forces If a belt is twisted make it straight so it can w...

Page 27: ...nt women Like all occupants they are more likely to be seriously injured if they don t wear safety belts A pregnant woman should wear a lap shoulder belt and the lap portion should be worn as low as p...

Page 28: ...f the belt out all the way you will engage the child restraint locking feature If this happens just let the belt go back all the way and start again Center Passenger Position Lap Belt If your vehicle...

Page 29: ...d be able to unbuckle the safety belt quickly if you ever had to Rear Seat Passengers It is very important for rear seat passengers to buckle up Accident statistics show that unbelted people in the re...

Page 30: ...u more slowly 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure When the shoulder belt is pulled out all the way it will lock If it does let i...

Page 31: ...he 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 o...

Page 32: ...fasten your dealer will order you an extender It s free When you go in to order it take the heaviest coat you will wear so the extender will be long enough for you The extender will be just for you a...

Page 33: ...der belt and get the additional restraint a shoulder belt can provide The shoulder belt should not cross the face or neck The lap belt should fit snugly below the hips just touching the top of the thi...

Page 34: ...t 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...

Page 35: ...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 Infants and Young Children Everyone...

Page 36: ...Instead they need to use a child restraint CAUTION People should never hold a baby in their arms while riding in a vehicle A baby doesn t weigh much until a crash During a crash a baby will become so...

Page 37: ...bag system is designed for them Young children and infants need the protection that a child restraint system can provide Q What are the different types of add on child restraints A Add on child restra...

Page 38: ...ongest part of an infant s body the back and shoulders Infants always should be secured in appropriate infant restraints CAUTION The body structure of a young child is quite unlike that of an adult or...

Page 39: ...or position a child on a continuous flat surface Make sure that the infant s head rests toward the center of the vehicle A rear facing infant seat B provides restraint with the seating surface against...

Page 40: ...es such as T shaped or shelf like shields A booster seat F G is a child restraint designed to improve the fit of the vehicle s safety belt system Some booster seats have a shoulder belt positioner and...

Page 41: ...dy A shelf or armrest type shield has straps that are attached to a wide shelf like shield that swings up or to the side When choosing a child restraint be sure the child restraint is designed to be u...

Page 42: ...ld restraint in this vehicle Here is why CAUTION A child in a rear facing child restraint can be seriously injured or killed if the passenger s air bag inflates This is because the back of the rear fa...

Page 43: ...r put a rear facing child restraint in the right front seat position Here is why CAUTION A child in a rear facing child restraint can be seriously injured or killed if the right front passenger s air...

Page 44: ...traint can move around in a collision or sudden stop and injure people in the vehicle even when no child is in it Top Strap Some child restraints have a top strap or top tether which can help hold the...

Page 45: ...e lap shoulder belt See Top Strap on page 1 38 if the child restraint has one Be sure to follow the instructions that came with the child restraint Secure the child in the child restraint when and as...

Page 46: ...houlder belt back into the retractor while you push down on the child restraint If you re using a forward facing child restraint you may find it helpful to use your knee to push down on the child rest...

Page 47: ...instructions that came with the child restraint Secure the child in the child restraint when and as the instructions say But don t use the center front passenger position if your vehicle has air bags...

Page 48: ...the 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 To tighten the belt pull its free end while you push down on the child...

Page 49: ...uspension seat There is no top strap anchor in this position Do not secure a child seat in this position if a national or local law requires that the top strap be anchored or if the instructions that...

Page 50: ...cle unless the passenger s air bag has been turned off Even though the air bag off switch is designed to turn off the passenger s frontal air bag no system is fail safe and no one can guarantee that a...

Page 51: ...ent has identified as a member of a passenger air bag risk group sit in the right front passenger s position for example don t secure a rear facing child restraint in the right front passenger s seat...

Page 52: ...s it will go before securing it in this seat See Seats in the index Never use a rear facing child restraint in this seat unless the air bag is off 2 Put the restraint on the seat 3 Pick up the latch p...

Page 53: ...oulder belt back into the retractor while you push down on the child restraint If you are using a forward facing child restraint you may find it helpful to use your knee to push down on the child rest...

Page 54: ...sitting there is a member of a passenger air bag risk group See Air Bag Off Switch on page 1 55 CAUTION If the right front passenger s air bag is turned off for a person who isn t in a risk group iden...

Page 55: ...nel in front of the right front passenger s seat your vehicle has an air bag for the driver only If it says AIR BAG on the middle part of the steering wheel but there is no right front passenger seat...

Page 56: ...peed frontal crashes or in many side crashes And for some unrestrained occupants air bags may provide less CAUTION Continued CAUTION Continued protection in frontal crashes than more forceful air bags...

Page 57: ...r its air bag system is designed for them Young children and infants need the protection that a child restraint system can provide Always secure children properly in your vehicle To read how see Older...

Page 58: ...Where Are the Air Bags The driver s air bag is in the middle of the steering wheel The right front passenger s air bag is in the instrument panel on the passenger s side 1 52...

Page 59: ...s What Makes an Air Bag Inflate In an impact of sufficient severity the air bag sensing system detects that the vehicle is in a crash The sensing system triggers a release of gas from the inflator whi...

Page 60: ...le with a history of asthma or other breathing trouble To avoid this everyone in CAUTION Continued CAUTION Continued the vehicle should get out as soon as it is safe to do so If you have breathing pro...

Page 61: ...t an air bag system won t work properly See your dealer for service Notice If you damage the covering for the driver s or the right front passenger s air bag the bag may not work properly You may have...

Page 62: ...physician makes it necessary for the infant to ride in the front seat so that the driver can constantly monitor the child s condition Child age 1 to 12 A child age 1 to 12 must ride in the front seat...

Page 63: ...ag and allowing the passenger even if belted to hit the dashboard or windshield in a crash CAUTION If the right front passenger s air bag is turned off for a person who isn t in a risk group identifie...

Page 64: ...ou that the air bag is off CAUTION If the air bag readiness light ever comes on when you have turned off the air bag it means that something may be wrong with the air bag system The right front passen...

Page 65: ...To turn the right front passenger s air bag on again insert your ignition key into the switch push in and move the switch to the on position United States Canada 1 59...

Page 66: ...manual see Service Publications Ordering Information on page 7 7 CAUTION For up to 10 minutes after the ignition key is turned off and the battery is disconnected an air bag can still inflate during i...

Page 67: ...of the air bag sensors If you have any questions about this you should contact Customer Assistance before you modify your vehicle The phone numbers and addresses for Customer Assistance are in Step T...

Page 68: ...ble If you ve 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...

Page 69: ...14 Starting Your DURAMAX Diesel Engine 2 19 Engine Checks Before Operating 2 22 Engine Coolant Heater 2 23 Diesel Engine Exhaust Brake 2 25 Two Speed Rear Axle Electric Shift Control 2 26 Automatic Tr...

Page 70: ...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...

Page 71: ...tions 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 and...

Page 72: ...is necessary See Battery Replacement under Remote Keyless Entry System Operation on page 2 4 If you are still having trouble see your dealer or a qualified technician for service Remote Keyless Entry...

Page 73: ...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 transmit...

Page 74: ...see your dealer for service Doors and Locks Door Locks CAUTION Unlocked doors can be dangerous Passengers especially children can easily open the doors and fall out of a moving vehicle When a door is...

Page 75: ...unlock your door from the outside use your key To lock your door from the inside slide the manual lever on your door down To unlock the door slide the manual lever up Power Door Locks If your vehicle...

Page 76: ...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 clos...

Page 77: ...windows the driver s door will have four switches on it that can control all of the windows If your vehicle is a crew cab model with power windows there will be switches located on the rear doors as w...

Page 78: ...cated above the four window switches on the driver s door When the switch is not engaged all windows will return to normal operation Sliding Rear Window To open the sliding rear window pull the latch...

Page 79: ...oid 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 Fol...

Page 80: ...e steering wheel like LOCK Use OFF if you must have your vehicle in motion while the engine is off for example if your vehicle is being pushed D RUN This is the position for driving E START This posit...

Page 81: ...engine rpm signal from the engine speed sensor Starting Your Engine 1 Without pushing the accelerator pedal turn your ignition key to START When the engine starts let go of the key The idle speed will...

Page 82: ...smission the vehicle may move slightly when you do this While your engine is idling before you turn it off you can make a list of any operational or handling concerns to give to responsible maintenanc...

Page 83: ...l 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 heater...

Page 84: ...o 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 temperature or oil pressure condition worsens the tone alarm will go to fi...

Page 85: ...f equipped is shifted from NEUTRAL N or PARK P The vehicle speed exceeds about 5 mph 8 km h The throttle is pressed Manual High Idle System If your vehicle has this feature the manual high idle switch...

Page 86: ...or valve located in the exhaust stream The valve closes to provide back pressure to the engine for the purpose of warming the engine quickly The exhaust restrictor operates while the engine is running...

Page 87: ...light See Wait to Start Indicator on page 3 36 This light may not come on if the engine is hot 2 As soon as the wait to start light goes off IMMEDIATELY turn the ignition key to START When the engine...

Page 88: ...temperature drops below 0 F 18 C use of the engine coolant heater is recommended If you experience longer cranking times notice an unusual amount of exhaust smoke or are at higher altitudes over 7 000...

Page 89: ...the RPO LLY engine it has a cold temperature high idle and exhaust restrictor feature which elevates the engines idle speed from 680 to 1200 rpms and restricts the exhaust gas flow when outside tempe...

Page 90: ...high idle after the normal delay if the conditions for engine coolant temperature and air intake temperature are still met Engine Checks Before Operating When you ve started your engine let it run for...

Page 91: ...ter charge indicator gage tells you the condition of your battery s charge The gage should be in the center area during engine operation The red area on the left indicates an undercharge condition the...

Page 92: ...uty three prong extension cord rated for at least 15 amps 4 Before starting the engine be sure to unplug the cord How long should you keep the coolant heater plugged in The answer depends on the outsi...

Page 93: ...nformation When using the exhaust brake the proper gear range selection is important The exhaust brake will be most effective if the gear range selected is the lowest possible range that does not allo...

Page 94: ...the switch down to change to low range The two speed axle should be in low when you park the vehicle You ll need to engage the transmission even move the vehicle a little to be sure the axle is in the...

Page 95: ...ow press the bottom of the switch release the accelerator and then quickly press it down again To operate off road or under a heavy load shift into low range when the vehicle is standing still and the...

Page 96: ...on Operation We build vehicles with five and six speed automatic transmissions This part of the manual covers the basics of these With some of the transmissions you will find another manual in your ve...

Page 97: ...brake pedal your vehicle could move very rapidly You could lose control and hit people or objects Do not shift into a drive gear while your engine is running at high speed Overdrive Defeat If your ve...

Page 98: ...en upshifting slow the engine until the engine rpm and road speed match When downshifting accelerate the engine until the engine rpm and road speed match Then quickly disengage the clutch and move the...

Page 99: ...e to a complete stop If the shift lever will not go into FIRST 1 put the lever in neutral and let up on the clutch pedal to fully engage the clutch Press the clutch pedal again Then shift into FIRST 1...

Page 100: ...is in the HI range Never move the range knob or lever with the shift lever in neutral while the vehicle is moving Never make a range shift while moving in REVERSE R Clutch Brake Vehicles with Non Syn...

Page 101: ...the regular brake pedal down with your right foot 3 Apply the parking brake 4 Shift the transmission to NEUTRAL or PARK P Hydraulic Brakes If your vehicle has hydraulic brakes it has either a parking...

Page 102: ...d following these instructions Make 10 stops using the parking brake hand lever or foot pedal from 20 mph 32 km h about 2 1 2 miles 4 km apart Between stops drive the vehicle at 20 mph 32 km h to allo...

Page 103: ...pplies the parking brake The park brake light will come on when the air parking brake is applied Vehicles built for use as tractors or towing vehicles have two air brake controls They look like this T...

Page 104: ...ps below 60 to 70 psi 413 to 482 kPa the primary brake light and warning buzzer will come on If the air pressure drops to 35 to 45 psi 241 to 310 kPa the red trailer air supply knob will automatically...

Page 105: ...consciousness and death You might have exhaust coming in if Your exhaust system sounds strange or different Your vehicle gets rusty underneath Your vehicle was damaged in a collision Your vehicle was...

Page 106: ...lace this can happen is a garage Exhaust with CO can come in easily NEVER park in a garage with the engine running Another closed in place can be a blizzard See Winter Driving on page 4 25 CAUTION It...

Page 107: ...the proper steps to be sure your vehicle will not move Mirrors Manual Rearview Mirror If your vehicle has this feature pull the tab under the mirror toward you to reduce glare from headlamps behind yo...

Page 108: ...ror by pressing the outer arrows on the switch until the mirror is in the desired position Outside Convex Mirrors Your vehicle has convex mirrors on the lower quarter of both the driver s and passenge...

Page 109: ...ed mirror feature is activated See Rear Window Defogger under Climate Control System on page 3 19 Storage Areas Your vehicle includes a number of storage compartments Some vehicles have storage areas...

Page 110: ...enger s seat To expose the storage compartment pull the strap to release the seatback Then fold the seatback forward To open the storage compartment press the release button and lift the lid rearward...

Page 111: ...Bag Off Light 3 28 Charging System Light 3 30 Voltmeter Gage 3 30 Service Transmission Warning Light 3 31 Range Inhibit Warning Indicator 3 31 Brake System Warning Light 3 31 Parking Brake Warning Li...

Page 112: ...ge 3 44 Hourmeter Gage 3 45 Audio System s 3 45 Setting the Time 3 45 AM FM Radio 3 46 Radio with Cassette 3 48 Radio with CD 3 53 Theft Deterrent Feature Non RDS Radios 3 57 Radio Reception 3 57 Care...

Page 113: ...NOTES 3 3...

Page 114: ...Instrument Panel Overview 3 4...

Page 115: ...age 3 13 G Turn Signal Multifunction Lever See Turn Signal Multifunction Lever on page 3 7 H Hazard Warning Flashers Button See Hazard Warning Flashers on page 3 5 I Audio System s See Audio System s...

Page 116: ...Devices If you carry reflective triangles you can set one up at the side of the road behind your vehicle in the recommended manner per Federal Motor Carrier Safety Regulation FMCSR Section 392 22 to...

Page 117: ...l is located on the left side of the steering column To tilt the wheel hold the wheel and pull the lever Then move the wheel to a comfortable position and release the lever to lock the wheel in place...

Page 118: ...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 5 87 If a bulb is burned out replace...

Page 119: ...frozen to the windshield carefully loosen or thaw them If your blades do become worn or damaged get new blades or blade inserts For more information see Windshield Wiper Blade Replacement on page 5 6...

Page 120: ...out keeping your foot on the accelerator Cruise control does not work at speeds below about 30 mph 48 km h If you have an automatic transmission and you apply your brakes the cruise control will shut...

Page 121: ...or more you can move the cruise control switch briefly from on to resume accelerate The vehicle will return to your chosen speed and stay there If you hold the switch at resume accelerate the vehicle...

Page 122: ...d load and the steepness of the hills When going up steep hills you may want to step on the accelerator pedal to maintain your speed When going downhill you may have to brake or shift to a lower gear...

Page 123: ...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 multifu...

Page 124: ...l 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...

Page 125: ...ll come on when you open a door You can also turn the dome lamps on by moving the thumbwheel located to the right of the exterior lamp control all the way up to the second position In this position th...

Page 126: ...u to enter or exit 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...

Page 127: ...Brake Switch See Diesel Engine Exhaust Brake on page 2 25 l Differential Lock Control Switch See Rear Axle Differential Lock Control on page 4 10 cd Air Bag Off Switch See Air Bag Off Switch on page...

Page 128: ...accessory or accessory bracket from the plug because the power outlets are designed for accessory power plugs only Ashtrays and Cigarette Lighter Your vehicle may have an ashtray and a cigarette light...

Page 129: ...s 6 Floor This mode directs most of the air to the floor vents Use this mode to send air to the rear of the vehicle Keep the area under the front seats free of objects that could obstruct airflow to t...

Page 130: ...ir and directs it through the instrument panel vents Bi Level Air Conditioning This setting divides airflow between the floor vents and instrument panel vents The air conditioning compressor will cycl...

Page 131: ...ture knob should be in the red area and the fan control toward high Do not drive the vehicle until all the windows are clear Rear Window Defogger The rear window defogger uses a warming grid to remove...

Page 132: ...tion Tips Keep the hood and front air inlets free of ice snow or any other obstruction such as leaves The heater and defroster will work far better reducing the chance of fogging the inside of your wi...

Page 133: ...ng 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 eng...

Page 134: ...gned to let you know at a glance how your vehicle is running You ll know how fast your going about how much fuel is left and many other things you ll need to drive safely and economically United State...

Page 135: ...is displayed will reset it To display the odometer reading with the ignition off press the reset button Engine Speed Limiting All engines have electronic engine speed limiting The engine limited speed...

Page 136: ...le to fasten their safety belts The safety belt light will also come on and stay on for several seconds Safety Belt Reminder Tone If your vehicle has this feature when you turn your key to RUN or STAR...

Page 137: ...o out This means the system is ready If the air bag readiness light stays on after you start the vehicle or comes on when you are driving your air bag system may not work properly Have your vehicle se...

Page 138: ...front passenger s air bag off this light will come on and stay on to remind you that the air bag has been turned off This light will go off when you turn the air bag back on again See Air Bag Off Swit...

Page 139: ...n the Index for more on this including important safety information CAUTION If the air bag readiness light ever comes on when you have turned off the air bag it means that something may be wrong with...

Page 140: ...lt in a lack of back up braking if the engine quits or the power steering pump should fail Voltmeter Gage When your engine is running the voltmeter gage shows the charging system voltage Readings in e...

Page 141: ...perate in all gears If you attempt to shift gears the vehicle may not continue to move Do not attempt to shift gears while the transmission warning light is on Instead drive directly to a GM dealer fo...

Page 142: ...en this light comes on you will also hear a warning tone If this light comes on have the system repaired immediately Both of these lights should come on briefly every time you start your engine If the...

Page 143: ...the nearest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the LOW AIR warning light comes on and the warning tone sounds the vehicle can stop sudde...

Page 144: ...e system this light will come on when you start your engine and it may stay on for several seconds That s normal If the light stays on or comes on when you re driving your vehicle needs service If the...

Page 145: ...an anti lock brake system equipped trailer is not connected this light is not functional Engine Coolant Temperature Gage This gage shows the engine coolant temperature If the gage pointer moves into...

Page 146: ...as you can This light may also come on if your vehicle is equipped with the automatic engine shutdown system and engine shutdown has begun See Engine Alarm and Automatic Shutdown under Starting Your...

Page 147: ...f you keep driving your vehicle with this light on after a while your emission controls may not work as well your fuel economy may not be as good and your engine may not run as smoothly This could lea...

Page 148: ...intenance may damage the engine The repairs would not be covered by your warranty Always follow the maintenance schedule in this manual for changing engine oil Low Oil Level Light This light should co...

Page 149: ...reset the change engine oil light see Engine Oil Caterpillar Diesel Engine on page 5 20 or Engine Oil Gasoline Engine on page 5 20 or Engine Oil DURAMAX Diesel on page 5 25 Engine Overspeed Warning L...

Page 150: ...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 lo...

Page 151: ...may be driven at a reduced speed while the reduced engine power light is on but acceleration and speed may be reduced Anytime the check engine light stays on the vehicle should be taken to an authoriz...

Page 152: ...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 equi...

Page 153: ...the ignition At the gas station the pump shuts off before the gage reads full It takes a little more or less fuel to fill up than the gage indicated If you have a Caterpillar diesel engine also see yo...

Page 154: ...ir Pressure Gage If your vehicle has air brakes the air pressure gage is located above the switchbank in the center of the instrument panel This gage shows the air pressure for both your front and rea...

Page 155: ...portant 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 oper...

Page 156: ...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 will go to a station play for a few secon...

Page 157: ...n two seconds until you hear a beep B and a zero or T and a zero will appear on the display To adjust both tone controls and both speaker controls to the middle position end out of audio by waiting fo...

Page 158: ...m the factory If CAL appears on the display it means that your radio has not been configured properly for your vehicle and must be returned to the dealer for service LOC Locked This message is display...

Page 159: ...ng presets The radio will seek and scan only to stations that are in the selected band and only to those with a strong signal Setting Preset Stations The six numbered pushbuttons let you return to you...

Page 160: ...more than two seconds until you hear a beep CEN will appear on the display Fade may not be available if you have a regular cab model Radio Messages CAL Calibration Your audio system has been calibrat...

Page 161: ...on the tape Pressing this pushbutton multiple times in the next mode will increase the number of selections to searched forward Pressing the PREV pushbutton will cancel the selections 3 REV Reverse Pr...

Page 162: ...sage will appear on the display and the player will eject the tape The radio will go back to playing the last station selected CLN Clean If this message appears on the display the cassette tape player...

Page 163: ...n and stay there To scan stations press and hold one of the SEEK arrows for two seconds until you hear a beep The radio will go to a station play for a few seconds and flash the station frequency then...

Page 164: ...le position end out of audio mode by waiting for the display to change to the time display Then press and hold AUDIO for more than two seconds until you hear a beep CEN will appear on the display Adju...

Page 165: ...acks and or difficulty in loading and ejecting If these problems occur try a known good CD Do not add paper labels to discs they could get caught in the CD player Do not play 3 inch discs without a st...

Page 166: ...he radio when a CD is playing The inactive CD will remain safely inside the radio for future listening CD Press this button to play a compact disc when listening to the radio CD will appear on the dis...

Page 167: ...can cause reduced sound quality ruined cassettes or a damaged mechanism Cassette tapes should be stored in their cases away from contaminants direct sunlight and extreme heat If they aren t they may n...

Page 168: ...cut tape detection feature will be active again You may also choose a non scrubbing action wet type cleaner which uses a cassette with a fabric belt to clean the tape head This type of cleaning casse...

Page 169: ...ent you can straighten it out by hand If the mast is badly bent you should replace it Check occasionally to be sure the mast is still tightened to the fender If tightening is required tighten by hand...

Page 170: ...NOTES 3 60...

Page 171: ...em TCS 4 11 Steering 4 12 Off Road Recovery 4 14 Passing 4 14 Loss of Control 4 16 Driving at Night 4 17 Driving in Rain and on Wet Roads 4 18 City Driving 4 21 Freeway Driving 4 22 Highway Hypnosis 4...

Page 172: ...driving task Anything that distracts from the driving task such as concentrating on a cellular telephone call reading or reaching for something on the floor makes proper defensive driving more difficu...

Page 173: ...rinking depends upon four things The amount of alcohol consumed The drinker s body weight The amount of food that is consumed before and during drinking The length of time it has taken the drinker to...

Page 174: ...ffected well below a BAC of 0 10 percent Research shows that the driving skills of many people are impaired at a BAC approaching 0 05 percent and that the effects are worse at night All drivers are im...

Page 175: ...nd judgment can be affected by even a small amount of alcohol You can have a serious or even fatal collision if you drive after drinking Please do not drink and drive or ride with a driver who has bee...

Page 176: ...much faster if you do a lot of heavy braking If you keep pace with the traffic and allow realistic following distances you will eliminate a lot of unnecessary braking That means better braking and lo...

Page 177: ...test is going on This is normal If there is a problem with the anti lock brake system this warning light will stay on See Anti Lock Brake System Warning Light on page 3 34 Let us say the road is wet a...

Page 178: ...ake pedal 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 enou...

Page 179: ...ou 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 hi...

Page 180: ...ht on snow or ice can damage the axle s Turn on this control only while the wheels are not spinning freely Rear Axle Differential Lock Control If your vehicle has a controlled traction or locking diff...

Page 181: ...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 bu...

Page 182: ...ondition of your tires and the road surface the angle at which the curve is banked and your speed While you are in a curve speed is the one factor you can control Suppose you are steering through a sh...

Page 183: ...ese First apply your brakes See Braking on page 4 6 It is better to remove as much speed as you can from a possible collision Then steer around the problem to the left or right depending on the space...

Page 184: ...nd the vehicle ahead then goes back into the right lane again A simple maneuver Not necessarily Passing another vehicle on a two lane highway is a potentially dangerous move since the passing vehicle...

Page 185: ...start that more than makes up for the distance you would lose by dropping back And if something happens to cause you to cancel your pass you need only slow down and drop back again and wait for anothe...

Page 186: ...s system or if the system is off then an acceleration skid is also best handled by easing your foot off the accelerator pedal Of course traction is reduced when water snow ice gravel or other material...

Page 187: ...oad ahead In remote areas watch for animals If you are tired pull off the road in a safe place and rest No one can see as well at night as in the daytime But as we get older these differences increase...

Page 188: ...tedly Remember that your headlamps light up far less of a roadway when you are in a turn or curve Keep your eyes moving that way it is easier to pick out dimly lighted objects Just as your headlamps s...

Page 189: ...streaking or missing areas on the windshield or when strips of rubber start to separate from the inserts Driving too fast through large water puddles or even going through some vehicle washes can cau...

Page 190: ...Standing Water Notice If you drive too quickly through deep puddles or standing water water can come in through your engine s air intake and badly damage your engine Never drive through water that is...

Page 191: ...to get to where you are going Get a city map and plan your trip into an unknown part of the city just as you would for a cross country trip Larger vehicles can not be driven everywhere smaller ones c...

Page 192: ...oothly with the traffic flow Once you are on the freeway adjust your speed to the posted limit or to the prevailing rate if it is slower Stay in the right lane unless you want to pass On some freeways...

Page 193: ...does your vehicle can leave the road in less than a second and you could crash and be injured What can you do about highway hypnosis First be aware that it can happen Then here are some tips Make sure...

Page 194: ...gerous Your brakes will have to do all the work of slowing down They 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 Alwa...

Page 195: ...de an ice scraper a small brush or broom a supply of windshield washer fluid a rag some winter outer clothing a small shovel a flashlight a red cloth and reflective warning triangles And if you will b...

Page 196: ...sand crews can get there Whatever the condition smooth ice packed blowing or loose snow drive with caution If you have traction control keep the system on It will improve your ability to accelerate w...

Page 197: ...y slippery road Watch for slippery spots The road might be fine until you hit a spot that is covered with ice On an otherwise clear road ice patches may appear in shaded areas where the sun can not re...

Page 198: ...vehicle Clear away snow from around the base of your vehicle if any is blocking your exhaust pipe And check around again from time to time to be sure snow does not collect there Open a window just a l...

Page 199: ...is stuck you will need to spin the wheels but you do not want to spin your wheels too fast The method known as rocking can help you get out when you are stuck but you must use caution CAUTION If you...

Page 200: ...ase the accelerator pedal while you shift and press lightly on the accelerator pedal when the transmission is in gear By slowly spinning your wheels in the forward and reverse directions you will caus...

Page 201: ...ur dealer or a professional towing service if you need to have your disabled vehicle towed See Roadside Assistance Program on page 7 4 Releasing Air Operated Parking Brakes If your vehicle has air bra...

Page 202: ...ide of the brake chamber Some chambers have studs which are visible at all times 3 Remove the rubber cap from the rear of the chamber 4 Put the release stud nut and flat washer into the chamber 5 Turn...

Page 203: ...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 the rubber cap Loading Your Vehicle There is a GVW Rating label on your...

Page 204: ...ading can shorten the life of your vehicle Using heavier suspension components to get added durability might not change your weight ratings Ask your dealer to help you load your vehicle the right way...

Page 205: ...ector is attached to a bracket on the platform hitch The Center High Mounted Stoplamp CHMSL wire is tied next to the trailer wiring harness for use with a trailer The eight wire harness contains the f...

Page 206: ...ting the trailer air line connections to another piece of equipment be sure to replace their protective caps Electrical Connections This system is a seven wire cable that will connect to the trailer s...

Page 207: ...ne Air Cleaner Filter 5 30 Automatic Transmission Fluid 5 31 Manual Transmission Fluid 5 32 Engine Coolant Gas and DURAMAX engines 5 32 Engine Coolant Caterpillar Diesel Engines 5 35 Coolant Surge Tan...

Page 208: ...strips 5 79 Cleaning the Outside of Your Vehicle 5 80 Sheet Metal Damage 5 82 Finish Damage 5 83 Underbody Maintenance 5 83 Chemical Paint Spotting 5 83 Vehicle Care Appearance Materials 5 84 Vehicle...

Page 209: ...ant 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...

Page 210: ...60 You should keep a record with all parts receipts and list the mileage and the date of any service work you perform See Part D Maintenance Record on page 6 31 CAUTION You can be injured and your veh...

Page 211: ...y damage the 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 Wint...

Page 212: ...normal This does not indicate a problem exists or that a higher octane fuel is necessary If you are using 87 octane or higher octane fuel and hear heavy knocking your engine needs service Gasoline Sp...

Page 213: ...e in your area to contribute to clean air General Motors recommends that you use these gasolines particularly if they comply with the specifications described earlier Notice Your vehicle was not desig...

Page 214: ...ove and below freezing conditions as oil companies blend Number 2 D fuel to address climate differences Number 1 D diesel fuel may be used in very cold temperatures when it stays below 0 F or 18 C how...

Page 215: ...els are blended for seasonal changes Diesel Type A fuel is blended for better cold weather starting below 0 F or 18 C however you may notice some power and fuel economy loss If Type A fuel is used in...

Page 216: ...s listed previously under the heading What Fuel to Use Notice Never use home heating oil or gasoline in your diesel engine They can cause engine damage In cold weather your fuel filter may become clog...

Page 217: ...light stays on see your dealer for assistance Water In Fuel Light Chart cont d Problem Recommended Action Light stays on at temperatures below freezing Drain fuel filter immediately If no water can b...

Page 218: ...tant container and properly dispose of the contaminated fuel To find out how to properly dispose of contaminated diesel fuel see Engine Oil Caterpillar Diesel Engine on page 5 20 or Engine Oil Gasolin...

Page 219: ...cur it is very likely that air has entered your fuel system and that you will need to prime the fuel system before operating the vehicle Air in the fuel lines will not harm the engine or the vehicle H...

Page 220: ...turns 6 Repeatedly push down on the fuel filter primer pump with the palm of your hand Let the pump return upward between pushes 7 Operate the priming pump until a small amount of fuel seeps from the...

Page 221: ...he 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 rp...

Page 222: ...ter sensor wire to the filter 6 Use the fuel filter priming procedure earlier in this section to prime the fuel filter 7 Tighten the air bleed valve by turning it clockwise until hand tight 8 Start yo...

Page 223: ...n happen if your tank is nearly full and is more likely in hot weather Open the fuel cap slowly and wait for any hiss noise to stop Then unscrew the cap all the way When you put the cap back on turn i...

Page 224: ...e 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...

Page 225: ...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 5 19...

Page 226: ...n 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 yo...

Page 227: ...e 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 at or below the cross...

Page 228: ...h 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 G...

Page 229: ...the starburst symbol on the front of the oil container Notice Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines...

Page 230: ...d service people who will perform this work using genuine GM parts and reset the system It is also important to check your oil regularly and keep it at the proper level If the system is ever reset acc...

Page 231: ...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...

Page 232: ...pan With a cool engine allow 30 minutes If you don t the oil dipstick might not show the actual level Pull out the dipstick and clean it with a paper towel or a cloth then push it back in all the way...

Page 233: ...on explains what kind of oil to use For engine oil crankcase capacity see Capacities and Specifications on page 5 93 Notice Do not add too much oil If your engine has so much oil that the oil level ge...

Page 234: ...d oils can result in engine damage not covered by your warranty SAE 15W 40 As shown in the viscosity chart SAE 15W 40 is best for your vehicle However you can use SAE 10W 30 at temperatures above 0 F...

Page 235: ...long Clean your skin and nails with soap and water or a good hand cleaner Wash or properly throw away clothing or rags containing used engine oil See the manufacturer s warning about the use and dispo...

Page 236: ...ge indicator at every oil change and replace the filter when the indicator tells you to Vehicles without a change indicator inspect the air cleaner filter at every oil change and replace at the first...

Page 237: ...se 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 Automatic Transmission Fluid When to Check A go...

Page 238: ...an inch of oil level equals about one gallon of fluid 3 If the fluid level is good install the plug and be sure it is fully seated If the fluid level is low add more fluid as described in the next ste...

Page 239: ...t damage aluminum parts If you use this coolant mixture you don t need to add anything else CAUTION Adding only plain water to your cooling system can be dangerous Plain water or some other liquid su...

Page 240: ...ng 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 on a level surface When your engine is cold the...

Page 241: ...ngines If your vehicle has a Caterpillar diesel engine see the Caterpillar Diesel Engine Operation Maintenance Manual provided with your vehicle to find out what to add also when and how to service yo...

Page 242: ...if you see or hear steam coming from it Just turn it off and get everyone away from the vehicle until it cools down Wait until there is no sign of steam or coolant before you open the hood If you kee...

Page 243: ...e road shift to park or neutral and let the engine idle 2 Turn on your heater to full hot at the highest fan speed and open the window as necessary 3 If climbing a hill downshift to raise engine and f...

Page 244: ...ehicle should be parked on a level surface The coolant level should be at COLD FILL or higher If it isn t you may have a leak at the pressure cap or in the radiator hoses heater hoses radiator water p...

Page 245: ...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 I...

Page 246: ...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 coolant su...

Page 247: ...nd crack the engine radiator heater core and other parts Use the recommended coolant and the proper coolant mixture CAUTION You can be burned if you spill coolant on hot engine parts Coolant contains...

Page 248: ...the engine and let it run until you can feel the upper radiator hose getting hot Watch out for the engine cooling fan By this time the coolant level inside the coolant surge tank may be lower If the l...

Page 249: ...d not be mistaken as the transmission slipping or making extra shifts It is merely the cooling system functioning properly The fan will slow down when additional cooling is not required and the clutch...

Page 250: ...information What to Use To determine what kind of fluid to use see Part C Recommended Fluids and Lubricants on page 6 29 Notice When adding power steering fluid or making a complete fluid change alway...

Page 251: ...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...

Page 252: ...edule to determine when to check your brake fluid CAUTION Do not add brake fluid before you check the level If you do you could get too much brake fluid Brake fluid could spill on the hot engine and i...

Page 253: ...of the vehicle If it is low add enough fluid to fill the reservoir to the proper level Checking Brake Fluid Hydro Boost System Apply the brake pedal several times with the ignition off Clean the cove...

Page 254: ...his 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 your...

Page 255: ...id increase in pedal travel This could be a sign of brake trouble Brake Adjustment Every time you make a brake stop your brakes adjust for wear Replacing Brake System Parts The braking system on a veh...

Page 256: ...sure you are at full pressure check your air pressure gage It should read at least 100 psi 692 kPa Moisture Ejector If you have air brakes with a moisture ejector the valve automatically ejects moistu...

Page 257: ...Free Travel If you have a manual transmission your clutch will need adjustment when pedal free travel gets down to about 1 4 inch 32 mm as measured at the clutch pedal pad You should have 1 1 2 to 2 i...

Page 258: ...Single Axle Models 5 52...

Page 259: ...ase gun only Hand pack upper bearing 9 Front Wheel Bearings Hand pack or lubricate 10 Steering Tie Rod Ends One fitting each end 11 Spring Slip Pads Multi leaf Only Apply chassis lubricant 12 Clutch R...

Page 260: ...akes only Applies to hydraulic brakes only Tandem Axle Models Item Number Item Remarks 1 Brake Camshafts One fitting each 2 Propshaft U Joint One fitting each joint Lubricate with GM Part No 1051344 W...

Page 261: ...not going to drive your vehicle for 25 days or more remove the black negative cable from the battery This will help keep your battery from running down If your vehicle has more than one battery be sur...

Page 262: ...to jump start your vehicle If you have a diesel engine vehicle with two batteries or more you should know before you begin that especially in cold weather you may not be able to get enough power from...

Page 263: ...hood They are located in the battery box on 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 purpos...

Page 264: ...Negative will go to a heavy unpainted metal engine part or to a remote negative terminal if the vehicle has one Don t connect the positive to negative or you ll get a short that would damage the batte...

Page 265: ...nal 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...

Page 266: ...ery 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 cabl...

Page 267: ...kind of lubricant to use See Part C Recommended Fluids and Lubricants on page 6 29 Rear Axle Shift Motor When to Check and Change Fluid If you have an optional air shift two speed controlled traction...

Page 268: ...epair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use...

Page 269: ...Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking See Wiper Blade Check under At Least Twice a Year on page 6 25 for more information Repla...

Page 270: ...ther Service Items Fuel Filter Fuel Filter Gasoline Engines The steel fuel filter is located near the engine compartment on the driver s side of the vehicle See your Maintenance Schedule for recommend...

Page 271: ...y 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 It has a clear plastic drain bowl at the bottom Check the d...

Page 272: ...erpillar Diesel Engine on page 5 20 or Engine Oil Gasoline Engine on page 5 20 or Engine Oil DURAMAX Diesel on page 5 25 for proper disposal procedures Automatic Ether Injection System If you have a C...

Page 273: ...fill plug in the center of the glass and then remove it Be careful not to allow any dirt or water to get into the oil Add enough of the recommended oil to bring it up to the level mark that you ll see...

Page 274: ...nger 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 tires are cold Over...

Page 275: ...gage to check tire pressure You can t tell if your tires are properly inflated simply by looking at them Radial tires may look properly inflated even when they re underinflated Be sure to put the val...

Page 276: ...if You can see cord or fabric showing through the tire s rubber The tread or sidewall is cracked cut or snagged deep enough to show cord or fabric The tire has a bump bulge or split The tire has a pun...

Page 277: ...properly tightened Follow the rules in this section to be sure they are This section lets you know how often to check the tightness of the wheel nuts on your vehicle and how tight they must be First u...

Page 278: ...ten the nuts to 400 lb ft 542 N m if an 8 hole stud or 480 lb ft 650 N m if a 10 hole stud using the following diagrams CAUTION Never use oil or grease on studs or the threads of the wheel nuts If you...

Page 279: ...hubs wheel nuts or wheels be sure to use GM original equipment parts CAUTION Rust or dirt on a wheel or on the parts to which it is fastened can make wheel nuts become loose after a time The wheel co...

Page 280: ...other thing to try to stop the leaking Get a new wheel or the proper type CAUTION Without the correct wheel you may not be able to stop properly and you could have other problems like a tire air out...

Page 281: ...tire will create a drag that pulls the vehicle toward that side Take your foot off the accelerator pedal and grip the steering wheel firmly Steer to maintain lane position and then gently brake to a s...

Page 282: ...and checked for damage So if you re stopped somewhere by a flat or damaged tire or wheel you should get expert help See Roadside Assistance Program on page 7 4 CAUTION Your vehicle when new did not i...

Page 283: ...vinyl leather plastic and painted surfaces with a clean damp cloth Cleaning Fabric Carpet Your dealer has cleaners for the cleaning of fabric and carpet They will clean normal spots and stains very we...

Page 284: ...lly scrape off excess stain then sponge the soiled area with cool water 2 If a stain remains follow the cleaner instructions described earlier 3 If an odor lingers after cleaning vomit or urine treat...

Page 285: ...als on page 5 84 Notice If you use abrasive cleaners when cleaning glass surfaces on your vehicle you could scratch the glass and or cause damage to the rear window defogger and the integrated radio a...

Page 286: ...chamois or an all cotton towel to avoid surface scratches and water spotting High pressure car washes may cause water to enter your vehicle Cleaning Exterior Lamps Lenses Use only lukewarm or cold wa...

Page 287: ...However 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...

Page 288: ...ed surface of the wheel and buff off immediately after application Don t take your vehicle through an automatic car wash that has silicone carbide tire cleaning brushes These brushes can also damage t...

Page 289: ...on 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 loosene...

Page 290: ...wire wheel covers Finish Enhancer Removes dust fingerprints and surface contaminants Spray on wipe off Vehicle Care Appearance Materials cont d Description Usage Swirl Remover Polish Removes swirl ma...

Page 291: ...is on your GVW Rating label Here is what each one means TRUCK SERVICE A vehicle made to carry property or special equipment It is made for uniform frame loading That includes using the vehicle to pull...

Page 292: ...dd On Electrical Equipment Notice Don t add anything electrical to your vehicle unless you check with your dealer first Some electrical equipment can damage your vehicle and the damage wouldn t be cov...

Page 293: ...size and insulation type Fusible link insulation is a special purpose high temperature material The hydraulic brake booster motor feed circuit and starter circuit are protected by a fusible link Vehic...

Page 294: ...ument panel fuse blocks located behind the instrument panel on the passenger 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...

Page 295: ...er Wiring SPARE Spare Fuse Relay Usage BRAKE LAMP C4 C5 Brake Lamps C6 C7 C8 Tractor Trailer Wiring IGN 4 Ignition Relay Usage MARKER LP Sidemarker and Clearance Lamps HTD FUEL LB7 LG4 Heated Fuel AIR...

Page 296: ...eaker Usage 8 Power Post 9 Courtesy Lamps 10 Warning Lights Gages and Indicators 11 Crank 12 Rear Axle 13 Trailer Turn Signals Hazard Warning Flashers 14 Radio Chime 15 Daytime Running Lamps 16 Air Ba...

Page 297: ...fuse blocks gently squeeze both sides of the cover to unlatch the tabs at the top Then unsnap both attachments at the bottom and remove the cover Be sure to replace fuses with fuses of the same rating...

Page 298: ...ENG 2 Engine 2 HTD FUEL Heated Fuel BLANK Empty Fuse Usage BLANK Empty BLANK Empty A C COMP Air Conditioning Compressor ABS 1 Anti Lock Brake System 1 ABS 2 Anti Lock Brake System 2 ABS 3 Anti Lock B...

Page 299: ...rior Exterior Lamps HVAC Comfort Control System NOTE C4 C5 Electric Brake C6 C7 C8 Brake Lamps Capacities and Specifications Capacities and Specifications Engine RPO 7 2L L6 HEUI Fuel System LG5 8 1L...

Page 300: ...h automatic transmission 27 3 quarts 25 8 liters C6 C7 C8 Models 8 1L with manual transmission 33 3 quarts 31 5 liters 8 1L with manual transmission air conditioning and increased cooling 34 9 quarts...

Page 301: ...ling 35 4 quarts 33 5 liters 7 8L 230 275 hp engine with automatic transmission 33 3 quarts 31 5 liters 7 2L 250 300 hp engine with manual transmission 32 8 quarts 31 0 liters 7 2L 250 300 hp engine w...

Page 302: ...tra oil to fill the auxiliary oil filter system For vehicles equipped with the LUBERFINER 750 C add 14 quarts 13 25 L Check fill level on the oil indicator after initial fill to make sure it is actual...

Page 303: ...ptional 50 gallons 35 gallons 50 gallons 70 gallons 75 gallons 100 gallons 189 2 liters 132 4 liters 189 2 liters 264 8 liters 283 8 liters 378 5 liters One 25 gallon 94 6 L tank and one 15 gallon 56...

Page 304: ...nts 6 0 liters RT6609 12 5 pints 5 9 liters RT8709B 25 1 pints 11 8 liters FS4205A FS4205B FS4205C 11 1 pints 5 3 liters FS5205A FS5205C 11 6 pints 5 5 liters FS5406 18 4 pints 8 7 liters FS6305A FS63...

Page 305: ...s 14 7 liters 21060S 31 0 pints 14 7 liters S150 28 0 pints 13 0 liters 23090S 40 0 pints 19 0 liters 23105S 56 0 pints 26 5 liters 26105S 54 0 pints 25 5 liters Two Speed Axle 19060T 38 0 pints 18 0...

Page 306: ...s 14 7 liters DS404 DS404P front 32 0 pints 15 1 liters RS404 rear 31 0 pints 14 7 liters Normal Maintenance Replacement Parts Allison Transmission External Filters See the Allison Transmission Operat...

Page 307: ...C7 C8 Models 8 1L L18 88937527 88937548 8837527 88937548 25313349 A1518C Donaldson P522606 Engine Oil Filter 6 6L LB7 LLY 7 2L LG5 7 8L LG4 8 1L L18 88917036 94392475 89028862 PF2232 PF454 CAT 1R0739...

Page 308: ...1L L18 15098649 25055052 CAT 1R0751 Spark Plugs 6 6L LB7 LLY 7 2L LG5 7 8L LG4 8 1L L18 41 983 Optional Davco K28 D350921 spin on type filter located on driver s side frame rail Optional Cold Weather...

Page 309: ...Engine Drive Belt Routing 8 1L Engine DURAMAX Diesel Engine Caterpillar Diesel Engine 5 103...

Page 310: ...NOTES 5 104...

Page 311: ...led Maintenance Services 6 4 Using Your Maintenance Schedule 6 4 Scheduled Maintenance Supplements 6 4 Scheduled Maintenance 6 5 Part B Owner Checks and Services 6 24 At Each Fuel Fill 6 24 At Least T...

Page 312: ...necessary to keep your vehicle in good working condition Any damage caused by failure to follow scheduled maintenance may not be covered by warranty Your Vehicle and the Environment Proper vehicle ma...

Page 313: ...uired know how and the proper tools and equipment for the job If you have any doubt have a qualified technician do the work If you want to get the service information see Service Publications Ordering...

Page 314: ...dule 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...

Page 315: ...ervice 46 Rear axle air shift motor service 11 7 500 Miles 12 000 km Gasoline Engine Only Check Oil Life System If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the...

Page 316: ...place fuel filter Steering system service 13 Front and rear suspension service 14 Spring to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 months whichever occurs first 3...

Page 317: ...len or damaged Wheel bearing grease type service or every 24 months whichever occurs first and whenever hubs are removed 23 46 Wheels and tires service 15 Hydraulic brake service or every 6 months whi...

Page 318: ...service 14 Spring to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 months whichever occurs first 3 4 17 Wheels and tires service 15 Hydraulic brake service or every 6 mon...

Page 319: ...brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first C...

Page 320: ...ity and inspect condition of cooling and heater hoses and clamps Replace hoses if cracked swollen or damaged Wheel bearing grease type service or every 24 months whichever occurs first and whenever hu...

Page 321: ...are changed reset system See Engine Oil Gasoline Engine in the Index 3 9 Check fluid levels or every 3 months whichever occurs first 1 6 Chassis lubrication service or every 6 months whichever occurs...

Page 322: ...12 Replace fuel filter s or every 12 months whichever occurs first 3 Inspect door hinge pins and bushings and replace as necessary Steering system service 13 Front and rear suspension service 14 Spri...

Page 323: ...hoses if cracked swollen or damaged Wheel bearing grease type service or every 24 months whichever occurs first and whenever hubs are removed 23 46 Wheels and tires service 15 Hydraulic brake service...

Page 324: ...ing to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 months whichever occurs first 3 4 17 Wheels and tires service 15 Hydraulic brake service or every 6 months whichever...

Page 325: ...s whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve operation and check for leaks or every month or every 30...

Page 326: ...ering system service 13 Front and rear suspension service 14 Spring to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 months whichever occurs first 3 4 17 Inspect door hin...

Page 327: ...or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check a...

Page 328: ...s first 120 000 Miles 192 000 km C600 C700 and C800 Gasoline Engines Only Replace engine drive belts C400 and C500 Gasoline Engines Only Engine drive belts service or every 12 months whichever occurs...

Page 329: ...heck fluid level in brake master cylinder power steering pump axle transmission and hydraulic spring parking brake pump if equipped A low fluid level in the brake master cylinder can indicate worn bra...

Page 330: ...s clutch linkage and release bearing if equipped bearing pads propshaft universal joints brake camshaft bracket slack adjusters pedal shaft clutch cross shaft clutch pedal springs and clutch cable bus...

Page 331: ...let exhaust fumes seep into the driver compartment Needed repairs should be made at once To help maintain system integrity replace exhaust pipes whenever a new muffler is put on 18 Check all gasoline...

Page 332: ...damage Check fuel cap gasket for even filler neck imprint Replace parts as needed 31 Check EGR system as described in the service manual See Service Publications Ordering Information on page 7 7 32 In...

Page 333: ...non serviceable Replace the air compressor filter element mounted on the air compressor For remote air compressor intake service refer to engine air cleaner filter replacement Remove disassemble clean...

Page 334: ...is important for you or a service station attendant to perform these underhood checks at each fuel fill Engine Oil Level Check Check the engine oil level and add the proper oil if necessary See Engin...

Page 335: ...p Lubrication 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 appli...

Page 336: ...re wear or steering wheel position An inspection or service is needed when the steering wheel is harder to turn or has too much free play or if there are strange sounds when turning or parking Brake S...

Page 337: ...djuster Check When adjusting a manual seat be sure seat adjusters latch by attempting to move the seat after latching Lamps Check Check panel lighting warning lights indicator lights and interior lamp...

Page 338: ...em At least every spring flush these materials from the underbody with plain water Take care to clean well any areas where mud and other debris can collect Sediment packed in closed areas of the frame...

Page 339: ...preferred viscosity for your vehicle s diesel engine see Engine Oil in the Index Usage Fluid Lubricant Engine Oil Caterpillar Diesel Engine See the Caterpillar Operation Maintenance Manual for engine...

Page 340: ...2 Category GC or GC LB GM Part No U S 1051344 in Canada 993037 Usage Fluid Lubricant Front Wheel Bearing Grease with Oil Filled Hubs SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part...

Page 341: ...med 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 re...

Page 342: ...Date Odometer Reading Serviced By Maintenance Record 6 32...

Page 343: ...es 7 3 Roadside Assistance Program 7 4 Vehicle Data Collection and Event Data Records 7 5 Reporting Safety Defects 7 6 Reporting Safety Defects to the United States Government 7 6 Reporting Safety Def...

Page 344: ...ting a member of dealership management it appears your concern cannot be resolved by the dealership without further help contact the Chevrolet or GMC Consumer Relations Manager by calling 1 800 TO CHE...

Page 345: ...y Refer to the web for updated information To register your vehicle visit www MyGMLink com United States or My GM Canada within www gmcanada com Canada Customer Assistance for Text Telephone TTY Users...

Page 346: ...ch 1 800 263 3830 For Text Telephone devices TTYs Roadside Assistance 1 800 268 6800 All Overseas Locations Please contact the local General Motors Business Unit Mexico Central America and Caribbean I...

Page 347: ...operations to facilitate repair of detected malfunctions other information is stored only in a crash or near crash event by computer systems commonly called event data recorders EDR In a crash or near...

Page 348: ...Safety Defects to the United States Government If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway...

Page 349: ...da in a situation like this we certainly hope you ll notify us Please call us at 1 800 862 4389 or write GM Medium Duty Truck Customer Assistance Center P O Box 44947 Detroit MI 48244 In Canada please...

Page 350: ...Includes a Portfolio Owner s Manual and Warranty Booklet RETAIL SELL PRICE 35 00 Without Portfolio Owner s Manual only RETAIL SELL PRICE 25 00 Current and Past Model Order Forms Service Publications...

Page 351: ...ems 5 50 Air Cleaner Filter Engine 5 30 Air Conditioning System 5 67 Air Connections 4 36 Air Dryer 5 50 Air Pressure Gage 3 44 Air Shift Control Automatic Transmission 2 27 Air Suspension 2 27 Air Su...

Page 352: ...omatic Transmission Shift Indicator Check 6 26 Axle Two Speed Rear Axle Electric Shift Control 2 26 B Battery 5 55 Battery Replacement 2 5 Bench Seat Split 1 6 Body Lubrication Service 6 25 Brake Dies...

Page 353: ...he Center Rear Seat Position Crew Cab or Center Front Position 1 41 Child Restraints cont Securing a Child Restraint in the Right Front Seat Position 1 43 Top Strap 1 38 Where to Put the Restraint 1 3...

Page 354: ...ernment 7 6 Roadside Assistance Program 7 4 Service Publications Ordering Information 7 7 D Daytime Running Lamps 3 14 Daytime Running Lamps Indicator Light 3 41 Defensive Driving 4 2 Defogging and De...

Page 355: ...hange Engine Oil Light 3 39 Check and Service Engine Soon Light 3 37 Engine cont Checks Before Operating 2 22 Coolant 5 32 5 35 Coolant Heater 2 23 Coolant Temperature Gage 3 35 Diesel Engine Exhaust...

Page 356: ...Four Wheel and Six Wheel Drum Brakes Air Only 5 49 Four Wheel Disc Brakes Hydraulic Only 5 49 Front Wheel Bearings with Oil Filled Hubs 5 67 Fuel 5 6 Additives 5 7 Diesel Engine Fuel 5 8 Filling a Po...

Page 357: ...ty Trailer Wiring Package 4 35 Height Adjustment 1 6 High Idle System Caterpillar Diesel and Gasoline Engines 2 16 Highway Hypnosis 4 23 Hill and Mountain Roads 4 23 Hood Checking Things Under 5 18 La...

Page 358: ...verview 3 4 Switchbank 3 16 Instrument Panel Brightness Control 3 15 Instrument Panel Fuse Block 5 88 Inter Axle Differential Lock Control 4 10 Interior Lamps 3 15 J Jump Starting 5 56 K Key Lock Cyli...

Page 359: ...r Door 2 7 Loss of Control 4 16 Low Coolant Warning Light 3 36 Low Washer Fluid Warning Light 3 42 Lumbar Adjustments 1 3 M Maintenance Normal Replacement Parts 5 100 Maintenance Schedule At Each Fuel...

Page 360: ...rts 5 100 O Odometer 3 25 Off Road Recovery 4 14 Oil Change Engine Oil Light 3 39 Engine 5 20 5 25 Low Oil Level Light 3 38 Pressure Gage 3 37 Older Children Restraints 1 27 Online Owner Center 7 3 Ot...

Page 361: ...Light 3 41 Steering Fluid 5 43 Windows 2 9 Power Steering 4 12 Propshaft Park Brake Burnish Procedure 2 34 Q Questions and Answers About Safety Belts 1 12 R Radio Messages 3 48 3 50 3 55 Radios 3 45 A...

Page 362: ...omatic Transmission 2 15 Restarting the Gasoline Engine While Moving Automatic Transmission 2 14 Restraint System Check 6 25 Checking Your Restraint Systems 1 61 Replacing Restraint System Parts After...

Page 363: ...o Safety Cautions about Engine Fan Breakage 5 5 Service Bulletins 7 8 Service Engine Soon Light 3 37 Service Manuals 7 7 Servicing Your Air Bag Equipped Vehicle 1 60 Setting Preset Stations 3 47 3 49...

Page 364: ...ater 2 24 Top Strap 1 38 Towing Power Take Off PTO 4 36 Your Vehicle 4 31 Traction Control System TCS 4 11 Tractor Protection Breakaway Valve Check 6 28 Trailer Connections 4 35 Trailer Brake Hand Con...

Page 365: ...3 23 Warnings Hazard Warning Flashers 3 5 Other Warning Devices 3 6 Safety and Symbols iii Vehicle Damage iv Washer Fluid Low Warning Light 3 42 Washing Your Vehicle 5 80 Water Fuel 5 10 Water in Fuel...

Page 366: ...Windows 2 8 Manual 2 8 Power 2 9 Sliding Rear 2 10 Windshield and Wiper Blades 5 81 Windshield Washer 3 9 Fluid 5 44 Windshield Washer Fluid Level Check 6 24 Windshield Wiper Blade Replacement 5 63 Fu...

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Chevrolet kodiak 2004, Owner'S Manual

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