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Chevrolet Kodiak 2008, Owner'S Manual

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Chevrolet Kodiak 2008 Owner'S Manual Download Page 267

Item Number

Item

Remarks

1

Brake Camshaft**

One fitting each (apply sparingly).

2

Steering Column Slip Joint*

One fitting.

3

Steering Drag Link Ends

One fitting each end.

4

Pivot Points and Hinges

Apply chassis lubricant.

5

Pivot Points and Hinges

Apply chassis lubricant.

6

Slack Adjuster**

One fitting.

7

Brake Cam Roller Pins at interface of pin

and shoe**

Apply engine oil.

8

Front Steering Knuckles

One fitting each side, lower bushing.

(Hand-operated grease gun only) Hand-pack upper

bearing.

9

Front Wheel Bearings

Hand-pack or lubricate.

10

Steering Tie Rod Ends

One fitting each end.

11

Spring Slip Pads* (Multi-Leaf Only)

Apply chassis lubricant.

12

Clutch Release Bearing*

Cup or fitting.

13

Battery Terminal (except “ST” type)

Keep coated with petroleum jelly.

14

Transmission

Fill to level of filler plug.

5-63

Summary of Contents for Kodiak 2008

Page 1: ...ur Vehicle 4 2 Towing 4 24 Service and Appearance Care 5 1 Service 5 4 Fuel 5 7 Checking Things Under the Hood 5 22 Rear Axle 5 72 Four Wheel Drive 5 73 Front Axle 5 74 Noise Control System 5 75 Bulb...

Page 2: ...have all of them For example more than one entertainment system may be offered or your vehicle may have been ordered without a front passenger or rear seats Keep this manual in the vehicle for quick r...

Page 3: ...ou were to ignore the warning CAUTION These mean there is something that could hurt you or other people We tell you what the hazard is and what to do to help avoid or reduce the hazard Please read the...

Page 4: ...The notice tells what to do to help avoid the damage When you read other manuals you might see CAUTION and NOTICE warnings in different colors or in different words There are also warning labels on th...

Page 5: ...straint in a Rear Outside Seat Position Crew Cab 1 40 Securing a Child Restraint in the Center Rear Seat Position Crew Cab 1 42 Securing a Child Restraint in the Center Front Seat Position 1 44 Securi...

Page 6: ...g The sudden movement could startle and confuse you or make you push a pedal when you do not want to Adjust the driver s seat only when the vehicle is not moving You can adjust the seat forward or rea...

Page 7: ...knob counterclockwise Seatback Adjustment CAUTION You can lose control of the vehicle if you try to adjust a manual driver s seat while the vehicle is moving The sudden movement could startle and con...

Page 8: ...k to the desired position then release the lever to lock the seatback in place 3 Push and pull on the seatback to make sure it is locked To return the seatback to an upright position do the following...

Page 9: ...go into it receiving neck or other injuries The lap belt cannot do its job either In a crash the belt could go up over your abdomen The belt forces would be there not at your pelvic bones This could c...

Page 10: ...y have a low back or high back air suspension seat There are several ways to adjust the seat Fore and Aft Adjustment If your vehicle has this lever it is located underneath the front of the driver s s...

Page 11: ...t pull the lever up to inflate Push the lever down to deflate Your seat cushion may also be able to be raised or lowered If your vehicle has this feature the seat cushion height adjustment handle is l...

Page 12: ...lower back turn the lumbar adjustment knob clockwise To decrease the amount of lumbar support turn the knob counterclockwise Seatback Adjustment Your vehicle has a seatback adjustment control located...

Page 13: ...p over your abdomen The belt forces would be there not at your pelvic bones This could cause serious internal injuries For proper protection when the vehicle is in motion have the seatback upright The...

Page 14: ...uckle the safety belts and return them to their normal stowed position before folding a rear seat The rear bench seat on the crew cab can be folded down to provide more cargo space To fold down the se...

Page 15: ...are more likely to be seriously injured or killed Do not allow people to ride in any area of your vehicle that is not equipped with seats and safety belts Be sure everyone in your vehicle is in a sea...

Page 16: ...Why Safety Belts Work When you ride in or on anything you go as fast as it goes Take the simplest vehicle Suppose it is just a seat on wheels Put someone on it 1 12...

Page 17: ...Get it up to speed Then stop the vehicle The rider does not stop The person keeps going until stopped by something In a real vehicle it could be the windshield 1 13...

Page 18: ...el or the safety belts With safety belts you slow down as the vehicle does You get more time to stop You stop over more distance and your strongest bones take the forces That is why safety belts make...

Page 19: ...lts not instead of them Whether or not an airbag is provided all occupants still have to buckle up to get the most protection That is true not only in frontal collisions but especially in side and oth...

Page 20: ...ut of the vehicle in a crash And they can strike others in the vehicle who are wearing safety belts First before you or your passenger s wear a safety belt there is important information you should kn...

Page 21: ...o loose It will not give as much protection this way CAUTION You can be seriously hurt if your shoulder belt is too loose In a crash you would move forward too much which could increase injury The sho...

Page 22: ...tection this way CAUTION You can be seriously hurt if your lap belt is too loose In a crash you could slide under the lap belt and apply force on your abdomen This could cause serious or even fatal in...

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 on 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 on the abdomen not on the pelvic bones and...

Page 25: ...houlder belt under your arm In a crash your body would move too far forward which would increase the chance of head and neck injury Also the belt would apply too much force to the ribs which are not a...

Page 26: ...sh you would not be restrained by the shoulder belt Your body could move too far forward increasing the chance of head and neck injury You might also slide under the lap belt The belt force would then...

Page 27: ...ss the body CAUTION You can be seriously injured by a twisted belt In a crash you would not have the full width of the belt to spread impact forces If a belt is twisted make it straight so it can work...

Page 28: ...the belt across you more slowly If you ever pull the shoulder portion of a passenger belt out all the way you may engage the child restraint locking feature If this happens just let the belt go back a...

Page 29: ...y belt through the latch plate to fully tighten the lap belt on smaller occupants To unlatch the belt push the button on the buckle The belt should go back out of the way Before you close a door be su...

Page 30: ...n the shoulder belt guide After you move the height adjuster to where you want it try to move it down without pressing in to make sure it has locked into position Safety Belt Use During Pregnancy Safe...

Page 31: ...ich has no retractor To make the belt longer tilt the latch plate and pull it along the belt To make the belt shorter pull its free end as shown until the belt is snug Buckle position and release it t...

Page 32: ...ll be long enough for you To help avoid personal injury do not let someone else use it and use it only for the seat it is made to fit The extender has been designed for adults Never use it for securin...

Page 33: ...d should sit in a position with a lap shoulder belt and get the additional restraint a shoulder belt can provide Q What is the proper way to wear safety belts A An older child should wear a lap should...

Page 34: ...a child is sitting in a seat that has a lap shoulder belt but the shoulder part is behind the child In a crash the child would not be restrained by the shoulder belt The child might slide under the la...

Page 35: ...UTION Children can be seriously injured or strangled if a shoulder belt is wrapped around their neck and the safety belt continues to tighten Never leave children unattended in a vehicle and never all...

Page 36: ...s not weigh much until a crash During a crash an infant will become so heavy it is not possible to hold it For example in a crash at only 25 mph 40 km h a 12 lb 5 5 kg infant will suddenly become a 24...

Page 37: ...or killed Airbags plus lap shoulder belts offer protection for adults and older children but not for young children and infants Neither the vehicle s safety belt system nor its airbag system is desig...

Page 38: ...will have a label saying that it meets federal motor vehicle safety standards The restraint manufacturer s instructions that come with the restraint state the weight and height limitations for a part...

Page 39: ...p around the child s abdomen In a crash the belt would apply force on a body area that is unprotected by any bony structure This alone could cause serious or fatal injuries Young children should alway...

Page 40: ...B provides restraint for the child s body with the harness A booster seat C D is a child restraint designed to improve the fit of the vehicle s safety belt system A booster seat can also help a child...

Page 41: ...ng an add on child restraint refer to the instructions that come with the restraint which may be on the restraint itself or in a booklet or both and to this manual The child restraint instructions are...

Page 42: ...in the right front passenger s position there is no place in your vehicle to secure a child restraint The only answer is to have infants and young children make the trip in another vehicle where they...

Page 43: ...s be secured in the rear seat even if the airbag is off If you secure a forward facing child restraint in the right front seat always move the front passenger seat as far back as it will go It is bett...

Page 44: ...ATCH system If a national or local law requires that your top tether be anchored do not use a child restraint in this vehicle because a top tether cannot be properly anchored You must use the safety b...

Page 45: ...he lap and shoulder portions of the vehicle s safety belt through or around the restraint The child restraint instructions will show you how 3 Push the latch plate into the buckle until it clicks Make...

Page 46: ...to be sure it is secure To remove the child restraint unbuckle the vehicle s safety belt and let it go back all the way Securing a Child Restraint in the Center Rear Seat Position Crew Cab This vehic...

Page 47: ...Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly if necessary 5 To tighten the belt pull its free end while you push down on the child restraint If y...

Page 48: ...for Securing a Child Restraint in the Center Rear Seat Position Crew Cab on page 1 42 to install a child restraint in the center front position Securing a Child Restraint in the Right Front Seat Posi...

Page 49: ...better to secure the child restraint in a rear seat CAUTION If the airbag readiness light ever comes on when you have turned off the airbag it means that something may be wrong with the airbag system...

Page 50: ...child restraint If you have no other choice but to install a rear facing child restraint in this seat make sure the airbag is off once the child restraint has been installed When the airbag off switc...

Page 51: ...der belt back into the retractor If you are using a forward facing child restraint you may find it helpful to use your knee to push down on the child restraint as you tighten the belt 7 Push and pull...

Page 52: ...person sitting there Do not turn off the passenger s airbag unless the person sitting there is in a risk group identified by the national government See Airbag Off Switch on page 1 56 for more on thi...

Page 53: ...restraints to the safety belts All airbags are designed to work with safety belts but do not replace them CAUTION Airbags are designed to deploy in moderate to severe frontal and near frontal crashes...

Page 54: ...Always wear your safety belt even with airbags The driver should sit as far back as possible while still maintaining control of the vehicle CAUTION Airbags plus lap shoulder belts offer the best prote...

Page 55: ...e airbag symbol The system checks the airbag electrical system for malfunctions The light tells you if there is an electrical problem See Airbag Readiness Light on page 3 28 for more information Where...

Page 56: ...attach or put anything on the steering wheel hub or on or near any other airbag covering When Should an Airbag Inflate Frontal airbags are designed to inflate in moderate to severe frontal or near fro...

Page 57: ...the airbags could inflate at a different crash speed than if the vehicle goes straight into the object Thresholds can also vary with specific vehicle design Frontal airbags are not intended to inflate...

Page 58: ...n Airbag Inflate on page 1 52 for more information Airbags should never be regarded as anything more than a supplement to safety belts What Will You See After an Airbag Inflates After a frontal airbag...

Page 59: ...reakage may also occur from the right front passenger airbag Airbags are designed to inflate only once After an airbag inflates you will need some new parts for the airbag system If you do not get the...

Page 60: ...a rear facing infant seat or The infant has a medical condition which according to the infant s physician makes it necessary for the infant to ride in the front seat so that the driver can constantly...

Page 61: ...r windshield in a crash CAUTION If the right front passenger s airbag is turned off for a person who is not in a risk group identified by the national government that person will not have the extra pr...

Page 62: ...ong with the airbag system The right front passenger s airbag could inflate even though the switch is off If this ever happens do not let anyone whom the national government has identified as a member...

Page 63: ...nd make sure the person performing work for you is qualified to do so Adding Equipment to Your Airbag Equipped Vehicle Q Is there anything I might add to or change about the vehicle that could keep th...

Page 64: ...ring Restraint System Check Checking the Restraint Systems Safety Belts Now and then make sure the safety belt reminder light and all your belts buckles latch plates retractors and anchorages are work...

Page 65: ...straint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or even death in a crash To help make sure your restraint systems ar...

Page 66: ...NOTES 1 62...

Page 67: ...gine Checks Before Operating 2 23 Engine Coolant Heater 2 25 Diesel Engine Exhaust Brake 2 26 Two Speed Rear Axle 2 27 Automatic Transmission Operation 2 29 Manual Transmission Operation 2 30 Power Ta...

Page 68: ...ed or killed if caught in the path of a closing window Do not leave the keys in a vehicle with children Your vehicle has one double sided key for the ignition and all door locks If you ever lose your...

Page 69: ...including interference that may cause undesired operation of the device Changes or modifications to this system by other than an authorized service facility could void authorization to use this equip...

Page 70: ...nt another transmitter from unlocking your vehicle If a transmitter is lost or stolen a replacement can be purchased through your dealer Remember to bring any remaining transmitters with you when you...

Page 71: ...battery replacement it may need to be resynchronized to your vehicle See Resynchronization following Resynchronization Resynchronization may be necessary due to the security method used by this system...

Page 72: ...into unlocked vehicles may be unable to get out A child can be overcome by extreme heat and can suffer permanent injuries or even death from heat stroke Always lock your vehicle whenever you leave it...

Page 73: ...ide the manual lever up Power Door Locks If your vehicle has power door locks press the bottom of the power door lock switch to lock all the doors at once To unlock all the doors at once press the top...

Page 74: ...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 75: ...h to stop the window from lowering Window Lockout Crew Cab o Window Lockout The driver s window switches include a lockout feature This prevents the passenger s from operating their windows The driver...

Page 76: ...gs can mean premature wear and earlier replacement Follow this breaking in guideline every time you get new brake linings Use the lowest gear you can when you start a loaded vehicle in motion and when...

Page 77: ...vehicle in motion while the engine is off D ON RUN This is the position for driving The battery could be drained if you leave the key in the ACCESSORY or RUN position with the engine off You may not...

Page 78: ...14 Automatic Transmission Set the parking brake and move your shift lever to NEUTRAL N or PARK P if so equipped Your engine will not start in any other position that is a safety feature Manual Transmi...

Page 79: ...operly Any resulting damage would not be covered by your vehicle s warranty If you ever need to have your vehicle towed see Towing Your Vehicle on page 4 24 Gasoline Engine Warm Up When you have start...

Page 80: ...o Caterpillar Diesel Engine 6 6L DURAMAX Diesel Engine Isuzu 6H Diesel Engine unless otherwise noted If you have a Caterpillar Diesel Engine also refer to your Caterpillar Diesel Engine Operation Main...

Page 81: ...er than 15 seconds at a time will cause your battery to be drained much sooner And the excessive heat can damage your starter motor Notice If the wait to start light stays on after starting your vehic...

Page 82: ...zu Diesel Engine on page 5 32 When the outside temperature drops below 0 F 18 C use of the optional engine coolant block heater is recommended If you experience longer cranking times notice an unusual...

Page 83: ...me of these features are discussed below Also remember that an automatic transmission adds heat to the cooling system through the heat exchanger in the radiator Because of this vehicles equipped with...

Page 84: ...Engine Alarm and Automatic Shutdown Your check gages warning light will come on if the system senses high engine temperature and a low or high engine oil pressure If high engine temperature is detect...

Page 85: ...e or oil pressure condition worsens the tone alarm will go to five beats per second If the system senses low engine coolant the five beat per second alarm and the low coolant warning light will come o...

Page 86: ...sing a diagnostic scan tool for a period of up to a maximum of 60 minutes The ENGINE SHUTDOWN WARNING LIGHT will come on and a continuous chime will alert the driver 30 seconds before the engine goes...

Page 87: ...o set any desired high idle speed To set a new temporary engine idle speed do the following 1 Make sure all of the previously described conditions are met 2 Press the accelerator pedal to the desired...

Page 88: ...gine coolant temperature faster For all engines this feature is already turned on The automatic quick warm up on the DURAMAX engine can be turned off and on by doing the following procedure 1 Turn the...

Page 89: ...igh 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 have started your engine let it run fo...

Page 90: ...uld come on when the ignition key is turned to ON RUN or START and should go out when the engine is running above idle If the light does not go out or comes back on during normal engine operation have...

Page 91: ...ld overheat and cause a fire You could be seriously injured Plug the cord into a properly grounded three prong 110 volt AC outlet If the cord will not reach use a heavy duty three prong extension cord...

Page 92: ...s most effective if the gear range selected is the lowest possible range that does not allow the engine rpm to go more than 200 rpm above rated full load rpm If you have a Caterpillar Diesel Engine do...

Page 93: ...kph will damage driveline components Drive below 50 mph 80 5 kph in Low Range If your vehicle has this feature there is a label on the headliner above the windshield or in another place near the driv...

Page 94: ...op of the switch to shift from High to Low Range 2 Release the accelerator pedal 3 Then push the accelerator pedal slowly until the axle shifts Split Upshift Manual Transmissions Only To downshift the...

Page 95: ...brake procedure Press the brake pedal while shifting from NEUTRAL N or PARK P to a drive gear All vehicles that have an with automatic transmission can be started in PARK P if equipped or in NEUTRAL N...

Page 96: ...begins its engagement If you do you can cause damage to your vehicle Double Clutching You must use the double clutching method when you shift an unsynchronized gear set Disengage the clutch shift to N...

Page 97: ...utch Brake Vehicles with Non Synchronized Transmission A clutch brake is used to stop transmission input shaft rotation so that FIRST 1 or REVERSE R gear selection can be initiated when the vehicle is...

Page 98: ...nufacturer s or installer s instructions Four Wheel Drive If your vehicle has four wheel drive you can send the engine s driving power to all four wheels for extra traction To get the most satisfactio...

Page 99: ...on the instrument panel Use this knob to shift into and out of four wheel drive An indicator light shows you which position the transfer case is in The indicator lights come on briefly when you turn o...

Page 100: ...traction such as on snowy or icy roads or in most off road situations Be sure the front wheel hubs are locked when you want to drive in Four Wheel High 4n Four Wheel Low This setting sends maximum po...

Page 101: ...or moving less than 3 mph 5 km h with the transmission in NEUTRAL N The preferred method for shifting into Four Wheel Low is to have your vehicle moving 1 or 2 mph 1 6 to 3 2 km h Turn the knob to Fo...

Page 102: ...If the knob is turned to Four Wheel High or Two Wheel High while your vehicle is in gear and or moving the Four Wheel High or Two Wheel high indicator light flashes for 30 seconds It will not complet...

Page 103: ...ture wear or damage to brake system parts Verify that the parking brake is fully released and the brake warning light is off before driving 7 Release the parking brake 8 Start the engine and shift the...

Page 104: ...rake With Air Brakes on page 2 41 for parking brake apply procedure 4 Shift the transmission to NEUTRAL for manual transmission or PARK P for automatic transmission Parking Brake With Hydraulic Brakes...

Page 105: ...is on when the parking brake is set the brake system warning light will come on Once the parking brake is applied slowly remove your foot from the regular brake pedal while checking to see if the vehi...

Page 106: ...ure or at the scheduled maintenance intervals If the vehicle is has a hand lever park brake system an in cab adjustment may be made to the park brake system This will adjust the parking brake holding...

Page 107: ...icle may seem sluggish to accelerate and or your park brake hand lever maybe very hard to pull up and apply the park brake If the park brake is over tightened turn the knob to the left until it stops...

Page 108: ...pply the parking brake by pulling the yellow parking brake knob out 3 Hook up the trailer air system properly 4 Get into the vehicle 5 Push and hold down the regular brake pedal 6 Push in both the yel...

Page 109: ...at your air brakes automatically apply there is a way that the tow operator can release the parking brakes to tow the vehicle See Towing Your Vehicle on page 4 24 Parking Brake Burnish Procedure All v...

Page 110: ...the operator to lower the deck height approximately 4 5 inches 11 5 cm from the normal frame height The switch to deflate and inflate the air suspension is located on the instrument panel Press the bo...

Page 111: ...icle gets rusty underneath Your vehicle was damaged in a collision CAUTION Continued CAUTION Continued Your vehicle was damaged when driving over high points on the road or over road debris Repairs we...

Page 112: ...regenerate self clean itself as part of normal operation During regeneration the green DPF indicator is lit and you will notice a difference in engine noise and engine speed but this is normal The En...

Page 113: ...tor light goes off to complete the regeneration in a single operation if possible During regeneration the green DPF indicator light will come on See Diesel Particulate Filter Warning Light on page 3 4...

Page 114: ...on you can clean the DPF by performing a manual regeneration When it is safe to do so stop the vehicle Perform manual DPF regeneration in a well ventilated area Manual DPF regeneration must be perform...

Page 115: ...nded during manual regeneration 9 When both the green and the yellow or red DPF indicator lights go off regeneration is completed Regeneration is normally completed in about 30 minutes Under certain o...

Page 116: ...a garage with the engine running Another closed in place can be a blizzard See Winter Driving on page 4 16 CAUTION It can be dangerous to get out of your vehicle if the automatic transmission shift le...

Page 117: ...de of your vehicle and the area beside your vehicle from a comfortable driving position The mirrors can be folded in to enter narrow areas Return the mirrors to the unfolded position before driving Ou...

Page 118: ...iver s side and the passenger s side They are curved to allow more to be seen from the driver s seat A convex mirror can make things look farther away than they really are Outside Heated Mirrors If yo...

Page 119: ...neath the floorboard on both sides of the vehicle Center Console Storage Your vehicle may have a center console compartment The back of your center bench seat may also fold forward to reveal a console...

Page 120: ...NOTES 2 54...

Page 121: ...System 3 24 Warning Lights Gages and Indicators 3 24 Instrument Panel Cluster 3 25 Speedometer and Odometer 3 26 Trip Odometer 3 26 Tachometer 3 26 Engine Speed Limiter 3 27 Safety Belt Reminders 3 2...

Page 122: ...42 Check Gages Warning Light 3 42 Fuel Gage 3 43 Water in Fuel Warning Light 3 44 Change Fuel Filter Warning Light 3 44 Diesel Particulate Filter Warning Light 3 45 Air Filter Restriction Indicator 3...

Page 123: ...NOTES 3 3...

Page 124: ...Instrument Panel Overview Automatic Transmission Shown Manual Transmission Similar 3 4...

Page 125: ...ed See Air Filter Restriction Indicator on page 3 45 F Auxiliary Gages See Warning Lights Gages and Indicators on page 3 24 G Exterior Lamp Control See Exterior Lamps on page 3 14 H Turn Signal Multif...

Page 126: ...When the hazard warning flashers are on your vehicle s turn signals will not work Other Warning Devices If you carry reflective triangles you can set them up at the side of the road about 300 feet 100...

Page 127: ...e lever Then move the wheel to a comfortable position and release the lever to lock the wheel in place Turn Signal Multifunction Lever The lever located on the left side of the steering column include...

Page 128: ...l you complete your lane change The lever will return by itself when you release it As you signal a turn or a lane change if the arrows don t flash but just stay on check the turn signal flasher and c...

Page 129: ...and toward you to the first solid band below the delay settings For high speed wiping turn the band farther to the last solid band below the delay settings To stop the wipers move the band to off Be s...

Page 130: ...r until the windshield is warmed Otherwise the washer fluid can form ice on the windshield blocking your vision Cruise Control If your vehicle has this feature it is located at the end of the multifun...

Page 131: ...inding roads or in heavy traffic Cruise control can be dangerous on slippery roads On such roads fast changes in tire traction can cause excessive wheel slip and you could lose control Do not use crui...

Page 132: ...Cruise Control There are two ways to go to a higher speed Use the accelerator pedal to get to the higher speed Press the button at the end of the lever then release the button and the accelerator peda...

Page 133: ...akes you out of cruise control Many drivers find this to be too much trouble and don t use cruise control on steep hills If your vehicle is equipped with the exhaust brake option and the exhaust brake...

Page 134: ...ng Marker Lamps Taillamps License Plate Lamps Instrument Panel Lights O Headlamps Turning the control to this position turns on the headlamps together with the previously listed lamps and lights You c...

Page 135: ...en the following conditions are met The ignition is on the exterior lamp control is off and the parking brake is released When the DRL are on only the headlamps will be on The taillamps sidemarker and...

Page 136: ...re is located to the right of the exterior lamp control Turn the thumbwheel up to brighten the lights When the thumbwheel is moved to the first position the radio display and transmission selection di...

Page 137: ...want to leave your door s open for an extended period of time and do not want to run the battery down If the dome override button is in the out position the interior lamps will work as usual Entry Lig...

Page 138: ...e 2 20 i Traction Control Switch See Traction Control System TCS on page 4 8 f Outside Heated Mirror Switch See Outside Heated Mirrors on page 2 52 L Diesel Particulate Filter Switch See Diesel Partic...

Page 139: ...ent when not in use and do not plug in equipment that exceeds the maximum amperage rating Certain electrical accessories may not be compatible with the accessory power outlet and could result in blown...

Page 140: ...g does not let the lighter back away from the heating element when it is hot Damage from overheating can occur to the lighter or heating element or a fuse could be blown Do not hold a cigarette lighte...

Page 141: ...send air to the rear of the vehicle Keep the area under the front seats free of objects that could obstruct airflow to the rear of the vehicle The mode knob can also be used to select the defrost mode...

Page 142: ...gers Use the defrost mode to remove fog or frost from the windshield more quickly For best results clear all snow and ice from the windshield before defrosting Turn the mode knob on the right of the c...

Page 143: ...ch a temporary vehicle license tape a decal or anything similar to the defogger grid Outlet Adjustment Your vehicle has air outlets on the instrument panel that allow you to adjust the direction and a...

Page 144: ...rning lights and gages could also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see in the details on the nex...

Page 145: ...o let you know at a glance how your vehicle is running You will know how fast you are going about how much fuel is left and many other things you will need to drive safely and economically Isuzu 6H Di...

Page 146: ...utton located to the right of the trip odometer to toggle between the trip odometer and the regular odometer Holding the reset button for two seconds while the engine is running and the trip odometer...

Page 147: ...though some tire sizes and tread patterns may limit maximum speed to 55 to 65 mph 86 to 105 km h You may have a label on the headliner of your vehicle with more information on your engine road speed g...

Page 148: ...out This means the system is ready If the airbag readiness light stays on after you start the vehicle or comes on when you are driving your airbag system may not work properly Have your vehicle servi...

Page 149: ...airbag on See Airbag Off Switch on page 1 56 for more on this including important safety information CAUTION If the right front passenger s airbag is turned off for a person who is not in a risk grou...

Page 150: ...that the right front passenger s frontal airbag is enabled may inflate See Airbag Off Switch on page 1 56 for more on this including important safety information Charging System Light The charging sy...

Page 151: ...t If your vehicle has an Allison automatic transmission certain transmission malfunctions will turn this light on This light is located with the auxiliary warning lights in the center of the instrumen...

Page 152: ...has either hydraulic or air brakes Each system has different warning lights Hydraulic Brake System Warning Lights Vehicles with hydraulic brake systems have two brake system warning lights on the ins...

Page 153: ...tart the engine However it is designed to come on and stay on when brake reservoir pressure has dropped below 60 psi 410 kPa When the warning light comes on while you are driving you should drive only...

Page 154: ...not have antilock brakes and there is a problem with your regular brakes See Brake System Warning Light on page 3 32 and Antilock Brake System ABS on page 4 5 for more information Trailer Antilock Bra...

Page 155: ...icle has a low coolant warning light If this light comes on the system is low on coolant and the engine may overheat The warning light should come on briefly as a check when you turn on the ignition W...

Page 156: ...flashes while you are driving two things can happen First you will not notice any difference in engine performance but the tail pipe emissions might increase Second the engine might not run properly...

Page 157: ...between 35 and 70 psi 240 to 480 kPa A reading in the low pressure zone may be caused by a dangerously low oil level or other problem If you have a Caterpillar diesel engine also see your Caterpillar...

Page 158: ...r engine oil maintenance 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 Change Engine Oil Light T...

Page 159: ...Gage If you have an automatic transmission and this gage it is located above the switchbank in the center of the instrument panel When your ignition is on the gage shows the temperature of the transmi...

Page 160: ...page 2 26 and Exhaust Restrictor Engine Warm Up on page 2 22 Differential Lock Indicator Light If your vehicle has this feature this light is located in the center of the instrument panel The light i...

Page 161: ...ehicle may be driven at a slower speed while the reduced engine power light is on but acceleration and speed may be limited Anytime the check engine light stays on the vehicle should be taken to an au...

Page 162: ...ower Take Off PTO on page 2 32 for more information Check Gages Warning Light This light will come on briefly when the engine is started If this light comes on and stays on while you are driving It me...

Page 163: ...the reading on the gage is the total fuel left in both tanks Here are four concerns of some operators None of these shows a problem with your fuel gage The gage moves a little when you turn a corner o...

Page 164: ...er in Fuel on page 5 12 Change Fuel Filter Warning Light For vehicles with this light it is located in the center of the instrument panel If your vehicle has the DURAMAX 6 6L engine this light will co...

Page 165: ...ht will come on and engine power will be reduced See Diesel Particulate Filter Diesel Engine on page 2 46 and Reduced Engine Power Light on page 3 41 for more information Air Filter Restriction Indica...

Page 166: ...Pa difference showing between the systems Don t drive until both pointers are showing at least 120 psi 827 kPa so you ll have enough air if you need to apply your brakes Hourmeter Gage To access the e...

Page 167: ...by presetting your favorite radio stations setting the tone and adjusting the speakers Then when driving conditions permit you can tune to your favorite radio stations using the presets and steering...

Page 168: ...off Radio s Your vehicle has one of these radios as its radio system Playing the Radio PWR Power Press to turn the system on and off VOL Volume Turn clockwise or counterclockwise to increase or to dec...

Page 169: ...io goes to the first preset station stored on the pushbuttons plays for a few seconds then goes to the next preset station Press either arrow again to stop scanning presets The radio only seeks and sc...

Page 170: ...AUDIO To adjust the balance between the right and the left speakers press and release the AUDIO button until BAL balance displays Then press and hold the up wor the down xarrow to move the sound towar...

Page 171: ...f it was the last selected audio source As each new track starts to play the track number displays The CD player can play the smaller 3 inch 8 cm single CDs with an adapter ring Full size CDs and the...

Page 172: ...e of foreign materials liquids and debris If an error displays see CD Messages later in this section 1 PREV Previous Press to go to the beginning of the current track if more than eight seconds have p...

Page 173: ...eject a CD Eject can be activated with either the ignition or radio off CDs may be loaded with the ignition and radio off if this button is pressed first CD Messages If the CD comes out it could be fo...

Page 174: ...her side of the tape when it reaches the end Cassette tape adapter kits for portable CD players works in the cassette tape player See CD Adapter Kits later for more information The tape bias is set au...

Page 175: ...an or preset scan features 5 SIDE Press to play the other side of the tape 6 RPT Repeat The tape must have at least three seconds of silence between each selection for repeat to work Press and release...

Page 176: ...best results use a scrubbing action non abrasive cleaning cassette with pads which scrub the tape head as the hubs of the cleaner cassette turn The recommended cleaning cassette is available through y...

Page 177: ...or if an error cannot be corrected contact your dealer retailer If the radio displays an error message write it down and provide it to your dealer retailer when reporting the problem CD Adapter Kits...

Page 178: ...e with FM signals causing the sound to fade in and out Fixed Mast Antenna The fixed mast antenna can withstand most car washes without being damaged If the mast should ever become slightly bent straig...

Page 179: ...ol System TCS 4 8 Steering 4 9 Off Road Recovery 4 11 Passing 4 11 Loss of Control 4 12 Driving at Night 4 13 Driving in Rain and on Wet Roads 4 14 Highway Hypnosis 4 15 Hill and Mountain Roads 4 15 W...

Page 180: ...1 CAUTION Assume that other road users pedestrians bicyclists and other drivers are going to be careless and make mistakes Anticipate what they might do and be ready In addition Allow enough following...

Page 181: ...r vehicle related deaths have been associated with the use of alcohol with about 250 000 people injured For persons under 21 it is against the law in every U S state to drink alcohol There are good me...

Page 182: ...cool between hard stops The brakes will wear out 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 unn...

Page 183: ...ressure faster than any driver could The computer is programmed to make the most of available tire and road conditions This can help you steer around the obstacle while braking hard As you brake the c...

Page 184: ...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 185: ...y to both rear wheels Let up on the accelerator before you turn on your rear axle differential lock Notice Turning on the inter axle differential lock while the rear wheels are spinning freely as they...

Page 186: ...in the top of the TCS button is on the TCS is off and will not limit wheel spin Adjust your driving accordingly The light in the top of the TCS button will come on if the TCS is turned off by pressin...

Page 187: ...ou will understand this The traction you can get in a curve depends on the condition of the tires and the road surface the angle at which the curve is banked and your speed While you are in a curve sp...

Page 188: ...ese First apply the brakes See Braking on page 4 4 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 a...

Page 189: ...g another vehicle on a two lane road can be dangerous To reduce the risk of danger while passing we suggest the following tips A vehicle like yours takes a longer time to reach passing speed so you wi...

Page 190: ...is best handled by easing your foot off the accelerator pedal If you have the Traction Control System TCS remember It helps avoid only the acceleration skid See Traction Control System TCS on page 4...

Page 191: ...ight vision problems or by fatigue Night driving tips include Drive defensively Do not drink and drive Reduce headlamp glare by adjusting the inside rearview mirror Slow down and keep more space betwe...

Page 192: ...to be carried away If this happens you and other vehicle occupants could drown Do not ignore police warnings and be very cautious about trying to drive through flowing water Hydroplaning Hydroplaning...

Page 193: ...cle serviced and in good shape Check all fluid levels and brakes tires cooling system and transmission Going down steep or long hills shift to a lower gear CAUTION If you do not shift down the brakes...

Page 194: ...ag of sand a piece of old carpet or a couple of burlap bags to help provide traction Be sure you properly secure these items in your vehicle Also see Tires on page 5 82 Driving on Snow or Ice Most of...

Page 195: ...ntilock Brake System ABS on page 4 5 ABS improves your vehicle s stability when you make a hard stop on a slippery road Whether your vehicle has ABS or not begin stopping sooner than you would on dry...

Page 196: ...extra clothing make body insulators from newspapers burlap bags rags floor mats anything you can wrap around yourself or tuck under your clothing to keep warm You can run the engine to keep warm but...

Page 197: ...ve the fuel as long as you can To help keep warm you can get out of the vehicle and do some fairly vigorous exercises every half hour or so until help comes If Your Vehicle is Stuck in Sand Mud Ice or...

Page 198: ...r pedal while you shift and press lightly on the accelerator pedal when the transmission is in gear By slowly spinning the wheels in the forward and reverse directions you will cause a rocking motion...

Page 199: ...s original tires and the inflation pressures needed to obtain the gross weight capacity of your vehicle This is called the Gross Vehicle Weight Rating GVWR The tire information could also be shown on...

Page 200: ...e right way Notice Overloading your vehicle may cause damage Repairs would not be covered by your warranty Do not overload your vehicle If you put things inside your vehicle like suitcases tools packa...

Page 201: ...at have certain front mounted equipment such as a snow plow it may be possible to load the front axle to the front gross axle weight rating GAWR but not have enough weight on the rear axle to have pro...

Page 202: ...g problem If your vehicle has to be towed because of a complete loss of air pressure from both systems the parking brakes will have automatically engaged The tow operator can release the brakes manual...

Page 203: ...rakes Follow the same procedure to release the other brake or brakes 7 At the repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from an external air supply or...

Page 204: ...Light Blue CHMSL Red Battery Feed Dark Blue Trailer Brake Trailer Connections C7 C8 Models Only If your vehicle has these trailer connections they are located at the rear of the cab for a tractor and...

Page 205: ...pillar Diesel Engine 5 23 Engine Oil Gasoline Engine 5 24 Engine Oil DURAMAX Diesel Engine 5 28 Engine Oil Isuzu Diesel Engine 5 32 Engine Oil Life System Gasoline Engine 5 36 Engine Oil Life System D...

Page 206: ...Time for New Tires 5 84 Buying New Tires 5 85 Wheel Alignment and Tire Balance 5 86 Tightening the Wheel Nuts 5 86 Wheel Replacement 5 90 If a Tire Goes Flat 5 92 Appearance Care 5 94 Interior Cleani...

Page 207: ...5 102 Headlamp Wiring 5 102 Windshield Wiper Fuses 5 102 Fusible Links 5 103 Power Windows and Other Power Options 5 103 Fuses and Circuit Breakers 5 103 Instrument Panel Fuse Block 5 103 Underhood F...

Page 208: ...e anti lock brakes traction control and stability control could be affected Some non dealer accessories could even cause malfunction or damage to parts and systems and would not be covered by the vehi...

Page 209: ...etrain Damage failure or reduced life of the engine transmission emission system drivetrain or other vehicle components caused by aftermarket engine performance enhancement products or modifications m...

Page 210: ...ce Publications Ordering Information on page 7 10 Your vehicle has an airbag system Before attempting to do your own service work see Servicing Your Airbag Equipped Vehicle on page 1 59 You should kee...

Page 211: ...maintain optimum vehicle performance we recommend the use of gasoline advertised as TOP TIER Detergent Gasoline Gasoline Octane Use regular unleaded gasoline with a posted octane rating of 87 or highe...

Page 212: ...vailable in your area We recommend that you use these gasolines if they comply with the specifications described earlier However E85 85 ethanol and other fuels containing more than 10 ethanol must not...

Page 213: ...lls you how to restart the engine What Fuel to Use Notice Use of diesel fuel other than Ultra Low Sulfur Diesel 15 ppm sulfur maximum or engine oil other than low ash CJ 4 oil will cause permanent dam...

Page 214: ...oncentration i e greater than B5 biodiesel containing fuels or the use of unmodified bio oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engi...

Page 215: ...ions about the fuel you are using contact your fuel supplier Canadian fuels are blended for seasonal changes Diesel Type A fuel is blended for better cold weather starting below 0 F or 18 C however yo...

Page 216: ...and the weather is warm or humid fungus and bacteria can grow in the fuel They can damage your fuel system A diesel fuel biocide can be used to sterilize your fuel system However your fuel system may...

Page 217: ...er for assistance Notice If you drive when this warning indicator is on you can damage your fuel injection system and your engine If the indicator comes on right after you refuel it means water was pu...

Page 218: ...ystem will need to be primed If the water in fuel light comes on again after driving a short distance or the engine runs rough or stalls a large amount of water has probably been pumped into the fuel...

Page 219: ...ne mounted fuel filter The vent valve and the fuel filter primer pump are located on top of the fuel filter housing The priming pump is hand operated and is designed to bring fuel to the engine to eli...

Page 220: ...nt valve 9 Clean any fuel which accumulated on the fuel filter 10 Start the engine and let it idle for a few minutes 11 Check the filter for leaks Priming the 7 8L DURAMAX Diesel Engine If your vehicl...

Page 221: ...d release the plunger at the top of the fuel filter priming pump about 20 more times This sends fuel to the engine 11 Use a clean cloth to remove any fuel from the fuel filter and surrounding area 12...

Page 222: ...keep matches or other ignition sources away First drain any water from the filter by following the water draining procedure earlier in this section Your vehicle s engine should be off until the end o...

Page 223: ...rned on reset the fuel filter change light To reset the Fuel Filter Change light 1 Turn the ignition key to RUN with the engine off 2 Fully press the accelerator and brake pedals at the same time for...

Page 224: ...oo quickly This spray can 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 pu...

Page 225: ...ay result in over filling the tank and fuel spillage Filling a Portable Fuel Container CAUTION Never fill a portable fuel container while it is in your vehicle Static electricity discharge from the co...

Page 226: ...l oil coolant brake fluid windshield washer and other fluids and plastic or rubber You or others could be burned Be careful not to drop or spill things that will burn onto a hot engine Hood Latches To...

Page 227: ...ough there are cables that will support it When you close the hood make sure both latches are secured Engine Oil Caterpillar Diesel Engine See your Caterpillar Operation Maintenance Manual for informa...

Page 228: ...you get fuel In order to get an accurate reading the oil must be warm and the vehicle must be on level ground The engine oil dipstick is located in the engine compartment on the driver s side of the...

Page 229: ...ice Do not add too much oil If the engine has so much oil that the oil level gets above the cross hatched area that shows the proper operating range the engine could be damaged The engine oil fill cap...

Page 230: ...n the viscosity chart SAE 5W 30 is best for your vehicle These numbers on an oil container show its viscosity or thickness Do not use other viscosity oils such as SAE 20W 50 American Petroleum Institu...

Page 231: ...rst symbol Failure to use the recommended oil can result in engine damage not covered by your warranty If you are in an area of extreme cold where the temperature falls below 20 F 29 C it is recommend...

Page 232: ...d the oil is warm turn off the engine and allow at least five minutes for the oil to drain back into the oil pan If you do not do this the oil dipstick might not show the actual level If the engine ha...

Page 233: ...on page 5 109 Notice Do not add too much oil If the engine has so much oil that the oil level gets above the cross hatched area that shows the proper operating range the engine could be damaged Add oi...

Page 234: ...can appear either alone or in combination with other American Petroleum Institute API designations such as API CJ 4 SL These letters show API levels of quality Notice Use only engine oils that have th...

Page 235: ...the correct oil It means that the oil has been certified by the American Petroleum Institute Look for this on the oil container and use only those oils that display this logo Engine Oil Additives Do n...

Page 236: ...bring it up to normal operating temperature and the oil is cool turn off the engine and allow 30 minutes for the oil to drain back into the oil pan If you do not do this the oil dipstick might not sh...

Page 237: ...or engine oil crankcase capacity see Capacities and Specifications on page 5 109 Add oil at the engine oil fill cap in the engine compartment Install and fully tighten the fill cap when you are throug...

Page 238: ...can appear either alone or in combination with other American Petroleum Institute API designations such as API CJ 4 SL These letters show API levels of quality Notice Use only engine oils that have th...

Page 239: ...ook for this on the oil container and use only those oils that display this logo Engine Oil Additives Do not add anything to the oil The recommended oils with the API service symbol are all you need f...

Page 240: ...reset Your dealer retailer has trained service people who will perform this work using genuine parts and reset the system It is also important to check the oil regularly and keep it at the proper lev...

Page 241: ...timing engine load and engine temperature and not on mileage Based on driving conditions the mileage at which an oil change will be indicated can vary considerably For the oil life system to work pro...

Page 242: ...e Oil Life System has not reset Repeat the procedure What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer Do not let used...

Page 243: ...il light being turned on reset the system To reset the Engine Oil Life System 1 Turn the ignition key to ON RUN with the engine off 2 Fully apply and hold the brake pedal while you fully press and rel...

Page 244: ...ting the engine with the air cleaner filter off can cause you or others to be burned The air cleaner not only cleans the air it helps to stop flames if the engine backfires If it is not there and the...

Page 245: ...r cleaner filter in place when you are driving The engine air cleaner filter is located in the center of the engine compartment To inspect the engine air cleaner filter perform the following 1 Disconn...

Page 246: ...cking of air remove the hood inlet seal by doing the following 1 Loosen the clamp that holds the seal to the air cleaner 2 Slide the seal off 3 Store the seal in the inlet located on the underside of...

Page 247: ...checked is when the engine oil is checked Refer to the Maintenance Schedule to find out when to check and change your manual transmission fluid See Scheduled Maintenance on page 6 5 How to Check and...

Page 248: ...OOL engine coolant This coolant is designed to remain in your vehicle for five years or 150 000 miles 240 000 km whichever occurs first if you add only DEX COOL extended life coolant The following exp...

Page 249: ...could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If you use an improper coolant mixture your engine could overheat and be bad...

Page 250: ...ut and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be parked on a level surface When your engine is cold the coolant level...

Page 251: ...ant on a hot engine When replacing the pressure cap make sure it is hand tight and fully seated Coolant Surge Tank Pressure Cap The coolant surge tank pressure cap is located in the engine compartment...

Page 252: ...heated engine can burn you badly even if you just open the hood Stay away from the engine if you see or hear steam coming from it Just turn it off and get everyone away from the vehicle until it cools...

Page 253: ...oad shift to PARK P or NEUTRAL and let the engine idle 2 Turn on your heater to full hot at the highest fan speed and open the windows as necessary 3 If climbing a hill downshift to raise engine and f...

Page 254: ...nd Maintenance Manual provided with your vehicle If the coolant inside the coolant surge tank is boiling do not do anything else until it cools down The vehicle should be parked on a level surface The...

Page 255: ...g fan speed should increase when idle speed is doubled by pushing the accelerator pedal down If it does not your vehicle needs service Turn off the engine Notice Engine damage from running the engine...

Page 256: ...can blow out and 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 CAUTION Continued CAUTION Cont...

Page 257: ...enough Do not spill coolant on a hot engine 1 You can remove the coolant surge tank pressure cap when the cooling system including the coolant surge tank pressure cap and upper radiator hose is no lo...

Page 258: ...r to provide more air to cool the engine In most everyday driving conditions the clutch is not fully engaged This improves fuel economy and reduces fan noise Under heavy vehicle loading trailer towing...

Page 259: ...e proper level then shut off the engine for 10 seconds This should reset the brake warning lights If one or both lights stay on see Hydraulic Brake System Warning Lights under Brake System Warning Lig...

Page 260: ...o 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 261: ...could spill on the hot engine and it can catch fire You could be burned and your vehicle could be damaged See Checking Brake Fluid in this section Checking Brake Fluid Apply the brake pedal several t...

Page 262: ...ch as engine oil in the brake hydraulic system can damage brake hydraulic system parts so badly that they will have to be replaced Do not let someone put in the wrong kind of fluid and do not use DOT...

Page 263: ...be serviced by a qualified service technician Notice Do not manually adjust automatic slack adjusters Manual adjustment of the automatic slack adjusters can result in a degradation of the slack adjust...

Page 264: ...r that purges air from the system through a self contained reservoir The other way to drain moisture from the air brake system is to manually activate drain valves at each reservoir Drain the air rese...

Page 265: ...own to about 1 4 inch 6 mm as measured at the clutch pedal pad You should have 1 1 2 to 2 inches 38 to 51 mm of clutch pedal free travel If the clutch ever needs service be sure to use only approved c...

Page 266: ...Single Axle Models 5 62...

Page 267: ...Brake Cam Roller Pins at interface of pin and shoe Apply engine oil 8 Front Steering Knuckles One fitting each side lower bushing Hand operated grease gun only Hand pack upper bearing 9 Front Wheel Be...

Page 268: ...7 Parking Brake Lever Pivot Apply chassis lubricant 18 Clutch Release Cross Shaft Master Cylinder Apply chassis lubricant fill to 1 4 inch 6 mm below opening 19 Release Bearing Clutch Cross Shaft Two...

Page 269: ...itting each 2 Propshaft U Joint One fitting each joint Lubricate with GM Part No 1051344 Wheel Bearing Lubricant 3 Rear Axles Fill to level of filler plug 4 Brake Shoe Roller Pins Apply engine oil at...

Page 270: ...burn you and gas that can explode You can be badly hurt if you are not careful See Jump Starting on page 5 67 for tips on working around a battery without getting hurt Infrequent Usage If you drive y...

Page 271: ...can be damaged Only use vehicles with 12 volt systems with negative grounds to jump start your vehicle If you have a diesel engine vehicle with two batteries or more you should know before you begin t...

Page 272: ...e remote positive terminal You will not see the battery or batteries of your vehicle under the hood They are located in a frame mounted battery box which is located on either the driver s or the passe...

Page 273: ...Negative will go to a heavy unpainted metal engine part or to a remote negative terminal if the vehicle has one Do not connect positive to negative or you will get a short that would damage the batter...

Page 274: ...e parts that move The electrical connection is just as good there and the chance of sparks getting back to the battery is much less 10 Now start the vehicle with the good battery and run the engine fo...

Page 275: ...vehicles do the following 1 Disconnect the black negative cable from the vehicle that had the dead battery 2 Disconnect the black negative cable from the vehicle with the good battery 3 Disconnect the...

Page 276: ...ing your vehicle through deep puddles or standing water If you must drive through water that is higher than the front or rear axle see your dealer immediately afterward to have the condition of the ax...

Page 277: ...ine what kind of lubricant to use See Part C Recommended Fluids and Lubricants on page 6 31 Four Wheel Drive Transfer Case When to Check Lubricant It is not necessary to regularly check transfer case...

Page 278: ...ur vehicle through deep water that is higher than the front or rear axle water may enter the axle housing and cause the axle lubricant to break down This could damage the gears inside Avoid driving yo...

Page 279: ...only to vehicles sold in the United States Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance r...

Page 280: ...d exhaust pipe clamps Removal of the DOC converter the Diesel Particulate Filter or the diesel exhaust gas cooler device Bulb Replacement It is recommended that all bulbs be replaced by your dealer re...

Page 281: ...the wiper blade 1 Pull the windshield wiper arm away from the windshield 2 Push the release lever and slide the wiper assembly toward the driver side of the vehicle 3 Install a new blade by reversing...

Page 282: ...il See Scheduled Maintenance on page 6 5 for recommended service intervals If your vehicle is equipped with the optional Davco spin on type filter it is located on the driver s side frame rail Fuel Fi...

Page 283: ...ater draining and element replacement procedure under Water in Fuel on page 5 12 Secondary Fuel Filter and Heater Your vehicle may have this fuel filter and fuel heater It is mounted on the left side...

Page 284: ...e bottom Occasionally check the bowl for any water or particles To check or drain the bowl do the following Shut off the engine Push up on the spring loaded drain valve until clear fuel is flowing fro...

Page 285: ...ecked If your vehicle has oil filled hubs occasionally check to see if they have enough oil You can tell if there is oil there by using the circular gage on the sight glass If there isn t clean the ru...

Page 286: ...uently to maintain the recommended pressure Tire pressure should be checked when your vehicle s tires are cold See Inflation Tire Pressure on page 5 82 CAUTION Continued CAUTION Continued Overinflated...

Page 287: ...operly inflated even when they are underinflated Check the tire s inflation pressure when the tires are cold Cold means your vehicle has been sitting for at least three hours or driven no more than 1...

Page 288: ...enance temperatures driving speeds vehicle loading and road conditions influence when you need new tires Replace your tires when the tread depth is down to 1 8 of an inch 3 2 mm for the front tires or...

Page 289: ...replacing tires in sets of six or eight as applicable This is because uniform tread depth on all tires will help keep your vehicle performing most like it did when the tires were new Replacing less t...

Page 290: ...e vibrating when driving on a smooth road your wheels may need to be balanced Tightening the Wheel Nuts CAUTION Wheel nuts that are not tight can work loose If all the nuts on a wheel come off the whe...

Page 291: ...the wheel and reduce run out 2 Put the tire and rim assembly on the axle hub Install the outer rear tire and rim assembly so that its valve stem is exactly opposite the valve stem on the inner tire a...

Page 292: ...0 lb ft 650 Y if a 10 hole stud using the following diagrams CAUTION Never use oil or grease on studs or the threads of the wheel nuts If you do the wheel nuts might come loose and the wheel could fal...

Page 293: ...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 294: ...fect the braking and handling of your vehicle make your tires lose air and make you lose control You could have a collision in which you or others could be injured Always use the correct wheel wheel b...

Page 295: ...ity diameter width offset and mounting configuration Using wheels and tires with higher load carrying limits than the original wheels and tires does not change the Gross Axle Weight Rating GAWR or the...

Page 296: ...ire 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 st...

Page 297: ...to be able to change a flat tire safely For example you would need a truck jack that can lift several thousand pounds and a torque wrench that can generate several hundred foot pounds Y of twisting fo...

Page 298: ...apply cleaner directly to the cleaning cloth 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 defogge...

Page 299: ...soil to absorb into the paper towel until no more can be removed For solid dry soils remove as much as possible and then vacuum To clean use the following instructions 1 Saturate a lint free clean whi...

Page 300: ...lter the appearance by increasing the gloss in a non uniform manner Some commercial products may increase gloss on your instrument panel The increase in gloss may cause annoying reflections in the win...

Page 301: ...finish with a soft clean chamois or an all cotton towel to avoid surface scratches and water spotting High pressure car washes may cause water to enter the vehicle Avoid using high pressure washes cl...

Page 302: ...sary Use special care with aluminum trim To avoid damaging protective trim never use auto or chrome polish steam or caustic soap to clean aluminum A coating of wax rubbed to high polish is recommended...

Page 303: ...he wheel and buff off immediately after application Tires To clean the tires use a stiff brush with tire cleaner Notice Using petroleum based tire dressing products on your vehicle may damage the pain...

Page 304: ...shaped discolorations and small irregular dark spots etched into the paint surface Although no defect in the paint job causes this we will repair at no charge to the owner the surfaces of new vehicle...

Page 305: ...fabrics vinyl leather and carpet Vehicle Identification Vehicle Identification Number VIN This is the legal identifier for your vehicle It appears on a plate in the front corner of the instrument pane...

Page 306: ...n keep other components from working as they should Add on equipment can drain your vehicle s battery even if your vehicle is not operating Your vehicle has an airbag system Before attempting to add a...

Page 307: ...Power Windows and Other Power Options Circuit breakers in the fuse panel protect the power windows and other power accessories When the current load is too heavy the circuit breaker opens This protec...

Page 308: ...rking Lamps 4 Powertrain Control Module 5 Auxiliary Wiring 6 Heater Air Conditioning Fuse Usage 7 Hazard Warning Flashers 8 Power Post 9 Courtesy Lamps 10 Warning Lights Gages and Indicators 11 Starte...

Page 309: ...Turn Signal Backup Lamps 23 Transmission 24 Hydraulics Air Brake A Spare B Spare Fuse Usage Blank Not Used BRK Brake Warning Lamp RT PRK Passenger Side Parking Lamps Blank Not Used Blank Not Used LT...

Page 310: ...goes out the problem could be in either the primary or secondary underhood fuse blocks These blocks use blade type fuses Both underhood fuse blocks are located in the engine compartment on the passen...

Page 311: ...ke System 1 ABS 2 Antilock Brake System 2 ABS 3 Antilock Brake System 3 ENGINE Engine E A PUMP Electronic Automatic Pump HORN Horn Fuse Usage NOTE 2 Fuel L18 LMM Electronic Control Module LF6 NOTE 4 E...

Page 312: ...Ignition 4 IGN 3 Ignition 3 BATT HAZ Battery Hazard Warning Flashers HEADLAMP Headlamps LIGHTING Interior Exterior Lamps HVAC Climate Control System NOTE C4 C5 Electric Brake C6 C7 C8 Brake Lamps Sec...

Page 313: ...stem refrigerant charge amount see the refrigerant caution label located under the hood See your dealer retailer for more information Cooling System C4 C5 Models 6 6L V8 Automatic Transmission 27 9 qt...

Page 314: ...8 Engine 33 3 qt 31 5 L 8 1L V8 Engine with A C and Increased Cooling 34 9 qt 33 0 L Engine Oil with Filter 6 6L V8 Engine 14 6 qt 13 8 L 7 2L L6 Caterpillar C7 Engine 30 0 qt 28 4 L Isuzu 6H1 Engine...

Page 315: ...nal Mid Mounted 60 gal 227 1 L Optional Mid Mounted 80 gal 302 8 L 1 One 25 gallon 94 6 L tank and one 15 gallon 56 8 L tank Fuel Capacity C6 C7 C8 Models Optional 35 gal 132 4 L Standard 50 gal 189 2...

Page 316: ...HPN 21060S HPP 22060S HPG 31 0 pt 14 7 L 23090S HPT 42 5 pt 20 1 L 23105D HNB 23105S HNA 51 0 pt 24 1 L 26105S HPA 51 0 pt 24 1 L S110 HD2 and S130 HD1 15 0 pt 7 1 L Rear Axle Tandem DS344 front HPI 3...

Page 317: ...Fluid Automatic 3000 RDS and EVS and 3500 RDS and EVS with PTO Provision 59 0 pt 28 1 L 3000 RDS and EVS and 3500 RDS and EVS without PTO Provision 52 0 pt 24 6 L 1000 HS RDS MH PTS and EVS 2200 HS RD...

Page 318: ...L RT8908LL 28 0 pt 13 2 L All capacities are approximate When adding be sure to fill to the approximate level as recommended in this manual Recheck the fluid level after filling Engine Specifications...

Page 319: ...6 6L V8 C4 C5 Models 19152817 A3102C 7 2L L6 Isuzu 6H C6 C7 C8 Models with Standard Air Cleaner 88937525 A2031C 7 2L L6 Isuzu 6H C6 C7 C8 Models with Heavy Duty Air Cleaner 889375251 A2031C 8 1L V8 C...

Page 320: ...6 NWB 15618921 Isuzu 6H 25014274 TP915D Isuzu 6H KUK 88983117 TP1519 8 1L V8 K28 and standard U Haul 25014476 TP1247 Spark Plugs 6 6L V8 7 2L L6 Isuzu 6H 8 1L V8 12578277 41 983 1 Optional air filter...

Page 321: ...Engine Drive Belt Routing Air conditioning compressor A Dual Generators B Air conditioning compressor A Air brake compressor B 8 1L V8 Engine C4 C5 8 1L V8 Engine C6 C7 C8 5 117...

Page 322: ...Dual Generators A Air conditioning compressor A 6 6L V8 DURAMAX Diesel Engine Isuzu 6H Diesel Engine 5 118...

Page 323: ...Air conditioning compressor A 7 2L I6 Caterpillar Diesel Engine 5 119...

Page 324: ...NOTES 5 120...

Page 325: ...uled Maintenance Services 6 4 Using the Maintenance Schedule 6 4 Scheduled Maintenance Supplements 6 4 Scheduled Maintenance 6 5 Part B Owner Checks and Services 6 26 At Each Fuel Fill 6 26 At Least T...

Page 326: ...l are 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 vehic...

Page 327: ...ools and equipment for the job If you have any doubt have a qualified technician do the work See Doing Your Own Service Work on page 5 6 If you want to purchase service information see Service Publica...

Page 328: ...service needs you will know that trained and supported service people will perform the work using genuine parts The proper fluids and lubricants to use are listed in Part C Make sure whoever services...

Page 329: ...9 The Footnotes at the end of this Maintenance Schedule further explain maintenance services See Service Publications Ordering Information on page 7 10 100 Miles 160 km Wheel stud nut service 36 1 000...

Page 330: ...s driven in dusty dirty conditions inspect filter at every engine oil change See Engine Air Cleaner Filter on page 5 39 for more information Diesel Engine Inspect engine air cleaner filter change indi...

Page 331: ...hinge pins and bushings and replace as necessary Cooling system service Clean the cooling system filter cap with clean water clean the core pressure test the cap and the system for proper pressure ca...

Page 332: ...ven in dusty dirty conditions inspect filter at every engine oil change See Engine Air Cleaner Filter on page 5 39 for more information Diesel Engine Inspect engine air cleaner filter change indicator...

Page 333: ...r filter dry element pleated paper air strainer service or every 6 months or every 1800 hours whichever occurs first 37 500 Miles 60 000 km Gasoline Engine Only Check engine oil life system If engine...

Page 334: ...ne oil change See Engine Air Cleaner Filter on page 5 39 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 hours of engine operation whichever occurs first Chassis lubric...

Page 335: ...months whichever occurs first 2 24 Gasoline Engine Air compressor remote mounted air filter dry element pleated paper air strainer service or every 6 months or every 1800 hours whichever occurs first...

Page 336: ...Isuzu Diesel in the Index 2 9 Gasoline Engine Only Vehicles with GVW greater than 16 000 lbs Spark plug service 2 25 Check fluid levels or every 3 months whichever occurs first 1 5 Gasoline Engine In...

Page 337: ...t pleated paper air strainer service or every 2 months or every 800 hours whichever occurs first C600 C700 and C800 Gasoline Engines Only Engine drive belts service or every 12 months whichever occurs...

Page 338: ...ped or every 24 months whichever occurs first 2 24 72 000 Miles 115 000 km Lubricate U joints or every 6 months whichever occurs first 75 000 Miles 120 000 km Gasoline Engine Only Check engine oil lif...

Page 339: ...32 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 33 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs...

Page 340: ...er occurs first 34 90 000 Miles 144 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 DURAMAX I...

Page 341: ...ake service or every 6 months whichever occurs first 21 Air brake service or every 6 months whichever occurs first 32 Air brake automatic slack adjuster service or every 500 hours whichever occurs fir...

Page 342: ...curs first 21 Air brake service or every 6 months whichever occurs first 32 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 33 Check air brake relay valve operatio...

Page 343: ...ilter DPF service Then every 100 000 miles 160 000 km 7 38 150 000 Miles 240 000 km Cooling system service or every 60 months since last service whichever occurs first 2 29 Diesel Engine Only Inspect...

Page 344: ...hicles sold in the United States and is recommended for vehicles sold in Canada 5 Check fluid level in brake master cylinder power steering pump front and rear axles transmission and hydraulic spring...

Page 345: ...c Inspect at 1 000 miles 1 600 km and 22 500 miles 36 000 km and then every 22 500 miles 36 000 km thereafter 11 Chassis Lubrication Service Lubricate all grease fittings in front suspension front axl...

Page 346: ...excessive or abnormal wear or damage Also check for damaged wheels Replace wheels and or tires as needed 15 Check spring to axle U bolts and shackle bolts for proper torque See the service manual for...

Page 347: ...correct routing or every 24 months whichever occurs first Replace parts as needed 25 Replace spark plugs Inspect wires for damage Check the wire boot and boot heat shield fit at spark plugs and coil R...

Page 348: ...as a reason to replace the cartridge Test air lines for leaks tighten as needed Replace compressor filter Inspect air parking brake chamber for leaks and damage Inspect lines and hoses for leaks crack...

Page 349: ...valves and valve boots as needed Using light oil lubricate brake pedal to brake application valve linkage components Check any rubber boots for cracks holes or deterioration and replace if necessary 3...

Page 350: ...per level Failure to keep the engine oil at the proper level can cause damage to the engine not covered by your warranty Check the engine oil level and add the proper oil if necessary See Engine Oil C...

Page 351: ...ubber cap bumpers should also be lubricated Part C tells you what to use More frequent lubrication may be required when exposed to a corrosive environment Parking Brake Check Park on a fairly steep hi...

Page 352: ...vice Inspect the hoses and have them replaced if they are cracked swollen or deteriorated Inspect all pipes fittings and clamps replace as needed Clean the outside of the radiator and air conditioning...

Page 353: ...earance lamps taillamps brake lamps turn signals backup lamps and hazard warning flashers Have headlamp aim checked at once if beams seem improperly aimed Glass Mirrors Lamps and or Reflectors Conditi...

Page 354: ...d be loosened before being flushed Engine Cover Check Check that the cab s engine cover and seal if the vehicle has one are not torn or damaged Be sure that the cover is clamped down firmly to the flo...

Page 355: ...erpillar Diesel Engine See the Caterpillar Operation Maintenance Manual for engine oil recommendations Usage Fluid Lubricant Engine Coolant Caterpillar Diesel Engine See the Caterpillar Operation Main...

Page 356: ...GM Part No U S 88861800 in Canada 88861801 Front Axle Four Wheel Drive SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part No U S 89021675 in Canada 10953512 Usage Fluid Lubricant Rear...

Page 357: ...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 358: ...Date Miles km Or Hours Serviced By Maintenance Record 6 34...

Page 359: ...Date Miles km Or Hours Serviced By Maintenance Record 6 35...

Page 360: ...Date Miles km Or Hours Serviced By Maintenance Record 6 36...

Page 361: ...the United States Government 7 9 Reporting Safety Defects to the Canadian Government 7 9 Reporting Safety Defects to General Motors 7 9 Service Publications Ordering Information 7 10 Vehicle Data Reco...

Page 362: ...acting a member of dealership management it appears your concern cannot be resolved by the dealership without further help contact the GM Medium Duty Truck Customer Assistance Center at 1 800 862 4389...

Page 363: ...ur case will generally be heard within 40 days If you do not agree with the decision given in your case you may reject it and proceed with any other venue for relief available to you You may contact t...

Page 364: ...Islands 1 800 496 9994 Fax Number 313 381 0022 Canada Customer Assistance General Motors of Canada Limited Customer Communication Centre CA1 163 005 1908 Colonel Sam Drive Oshawa Ontario L1H 8P7 1 800...

Page 365: ...engine warranty period to the nearest authorized GM Medium Duty dealer This service combines the efforts of trained telephone representatives with a network of GM Medium Duty truck services Call GM M...

Page 366: ...f the vehicle A recycled original equipment GM part may be an acceptable choice to maintain your vehicle s originally designed appearance and safety performance however the history of these parts is n...

Page 367: ...ash Occurs Here is what to do if you are involved in a crash Try to relax and then check to make sure you are all right If you are uninjured make sure that no one else in your vehicle or the other veh...

Page 368: ...e If you have a question ask for an explanation Reputable shops welcome this opportunity Managing the Vehicle Damage Repair Process In the event that your vehicle requires damage repairs GM recommends...

Page 369: ...400 Seventh Street SW Washington D C 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Reporting Safety Defects to the Canadian Government If you live...

Page 370: ...Portfolio Owner Manual and Warranty Booklet RETAIL SELL PRICE 35 00 U S plus processing fee Without Portfolio Owner Manual only RETAIL SELL PRICE 25 00 U S plus processing fee Current and Past Model O...

Page 371: ...n EDR is to record in certain crash or near crash like situations such as an airbag deployment or hitting a road obstacle data that will assist in understanding how a vehicle s systems performed The E...

Page 372: ...ific vehicle or vehicle owner OnStar Isuzu 7 8L L6 Engine If your vehicle has OnStar and you subscribe to the OnStar services please refer to the OnStar Terms and Conditions for information on data co...

Page 373: ...rbag Equipped Vehicle 1 59 What Makes an Airbag Inflate 1 53 Antenna Fixed Mast 3 58 Antilock Brake System ABS 4 5 Antilock Brake System Warning Light 3 34 Antilock Brakes Trailer System Warning Light...

Page 374: ...5 109 Carbon Monoxide 2 45 4 16 Care of Safety Belts 5 96 Center Console Storage Area 2 53 Change Fuel Filter Warning Light 3 44 Charging System Light 3 30 Check Engine Light 3 36 Gages Warning Light...

Page 375: ...Telephone TTY Users 7 3 Customer Assistance Offices 7 4 Customer Assistance Information cont Customer Satisfaction Procedure 7 2 GM Mobility Reimbursement Program 7 5 Reporting Safety Defects to Gener...

Page 376: ...hield Wiper Fuses 5 102 Engine Air Cleaner Filter 5 39 Alarm and Automatic Shutdown 2 18 Change Engine Oil Light 3 38 Check and Service Engine Soon Light 3 36 Checks Before Operating 2 23 Coolant 5 44...

Page 377: ...Fuel Container 5 21 Filling the Tank 5 20 Filter 5 78 Filter Replacement 5 18 Fuels in Foreign Countries 5 19 Fuel cont Gage 3 43 Gasoline Octane 5 7 Gasoline Specifications 5 7 Primary Filter and Wa...

Page 378: ...s 3 14 High Low Beam Changer 3 8 On Reminder 3 15 Heater 3 20 High Idle System 2 20 Highbeam On Light 3 41 Highway Hypnosis 4 15 Hill and Mountain Roads 4 15 Hood Checking Things Under 5 22 Latches 5...

Page 379: ...ine Shutdown Warning 3 39 Exhaust Brake Indicator 3 40 Highbeam On 3 41 Light cont Low Coolant Warning 3 35 Low Oil Level 3 38 Low Washer Fluid Warning 3 42 Malfunction Indicator 3 36 Power Take Off 3...

Page 380: ...30 Manual Using ii Manual Windows 2 8 Marker Lamps 3 16 Mirrors Manual Rearview Mirror 2 51 Outside Convex Mirrors 2 52 Outside Heated Mirrors 2 52 Mirrors cont Outside Manual Mirrors 2 51 Outside Pow...

Page 381: ...ng 4 11 Perchlorate Materials Requirements California 5 5 Power Door Locks 2 7 Electrical System 5 103 Reduced Engine Light 3 41 Power cont Steering Fluid 5 54 Windows 2 9 Power Take Off Light 3 42 Po...

Page 382: ...Safety Belts cont Safety Belt Use During Pregnancy 1 26 Safety Belts Are for Everyone 1 11 Safety Warnings and Symbols iii Scheduled Maintenance 6 4 Scheduled Maintenance Supplements 6 4 Seats Air Sus...

Page 383: ...ning 5 99 Dual Tire Operation 5 84 If a Tire Goes Flat 5 92 Inflation Tire Pressure 5 82 Tightening the Wheel Nuts 5 86 Tires cont Wheel Alignment and Tire Balance 5 86 Wheel Loading 5 83 Wheel Replac...

Page 384: ...evices 3 6 Safety and Symbols iii Vehicle Damage iv Washer Fluid Low Warning Light 3 42 Water Fuel 5 12 Water in Fuel Warning Light 3 44 What Fuel to Use 5 9 Wheels Alignment and Tire Balance 5 86 Fro...

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