GMC 2003 DURAMAX Owner'S Manual Download

Page: 1 / 88

Features and Controls ..................................... 2-1

Starting and Operating Your Vehicle

............. 2-2

Instrument Panel ............................................. 3-1

Warning Lights, Gages and Indicators

........... 3-2

Service and Appearance Care .......................... 5-1

Diesel Fuel Requirements and

Fuel System

.......................................... 5-2

Checking Things Under the Hood

............... 5-14

Capacities and Specifications

..................... 5-38

Maintenance Schedule ..................................... 6-1

Maintenance Schedule

................................ 6-2

Index ................................................................ 1

2003 DURAMAX™ Diesel Engine

Summary of Contents for 2003 DURAMAX

Page 1: ...l 3 1 Warning Lights Gages and Indicators 3 2 Service and Appearance Care 5 1 Diesel Fuel Requirements and Fuel System 5 2 Checking Things Under the Hood 5 14 Capacities and Specifications 5 38 Mainte...

Page 2: ...d If you sell your vehicle leave this manual and the owner manual with the vehicle This manual includes the latest information at the time it was printed We reserve the rights to make changes in the p...

Page 3: ...Starting and Operating Your Vehicle 2 2 Starting Your Diesel Engine 2 2 Winter Cover 2 6 Engine Coolant Heater 2 7 Section 2 Features and Controls 2 1...

Page 4: ...ft lever to neutral and hold the clutch pedal to the floor while starting the engine Your vehicle won t start if the clutch pedal is not all the way down that s a safety feature Starting Your Engine 1...

Page 5: ...le This lets oil pressure build up Your engine will sound louder when it s cold Notice If you are not in an idling vehicle and the engine overheats you would not be there to see the overheated engine...

Page 6: ...ne still won t start your vehicle needs service If the light does not come on when the engine is cold your vehicle needs service If your batteries don t have enough charge to start your engine see Bat...

Page 7: ...than eight seconds 3 Release the accelerator pedal and start the engine When the engine is started it will slowly ramp up to the high idle speed after a delay of a few seconds up to approximately two...

Page 8: ...l the vehicle the winter cover should not be used The following usage guidelines will allow adequate airflow for proper radiator grille and air cooler performance Do not use the winter cover when temp...

Page 9: ...back of the patch Grille Cover Installation 1 Pre bend all the small black tabs into the shape of a J 2 Remove the four push pins and slide them through each of the pre punched tabs 3 Install the fou...

Page 10: ...o unplug and store the cord as it was before to keep it away from moving engine parts If you don t it could be damaged How long should you keep the coolant heater plugged in The answer depends on the...

Page 11: ...ts Gages and Indicators 3 2 Instrument Panel Cluster 3 2 Malfunction Indicator Lamp 3 3 Oil Pressure Gage 3 5 Wait to Start Light 3 6 Fuel Gage 3 6 Driver Information Center DIC 3 7 Section 3 Instrume...

Page 12: ...Warning Lights Gages and Indicators Instrument Panel Cluster United States Version shown Canada similar 3 2...

Page 13: ...e any problem is apparent This may prevent more serious damage to your vehicle This system is also designed to assist your service technician in correctly diagnosing any malfunction Notice If you keep...

Page 14: ...ler has the proper test equipment and diagnostic tools to fix any mechanical or electrical problems that may have developed Emissions Inspection and Maintenance Programs Some state provincial and loca...

Page 15: ...a under certain conditions especially in cold temperatures This is a normal operating range CAUTION Do not keep driving if the oil pressure is low If you do your engine can become so hot that it catch...

Page 16: ...functioning properly and tells you when the engine is ready to be started For more information see Starting Your Diesel Engine on page 2 2 Fuel Gage When the ignition is on the fuel gage shows you app...

Page 17: ...oler To clean powerwash the bottom of the vehicle Driver Information Center DIC The Driver Information Center DIC is located on the instrument panel cluster above the steering wheel The DIC comes on w...

Page 18: ...OWER On diesel engines a computer monitors the operation of the electric accelerator If the REDUCED ENGINE POWER message comes on while you are driving the computer is indicating that your vehicle has...

Page 19: ...10 Filling Your Tank 5 12 Filling a Portable Fuel Container 5 13 Checking Things Under the Hood 5 14 Engine Compartment Overview 5 14 Engine Oil 5 16 Engine Air Cleaner Filter 5 21 Automatic Transmis...

Page 20: ...l could damage your fuel system and engine Your warranty would not cover this damage And Diesel fuel that has been mixed with engine oil or automatic transmission fluid could damage your engine and em...

Page 21: ...ning up to 5 biodiesel B5 but the final blended fuel must meet the same specification ASTM D975 02 Grade Low Sulfur as other fuels used in your vehicle and the biodiesel used for making this fuel must...

Page 22: ...Manufacturers Association EMA has identified properties of an improved diesel fuel for better engine performance and durability FQP 1A Diesel fuels corresponding to the EMA description could provide b...

Page 23: ...otice If there is water in your diesel fuel and the weather is warm or humid fungus and bacteria can grow in the fuel They can damage your fuel system A diesel fuel biocide can be used to sterilize yo...

Page 24: ...Immediately after refueling large amount of water possibly pumped into fuel tank Fuel tank purging required See your dealer for assistance Notice If you drive when this warning indicator is on you can...

Page 25: ...under Engine Oil on page 5 16 6 Install the fuel cap 7 Start the engine and let it run for a few minutes If the engine stalls the fuel system may need to be primed While draining the water from the fu...

Page 26: ...he engine may not be able to start until the fuel system is primed and the air is removed Q How do I prime the vehicle A Your vehicle is equipped with a priming pump which is part of the engine mounte...

Page 27: ...ur hand The pump is located on top of the fuel filter housing Let the pump return upward between pushes 7 Operate the priming pump until a small amount of fuel seeps from the vent valve When you see t...

Page 28: ...RT for 10 to 15 seconds at a time until your engine starts If the engine tries to run but does not run smoothly increase the rpm a little using the accelerator pedal This will help force air through t...

Page 29: ...switch located on the bottom of the fuel filter 4 Install the new filter element 5 Reinstall and tighten the filter container and reconnect the water sensor wire to the filter 6 Use the fuel filter p...

Page 30: ...ab models refuel the front tank first or in instances when only a partial fuel fill is desired An automatic transfer mechanism will maintain approximately equal fuel levels in both tanks so no switchi...

Page 31: ...not fit properly Filling a Portable Fuel Container CAUTION Never fill a portable fuel container while it is in your vehicle Static electricity discharge from the container can ignite the gasoline vapo...

Page 32: ...Checking Things Under the Hood Engine Compartment Overview When you open the hood on the 6 6L DURAMAX Diesel Engine you ll see 5 14...

Page 33: ...Engine Oil Dipstick E Automatic Transmission Dipstick F Engine Oil Fill Cap G Engine Fan H Power Steering Fluid Reservoir I Remote Negative Terminal J Remote Positive Terminal K Brake Fluid Reservoir...

Page 34: ...partment Overview on page 5 14 for more information on its location In order to get an accurate reading the oil must be warm at normal operating temperature and the vehicle must be on level ground Tur...

Page 35: ...o not add too much oil If your engine has so much oil that the oil level gets above the F mark that shows the proper operating range your engine could be damaged The engine oil fill cap is located nea...

Page 36: ...nty 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 18 C When it s very cold below 0 F 18 C you should use SAE 5...

Page 37: ...et the system every time the oil is changed When the system has calculated that oil life has been diminished it will indicate that an oil change is necessary A CHANGE ENGINE OIL message will come on C...

Page 38: ...Oil Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer Don t let used oil stay on your skin for very long Clean your skin and nails with soap an...

Page 39: ...nspect Inspect the air cleaner filter every 15 000 miles 25 000 km and replace the filter if necessary How to Inspect When the restriction indicator turns black or is in the red orange change zone rep...

Page 40: ...Maintenance Schedule to determine when to replace the engine air cleaner filter CAUTION Operating the engine with the air cleaner filter off can cause you or others to be burned The air cleaner not o...

Page 41: ...enance on page 6 5 How to Check Because this operation can be a little difficult you may choose to have this done at the dealership service department If you do it yourself be sure to follow all the i...

Page 42: ...luid level rises as fluid temperature increases DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures 1 Pull out the dipstick and wipe it with a clean...

Page 43: ...the procedures described previously Consistency repeatable readings is important to maintaining proper fluid level If inconsistent readings persist check the transmission breather to be sure it is cle...

Page 44: ...50 50 mixture of clean drinkable water and DEX COOL coolant will Give freezing protection down to 34 F 37 C Give boiling protection up to 265 F 129 C Protect against rust and corrosion Help keep the...

Page 45: ...could get too hot but you would not get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If...

Page 46: ...ngine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle mus...

Page 47: ...spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if the engine parts are hot enough Do not spill coolant on a hot engine When replacing the pressure cap make sure i...

Page 48: ...y away from the engine if you see or hear steam coming from it Just turn it off and get everyone away from the vehicle until it cools down Wait until there is no sign of steam or coolant before you op...

Page 49: ...ffic let the engine idle in neutral while stopped If it is safe to do so pull off the road shift to park or neutral and let the engine idle 2 Turn on your heater to full hot at the highest fan speed a...

Page 50: ...coolant inside the coolant surge tank is boiling don t do anything else until it cools down The vehicle should be parked on a level surface The coolant level should be at or above the FULL COLD mark...

Page 51: ...fan speed should increase when idle speed is doubled by pushing the accelerator pedal down If it doesn t your vehicle needs service Turn off the engine Notice Engine damage from running your engine w...

Page 52: ...tank but be sure the cooling system including the coolant surge tank pressure cap is cool before you do it See Engine Coolant on page 5 26 for more information If no coolant is visible in the surge t...

Page 53: ...d get too hot but you would not get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice In cold...

Page 54: ...while turning the pressure cap If you hear a hiss wait for that to stop A hiss means there is still some pressure left 2 Then keep turning the cap but now push down as you turn it Remove the pressure...

Page 55: ...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 leve...

Page 56: ...Capacities Application Capacities English Metric Cooling System Automatic Transmission Manual Transmission 22 0 quarts 22 0 quarts 21 0L 21 0L Engine Oil With Filter 6 6L V8 10 0 quarts 9 5L All quan...

Page 57: ...identified below by name part number or specification can be obtained from your dealer Part GM Part Number ACDelco Part Number Oil Filter 88917036 PF2232 Engine Air Cleaner Filter 25332443 A1618C Fue...

Page 58: ...NOTES 5 40...

Page 59: ...Each Fuel Fill 6 14 At Least Once a Month 6 15 At Least Twice a Year 6 15 At Least Once a Year 6 16 Part C Periodic Maintenance Inspections 6 19 Steering and Suspension Inspection 6 19 Exhaust System...

Page 60: ...the environment Improper vehicle maintenance can even affect the quality of the air we breathe Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle...

Page 61: ...u have any doubt have a qualified technician do the work If you want to get the service information see Service and Owner Publications in your owner s manual Part B Owner Checks and Services tells you...

Page 62: ...your vehicle in good condition see your dealer This part tells you the maintenance services you should have done and when to schedule them When you go to your dealer for your service needs you will k...

Page 63: ...on page 6 14 and Part C Periodic Maintenance Inspections on page 6 19 Footnotes The U S Environmental Protection Agency or the California Air Resources Board has determined that the failure to perform...

Page 64: ...east once a year and at this time the system must be reset Your dealer has GM trained service people who will perform this work using genuine GM parts and reset the system It is also important to chec...

Page 65: ...ricants on page 6 20 for the proper fluid to use Rotate tires See Tire Inspection and Rotation in your owner s manual for proper rotation pattern and additional information See Tires in your owner s m...

Page 66: ...n in your owner s manual for proper rotation pattern and additional information See Tires in your owner s manual See footnote 25 000 Miles 41 500 km Allison Transmission Only Change automatic transmis...

Page 67: ...e properly sealed and that all hose connections fasteners and other components are tight Also check to be sure that the air cleaner housing is properly seated and the cover fits tightly Tighten connec...

Page 68: ...roperly seated and the cover fits tightly Tighten connections and fasteners or replace damaged parts as necessary This is a Noise Emission Control Service Applicable only to vehicles sold in the Unite...

Page 69: ...system installation to assure that gaskets are properly sealed and that all hose connections fasteners and other components are tight Also check to be sure that the air cleaner housing is properly se...

Page 70: ...intake system installation to assure that gaskets are properly sealed and that all hose connections fasteners and other components are tight Also check to be sure that the air cleaner housing is prope...

Page 71: ...level and add fluid as needed Check constant velocity joints and axle seals for leaking See Part D Recommended Fluids and Lubricants on page 6 20 for the proper fluid to use Rotate tires See Tire Ins...

Page 72: ...00 Miles 240 000 km Drain flush and refill the cooling system or every 60 months since last service whichever occurs first See Engine Coolant on page 5 26 for what to use An Emission Control Service P...

Page 73: ...ur owner s manual for further details At Least Twice a Year Restraint System Check Make sure the safety belt reminder light and all your belts buckles latch plates retractors and anchorages are workin...

Page 74: ...d leak is the only reason for fluid loss Have the system inspected and repaired if needed Automatic Transmission Check Check the transmission fluid level add if needed See Automatic Transmission Fluid...

Page 75: ...and try to start the engine The starter should work only when the clutch is pushed down all the way to the floor If the starter works when the clutch is not pushed all the way down your vehicle needs...

Page 76: ...the parking brake To check the parking brake s holding ability With the engine running and transmission in NEUTRAL N slowly remove foot pressure from the regular brake pedal Do this until the vehicle...

Page 77: ...er hook up binding leaks cracks chafing etc Exhaust System Inspection Inspect the complete exhaust system Inspect the body near the exhaust system Look for broken damaged missing or out of position pa...

Page 78: ...ing brake etc You may need to have your brakes inspected more often if your driving habits or conditions result in frequent braking Part D Recommended Fluids and Lubricants Fluids and lubricants ident...

Page 79: ...ed without Low Gear RPO MG5 Synchromesh Transmission Fluid GM Part No U S 12345349 in Canada 10953465 or equivalent Usage Fluid Lubricant Manual Transmission 6 Speed TranSynd Synthetic Transmission Fl...

Page 80: ...377985 in Canada 88901242 or equivalent or lubricant meeting requirements of NLGI 2 Category LB or GC LB Usage Fluid Lubricant Hood Hinges Multi Purpose Lubricant Superlube GM Part No U S 12346241 in...

Page 81: ...dometer reading and who performed the service and any additional information from Owner Checks and Services or Periodic Maintenance on the following record pages Also you should retain all maintenance...

Page 82: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance Record 6 24...

Page 83: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance Record 6 25...

Page 84: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance Record 6 26...

Page 85: ...ne 2 3 Coolant Engine 5 26 Surge Tank Pressure Cap 5 29 Cooling System 5 32 D Diesel Engine Fuel 5 2 Filling a Portable Fuel Container 5 13 Filling Your Tank 5 12 Fuel Requirements and Fuel System 5 2...

Page 86: ...ing Out of 5 10 System Inspection 6 19 Water in Fuel 5 5 Water in Fuel Light Chart 5 6 What to Use 5 3 Fuel Priming 5 7 G Gage Fuel 3 6 Oil Pressure 3 5 H How to Add Coolant to the Coolant Surge Tank...

Page 87: ...ces 6 4 Part B Owner Checks and Services 6 14 Part C Periodic Maintenance Inspections 6 19 Maintenance Schedule cont Part D Recommended Fluids and Lubricants 6 20 Part E Maintenance Record 6 23 Schedu...

Page 88: ...ire Inflation Check 6 15 To Use the Engine Coolant Heater 2 8 Transfer Case and Front Axle Four Wheel Drive Inspection 6 20 Transmission Automatic Fluid 5 23 U Underbody Flushing Service 6 18 Usage Gu...

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