GMC TopKick 2007 Owner'S Manual Download Page 242 | Manualshive

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Front Axle

................................................... 312

Noise Control System

................................. 313

Tampering with Noise Control System

Prohibited .............................................. 313

Bulb Replacement

....................................... 314

Windshield Wiper Blade Replacement

....... 314

Other Service Items

.................................... 316

Fuel Filter .................................................. 316
Primary Fuel Filter and Water Separator ...... 316
Secondary Fuel Filter and Water

Separator/Heater (Caterpillar

®

Diesel) ...... 317

Automatic Ether Injection System

(Caterpillar

®

Diesel) ................................ 318

Front Wheel Bearings with

Oil-Filled Hubs ........................................ 319

Air Conditioning System ............................ 319

Tires

............................................................ 320

Inflation - Tire Pressure ............................. 321
Wheel Loading .......................................... 321
Dual Tire Operation ................................... 322
When It Is Time for New Tires .................. 322
Wheel Alignment and Tire Balance ............ 323

Tightening the Wheel Nuts ........................ 324
Wheel Replacement .................................. 328
If a Tire Goes Flat .................................... 330

Appearance Care

........................................ 331

Cleaning the Inside of Your Vehicle .......... 331
Fabric/Carpet ............................................. 333
Instrument Panel, Vinyl, and

Other Plastic Surfaces ........................... 334

Care of Safety Belts .................................. 334
Weatherstrips ............................................ 334
Washing Your Vehicle ............................... 335
Cleaning Exterior Lamps/Lenses ................ 335
Finish Care ............................................... 336
Windshield and Wiper Blades .................... 337
Aluminum or Chrome-Plated Wheels ......... 337
Tires ......................................................... 338
Sheet Metal Damage ................................. 338
Finish Damage .......................................... 338
Underbody Maintenance ............................ 338
Chemical Paint Spotting ............................ 339

Vehicle Identification

.................................. 340

Vehicle Identification Number (VIN) ........... 340
Service Parts Identification Label ............... 341

Section 5

Service and Appearance Care

242

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Summary of Contents for TopKick 2007

Page 1: ...Overview 138 Climate Controls 155 Warning Lights Gages and Indicators 159 Audio System s 182 Driving Your Vehicle 201 Your Driving the Road and Your Vehicle 202 Towing 237 Service and Appearance Care 241 Service 244 Fuel 247 Checking Things Under the Hood 263 Rear Axle 309 Four Wheel Drive 311 Front Axle 312 Noise Control System 313 Bulb Replacement 314 Windshield Wiper Blade Replacement 314 Other...

Page 2: ...s and Specifications 348 Normal Maintenance Replacement Parts 354 Maintenance Schedule 359 Maintenance Schedule 360 Customer Assistance Information 403 Customer Assistance and Information 404 Reporting Safety Defects 414 Index 417 2 ...

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

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

Page 5: ...o warning labels on the vehicle They use the same words CAUTION or NOTICE Vehicle Symbols The vehicle has components and labels that use symbols instead of text Symbols are shown along with the text describing the operation or information relating to a specific component control message gage or indicator If you need help figuring out a specific name of a component gage or indicator reference the f...

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

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

Page 8: ...ag Restrain 74 What Will You See After an Airbag Inflates 74 Airbag Off Switch 76 Servicing Your Airbag Equipped Vehicle 79 Adding Equipment to Your Airbag Equipped Vehicle 80 Restraint System Check 81 Checking the Restraint Systems 81 Replacing Restraint System Parts After a Crash 82 Section 1 Seats and Restraint Systems 8 ...

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

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

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

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

Page 13: ... seat Fore and Aft Adjustment If your vehicle has this lever it is located underneath the front of the driver s seat To slide the seat forward or rearward move the lever toward the outboard side of the seat The seat will lock in at 1 2 inch 1 5 cm increments If your vehicle has an adjustment bar it is located under the front of the seat cushion Lift the bar to unlock the seat Slide the seat to whe...

Page 14: ...Height Adjustment If your vehicle has an air suspension seat height adjustment lever it is located on the front inboard side of the seat Seat Height Adjustment Lever Seat Height Adjustment Switch 14 ...

Page 15: ...cushion on the inboard side of the seat Push the left side of the switch to inflate Push the right side of the switch to deflate Your seat cushion may also be able to be raised or lowered If your vehicle has this feature the seat cushion height adjustment handle is located underneath the front of the seat To adjust the height of the cushion lift the handle up and pull it forward You can choose bet...

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

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

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

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

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

Page 21: ...ed or killed In the same crash you might not be if you are buckled up Always fasten your safety belt and check that your passengers belts are fastened properly too CAUTION It is extremely dangerous to ride in a cargo area inside or outside of a vehicle In a collision people riding in these areas are more likely to be seriously injured or killed Do not allow people to ride in any area of your vehic...

Page 22: ...urvive But most crashes are in between In many of them people who buckle up can survive and sometimes walk away Without belts they could have been badly hurt or killed After more than 40 years of safety belts in vehicles the facts are clear In most crashes buckling up does matter a lot Why Safety Belts Work Q Aren t safety belts for kids A Yes And they are for adult truckers and anyone else who ri...

Page 23: ...If the vehicle hits something it stops right then But nothing stops the people They keep moving Then something will stop them It could be the windshield 23 ...

Page 24: ...s were to give that big vehicle a chance to deal with the force of the impact instead of you With safety belts you slow down as the vehicle does You get more time to stop You stop over more distance and your strongest bones take the forces Safety belts are for everyone 24 ...

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

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

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

Page 28: ...would be less likely to slide under the lap belt If you slid under it the belt would apply force at your abdomen This could cause serious or even fatal injuries The shoulder belt should go over the shoulder and across the chest These parts of the body are best able to take belt restraining forces The safety belt locks if there is a sudden stop or crash 28 ...

Page 29: ...too loose It will not give nearly as much protection this way CAUTION You can be seriously hurt if your shoulder belt is too loose In a crash you would move forward too much which could increase injury The shoulder belt should fit against your body 29 ...

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

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

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

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

Page 34: ...d across the body CAUTION You can be seriously injured by a twisted belt In a crash you would not have the full width of the belt to spread impact forces If a belt is twisted make it straight so it can work properly or ask your dealer to fix it 34 ...

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

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

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

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

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

Page 40: ...uld go over the shoulder and across the chest These parts of the body are best able to take belt restraining forces The safety belt locks if there is a sudden stop or a crash or if you pull the belt very quickly out of the retractor Each position next to the windows has a shoulder belt height adjuster See Shoulder Belt Height Adjustment on page 35 CAUTION You can be seriously hurt if your shoulder...

Page 41: ...When you go in to order it take the heaviest coat you will wear so the extender will be long enough for you To help avoid personal injury do not let someone else use it and use it only for the seat it is made to fit The extender has been designed for adults Never use it for securing child seats To wear it just attach it to the regular safety belt For more information see the instruction sheet that...

Page 42: ...tional restraint a shoulder belt can provide The shoulder belt should not cross the face or neck The lap belt should fit snugly below the hips just touching the top of the thighs It should never be worn over the abdomen which could cause severe or even fatal internal injuries in a crash According to accident statistics children are safer when properly restrained in the rear seating positions than ...

Page 43: ...lt but the child is so small that the shoulder belt is very close to the child s face or neck A Move the child toward the center of the vehicle but be sure that the shoulder belt still is on the child s shoulder so that in a crash the child s upper body would have the restraint that belts provide If the child is so small that the shoulder belt is still very close to the child s face or neck you mi...

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

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

Page 46: ...does not weigh much until a crash During a crash a baby will become so heavy it is not possible to hold it For example in a crash at only 25 mph 40 km h a 12 lb 5 5 kg baby will suddenly become a 240 lb 110 kg force on a person s arms A baby should be secured in an appropriate restraint 46 ...

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

Page 48: ...nt will have a label saying that it meets federal motor vehicle safety standards The restraint manufacturer s instructions that come with the restraint state the weight and height limitations for a particular child restraint In addition there are many kinds of restraints available for children with special needs CAUTION Newborn infants need complete support including support for the head and neck ...

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

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

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

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

Page 53: ...s that are attached to a flat pad which rests low against the child s body A shelf or armrest type shield has straps that are attached to a wide shelf like shield that swings up or to the side CAUTION A child can be seriously injured or killed in a crash if the child is not properly secured in the child restraint Make sure the child is properly secured following the instructions that came with tha...

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

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

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

Page 57: ...en when no child is in it Lower Anchors and Tethers for Children LATCH Some child restraints have a LATCH system As part of the LATCH system your child restraint may have lower attachments and or a top tether The LATCH system can help hold the child restraint in place during driving or in a crash Some vehicles have lower and or top tether anchors designed to secure a child restraint with lower att...

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

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

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

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

Page 62: ...wn on the child restraint If you are using a forward facing child restraint you may find it helpful to use your knee to push down on the child restraint as you tighten the belt 6 Push and pull the child restraint in different directions to be sure it is secure To remove the child restraint just unbuckle the vehicle s safety belt It will be ready to work for an adult or large child passenger 62 ...

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

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

Page 65: ...n this including important safety information You will be using the lap shoulder belt Be sure to follow the instructions that came with the child restraint Secure the child in the child restraint when and as the instructions say 1 If your vehicle has a right front passenger s airbag see Airbag Off Switch on page 76 If your vehicle has a right front passenger s airbag and your child restraint is fo...

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

Page 67: ... 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 the child restraint in different directions to be sure it is secure To remove the child restraint just unbuckle the vehicle s safety belt and let it go back all the way The safety belt will move freely again and be ready to work for an adult or larger child p...

Page 68: ...this including important safety information Airbag System If it says AIR BAG on the middle part of the steering wheel and AIR BAG on the instrument panel in front of the right front passenger s seat your vehicle has an airbag for the driver and an airbag for the right front passenger If it says AIR BAG on the middle part of the steering wheel but it does not say AIR BAG on the instrument panel in ...

Page 69: ...o the safety belts All airbags are designed to work with safety belts but do not replace CAUTION Continued CAUTION Continued them Airbags are designed to deploy in moderate to severe frontal and near frontal crashes They are not designed to inflate in rollover rear crashes or in many side crashes And for some unrestrained occupants airbags may provide less protection in frontal crashes than more f...

Page 70: ...your vehicle has an airbag for the right front passenger please read this CAUTION Anyone who is up against or very close to any airbag when it inflates can be seriously injured or killed Airbags plus lap shoulder belts offer the best protection for adults but not for young children and infants Neither the vehicle s safety belt system nor its airbag system is designed for them Young children and in...

Page 71: ... 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 163 for more information Where Are the Airbags The driver s airbag is in the middle of the steering wheel 71 ...

Page 72: ... an airbag the bag might not inflate properly or it might force the object into that person causing severe injury or even death The path of an inflating airbag must be kept clear Do not put anything between an occupant and an airbag and do not attach or put anything on the steering wheel hub or on or near any other airbag covering 72 ...

Page 73: ...rent crash speeds For example If the vehicle hits a stationary object the airbags could inflate at a different crash speed than if the vehicle hits a moving object If the vehicle hits an object that deforms the airbags could inflate at a different crash speed than if the vehicle hits an object that does not deform If the vehicle hits a narrow object like a pole the airbags could inflate at a diffe...

Page 74: ...many types of collisions including rollovers rear impacts and many side impacts primarily because an occupant s motion is not toward those airbags Airbags should never be regarded as anything more than a supplement to safety belts and then only in moderate to severe frontal or near frontal collisions What Will You See After an Airbag Inflates After an airbag inflates it quickly deflates so quickly...

Page 75: ...hicle deformation Additional windshield breakage may also occur from the right front passenger airbag Airbags are designed to inflate only once After they inflate you will need some new parts for your airbag system If you do not get them the airbag system will not be there to help protect you in another crash A new system will include airbag modules and possibly other parts The service manual for ...

Page 76: ...g 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 monitor the child s condition Child Age 1 to 12 A child age 1 to 12 must ride in the front seat because My vehicle has no rear seat Although children ages 1 to 12 ride in the rear seat s whenever possible childre...

Page 77: ...ndshield 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 protection of an airbag In a crash the airbag will not be able to inflate and help protect the person sitting there Do not turn off the passenger s airbag unless the person sitting there is in a risk group ...

Page 78: ...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 of a passenger airbag risk group sit in the right front passenger s position for example do not secure a rear facing child restraint in the right front passenger s seat until you have your vehicle serviced See Airbag Readiness Light on ...

Page 79: ...ystem To purchase a service manual see Service Publications Ordering Information on page 415 CAUTION For up to 10 seconds after the ignition is turned off and the battery is disconnected an airbag can still inflate during improper service You can be injured if you are close to an airbag when it inflates Avoid yellow connectors They are probably part of the airbag system Be sure to follow proper se...

Page 80: ... modify your vehicle The phone numbers and addresses for Customer Assistance are in Step Two of the Customer Satisfaction Procedure on page 404 Q Because I have a disability I have to get my vehicle modified How can I find out whether this will affect my airbag system A Changing or moving any parts of the front seats safety belts the airbag sensing and diagnostic module steering wheel the instrume...

Page 81: ... Torn or frayed safety belts may not protect you in a crash They can rip apart under impact forces If a belt is torn or frayed get a new one right away Also look for any opened or broken airbag covers and have them repaired or replaced The airbag system does not need regular maintenance Notice If you damage the covering for the driver s or the right front passenger s airbag the airbag may not work...

Page 82: ...ible If you have had a crash do you need new belts After a very minor collision nothing may be necessary But if the belts were stretched as they would be if worn during a more severe crash then you need new parts If belts are cut or damaged replace them Collision damage also may mean you will need to have safety belt or seat parts repaired or replaced New parts and repairs may be necessary even if...

Page 83: ...rating 107 Engine Coolant Heater 108 Diesel Engine Exhaust Brake 109 Two Speed Rear Axle Electric Shift Control 111 Air Shift Control Automatic Transmission 112 Automatic Transmission Operation 113 Manual Transmission Operation 114 Power Take Off PTO 116 Four Wheel Drive 117 Parking 123 Parking Brake With Hydraulic Brakes 124 Parking Brake with Air Brakes 125 Parking Brake Burnish Procedure 127 Ai...

Page 84: ...th the ignition key is dangerous for many reasons They could operate the power windows or other controls or even make the vehicle move The children or others could be badly injured or even killed Do not leave the keys in a vehicle with children 84 ...

Page 85: ... Federal Communications Commission FCC Rules and with Industry Canada This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause interference 2 This device must accept any interference received including interference that may cause undesired operation of the device This device complies with RSS 210 of Industry Canada Operatio...

Page 86: ...ssary See Battery Replacement under Remote Keyless Entry RKE System Operation on page 86 If you are still having trouble see your dealer or a qualified technician for service Remote Keyless Entry RKE System Operation If your vehicle has this feature you can lock and unlock your doors from about 3 feet 1 m up to 30 feet 9 m away using the remote keyless entry transmitter supplied with your vehicle ...

Page 87: ...mum of four transmitters matched to it Battery Replacement Under normal use the battery in your remote keyless entry transmitter should last about two years You can tell the battery is weak if the transmitter won t work at the normal range in any location If you have to get close to your vehicle before the transmitter works it s probably time to change the battery Notice When replacing the battery...

Page 88: ...is system The transmitter does not send the same signal twice to the receiver The receiver will not respond to a signal it has been sent previously This prevents anyone from recording and playing back the signal from the transmitter To resynchronize your transmitter stand close to your vehicle and simultaneously press and hold the LOCK and UNLOCK buttons on the transmitter for at least five second...

Page 89: ...y belts properly and lock the doors whenever you drive CAUTION Continued CAUTION Continued Young children who get into unlocked vehicles may be unable to get out A child can be overcome by extreme heat and can suffer permanent injuries or even death from heat stroke Always lock your vehicle whenever you leave it Outsiders can easily enter through an unlocked door when you slow down or stop your ve...

Page 90: ...tside use your key To lock the door from the inside slide the manual lever on the door down To unlock the door slide the manual lever up Power Door Locks If your vehicle has power door locks press the bottom of the power door lock switch to lock all the doors at once To unlock all the doors at once press the top of the power door lock switch When a door is locked the inside door handle will not wo...

Page 91: ...s They can be overcome by the extreme heat and suffer permanent injuries or even death from heat stroke Never leave a child a helpless adult or a pet alone in a vehicle especially with the windows closed in warm or hot weather Manual Windows Turn the hand crank on each door to raise or lower the window 91 ...

Page 92: ...initiate the express down feature Press the top of the switch to stop the window from lowering Window Lockout Crew Cab o Window Lockout The driver s window switches include a lockout feature This prevents the passenger s from operating their windows The driver can still operate all windows with the lockout on Press the button to turn the lockout feature on and off Sliding Rear Window To open the s...

Page 93: ...he first 500 miles 805 km Do not make full throttle starts Avoid making hard stops for the first 200 miles 322 km or so During this time your new brake linings are not yet broken in Hard stops with new linings can mean premature wear and earlier replacement Follow this breaking in guideline every time you get new brake linings Use the lowest gear you can when you start a loaded vehicle in motion a...

Page 94: ...heel and transmission It is a theft deterrent feature You will only be able to remove your key when the ignition is turned to LOCK C OFF This position lets you turn off the engine but still turn the steering wheel It does not lock the steering wheel like LOCK Use OFF if you must have your vehicle in motion while the engine is off D RUN This is the position for driving The battery could be drained ...

Page 95: ...system If the starter motor overheats and shuts off due to over cranking the motor must cool down before it will reset and allow starter operation It can take up to six minutes before the starter will work again Starting the Gasoline Engine The 8th digit of your Vehicle Identification Number VIN shows the code letter for your engine Use this number to verify the type of engine in your vehicle See ...

Page 96: ...dle speed will go down as your engine gets warm 2 If the engine does not start in 10 seconds push the accelerator pedal all the way down and crank the engine for five more seconds unless it starts sooner 3 If your engine still will not start or starts but then stops it could be flooded with too much gasoline Wait 15 seconds to let the starter motor cool down Do Steps 1 through 3 again When the eng...

Page 97: ...et your engine idle for a few seconds before turning it off after you have finished driving your vehicle If you shift to NEUTRAL N or PARK P set the parking brake If your vehicle has a two speed axle put the range selector in low To be sure the axle has shifted into low engage the clutch and transmission the vehicle may move slightly when you do this While your engine is idling and before you turn...

Page 98: ...sion Shift to PARK P only when your vehicle is stopped Manual Transmission Move your shift lever to NEUTRAL and hold the clutch pedal to the floor while starting the engine Your vehicle will not start if the clutch pedal is not all the way down that is a safety feature Starting Your Engine 1 Turn your ignition key to RUN Observe the wait to start light See Wait to Start Indicator on page 172 This ...

Page 99: ...d up Your engine will sound louder when it is cold Notice If you are not in an idling vehicle and the engine overheats you would not be there to see the overheated engine indication This could damage your vehicle Do not let your engine run when you are not in your vehicle Cold Weather Starting If your vehicle has the 6 6L DURAMAX Diesel Engine and the Isuzu 6H Diesel Engine the following notice ap...

Page 100: ...r See Engine Coolant Heater on page 108 See What Fuel to Use on page 249 for information on what fuel to use in cold weather Cold Weather Starting Caterpillar Diesel Because the diesel engine uses compression ignition it is harder to start in cold weather than a gasoline engine The air intake heater and use of the proper engine oil optional engine coolant heaters and optional ether injection syste...

Page 101: ...smission adds heat to the cooling system through the heat exchanger in the radiator Because of this vehicles equipped with automatic transmissions are often able to retain engine coolant heat better than manual transmission vehicles See your Caterpillar Operation Maintenance manual for additional diesel engine warm up information If Your Diesel Engine Will Not Start If you have run out of fuel see...

Page 102: ...e which could cause serious personal injury Engine Alarm and Automatic Shutdown Your check gages warning light will come on if the system senses high engine temperature or low engine oil pressure If high engine temperature or low engine oil pressure is detected you will also hear a tone alarm at two beats per second The alarm and the light will remain on until the condition is fixed If the engine ...

Page 103: ...damage the vehicle Have your vehicle repaired as soon as possible Ambulance Fire and Rescue Packages Your check gages warning light will come on if the system senses high engine temperature or low engine oil pressure If high engine temperature or low engine oil pressure is detected you will also hear a tone alarm at two beats per second The alarm and the light will remain on until the condition is...

Page 104: ...nual high idle feature is activated by pressing the switch on the instrument panel When the switch is pressed again or any of the previous conditions are not met manual high idle will be deactivated The manual high idle has been preset at the factory Your dealer may change the setting to fit your needs For vehicles with Caterpillar diesel engines the high idle switch can be used to set any desired...

Page 105: ... or PARK P The vehicle speed exceeds about 5 mph 8 km h The throttle is pressed Exhaust Restrictor Engine Warm Up Exhaust Restrictor If your vehicle has a Isuzu 6H or Caterpillar Diesel Engine it may have a feature called an Exhaust Restrictor NPE which uses an air actuated valve in the exhaust system to restrict exhaust gas flow which enhances the engine and heater warm up Automatic Quick Warm Up...

Page 106: ...r a delay of a few seconds up to about two minutes For this method to work properly there must be no throttle or brake pedal faults and the throttle pedal must not fall below 75 percent of wide open throttle while pressing the brake pedal The engine idle speed will return to normal once the following conditions are met Once engine coolant temperature reaches about 150 F 65 C The intake temperature...

Page 107: ...and gages If oil pressure does not begin to rise within 15 seconds of starting stop the engine and find the cause See Oil Pressure Gage on page 173 for more information If the engine coolant temperature gage needle goes into the hot area on the gage stop the engine and find the cause of the overheating See Engine Coolant Temperature Gage on page 171 for more information If you have air brakes the ...

Page 108: ...have the battery and charging system checked right away See Voltmeter Gage on page 166 for more information Notice Do not allow the engine to operate at low idle for more than five minutes This can cause low engine operating temperatures which can affect engine operation and reduce engine life Engine idle speed should be increased to 1200 rpm whenever extended idle is required Once started the eng...

Page 109: ... cord as it was before to keep it away from moving engine parts If you do not it could be damaged How long should you keep the coolant heater plugged in The answer depends on the outside temperature the kind of oil you have and some other things Instead of trying to list everything here we ask that you contact your dealer in the area where you will be parking your vehicle The dealer can give you t...

Page 110: ...load rpm If you have a Caterpillar Diesel Engine do not exceed 2900 rpm If you have a Isuzu 6H Diesel engine do not exceed 2550 rpm If you have a DURAMAX 6600 Diesel Engine do not exceed 3600 rpm If your vehicle has an Allison 1000 2200 2300 2500 series automatic transmission and press this button the transmission will downshift to a factory default setting of third gear To change the default sett...

Page 111: ...range The two speed axle control should be in the up position or low range when you park the vehicle You will need to engage the transmission and move the vehicle a little to assure the axle is in the low range Then apply the parking brake shift into NEUTRAL and shut off the engine Also always start the vehicle in motion with the two speed axle in the low range To shift up from low to high do the ...

Page 112: ...ft into PARK P apply the parking brake and shut off the engine To shift up from low to high range while driving press the bottom of the rear axle shift control switch as you are releasing the accelerator pedal After the shift has occurred apply the accelerator as desired To shift from high to low range while driving press the top of the rear axle shift control switch as you release the accelerator...

Page 113: ...AL N or PARK P to a drive gear All vehicles equipped with automatic transmissions can be started in PARK P if equipped or in NEUTRAL N See the Allison Transmission Operator s Manual in your vehicle for more information about this CAUTION It can be dangerous to get out of your vehicle without the parking brake firmly set Your vehicle can roll If you have left the engine running the vehicle can move...

Page 114: ...the engine speed at idle Then start to engage the clutch and listen for an engine speed drop of about 100 rpm At this point the clutch is engaging so you should increase the engine speed and fully engage the clutch It is important not to increase the engine speed sooner or before the clutch begins its engagement If you do you can cause damage to your vehicle Double Clutching You must use the doubl...

Page 115: ... to double clutch if required Eaton Fuller Nine and Ten Speed Non Synchronized Manual Transmissions If your vehicle has one of these transmissions the engine rpm and road speed must match when upshifting and downshifting The label above the windshield will tell you the operating basics you need to know The following are driving tips Always choose an initial starting gear suitable for the load and ...

Page 116: ...ing light pressure to the shift lever This will provide for a smooth shift into either FIRST 1 or REVERSE R gear Notice Using the clutch brake for shifting into any gear other than FIRST 1 or REVERSE R may cause premature wear of the clutch brake and make gear shift effort more difficult Do not use the clutch brake for shifting after engaging FIRST 1 or REVERSE R Power Take Off PTO If your vehicle...

Page 117: ...onditions Notice Driving on clean dry pavement in four wheel drive for an extended period of time can cause premature wear on your vehicle s powertrain Do not drive on clean dry pavement in four wheel drive for extended periods of time Locking Hubs Turn the dial of the hublock A from the Free position to the Lock position to lock the front axle Turn the dial of the hublock A from the Lock position...

Page 118: ...r case cannot make a requested shift it returns to the last chosen setting Recommended Transfer Case Settings Driving Conditions Transfer Case Settings 2 m 4 m 4 n N Normal YES Severe YES Extreme YES Vehicle in Tow YES See Towing Your Vehicle on page 237 for further information 2m Two Wheel High This setting is for driving in most street and highway situations The transfer case does not drive the ...

Page 119: ...to PARK P and make sure the transfer case is in a drive gear Notice If your vehicle has an Allison transmission and you try to put the transmission in PARK P while the transfer case is in Four Wheel Low the transmission might not go into PARK P and could damage your vehicle When parking your vehicle make sure the transfer case is in Two Wheel High or Four Wheel High NEUTRAL Shift the vehicle s tra...

Page 120: ...ission into gear Be sure to lock the front hubs Notice Shifting the transmission into gear before the Four Wheel Drive Low indicator light has stopped flashing could damage the transfer case To help avoid damaging your vehicle always wait for the Four Wheel Drive Low indicator light to stop flashing before shifting the transmission into gear If you turn the knob to Four Wheel Low while your vehicl...

Page 121: ...remain on before shifting the transmission into gear Notice Shifting the transmission into gear before the Four Wheel High or Two Wheel High indicator light has stopped flashing could damage the transfer case To help avoid damaging your vehicle always wait for the Four Wheel High or Two Wheel High indicator light to stop flashing before shifting the transmission into gear If the knob is turned to ...

Page 122: ...ARK P 9 Turn the ignition to LOCK Shifting Out of NEUTRAL To shift the transfer case out of NEUTRAL do the following 1 Set the parking brake and apply the regular brake pedal 2 Turn the ignition to RUN with the engine off 3 Put the transmission in NEUTRAL N 4 Turn the transfer case knob to the desired shift position Two Wheel High Four Wheel High Four Wheel Low 5 After the transfer case has shifte...

Page 123: ...perly it can roll If you have left the engine running it can move very quickly You or others could be injured To be sure your vehicle will not move even when you are on level ground follow the steps below Parking a Vehicle With the Two Speed Rear Axle 1 With the engine running shift the two speed rear axle into low To be sure it is in low you will need to move the vehicle in gear just a little 2 H...

Page 124: ...t foot To set the hand lever parking brake hold the regular brake pedal down with your right foot Pull up on the handle with your right hand until it stops If the ignition is on when the parking brake is set the brake system warning light will come on To release the foot pedal parking brake hold the regular brake pedal down Pull the brake release handle located just above the parking brake pedal t...

Page 125: ...ll come on when the air parking brake is applied Vehicles built for use as tractors or towing vehicles have two air brake controls They look like this CAUTION When the yellow PARKING BRAKE and the red TRAILER AIR SUPPLY knobs are both pushed in your rig will be free to move It could strike someone or something When both of these knobs are pushed in hold the regular brake pedal down to keep your ri...

Page 126: ...trailer system should be fully charged When it is the air pressure gage will show about 125 to 135 psi 862 to 931 kPa See Air Pressure Gage on page 181 for more information For driving with a trailer the yellow and red if equipped knobs must be pushed in When you are not pulling a trailer the red trailer air supply knob must be pulled out CAUTION If you apply any one of the air brake parking contr...

Page 127: ... on page 237 Parking Brake Burnish Procedure All vehicles which have hydraulic brakes will have a parking brake It is recommended that the parking brake be burnished as part of the new vehicle break in The parking brake will work best after it has been burnished following these instructions 1 Making sure that there is no other traffic around get the vehicle speed up to 20 mph 32 km h and pull up t...

Page 128: ...ries single axle air suspension you may have this control The air suspension dump control allows the operator to lower the deck height approximately 4 5 inches 11 5 cm from the normal frame height The switch to deflate and inflate the air suspension is located in the instrument panel Press the bottom of the switch to deflate the air suspension and lower the deck height Press the top of the switch ...

Page 129: ...Parking Over Things That Burn CAUTION Things that can burn could touch hot exhaust parts under your vehicle and ignite Do not park over papers leaves dry grass or other things that can burn 129 ...

Page 130: ... vehicle gets rusty underneath Your vehicle was damaged in a collision CAUTION Continued CAUTION Continued Your vehicle was damaged when driving over high points on the road or over road debris Repairs were not done correctly Your vehicle or exhaust system has been modified improperly If you ever suspect exhaust is coming into your vehicle Drive it only with all the windows down to blow out any CO...

Page 131: ... a garage with the engine running Another closed in place can be a blizzard See Winter Driving on page 227 CAUTION It can be dangerous to get out of your vehicle if the automatic transmission shift lever is not fully in PARK P with the parking brake firmly set Your vehicle can roll Do not leave your vehicle when the engine is running unless you have to If you have left the engine running the vehic...

Page 132: ...icle from a comfortable driving position All mirrors can be folded in to enter narrow passageways Outside Power Mirrors If you have outside power mirrors they can be adjusted from the inside of the vehicle The control for this feature is located on the driver s door Select the mirror you want to move by turning the switch clockwise to adjust the passenger s side mirror or counterclockwise to adjus...

Page 133: ...driver s side and the passenger s side They are curved to allow more to be seen from the driver s seat A convex mirror can make things look farther away than they really are Outside Heated Mirrors If your vehicle has this feature your outside rearview mirrors can be defrosted The switch for this feature is located in the instrument panel switchbank Press the bottom of the switch to turn the outsid...

Page 134: ...th sides of the vehicle Center Console Storage Area Your vehicle may have a center console compartment if you have the bucket or suspension seats The back of your center bench seat may also fold forward to reveal a console compartment The release strap for the center console is located between the center seat and passenger s seat To expose the storage compartment pull the strap to release the seat...

Page 135: ...sory Power Outlet s 154 Ashtray s and Cigarette Lighter 155 Climate Controls 155 Climate Control System 155 Outlet Adjustment 158 Rear Heating System 159 Warning Lights Gages and Indicators 159 Instrument Panel Cluster 160 Speedometer and Odometer 161 Trip Odometer 161 Tachometer 161 Engine Speed Limiter 161 Safety Belt Reminder Light 162 Safety Belt Reminder Tone 162 Airbag Readiness Light 163 Ai...

Page 136: ...r Light 177 Highbeam On Light 178 Daytime Running Lamps DRL Indicator Light 178 Low Washer Fluid Warning Light 178 Check Gages Warning Light 179 Fuel Gage 179 Water in Fuel Warning Light 180 Air Filter Restriction Indicator 181 Air Pressure Gage 181 Hourmeter Gage 182 Audio System s 182 Setting the Time 183 AM FM Radio 184 Radio with Cassette 186 Radio with CD 192 Theft Deterrent Feature Non RDS R...

Page 137: ... NOTES 137 ...

Page 138: ...Instrument Panel Overview Automatic Transmission Shown 138 ...

Page 139: ...pped See Air Filter Restriction Indicator on page 181 F Auxiliary Gages See Warning Lights Gages and Indicators on page 159 G Exterior Lamp Control See Exterior Lamps on page 148 H Turn Signal Multifunction Lever See Turn Signal Multifunction Lever on page 141 I Hazard Warning Flashers Button See Hazard Warning Flashers on page 140 J Audio System s See Audio System s on page 182 K Climate Controls...

Page 140: ...Other Warning Devices If you carry reflective triangles you can set them up at the side of the road about 300 feet 100 m behind your vehicle Horn Sound the horn by pushing the center of the steering wheel If you have the optional air horn it is controlled by a cord that you will find up above and to the left of the driver The harder you pull on the cord the louder the air horn will sound The air h...

Page 141: ...heel in place Turn Signal Multifunction Lever The lever located on the left side of the steering column includes the following Turn and Lane Change Signals See Turn and Lane Change Signals on page 142 Headlamp High Low Beam Changer See Headlamp High Low Beam Changer on page 142 Windshield Wipers See Windshield Wipers on page 143 Windshield Washer See Windshield Washer on page 144 Cruise Control Op...

Page 142: ...til you complete your lane change The lever will return by itself when you release it As you signal a turn or a lane change if the arrows don t flash but just stay on check the turn signal flasher and circuit breaker See Fuses and Circuit Breakers on page 342 If a bulb is burned out replace it to help avoid an accident If the arrows don t go on at all when you signal a turn check the circuit break...

Page 143: ... band toward you to the first solid band below the delay settings For high speed wiping turn the band farther to the last solid band below the delay settings To stop the wipers move the band to off Be sure to clear ice and snow from the wiper blades before using them If they are frozen to the windshield carefully loosen or thaw them If your blades do become worn or damaged get new blades or blade ...

Page 144: ...her until the windshield is warmed Otherwise the washer fluid can form ice on the windshield blocking your vision Cruise Control If your vehicle has this feature it is located at the end of the multifunction lever T Set Pressing in this button at the end of the lever sets the cruise control speed 9 Off Moving the switch to this position turns off the cruise control R On Moving the switch to this p...

Page 145: ...winding roads or in heavy traffic Cruise control can be dangerous on slippery roads On such roads fast changes in tire traction can cause excessive wheel slip and you could lose control Do not use cruise control on slippery roads Setting Cruise Control CAUTION If you leave your cruise control on when you are not using cruise you might hit a button and go into cruise when you do not want to You cou...

Page 146: ...witch or apply the brake So unless you want to go faster don t hold the switch at resume accelerate Increasing Speed While Using Cruise Control There are two ways to go to a higher speed Use the accelerator pedal to get to the higher speed Press the button at the end of the lever then release the button and the accelerator pedal You ll now cruise at the higher speed Move the cruise switch from on ...

Page 147: ...se control will work on hills depends upon your speed load and the steepness of the hills When going up steep hills you may want to step on the accelerator pedal to maintain your speed When going downhill you may have to brake or shift to a lower gear to keep your speed down Of course applying the brake or clutch takes you out of cruise control Many drivers find this to be too much trouble and don...

Page 148: ...ransmissions Press the clutch pedal to the floor manual transmissions Move the cruise switch to off or Shift the transmission to NEUTRAL N Erasing Speed Memory When you turn off the ignition your cruise control set speed memory is erased Exterior Lamps The control located to the left of the steering column operates the exterior lamps 148 ...

Page 149: ...ou have an electrical overload your headlamps will flicker on and off Have your headlamp wiring checked right away if this ever happens Headlamps on Reminder If you have this system a tone will sound when your headlamps and or parking lamps are turned on and your ignition is in LOCK or ACCESSORY Daytime Running Lamps DRL Daytime Running Lamps DRL can make it easier for others to see the front of y...

Page 150: ...lamps will change to the reduced brightness of DRL To idle your vehicle with the DRL off set the parking brake The DRL will stay off until you release the parking brake As with any vehicle you should turn on the regular headlamp system when you need it Marker Lamps If your vehicle has this feature you can manually blink the marker and clearance lamps The marker lamp defeat switch is located in the...

Page 151: ... when you open a door You can also turn the dome lamps on by moving the thumbwheel located to the right of the exterior lamp control all the way up to the second position In this position the dome lamps will remain on whether a door is open or closed You can use the dome override button to set the dome lamps to automatically come on when a door is open or to remain off The dome override button is ...

Page 152: ...t your vehicle with the lights on for about 20 seconds after the door is closed or the ignition is cycled Reading Lamps If your vehicle has reading lamps press the button next to the lamp to turn the lamp on or off Instrument Panel Switchbank Vehicles Without Four Wheel Drive 152 ...

Page 153: ...itch See Power Take Off PTO on page 116 h Rear Air Suspension Dump Control Switch Air Suspension on page 128 k Rear Axle Shift Control Switch See Air Shift Control Automatic Transmission on page 112 q Exhaust Brake Switch See Diesel Engine Exhaust Brake on page 109 l Differential Lock Control Switch See Rear Axle Differential Lock Control on page 211 c Airbag On Off Switch See Airbag Off Switch on...

Page 154: ...not be compatible with the accessory power outlet and could result in blown vehicle or adapter fuses If you experience a problem see your dealer for additional information on accessory power outlets Notice Adding any electrical equipment to your vehicle may damage it or keep other components from working as they should The repairs would not be covered by your warranty Do not use equipment exceedin...

Page 155: ...l pop back out by itself Notice Holding a cigarette lighter in while it is heating will not allow the lighter to back away from the heating element when it is hot Damage from overheating may occur to the lighter or heating element or a fuse could be blown Do not hold a cigarette lighter in while it is heating Climate Controls Climate Control System With these systems you can control the heating co...

Page 156: ... speed To increase airflow turn the knob clockwise To decrease airflow turn it counterclockwise To turn the fan off turn the mode knob on the far right counterclockwise to the off position Temperature Knob Turn the middle knob located clockwise or counterclockwise to increase or decrease the temperature inside of your vehicle Turn the knob toward the red area for warmer air Turn the knob toward th...

Page 157: ... more quickly For best results clear all snow and ice from the windshield before defrosting Turn the mode knob on the right of the climate control panel to select the defog or defrost mode Defog With this setting the outside air comes out of both the floor and defroster outlets Adjust the temperature knob for warmer or cooler air The air conditioning compressor may operate in this setting to dehum...

Page 158: ...ch a temporary vehicle license tape a decal or anything similar to the defogger grid Outlet Adjustment Your vehicle has air outlets on the instrument panel that allow you to adjust the direction and amount of airflow inside the vehicle Move the lever on the outlet up or down to direct the airflow Increase or reduce the amount of airflow by opening and closing the louvers The outlets can be moved s...

Page 159: ...warning lights and gages could also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see in the details on the next few pages some warning lights come on briefly when you start the engine just to let you know they are working If you are familiar with this section you should not be alarmed when this happens Gage...

Page 160: ...you know at a glance how your vehicle is running You will know how fast you are going about how much fuel is left and many other things you will need to drive safely and economically United States Isuzu 6H Diesel Engine shown Canada 6 6L Diesel and Gasoline Engine similar 160 ...

Page 161: ...er and the regular odometer Holding the reset button for two seconds while the engine is running and the trip odometer is displayed will reset it To display the odometer reading with the ignition off press the reset button The hourmeter gage is accessed through the trip odometer for more information see Hourmeter Gage on page 182 Tachometer This gage shows the safe operating range for the engine s...

Page 162: ...6 to 105 km h You may have a label on the headliner of your vehicle with more information on your engine road speed governor See your GM dealer for assistance with programming your engine limited speed Safety Belt Reminder Light When the key is turned to RUN or START a light will come on for several seconds to remind people to fasten their safety belts The safety belt light will also come on and s...

Page 163: ...o out This means the system is ready If the airbag readiness light stays on after you start the vehicle or comes on when you are driving your airbag system may not work properly Have your vehicle serviced right away The airbag readiness light should flash for a few seconds when you turn the ignition key to RUN or START If the light doesn t come on then have it fixed so it will be ready to warn you...

Page 164: ...important safety information CAUTION If the right front passenger s airbag is turned off for a person who is not in a risk group identified by the national government that person will not have the extra protection of an airbag In a crash the airbag will not be able to inflate and help protect the person sitting there Do not turn off the passenger s airbag unless the person sitting there is in a ri...

Page 165: ...3 for more on this including important safety information Charging System Light The charging system light may be located in the instrument panel cluster or with the auxiliary warning lights in the center of the instrument panel It should come on briefly when you turn on the ignition before the engine is running as a check to show that it is working If it stays on or comes on while you are driving ...

Page 166: ...rating in the vehicle and the engine is left at an idle for an extended period This condition is normal since the charging system may not be able to provide full power at engine idle As engine speeds are increased this condition should correct itself because higher engine speeds allow the charging system to create maximum power You can only drive a short time on the battery Be sure to shut off the...

Page 167: ...While this light is on the transmission cannot operate in all gears If you attempt to shift gears the vehicle may not continue to move Do not attempt to shift gears while the transmission warning light is on Instead drive directly to an authorized dealer for service If you cannot drive to a dealer immediately have the vehicle towed Range Inhibit Warning Indicator If your vehicle has an Allison 100...

Page 168: ...will also hear a warning tone The BRAKE warning light may come on and the warning tone may sound when you re turning and braking at the same time This is normal See Hydraulic Brake Systems under Braking on page 206 Parking Brake Warning Light Your vehicle has a brake warning light When the ignition is on this light will come on when you set your parking brake The light will stay on if your parking...

Page 169: ...rest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the air brake system warning light comes on and the warning tone sounds the vehicle can stop suddenly and without further warning This is because the parking brake will come on if the pressure falls below 35 to 45 psi 240 to 310 kPa You or others could be injured If the air brake system warning ...

Page 170: ...e 208 for more information The anti lock brake system warning light should come on briefly when you turn the ignition key to ON If the light does not come on then have it fixed so it will be ready to warn you if there is a problem Trailer Anti Lock Brake System Warning Light This light is located above the climate controls in the center of the instrument panel If your vehicle is connected to a tra...

Page 171: ...ing light If this light comes on your system is low on coolant and the engine may overheat The warning light should come on briefly as a check when you turn on the ignition When it comes on you will also hear a warning tone at several beats per second for 10 seconds See Engine Coolant Gas and DURAMAX Isuzu Engines on page 282 or Engine Coolant Caterpillar Diesel Engines on page 285 and have your v...

Page 172: ...ight comes on or flashes while you are driving two things may happen First you will not notice any difference in engine performance but your tail pipe emissions may increase Second your engine may not run properly or may stall without warning If either of these things happen drive or tow your vehicle to your dealer for service This light should come on when the ignition is on but the engine is not...

Page 173: ...5 and 70 psi 240 to 480 kPa A reading in the low pressure zone may be caused by a dangerously low oil level or other problem If you have a Caterpillar diesel engine also see your Caterpillar Operation Maintenance Manual CAUTION Do not keep driving if the oil pressure is low If you do your engine can become so hot that it catches fire You or others could be burned Check your oil as soon as possible...

Page 174: ...r engine is low on oil You need to check the oil level right away See Engine Oil Caterpillar Diesel Engine on page 264 or Engine Oil Gasoline Engine on page 265 or Engine Oil DURAMAX Isuzu Diesel Engine on page 268 for further information Notice Lack of proper engine oil maintenance may damage the engine The repairs would not be covered by your warranty Always follow the maintenance schedule in th...

Page 175: ...X Diesel on page 274 or Engine Oil Life System Caterpillar Diesel Engine on page 276 Engine Overspeed Warning Light If your vehicle has this light it will come on if your engine is operating at too many revolutions per minute rpm It will also come on for a moment as a check when you start your engine If it comes on when you re driving reduce your engine speed immediately Engine Shutdown Warning Li...

Page 176: ...e above normal operating range you can damage the transmission This could lead to costly repairs that would not be covered by your warranty Do not drive your vehicle while the transmission temperature gage reading is above normal See your dealer for service Exhaust Brake Indicator Light If your vehicle is equipped with an exhaust brake you will have this light located above the climate controls in...

Page 177: ...tion Reduced Engine Power Light If the check engine and reduced engine power lights are on the electronic throttle control may be disabled and a noticeable change in the vehicle s performance may occur If the reduced engine power light is on but there is no change in performance proceed to your destination The performance may be reduced the next time the vehicle is driven The vehicle may be driven...

Page 178: ...he Daytime Running Lamps are on See Daytime Running Lamps DRL on page 149 for more information When it begins to get dark the DRL indicator light is a reminder to turn on your headlamps Low Washer Fluid Warning Light This light is located above the climate controls in the center of the instrument panel This light will come on when your vehicle is low on windshield washer fluid For more information...

Page 179: ...oblem is corrected This light may also come on if your vehicle is equipped with the optional automatic engine shutdown system and engine shutdown has begun See Engine Alarm and Automatic Shutdown under Starting the Diesel Engine on page 98 Fuel Gage Your fuel gage is located on the right side of your instrument panel cluster When the ignition is on your fuel gage lets you know about how much fuel ...

Page 180: ...s a little more or less fuel to fill up than the gage indicated If you have a Caterpillar diesel engine also see your Caterpillar Operation Maintenance Manual Water in Fuel Warning Light This light is located above the climate controls in the center of the instrument panel If your vehicle has the 6 6L DURAMAX or Isuzu 6H diesel engine this light will come on to warn you that there is water in the ...

Page 181: ...l Air Pressure Gage If your vehicle has air brakes the air pressure gage is located above the switchbank in the center of the instrument panel This gage shows the air pressure for both your front and rear brake systems If the needle on the gage indicates that the air pressure is below 60 to 75 psi 415 to 517 kPa the low air warning light will come on An alarm will also sound if this happens The to...

Page 182: ...ermine which radio your vehicle has and then read the pages following to familiarize yourself with its features Driving without distraction is a necessity for a safer driving experience See Defensive Driving on page 202 By taking a few moments to read this manual and get familiar with your vehicle s audio system you can use it with less effort as well as take advantage of its features While your v...

Page 183: ...lso check federal rules covering mobile radio and telephone units If sound equipment can be added it is very important to do it properly Added sound equipment may interfere with the operation of your vehicle s engine radio or other systems and even damage them Your vehicle s systems may interfere with the operation of sound equipment that has been added Notice The chime signals related to safety b...

Page 184: ... Press the right or the left arrow to go to the next or to the previous station and stay there To scan stations press and hold either SEEK arrow for two seconds until a beep sounds The radio goes to a station plays for a few seconds then goes to the next station Press either SEEK arrow again to stop scanning To scan preset stations press and hold either SEEK arrow for more than four seconds until ...

Page 185: ...s B balance and a zero or T treble and a zero displays To adjust both tone controls and both speaker controls to the middle position first exit out of audio mode by pressing another button causing the radio to perform that function or wait five seconds for the display to return to time of day Then press and hold AUDIO for more than two seconds until a beep sounds CEN center displays Adjusting the ...

Page 186: ...y If CAL displays it means that the radio has not been configured properly for your vehicle and must be returned to your dealer for service LOC Locked This message is displayed when the THEFTLOCK system has locked up Take the vehicle to your dealer for service If any error occurs repeatedly or if an error cannot be corrected contact your dealer Radio with Cassette Playing the Radio PWR Power Press...

Page 187: ...n four seconds until you hear two beeps The radio goes to the first preset station stored on the pushbuttons plays for a few seconds and flashes the station frequency then goes to the next preset station Press one of the SEEK arrows again to stop scanning presets The radio only seeks and scans stations with a strong signal that are in the selected band Setting Preset Stations Up to 18 stations six...

Page 188: ... the balance between the right and the left speakers press and release AUDIO until BAL balance appears on the display Then press and hold the up or the down arrow to move the sound toward the right or the left speakers To adjust the fade between the front and the rear speakers press and release AUDIO until FAD fade appears on the display Then press and hold the up or the down arrow to move the sou...

Page 189: ... or hear a garbled sound the tape may not be in squarely Press the eject button to remove the tape and start over If the ignition and the radio are off press the eject button or the RCL knob to insert and to begin play of a tape If the ignition is on and the radio is off the tape can be inserted and begins playing CAS cassette appears on the display when a tape is inserted While the tape is playin...

Page 190: ...ssing this pushbutton multiple times in the next mode increases the number of selections to be searched forward Pressing the PREV pushbutton cancels the selections 3 REV Reverse Press this pushbutton to quickly reverse the tape FR appears on the display The radio plays while the tape reverses Press it again to return to playing speed Select stations during reverse operation by using the TUNE or SE...

Page 191: ...with the radio off Cassette tapes can be loaded with the ignition and radio off if this button is pressed first Cassette Tape Messages ERR Error If the player detects a tight or broken tape this message appears on the display and the player ejects the tape The radio goes back to playing the last station selected CLN Clean If this message appears on the display the cassette tape player needs to be ...

Page 192: ...ed CAS flashes indicating that the TIGHT LOOSE TAPE sensor feature is no longer active 4 Insert the adapter into the cassette slot The override feature remains active until the eject button is pressed Radio with CD Playing the Radio PWR Power Press this knob to turn the system on and off VOL Volume Turn this knob clockwise or counterclockwise to increase or to decrease the volume RCL Recall Press ...

Page 193: ...the next preset station Press either SEEK arrow again to stop scanning presets The radio only seeks and scans stations with a strong signal that are in the selected band Setting Preset Stations Up to 18 stations six FM1 six FM2 and six AM can be programmed on the six numbered pushbuttons by performing the following steps 1 Turn the radio on 2 Press AM FM to select FM1 FM2 or AM 3 Tune in the desir...

Page 194: ...press and hold the up or the down arrow to move the sound toward the right or the left speakers To adjust the fade between the front and the rear speakers press and release the AUDIO button until FAD fade appears on the display Then press and hold the up or the down arrow to move the sound toward the front or the rear speakers To adjust balance or fade to the middle position select BAL or FAD Then...

Page 195: ...s turned off with a CD in the player it stays in the player When the ignition or radio is turned on the CD starts playing where it stopped if it was the last selected audio source As each new track starts to play the track number appears on the display The CD player can play the smaller 3 inch 8 cm single CDs with an adapter ring Full size CDs and the smaller CDs are loaded in the same manner If p...

Page 196: ...ressed more than once the player continues moving backward through the CD 2 NEXT Press this pushbutton to go to the next track The track number appears on the display If this pushbutton is held or pressed more than once the player continues moving forward through the CD 3 REV Reverse Press and hold this pushbutton to reverse quickly within a track Release this pushbutton to play the passage The el...

Page 197: ... activated with either the ignition or radio off CDs may be loaded with the ignition and radio off if this button is pressed first CD Messages If the CD comes out it could be for one of the following reasons It is very hot When the temperature returns to normal the CD should play You are driving on a very rough road When the road becomes smoother the CD should play The CD is dirty scratched wet or...

Page 198: ...han for FM especially at night The longer range can cause station frequencies to interfere with each other For better radio reception most AM radio stations will boost the power levels during the day and then reduce these levels during the night Static can also occur when things like storms and power lines interfere with radio reception When this happens try reducing the treble on your radio FM St...

Page 199: ... the cleaning cassette from being ejected use the following steps 1 Turn the ignition on 2 Turn the radio off 3 Press and hold the TAPE button for two seconds until the radio produces one beep CAS will flash on the display for five seconds 4 Insert the scrubbing action cleaning cassette 5 Eject the cleaning cassette after the manufacturer s recommended cleaning time After the cleaning cassette is ...

Page 200: ...d Mast Antenna The fixed mast antenna can withstand most vehicle washes without being damaged If the mast should ever become slightly bent straighten it out by hand If the mast is badly bent replace it Check occasionally to make sure the mast is still tightened to the fender If tightening is required tighten by hand then with a wrench one quarter turn Chime Level Adjustment The radio is used to ad...

Page 201: ...m TCS 212 Steering 213 Off Road Recovery 215 Passing 216 Loss of Control 217 Driving at Night 219 Driving in Rain and on Wet Roads 220 City Driving 223 Freeway Driving 224 Highway Hypnosis 225 Hill and Mountain Roads 226 Winter Driving 227 If Your Vehicle is Stuck in Sand Mud Ice or Snow 232 Rocking Your Vehicle to Get It Out 232 Tow Hooks 233 Loading Your Vehicle 234 Adding a Snow Plow or Similar...

Page 202: ... pedestrians or other drivers are going to be careless and make mistakes Anticipate what they might do and be ready Rear end collisions are about the most preventable of accidents Yet they are common Allow enough following distance Defensive driving requires that a driver concentrate on the driving task Anything that distracts from the driving task makes proper defensive driving more difficult and...

Page 203: ...ates nearly half the adult population choose never to drink alcohol so they never drive after drinking For persons under 21 it is against the law in every U S state to drink alcohol There are good medical psychological and developmental reasons for these laws The obvious way to eliminate the leading highway safety problem is for people never to drink alcohol and then drive But what if people do Ho...

Page 204: ... drinking will have a somewhat lower BAC level There is a gender difference too Women generally have a lower relative percentage of body water than men Since alcohol is carried in body water this means that a woman generally will reach a higher BAC level than a man of her same body weight will when each has the same number of drinks The law in most U S states and throughout Canada sets the legal l...

Page 205: ...t answer What if there is an emergency a need to take sudden action as when a child darts into the street A person with even a moderate BAC might not be able to react quickly enough to avoid the collision There is something else about drinking and driving that many people do not know Medical research shows that alcohol in a person s system can make crash injuries worse especially injuries to the b...

Page 206: ...ot and do it That is reaction time Average reaction time is about three fourths of a second But that is only an average It might be less with one driver and as long as two or three seconds or more with another Age physical condition alertness coordination and eyesight all play a part So do alcohol drugs and frustration But even in three fourths of a second a vehicle moving at 60 mph 100 km h trave...

Page 207: ... assist is used up it may take longer to stop and the brake pedal will be harder to push Hydraulic Brake Systems If your engine stops running or if your primary brake system stops working your vehicle has a reserve power assist system to help you slow down Just slowly and steadily apply the brake pedal until you can safely get off the road The pedal will seem harder to push down Do not pump the pe...

Page 208: ...this test is going on This is normal If there is a problem with ABS this warning light will stay on See Anti Lock Brake System Warning Light on page 170 Let us say the road is wet and you are driving safely Suddenly an animal jumps out in front of you You slam on the brakes and continue braking Here is what happens with ABS A computer senses that wheels are slowing down If one of the wheels is abo...

Page 209: ... or always decrease stopping distance If you get too close to the vehicle in front of you you will not have time to apply your brakes if that vehicle suddenly slows or stops Always leave enough room up ahead to stop even though you have ABS Using ABS Do not pump the brakes Just hold the brake pedal down firmly and let anti lock work for you You may feel the brakes pulsate or you may hear air exhau...

Page 210: ...you have to Use this control only when you are driving Do not use it for parking or to hold the rig on a hill CAUTION Using the trailer brake hand control for parking or for holding the vehicle on a hill may not keep the vehicle from rolling This can happen if someone hits the valve by accident or if air pressure bleeds from the system If the vehicle rolls you or others could be injured To park th...

Page 211: ...ly to both rear wheels Let up on the accelerator before you turn on your rear axle differential lock Notice Turning on the inter axle differential lock while the rear wheels are spinning freely as they might on snow or ice can damage the axle s Turn on this control only while the wheels are not spinning freely Interaxle Differential Lock This switch is located on the center instrument panel You wi...

Page 212: ...s of these conditions include a hard acceleration in a turn an abrupt upshift or downshift of the transmission or driving on rough roads When the light in the top of the TCS button is on the TCS is off and will not limit wheel spin Adjust your driving accordingly The light in the top of the TCS button will come on if the TCS is turned off by pressing the TCS on off button The light may also come o...

Page 213: ...akes the power steering and main hydraulic brake system both use the power steering pump See Braking on page 206 Steering Tips Driving on Curves It is important to take curves at a reasonable speed A lot of the driver lost control accidents mentioned on the news happen on curves Here is why Experienced driver or beginner each of us is subject to the same laws of physics when driving on curves The ...

Page 214: ...ower If you need to reduce your speed as you approach a curve do it before you enter the curve while your front wheels are straight ahead Try to adjust your speed so you can drive through the curve Maintain a reasonable steady speed Wait to accelerate until you are out of the curve and then accelerate gently into the straightaway Steering in Emergencies There are times when steering can be more ef...

Page 215: ...od reason to practice defensive driving at all times and wear safety belts properly Off Road Recovery You may find that your right wheels have dropped off the edge of a road onto the shoulder while you are driving If the level of the shoulder is only slightly below the pavement recovery should be fairly easy Ease off the accelerator and then if there is nothing in the way steer so that your vehicl...

Page 216: ...y doubt whatsoever about making a successful pass wait for a better time Watch for traffic signs pavement markings and lines If you can see a sign up ahead that might indicate a turn or an intersection delay your pass A broken center line usually indicates it is all right to pass providing the road ahead is clear Never cross a solid line on your side of the lane or a double solid line even if the ...

Page 217: ...ght outside mirror is convex the vehicle you just passed may seem to be further away from you than it really is Try not to pass more than one vehicle at a time on two lane roads Reconsider before passing the next vehicle Do not overtake a slowly moving vehicle too rapidly Even though the brake lamps are not flashing it may be slowing down or starting to turn If you are being passed make it easy fo...

Page 218: ... reduced when water snow ice gravel or other material is on the road For safety you will want to slow down and adjust your driving to these conditions It is important to slow down on slippery surfaces because stopping distance will be longer and vehicle control more limited While driving on a surface with reduced traction try your best to avoid sudden steering acceleration or braking including red...

Page 219: ...at night as in the daytime But as we get older these differences increase A 50 year old driver may require at least twice as much light to see the same thing at night as a 20 year old What you do in the daytime can also affect your night vision For example if you spend the day in bright sunshine you are wise to wear sunglasses Your eyes will have less trouble adjusting to night But if you are driv...

Page 220: ...jects Just as the headlamps should be checked regularly for proper aim so should your eyes be examined regularly Some drivers suffer from night blindness the inability to see in dim light and are not even aware of it Driving in Rain and on Wet Roads Rain and wet roads can mean driving trouble On a wet road you cannot stop accelerate or turn as well because your tire to road traction is not as good...

Page 221: ...rakes work normally Driving too fast through large water puddles or even going through some vehicle washes can cause problems too The water may affect your brakes Try to avoid puddles But if you cannot try to slow down before you hit them Hydroplaning Hydroplaning is dangerous So much water can build up under your tires that they can actually ride on the water This can happen if the road is wet en...

Page 222: ... can be carried away As little as six inches of flowing water can carry away a smaller vehicle If this happens you and other vehicle occupants could drown Do not ignore police warning signs and otherwise be very cautious about trying to drive through flowing water Some Other Rainy Weather Tips Turn on your low beam headlamps and your marker and clearance lamps if your vehicle has them not just you...

Page 223: ...y trip Larger vehicles cannot be driven everywhere smaller ones can There are low underpasses truck routes and other special situations Usually these are well marked so be sure to watch for the signs Try to use the freeways that rim and crisscross most large cities You will save time and energy See Freeway Driving on page 224 Treat a green light as a warning signal A traffic light is there because...

Page 224: ... entrance there is usually a ramp that leads to the freeway If you have a clear view of the freeway as you drive along the entrance ramp you should begin to check traffic Try to determine where you expect to blend with the flow Try to merge into the gap at close to the prevailing speed Switch on your turn signal check your mirrors and try to blend smoothly with the traffic flow Once you are on the...

Page 225: ...ghway hypnosis Or is it just plain falling asleep at the wheel Call it highway hypnosis lack of awareness or whatever When you drive the vehicle for a long distance there is something about an easy stretch of road with the same scenery along with the hum of the tires on the road the drone of the engine and the rush of the wind against the vehicle that can make you sleepy Do not let it happen to yo...

Page 226: ...t down your brakes could get so hot that they would not work well You would then have poor braking or even none going down a hill You could crash Shift down to let your engine assist your brakes on a steep downhill slope CAUTION Coasting downhill in NEUTRAL N or with the ignition off is dangerous Your brakes will have to do all the work of slowing down They could get so hot that they would not wor...

Page 227: ...nter of the road Drive at speeds that let you stay in your own lane As you go over the top of a hill be alert There could be something in your lane like a stalled car or an accident You may see highway signs on mountains that warn of special problems Examples are long grades passing or no passing zones a falling rocks area winding roads and special truck lanes Be alert to these and take appropriat...

Page 228: ...e the tires meet the road probably have good traction However if there is snow or ice between the tires and the road you can have a very slippery situation You will have a lot less traction or grip and will need to be very careful What is the worst time for this Wet ice Very cold snow or ice can be slick and hard to drive on But wet ice can be even more trouble because it may offer the least tract...

Page 229: ...ake very gently too If you do have ABS see Anti Lock Brake System ABS on page 208 ABS improves your vehicle s stability when you make a hard stop on a slippery road Whether you have ABS or not you will want to begin stopping sooner than you would on dry pavement Without ABS if you feel your vehicle begin to slide let up on the brakes a little Push the brake pedal down steadily to get the most trac...

Page 230: ... help and keep yourself and your passengers safe Turn on your hazard flashers Tie a red cloth to your mirror arm to alert police that you have been stopped by the snow Put on extra clothing or wrap a blanket around you If you do not have blankets or extra clothing make body insulators from newspapers burlap bags rags floor mats anything you can wrap around yourself or tuck under your clothing to k...

Page 231: ...t go a little faster than just idle That is push the accelerator slightly This uses less fuel for the heat that you get and it keeps the battery or batteries charged You will need a well charged battery or batteries to restart the vehicle and possibly for signaling later on with your headlamps Let the heater run for a while If you have a diesel engine you may have to run it at a higher speed to ge...

Page 232: ...ack and forth you can destroy the transmission Rocking Your Vehicle to Get It Out First turn the steering wheel left and right That will clear the area around the front wheels If you have a four wheel drive vehicle shift into 4HI See Four Wheel Drive on page 117 If your vehicle has traction control you should turn the traction control system off See Traction Control System TCS on page 212 Then shi...

Page 233: ...could be injured from the chain or cable snapping back Notice Never use tow hooks to tow the vehicle Your vehicle could be damaged and it would not be covered by warranty If your vehicle has tow hooks the hooks are at the front and on some models the rear of the vehicle You may need to use them if you are stuck off road and need to be pulled to some place where you can continue driving 233 ...

Page 234: ... the maximum weight for the front and rear axles called the Gross Axle Weight Rating GAWR To find out the actual loads on your front and rear axles go to a weigh station and weigh your vehicle Your dealer can help you with this Be sure to spread out your load equally on both sides of the center line Never exceed the GVWR for your vehicle or the GAWR for either the front or rear axle And if you do ...

Page 235: ... as the vehicle goes If you have to stop or turn quickly or if there is a crash they keep going CAUTION Things you put inside your vehicle can strike and injure people in a sudden stop or turn or in a crash Put things in the cargo area of your vehicle Try to spread the weight evenly Never stack heavier things like suitcases inside the vehicle so that some of them are above the tops of the seats Do...

Page 236: ... certain front mounted equipment such as a snow plow it may be possible to load the front axle to the front gross axle weight rating GAWR but not have enough weight on the rear axle to have proper braking performance If your brakes can not work properly you could have a crash To help your brakes work properly when a snow plow is installed always follow the snow plow manufacturer or installer s rec...

Page 237: ...roblem If your vehicle has to be towed because of a complete loss of air pressure from both systems the parking brakes will have automatically engaged The tow operator can release the brakes manually by using the following steps Then your vehicle can be towed with all wheels or only the rear wheels on the ground 1 Block the wheels of the vehicle 2 Remove the release stud and nut from the side of t...

Page 238: ... brakes Follow the same procedure to release the other brake or brakes 7 At the repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from an external air supply or the vehicle s air system 8 Turn the stud nut counterclockwise several turns Remove the stud from the chamber 9 Replace the stud and washer and tighten the nut into the side of the chamber 10 Replace...

Page 239: ...ps Light Blue CHMSL Red Battery Feed Dark Blue Trailer Brake Trailer Connections C7 C8 Models Only If your vehicle has these trailer connections they are located at the rear of the cab for a tractor and at the rear of the chassis when towing a trailer There will be an air connection and an electrical connection Be sure that the couplings to the trailer are made correctly Air Connections If you are...

Page 240: ... NOTES 240 ...

Page 241: ...l Gasoline Engine 265 Engine Oil DURAMAX Isuzu Diesel Engine 268 Engine Oil Life System Gasoline Engine 272 Engine Oil Life System DURAMAX Diesel 274 Engine Oil Life System Caterpillar Diesel Engine 276 Engine Air Cleaner Filter 277 Automatic Transmission Fluid 280 Manual Transmission Fluid 280 Engine Coolant Gas and DURAMAX Isuzu Engines 282 Engine Coolant Caterpillar Diesel Engines 285 Coolant S...

Page 242: ... When It Is Time for New Tires 322 Wheel Alignment and Tire Balance 323 Tightening the Wheel Nuts 324 Wheel Replacement 328 If a Tire Goes Flat 330 Appearance Care 331 Cleaning the Inside of Your Vehicle 331 Fabric Carpet 333 Instrument Panel Vinyl and Other Plastic Surfaces 334 Care of Safety Belts 334 Weatherstrips 334 Washing Your Vehicle 335 Cleaning Exterior Lamps Lenses 335 Finish Care 336 W...

Page 243: ...342 Fusible Links 342 Power Windows and Other Power Options 342 Fuses and Circuit Breakers 342 Instrument Panel Fuse Block 342 Underhood Fuse Block 345 Capacities and Specifications 348 Normal Maintenance Replacement Parts 354 Engine Drive Belt Routing 356 Section 5 Service and Appearance Care 243 ...

Page 244: ...want to keep your GM vehicle all GM Genuine GM parts have one of these marks California Proposition 65 Warning Most motor vehicles including this one contain and or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Engine exhaust many parts and systems including some inside the vehicle many fluids and some component wear by products contai...

Page 245: ...rong fasteners parts can later break or fall off You could be hurt If you want to do some of your own service work you will want to use the proper service manual It tells you much more about how to service your vehicle than this manual can To order the proper service manual see Service Publications Ordering Information on page 415 Your vehicle has an airbag system Before attempting to do your own ...

Page 246: ... vehicle Do not change the fan drive ratio or increase the governed speed of the vehicle without getting the necessary information from your dealer CAUTION Continued CAUTION Continued Winter Fronts Grille Covers or Obstructions Winter Fronts grille covers or other add on equipment causing obstructions in front or behind the fan should not be used on this vehicle If this causes the fan to eventuall...

Page 247: ...meet ASTM specification D 4814 in the United States or CAN CGSB 3 5 in Canada Some gasolines may contain an octane enhancing additive called methylcyclopentadienyl manganese tricarbonyl MMT General Motors recommends against the use of gasolines containing MMT See Additives on page 247 for additional information Additives To provide cleaner air all gasolines in the United States are now required to...

Page 248: ... emission control system may be affected The malfunction indicator lamp may turn on If this occurs return to your dealer for service Diesel Engine Fuel For the Caterpillar diesel see the Caterpillar Operation Maintenance Manual for information concerning fuel usage Notice Diesel fuel or fuel additives not recommended in this manual could damage your fuel system and engine Your warranty would not c...

Page 249: ...mponents and may cause reduced performance excessive smoke and unpleasant odor At a minimum the diesel fuel you use should meet the latest version of ASTM specification D 975 Grades No 2 D or No 1 D S15 commonly known as Ultra Low Sulfur diesel in the United States In addition the Engine Manufacturers Association EMA has identified properties of an improved diesel fuel for better engine performanc...

Page 250: ...tart and people could be burned To help avoid this fill your fuel tank only until the automatic nozzle shuts off Do not try to top it off What Fuel to Use in Canada 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 you may notice some power and fuel economy loss If Type A fuel is used in warmer temperatures stal...

Page 251: ...of ASTM specification D 6751 Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to your fuel system and engine Higher concentration i e greater than B5 biodiesel containing fuels or the use of unmodified bio oils blended into diesel fuel at any concentration is not recommended and could damage your fuel system and engine S...

Page 252: ...ur fuel system may still need to be cleaned Your dealer can advise you of the appropriate solution If your fuel tank needs to be purged to remove water see your dealer or a qualified technician Improper purging can damage your fuel system Sometimes water can be pumped into your fuel tank along with your diesel fuel This can happen if a service station does not regularly inspect and clean its fuel ...

Page 253: ...g is required See your dealer for assistance Notice If you drive when this warning indicator is on you can damage your fuel injection system and your engine If the indicator comes on right after you refuel it means water was pumped into your fuel tank Turn off your engine immediately Then have the water drained at once To drain water do the following 1 Stop and park the vehicle in a safe place Tur...

Page 254: ... Engine on page 265 or Engine Oil DURAMAX Isuzu Diesel Engine on page 268 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 fuel filter air may enter the fuel system If air has entered the fuel system the fuel system will need to be primed If the water in fuel light comes on again ...

Page 255: ...ed for servicing The fuel filter water drain valve is opened while the engine is running If one or more of the above occurred it is very likely that air has entered your fuel system and that you will need to prime the fuel system before operating the vehicle Air in the fuel lines will not harm the engine or the vehicle However the engine may not be able to start until the fuel system is primed and...

Page 256: ... Open the fuel filter vent valve by turning the screw counterclockwise several full turns 6 Repeatedly push down on the fuel filter primer pump with the palm of your hand Let the pump return upward between pushes 7 Operate the priming pump until a small amount of fuel seeps from the vent valve When you see the fuel the filter is now full of fuel and the system should be primed 8 Close the vent val...

Page 257: ...el filter priming pump Continue until the plunger resistance becomes firm This may take from 20 to 100 times depending upon fuel tank location 7 Turn the fuel filter breather valve screw 2 counterclockwise several turns to open the breather valve 8 Use the palm of your hand to repeatedly press and release the plunger 1 at the top of the fuel filter priming pump until fuel begins to seep from the b...

Page 258: ... least 2 gallons 7 6 liters of fuel However if you are parked on a slope you may need to add up to 5 gallons 18 9 liters of fuel 2 Follow the fuel priming procedure earlier in this section to prime the fuel filter 3 Close the air bleed valve 4 Turn the ignition key to START for 10 to 15 seconds at a time until your engine starts If the engine tries to run but does not run smoothly increase the rpm...

Page 259: ...d of this procedure If your vehicle has the 6 6L engine the fuel filter is located in the engine compartment on the driver s side of the vehicle If your vehicle has either the 7 2L or 7 8L engine the fuel filters are located in the engine compartment on the driver s side of the vehicle and on the driver s side frame rail in front of the fuel tank 1 Apply the parking brake 2 Unplug the water sensor...

Page 260: ...ign Countries If you plan on driving in another country outside the United States or Canada the proper fuel may be hard to find Never use leaded gasoline or any other fuel not recommended in the previous text on fuel Costly repairs caused by use of improper fuel would not be covered by your warranty To check the fuel availability ask an auto club or contact a major oil company that does business i...

Page 261: ...inued CAUTION Continued 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 put the cap back on turn it clockwise until it is tight Notice If you need a new fuel cap be sure to get the right type Your dealer can get one for you If you get the wrong type it may not fit properl...

Page 262: ...le 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 vapor You can be badly burned and your vehicle damaged if this occurs To help avoid injury to you and others Dispense gasoline only into approved containers Do not fill a container while it is inside a vehicle in a vehicle s trunk pickup...

Page 263: ...el 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 tilt the hood forward pull back and up on each of the hood latches located above the wheel wells on both sides of the vehicle 263 ...

Page 264: ... far enough the cables 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 information on oil quality and viscosities as well as the temperature range chart 264 ...

Page 265: ... every time 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 vehicle 1 Turn off the engine and give the oil several minutes to drain back into the oil pan If you do not do this the oil dipstick might not show the actual level 2 Pull out the dipstick ...

Page 266: ...s on page 348 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 The engine oil fill cap is located near the engine oil dipstick in the engine compartment on the driver s side of the vehicle Be sure to add enough oil to put the level somewhere in the proper operating ran...

Page 267: ...tarburst symbol on the container This symbol indicates that the oil has been certified by the American Petroleum Institute API You should look for this information on the oil container and use only those oils that are identified as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container Notice Use only engine oil identified as meeting GM Standard GM6094M and sho...

Page 268: ...et fuel The engine oil dipstick is located in the engine compartment on the driver s side of the vehicle In order to get an accurate reading the engine should be at normal operating temperature so that the oil is warm and the vehicle must be on level ground 1 If the engine is at normal operating temperature and the oil is warm turn off the engine and allow at least five minutes for the oil to drai...

Page 269: ...e lower hole at the tip of the dipstick for the Isuzu 6H engine you will need to add at least one quart liter of oil But you must use the right kind This section explains what kind of oil to use For engine oil crankcase capacity see Capacities and Specifications on page 348 Notice Do not add too much oil If the engine has so much oil that the oil level gets above the cross hatched area for the 6 6...

Page 270: ...k for these two things CJ 4 or CI 4 Oils designated as API CJ 4 or CI 4 are recommended for your vehicle The CJ 4 or CI 4 designations may appear either alone together or in combination with other API designations such as API CJ 4 SM These letters show American Petroleum Institute API levels of quality Notice Use only engine oils that have one of these designations CJ 4 or CI 4 for the diesel engi...

Page 271: ...d for use at high temperatures above 100 F 38 C These numbers on the oil container show its viscosity or thickness Do not use other viscosity oils such as SAE 10W 40 or SAE 20W 50 This doughnut shaped logo symbol is used on most oil containers to help you select the correct oil It means that the oil has been certified by the American Petroleum Institute You should look for this on the oil containe...

Page 272: ...Scheduled Maintenance on page 363 Engine Oil Life System Gasoline Engine When to Change Engine Oil Your vehicle has a computer system that lets you know when to change the engine oil and filter This is based on engine revolutions and engine temperature and not on mileage Based on driving conditions the mileage at which an oil change will be indicated can vary considerably For the oil life system t...

Page 273: ...ne Oil Life System calculates when to change your engine oil and filter based on vehicle use Anytime your oil is changed reset the system so it can calculate when the next oil change is required If a situation occurs where you change your oil prior to a change engine oil light being turned on reset the system To reset the change engine oil light do the following 1 Turn the ignition key to RUN with...

Page 274: ...Life System DURAMAX Diesel When to Change Engine Oil If your vehicle has the Engine Oil Life System it has a computer system that lets you know when to change the engine oil and filter This is based on injection 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 ...

Page 275: ...change your oil prior to a change engine oil light being turned on reset the system To reset the Engine Oil Life System do the following 1 Turn the ignition key to RUN with the engine off 2 Fully press and release the accelerator pedal slowly three times within 10 seconds If the change engine oil light flashes for five seconds the system is resetting 3 Turn the key to OFF If the change engine oil ...

Page 276: ... Oil Life System calculates when to change your engine oil and filter based on vehicle use Anytime your oil is changed reset the system so it can calculate when the next oil change is required If a situation occurs where you change your oil prior to a change engine oil light being turned on reset the system To reset the Engine Oil Life System do the following 1 Turn the ignition key to RUN with th...

Page 277: ...leaner Filter If your vehicle has an air cleaner filter change indicator inspect the indicator at every oil change and replace the filter when the indicator tells you to For vehicles without a change indicator inspect the air cleaner filter at every oil change and replace the filter at the first oil change after 25 000 miles 40 000 km 277 ...

Page 278: ... filter is required CAUTION Operating 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 engine backfires you could be burned Do not drive with it off and be careful working on the engine with the air cleaner filter off Notice If the air cleaner filter is ...

Page 279: ...blocking 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 Seal off 3 Store the seal in the inlet located on the underside of the hood 4 Store the clamp on the coolant surge tank Pull the overflow tube out of the white plastic retainer slip the clamp over and reinstall the hose The seal will need to be replaced on to the air ...

Page 280: ...h the vehicle shows how to check the automatic transmission fluid and what fluid to use Automatic Transmission External Filter Your automatic transmission filter requires periodic replacement Consult the Allison Automatic Transmission Operator s Manual that came with the vehicle for proper change intervals Manual Transmission Fluid When to Check A good time to have it checked is when the engine oi...

Page 281: ...uid level is good reinstall the plug and be sure it is fully seated If the fluid level is low add more fluid as described in the next steps Refer to the Maintenance Schedule to determine what kind of fluid to use See Part C Recommended Fluids and Lubricants on page 397 How to Add Fluid To add transmission fluid do the following 1 Remove the filler plug 2 Add fluid at the filler plug hole Add only ...

Page 282: ...rotection down to 34 F 37 C Give boiling protection up to 265 F 129 C Protect against rust and corrosion Help keep the proper engine temperature Let the warning lights and gages work as they should Notice Using coolant other than DEX COOL may cause premature engine heater core or radiator corrosion In addition the engine coolant may require changing sooner at 30 000 miles 50 000 km or 24 months wh...

Page 283: ...ater and DEX COOL coolant Notice If you use an improper coolant mixture your engine could overheat and be badly damaged The repair cost would not be covered by your warranty Too much water in the mixture can freeze and crack the engine radiator heater core and other parts If you have to add coolant more than four times a year have your dealer check your cooling system Notice If you use extra inhib...

Page 284: ... out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be parked on a level surface When your engine is cold the coolant level should be at the FULL COLD mark or higher If the low coolant warning light comes on in the instrument panel cluster and stays on it means you are low on engine coolant See Low Coolant Warning Light...

Page 285: ...l Engines If your vehicle has a Caterpillar diesel engine see the Caterpillar Diesel Engine Operation Maintenance Manual provided with your vehicle to find out what to add as well as when and how to service your cooling system Coolant Surge Tank Pressure Cap The coolant surge tank pressure cap is located in the engine compartment on the driver s side of the vehicle Notice Your vehicle s surge tank...

Page 286: ...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 down Wait until there is no sign of steam or coolant before you open the hood If you keep driving when your engine is overheated the liquids in it can catch fire You or others could be badly burned S...

Page 287: ...road shift to PARK P or NEUTRAL and let the engine idle 2 Turn on your heater to full hot at the highest fan speed and open the windows as necessary 3 If climbing a hill downshift to raise engine and fan speeds If you no longer have the overheat warning you can drive Just to be safe drive slower for about 10 minutes If the warning does not come back on you can drive normally If the warning continu...

Page 288: ...gine Operation and Maintenance Manual provided with your vehicle If the coolant inside the coolant surge tank is boiling do not do anything else until it cools down The vehicle should be parked on a level surface The coolant level should be at the FULL COLD mark or higher If it is not you may have a leak at the pressure cap or in the radiator hoses heater hoses radiator water pump or somewhere els...

Page 289: ...than DEX COOL may cause premature engine heater core or radiator corrosion In addition the engine coolant could require changing sooner at 30 000 miles 50 000 km or 24 months whichever occurs first Any repairs would not be covered by your warranty Always use DEX COOL silicate free coolant in your vehicle How to Add Coolant to the Coolant Surge Tank If you have not found a problem yet check to see ...

Page 290: ...o turn the pressure cap CAUTION Adding only plain water to your cooling system can be dangerous Plain water or some other liquid such as alcohol can boil before the proper coolant mixture will Your vehicle s coolant warning system is set for the proper coolant mixture With plain water or the wrong mixture your engine could get too hot but you would not get the overheat warning Your engine could ca...

Page 291: ...ge tank pressure cap when the cooling system including the coolant surge tank pressure cap and upper radiator hose is no longer hot Turn the pressure cap slowly counterclockwise about one full turn If you hear a hiss wait for that to stop A hiss means there is still some pressure left 2 Then keep turning the pressure cap slowly and remove it 3 Fill the coolant surge tank with the proper mixture to...

Page 292: ...cooling fan When the clutch is engaged the fan spins faster to provide more air to cool the engine In most everyday driving conditions the clutch is not fully engaged This improves fuel economy and reduces fan noise Under heavy vehicle loading trailer towing and or high outside temperatures the fan speed increases when the clutch engages So you may hear an increase in fan noise This is normal and ...

Page 293: ... remains on after you have added power steering fluid to the proper level then shut off the engine for 10 seconds This should reset the brake warning lights If one or both lights stay on see Hydraulic Brake System Warning Lights under Brake System Warning Light on page 168 for more information What to Use To determine what kind of fluid to use see Part C Recommended Fluids and Lubricants on page 3...

Page 294: ...ur washer fluid tank and other parts of the washer system Also water does not clean as well as washer fluid Fill your washer fluid tank only three quarters full when it is very cold This allows for expansion if freezing occurs which could damage the tank if it is completely full Do not use engine coolant antifreeze in your windshield washer It can damage your washer system and paint Brakes Brake F...

Page 295: ...Checking Brake Fluid in this section Checking Brake Fluid Apply the brake pedal several times with the ignition off The brake fluid reservoir is in the engine compartment on the driver side of the vehicle Clean one of the reservoir caps and the area around the cap and remove it The fluid level should be even with the bottom ring of the filler opening If it is low add enough fluid to fill the reser...

Page 296: ...is could cause a crash Always use the proper brake fluid Notice Using the wrong fluid can badly damage brake system parts For example just a few drops of mineral based oil such as engine oil in the brake system can damage brake system parts so badly that they will have to be replaced Do not let someone put in the wrong kind of fluid and do not use DOT 5 silicone brake fluid If you spill brake flui...

Page 297: ...al height or if there is a rapid increase in pedal travel This could be a sign that brake service is needed Brake Adjustment Every time you make a brake stop the brakes adjust for wear Brake Adjustment on Air Braked Vehicles Your vehicle has automatic slack adjusters Every time you make a brake stop the brakes automatically adjust for wear Slack adjusters should never be manually adjusted to corre...

Page 298: ... are two ways to do this One is automatic through the air brake vehicle s air dryer with intregal automatic moisture ejector that purges air from the system through a self contained reservoir The other way to drain moisture from the air brake system is to manually activate drain valves at each reservoir Drain the air reservoirs occasionally to be sure the air dryer is working properly Drain the ai...

Page 299: ... on a weekly basis Clutch Pedal Free Travel If you have a V8 engine and a manual transmission the clutch will need adjustment when pedal free travel gets down to about 1 4 inch 6 mm as measured at the clutch pedal pad You should have 1 1 2 to 2 inches 38 to 51 mm of clutch pedal free travel If the clutch ever needs service be sure to use only GM clutch replacement parts Chassis Lubrication Your Ma...

Page 300: ...Single Axle Models Item Number Item Remarks 1 Brake Camshaft One fitting each apply sparingly 2 Steering Column Slip Joint One fitting 3 Steering Drag Link Ends One fitting each end 300 ...

Page 301: ... Apply chassis lubricant 12 Clutch Release Bearing Cup or fitting 13 Battery Terminal except ST type Keep coated with petroleum jelly 14 Transmission Fill to level of filler plug 15 Propshaft U Joints Lubricate with GM Part No 1051344 Wheel Bearing Lubricant 16 Parking Brake Clevis Pin Apply chassis lubricant 17 Parking Brake Lever Pivot Apply chassis lubricant 18 Clutch Release Cross Shaft Master...

Page 302: ...fitting 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 pin to shoe joint only 5 Rear Spring Pin One fitting each side 302 ...

Page 303: ...fter handling Vehicle Storage If you are not going to drive your vehicle for 25 days or more remove the black negative cable from the battery This will help keep your battery from running down If your vehicle has more than one battery be sure to remove the negative battery cable from each battery CAUTION Batteries have acid that can burn you and gas that can explode You can be badly hurt if you ar...

Page 304: ...our warranty Trying to start your vehicle by pushing or pulling it will not work and it could damage your vehicle 1 Check the other vehicle It must have a 12 volt battery or batteries with a negative ground system Notice If the other vehicle s system is not a 12 volt system with a negative ground both vehicles can be damaged Only use vehicles with 12 volt systems with negative grounds to jump star...

Page 305: ... you leave your radio or other accessories on during the jump starting procedure they could be damaged The repairs would not be covered by your warranty Always turn off your radio and other accessories when jump starting your vehicle 3 Turn off the ignition on both vehicles Unplug unnecessary accessories plugged into the cigarette lighter or accessory power outlets Turn off the radio and all lamps...

Page 306: ...u need more light Be sure the batteries have enough water You do not need to add water to the ACDelco battery or batteries installed in your new vehicle CAUTION Continued CAUTION Continued But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present Battery fluid contains acid that can bur...

Page 307: ...ive cable to the negative terminal on the dead battery because this can cause sparks 6 Connect the red positive cable to the positive terminal of the dead battery Use a remote positive terminal if the vehicle has one 7 Do not let the other end touch metal Connect it to the positive terminal of the good battery Use a remote positive terminal if the vehicle has one 8 Now connect the black negative c...

Page 308: ...the vehicle that had the dead battery If it will not start after a few tries it probably needs service Notice If the jumper cables are connected or removed in the wrong order electrical shorting may occur and damage the vehicle The repairs would not be covered by your warranty Always connect and remove the jumper cables in the correct order making sure that the cables do not touch each other or ot...

Page 309: ...d Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it See Scheduled Maintenance on page 363 Notice If you drive your vehicle through deep water that is higher than the front or rear axle water may enter the axle housing and cause the axle lubricant to break down This could damage the gears inside Avoid driving your vehicle through ...

Page 310: ... Lubricants on page 397 Rear Axle Shift Motor When to Check and Change Fluid If you have an optional air shift two speed controlled traction or locking differential type rear axle a good time to check the fluid level in the axle shift motor is when the rear axle lubricant is checked How to Check Fluid Remove the plug on the front plate of the axle shift motor add enough fluid to raise the level to...

Page 311: ... on a level surface If the level is below the bottom of the fill plug hole located on the transfer case you ll need to add some lubricant Add enough lubricant to raise the level to the bottom of the fill plug hole Use care not to overtighten the plug When to Change Lubricant Refer to the Maintenance Schedule to determine how often to change the lubricant See Scheduled Maintenance on page 363 What ...

Page 312: ...ur vehicle through deep water You should avoid driving your vehicle through deep puddles or standing water If you must drive through water that is higher than the front or rear axle see your dealer immediately afterward to have the condition of the axle lubricant checked How to Check Lubricant To get an accurate reading the vehicle should be on a level surface If the level is below the bottom of t...

Page 313: ...e The noise control system warranty is given in your warranty booklet These standards apply 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 repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of...

Page 314: ...moval of the fan shroud if the vehicle has one Air Intake Removal of the air cleaner silencer Modification of the air cleaner Exhaust Removal of the muffler and or resonator Removal of the exhaust pipes and exhaust pipe clamps Bulb Replacement It is recommended that all bulbs be replaced by your dealer Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a ...

Page 315: ...e the wiper blade 1 Pull the windshield wiper arm away from the windshield 2 Push the release lever and slide the wiper assembly toward the driver s side of the vehicle 3 Install a new blade by reversing Steps 1 and 2 315 ...

Page 316: ...me rail Fuel Filter Diesel Engines If you have a diesel engine your fuel filter is located in the engine compartment on the driver s side of the vehicle or along the driver s side frame rail See Fuel Filter Replacement earlier in this section for further information Also see Scheduled Maintenance on page 363 for recommended service intervals Primary Fuel Filter and Water Separator If you have a di...

Page 317: ... It will be mounted in the engine compartment on the driver s side of the vehicle It has a metal drain bowl at the bottom Occasionally check the bowl for any water or particles To check or drain the bowl do the following Shut off the engine Push up on the spring loaded drain valve until clear fuel is flowing from the valve The particles or water will drain out first See Engine Oil Caterpillar Dies...

Page 318: ...the neck of the cylinder and the top of the valve before you take out the cylinder 4 Check the inside of the valve for any foreign matter Clean the valve as necessary 5 Cover the valve to protect it from dirt and take out the cylinder 6 Install a new gasket whenever you take out the cylinder Use only one gasket and spread a light film of clean oil on it before installation 7 Put in the new cylinde...

Page 319: ...here by using the circular gage on the sight glass If there isn t clean the rubber fill plug in the center of the glass and then remove it Be careful not to allow any dirt or water to get into the oil Add enough of the recommended oil to bring it up to the level mark that you ll see on the glass Refer to your Maintenance Schedule for the proper oil to use When you fill the hub check the glass agai...

Page 320: ... an air out and a serious accident See Loading Your Vehicle on page 233 CAUTION Continued CAUTION Continued Underinflated tires pose the same danger as overloaded tires The resulting accident could cause serious injury Check all tires frequently to maintain the recommended pressure Tire pressure should be checked when your vehicle s tires are cold See Inflation Tire Pressure on page 321 Overinflat...

Page 321: ...get the following Unusual wear Poor handling Rough ride Needless damage from road hazards When to Check Check your tires once a month or more Also check the tire pressure of the spare tire if your vehicle has one How to Check Use a good quality pocket type gage to check tire pressure You cannot tell if your vehicle s tires are properly inflated simply by looking at them Radial tires may look prope...

Page 322: ...ted tire can lose air suddenly or catch fire You or others could be injured Be sure all tires including the spare if any are properly inflated See Tires on page 320 and Inflation Tire Pressure on page 321 for more information on proper tire inflation When It Is Time for 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 1 16 of an inch 1 6 mm ...

Page 323: ...er case may be damaged if tires of different sizes brands or tread types are installed on the front and rear axles That damage would not be covered under your warranty Wheel Alignment and Tire Balance The wheels on your vehicle were aligned at the factory to give you the longest tire life and best overall performance Proper front wheel alignment must be maintained in order to ensure efficient stee...

Page 324: ...uts must be properly tightened Follow the rules in this section to be sure they are This section lets you know how often to check the tightness of the wheel nuts on your vehicle and how tight they must be First use these pictures to decide what kind of wheels you have Then refer to the following steps for the wheels you have Hub Piloted Type 8 Hole Hub Piloted Type 10 Hole 324 ...

Page 325: ...er 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 and rim assembly 3 Put on the wheel nuts 4 Finger tighten the nuts 5 Oil the surfaces B between the nuts C and washers A Do not oil the studs or the threads of the nut 325 ...

Page 326: ...480 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 fall off causing a crash 8 Hole 10 Hole Front 10 Hole Rear 326 ...

Page 327: ...eels for damage Because of loose running wheels piloting pad damage may occur and require replacement of the entire hub for proper centering of the wheels When replacing studs hubs wheel nuts or wheels be sure to use GM original equipment parts CAUTION Rust or dirt on a wheel or on the parts to which it is fastened can make wheel nuts become loose after a time The wheel could come off and cause a ...

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

Page 329: ...hange the Gross Axle Weight Rating GAWR or the Gross Vehicle Weight Rating GVWR of your vehicle See Loading Your Vehicle on page 233 for more information Notice The wrong wheel can cause trouble in bearing life brake cooling speedometer odometer calibration headlamp aim bumper height vehicle ground clearance stopping distance and tire clearance to the body and chassis You could also have other pro...

Page 330: ...ant the vehicle to go It may be very bumpy and noisy but you can still steer Gently brake to a stop well off the road if possible If a tire goes flat avoid further tire and wheel damage by driving slowly to a level place and turn on your hazard warning flashers See Hazard Warning Flashers on page 140 CAUTION Your vehicle when new did not include tire changing equipment or a place to store a tire i...

Page 331: ... Vehicle Your vehicle s interior will continue to look its best if it is cleaned often Although not always visible dust and dirt can accumulate on your upholstery Dirt can damage carpet fabric leather and plastic surfaces Regular vacuuming is recommended to remove particles from your upholstery It is important to keep your upholstery from becoming and remaining heavily soiled Soils should be remov...

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

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

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

Page 335: ...ucts can be obtained from your dealer See Vehicle Care Appearance Materials on page 339 Do not use cleaning agents that are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface or they could stain Dry the finish with a soft clean chamois or an all cotton towel to avoid surface scratches and water spotting High pressu...

Page 336: ...ap bird droppings chemicals from industrial chimneys etc can damage your vehicle s finish if they remain on painted surfaces Wash the vehicle as soon as possible If necessary use non abrasive cleaners that are marked safe for painted surfaces to remove foreign matter Exterior painted surfaces are subject to aging weather and chemical fallout that can take their toll over a period of years You can ...

Page 337: ...oth with mild soap and water Rinse with clean water After rinsing thoroughly dry with a soft clean towel A wax may then be applied Notice If you use strong soaps chemicals abrasive polishes cleaners brushes or cleaners that contain acid on aluminum or chrome plated wheels you could damage the surface of the wheel s The repairs would not be covered by your warranty Use only GM approved cleaners on ...

Page 338: ...in the finish should be repaired right away Bare metal will corrode quickly and may develop into major repair expense Minor chips and scratches can be repaired with touch up materials available from your dealer Larger areas of finish damage can be corrected in your dealer s body and paint shop Underbody Maintenance Chemicals used for ice and snow removal and dust control can collect on the underbo...

Page 339: ...terials Description Usage Polishing Cloth Wax Treated Interior and exterior polishing cloth Tar and Road Oil Remover Removes tar road oil and asphalt Chrome Cleaner and Polish Use on chrome or stainless steel Vehicle Care Appearance Materials cont d Description Usage White Sidewall Tire Cleaner Removes soil and black marks from whitewalls Vinyl Cleaner Cleans vinyl Glass Cleaner Removes dirt grime...

Page 340: ...r used on 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 panel on the driver s side You can see it if you look through the windshield from outside your vehicle The VIN also appears on the Certification Tire and Service Parts labels and the certificate...

Page 341: ...Electrical Equipment Notice Do not add anything electrical to your vehicle unless you check with your dealer first Some electrical equipment can damage your vehicle and the damage would not be covered by your warranty Some add on electrical equipment can keep other components from working as they should Headlamp Wiring The headlamp wiring is protected by a circuit breaker in the light switch An el...

Page 342: ...re the hydraulic brake booster motor feed circuit the generator output circuit and the intake heater feed circuit in vehicles with a diesel engine 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 protects the circuit until the current load returns to norma...

Page 343: ...Fuse Usage 1 Stoplamps 2 Center High Mounted Stoplamp 3 Parking Lamps 4 Powertrain Control Module Fuse Usage 5 Auxiliary Wiring 6 Heater Air Conditioning 7 Hazard Warning Flashers 8 Power Post 343 ...

Page 344: ...ower 20 Ignition 4 21 Sidemarker Lamps 22 Turn Signal Backup Lamps 23 Transmission 24 Hydraulics Air Brake Fuse Usage A Spare B Spare Fuse Usage Blank Not Used BRK Brake Warning Lamp RT PRK Passenger s Side Parking Lamps Blank Not Used Blank Not Used LT PARK Driver s Side Parking Lamps RT REAR TRN STOP Passenger s Side Rear Turn Signal Stoplamp LT REAR TRN STOP Driver s Side Rear Turn Signal Stopl...

Page 345: ...nal Blank Not Used Blank Not Used Blank Not Used Underhood Fuse Block When a circuit goes out the problem could be in either the primary or secondary underhood fuse blocks These blocks use blade type fuses Both underhood fuse blocks are located in the engine compartment on the passenger s side of the vehicle To access the fuse blocks gently squeeze both sides of the cover to unlatch the tabs at th...

Page 346: ... Not Used 02A Emissions A C COMP Air Conditioning Compressor ABS 1 Anti lock Brake System 1 ABS 2 Anti lock Brake System 2 ABS 3 Anti lock Brake System 3 ENGINE Engine E A PUMP Electronic Automatic Pump HORN Horn NOTE 2 L18 Fuel LG4 Powertrain Control Valve LG5 Electronic Control Module NOTE 3 L18 Fuel LG4 Powertrain Control Valve LG5 Electronic Control Module Primary Underhood Fuse Block 346 ...

Page 347: ...Off Engine Control Unit Diesel 7 8L LG4 REVERSE Reverse Relay NEUTRAL START Neutral Start LG4 Allison Automatic Transmission Series 3000 3500 Fuse Usage IGN 1 Ignition 1 IGN 4 Ignition 4 IGN 3 Ignition 3 BATT HAZ Battery Hazard Warning Flashers HEADLAMP Headlamps LIGHTING Interior Exterior Lamps HVAC Climate Control System NOTE C4 C5 Electric Brake C6 C7 C8 Brake Lamps Secondary Underhood Fuse Blo...

Page 348: ...harge amount see the refrigerant caution label located under the hood See your dealer for more information Cooling System C4 C5 Models 6 6L Automatic Transmission 27 3 qt 25 8 L 8 1L Automatic Transmission 29 8 qt 28 2 L 8 1L Manual Transmission 30 1 qt 28 5 L Cooling System C6 C7 C8 Automatic Transmission 7 2L Engine hp 207 230 31 4 qt 29 7 L 7 2L Engine hp 250 300 31 2 qt 29 5 L Isuzu 6H Engine ...

Page 349: ...hp Engine with A C and Increased Cooling 33 3 qt 31 5 L Isuzu 6H 200 230 hp Engine 31 6 qt 29 9 L Isuzu 6H 200 230 hp Engine with A C and Increased Cooling 35 3 qt 33 4 L Isuzu 6H 250 300 hp Engine 34 9 qt 33 0 L Isuzu 6H 250 300 hp Engine with A C and Increased Cooling 35 4 qt 33 5 L 8 1L 225 295 hp Engine 33 3 qt 31 5 L 8 1L with A C and Increased Cooling 34 9 qt 33 0 L Engine Oil with Filter 6 ...

Page 350: ...l filter system For vehicles equipped with the LUBERFINER 750 C add 14 quarts 13 25 L Fuel Capacity C4 C5 Models Standard Mid Mounted 25 gal 94 6 L Optional1 Dual Tank Mid Mounted 40 gal 151 4 L Optional Mid Mounted 32 gal 121 1 L Optional Side Mounted 35 gal 132 5 L Optional Mid Mounted 40 gal 151 4 L Optional Mid Mounted 40 gal 151 4 L Optional Mid Mounted 60 gal 227 1 L Optional Mid Mounted 80 ...

Page 351: ...6 L tank and one 50 gallon 189 2 L tank 3 Two 50 gallon 189 2 L tanks Front 4WD Axle G38 7 0 pt 3 6 L Rear Axle Single Speed 80 GL4 8 0 pt 3 7 L 19060D HPM 19060S HPK 21060D 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 34 0 pt 16 1 L DS344 rear H...

Page 352: ... Case Four Wheel Drive 4 0 pt 1 9 L Transmission 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 RDS MH PTS and EVS 2500 HS and RDS and 2300 HS and RDS 35 0 pt 16 5 L Add 2 pints 1 L when changing spin on or remote filter See the Allison Automatic Tr...

Page 353: ... 3 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 Engine RPO Type 6 6L V8 DURAMAX LLY Common Rail Fuel System 7 2L L6 Caterpillar C7 LG5 Hydraulic Electronic Unit Injector Fuel System 7 8L Isuzu 6H LG4 Common Rail Fuel System 8 1L V8 VORTEC L18 Si...

Page 354: ... C5 Models 88937527 A2032C 7 2L 7 8L C6 C7 C8 Models with Standard Air Cleaner 88937525 A2031C 7 2L 7 8L C6 C7 C8 Models with Heavy Duty Air Cleaner 889375251 A2031C 8 1L C6 C7 C8 Models with Heavy Duty Air Cleaner 88937525 A2031C 8 1L C6 C7 C8 Models with Standard Air Cleaner 88937545 A2034C Engine Oil Filter 6 6L 88917036 PF2232 7 2L 1R 1807 7 8L 94037791 8 1L 25324052 PF454 Fuel Filter 6 6L 973...

Page 355: ...1L K28 and standard Uhaul 25014476 TP1247 Spark Plugs 6 6L 7 2L 7 8L 8 1L 12578277 41 983 1 Optional air filter GM Part No 88937548 AC Delco No A2035C for C6 C7 C8 Models Fits inside standard size filter GM Part No 88937525 AC Delco No A2031C listed previously Racor part number Caterpillar part number See the Allison Transmission Operator s Manual in your vehicle for external filter part numbers a...

Page 356: ...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 356 ...

Page 357: ...Dual Generators A Air conditioning compressor A 6 6L V8 DURAMAX Diesel Engine Isuzu 6H Diesel Engine 357 ...

Page 358: ...Air conditioning compressor A 7 2L V6 Caterpillar Diesel Engine 358 ...

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

Page 360: ...ps to keep your vehicle in good working condition but also helps the environment Improper vehicle maintenance can even affect the quality of the air we breathe Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle To help protect our environment and to keep your vehicle in good condition be sure to maintain your vehicle properly How This Section is...

Page 361: ... Information on page 415 Part B Owner Checks and Services tells you what should be checked and when It also explains what you can easily do to keep your vehicle in good condition Part C Recommended Fluids and Lubricants lists some recommended products necessary to help keep your vehicle properly maintained These products or their equivalents should be used whether you do the work yourself or have ...

Page 362: ... your vehicle in good condition see your dealer This part tells you the maintenance services you should have done and when to schedule them When you go to your dealer for your service needs you will know that GM trained and supported service people will perform the work using genuine GM parts The proper fluids and lubricants to use are listed in Part C Make sure whoever services your vehicle uses ...

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

Page 364: ...ack adjuster service or every 500 hours whichever occurs first 33 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber service or every 2 months whichever occurs first 34 12 000 Miles 20 000 km Isuzu 6H Diese...

Page 365: ...inspect filter at every engine oil change See Engine Air Cleaner Filter on page 277 for more information Diesel Engine Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 277 for more information DURAMAX Isuzu Diesel Only Rep...

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

Page 367: ...rs first 3 4 23 Evaporative Control System service if equipped or every 24 months whichever occurs first 2 24 Rear axle air shift motor service 10 24 000 Miles 40 000 km Isuzu 6H Diesel Without Engine Oil Life System Only Change engine oil and filter or every 12 months or every 600 hours of engine operation whichever occurs first 2 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life sy...

Page 368: ...il change See Engine Air Cleaner Filter on page 277 for more information Diesel Engine Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 277 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 ho...

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

Page 370: ...hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber service or every 2 months whichever occurs first 34 45 000 Miles 72 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system See Engine Oil Gasoline Engine in the Index 2 8 6 6L DURAMAX Diese...

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

Page 372: ...iner service or every 6 months or every 1800 hours whichever occurs first 48 000 Miles 75 000 km Isuzu 6H Diesel Without Engine Oil Life System Only Change engine oil and filter or every 12 months or every 600 hours of engine operation whichever occurs first 2 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life system or every 12 months or every 600 hours of engine operation whichever ...

Page 373: ...y valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber service or every 2 months whichever occurs first 34 60 000 Miles 96 000 km Gasoline Engine Only Check engine oil life system If engine oil and filter are changed reset system ...

Page 374: ...replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 277 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 hours of engine operation whichever occurs first Chassis lubrication service or every 6 months whichever occurs first 11 Replace fuel filter s or every 1...

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

Page 376: ...er occurs first 2 24 72 000 Miles 115 000 km Isuzu 6H Diesel Without Engine Oil Life System Only Change engine oil and filter or every 12 months or every 600 hours of engine operation whichever occurs first 2 Isuzu 6H Diesel With Engine Oil Life System Only Check oil life system or every 12 months or every 600 hours of engine operation whichever occurs first If engine oil and filter are changed re...

Page 377: ...e Air Cleaner Filter on page 277 for more information DURAMAX Isuzu Diesel Only Replace fuel filter or every 750 hours of engine operation whichever occurs first Steering system service 12 Front and rear suspension service 13 Spring to axle U bolts and shackle bolts service 15 Exhaust system service or every 6 months whichever occurs first 2 3 16 Wheels and tires service 14 Hydraulic brake service...

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

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

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

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

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

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

Page 384: ...vel or every 6 months whichever occurs first and have serviced if needed Check brakes more often if driving habits and conditions result in frequent braking 7 This vehicle has the Engine Oil Life System This system will show you when to change the engine oil and filter usually between 3 000 miles 5 000 km and 12 000 miles 20 000 km since your last oil change Under severe conditions the indicator m...

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

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

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

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

Page 389: ...oller bearing 32 Air brake service Inspect brake lines and hoses for proper hook up binding leaks cracks chafing etc Inspect drum brake linings for wear or cracks Inspect other brake parts at each wheel including drums and wheel speed sensor wiring Check brake pedal for excessive free play or travel or every 6 months whichever occurs first and have serviced if needed Check brakes more often if dri...

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

Page 391: ...rform these underhood checks at each fuel fill Engine Oil Level Check Check the engine oil level and add the proper oil if necessary See Engine Oil Caterpillar Diesel Engine on page 264 or Engine Oil Gasoline Engine on page 265 or Engine Oil DURAMAX Isuzu Diesel Engine on page 268 Engine Coolant Level Check Check the engine coolant level and add DEX COOL coolant mixture if necessary See Engine Coo...

Page 392: ...brication Silicone grease on weatherstrips will make them last longer seal better and not stick or squeak Apply silicone grease with a clean cloth During very cold damp weather more frequent application may be required Part C tells you what to use Body Lubrication Service Lubricate all exposed surfaces such as door checks door lock bolts lock strike plates door hinge bushings latches and dovetail ...

Page 393: ...ly when the clutch pedal is all the way down Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen Steering Check Be alert for any changes in steering action abnormal front tire wear or steering wheel position An inspection or service is needed when the steering wheel is harder to turn or has too much free play or if there are strange sounds when turning o...

Page 394: ... are signs the system may be leaking Have it checked and or repaired at once Refer to Engine Exhaust on page 130 and Running the Engine While Parked on page 131 Windshield Wipers and Washers Check Check operation and condition of the wiper blades Check the flow of the washer spray Defroster Check Move the control to the defrost symbol and the fan to HI or the high symbol Then check the airflow fro...

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

Page 396: ...e should be loosened before being flushed Engine Cover Check Check that the cab s engine cover and seal if equipped are not torn or damaged Be sure that the cover is clamped down firmly to the floor At Least Once a Year Key Lock Cylinders Service Lubricate the key lock cylinders with the lubricant specified in Part C Underbody Flushing Service At least every spring use plain water to flush any cor...

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

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

Page 399: ...512 Rear Axle and Rear Hubs SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part No U S 89021675 in Canada 10953512 Usage Fluid Lubricant Rear Axle Shift Motor Lubricant Refrigerant Oil GM Part No U S 5416939 in Canada 10953496 Propshafts and Splines Wheel bearing lubricant meeting requirements of NLGI 2 Category GC or GC LB GM Part No U S 1051344 in Canada 993037 Cab Door Hinges and...

Page 400: ...rmed record the date odometer reading and who performed the service and any additional information from Owner Checks and Services on the following record pages Also you should retain all maintenance receipts Date Miles km Or Hours Serviced By Maintenance Record 400 ...

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

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

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

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

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

Page 406: ...er to the addresses below United States Customer Assistance GM Medium Duty Truck Customer Assistance Center Customer Assistance Center P O Box 44947 Detroit MI 48244 www GMC com 1 800 862 4389 1 800 462 8583 For Text Telephone devices TTYs Fax Number 313 381 0022 From Puerto Rico 1 800 496 9992 English 1 800 496 9993 Spanish Fax Number 313 381 0022 U S Virgin Islands 1 800 496 9994 Fax Number 313 ...

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

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

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

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

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

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

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

Page 414: ...88 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington D C 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Reporting Safety Defects to the Canadian Government If you live in Canada and you believe that your vehicle has a safety defect you should immediately notify Transport Canada...

Page 415: ...c Transmission Transaxle Transfer Case Unit Repair Manual This manual provides information on unit repair service procedures adjustments and specifications for GM transmissions transaxles and transfer cases Service Bulletins Service Bulletins give technical service information needed to knowledgeably service General Motors cars and trucks Each bulletin contains instructions to assist in the diagno...

Page 416: ...tins and Manuals are available for current and past model GM vehicles To request an order form please specify year and model name of the vehicle ORDER TOLL FREE 1 800 551 4123 Monday Friday 8 00 AM 6 00 PM Eastern Time For Credit Card Orders Only VISA MasterCard Discover visit Helm Inc on the World Wide Web at www helminc com Or you can write to Helm Incorporated P O Box 07130 Detroit MI 48207 Pri...

Page 417: ...Airbag Off Switch 76 How Does an Airbag Restrain 74 Airbag System cont Servicing Your Airbag Equipped Vehicle 79 What Makes an Airbag Inflate 74 What Will You See After an Airbag Inflates 74 When Should an Airbag Inflate 73 Where Are the Airbags 71 AM FM Radio 184 Antenna Fixed Mast 200 Anti Lock Brake System ABS 208 Anti Lock Brake System Warning Light 170 Anti Lock Brakes Trailer System Warning ...

Page 418: ...ntenna 200 Radio with Cassette 186 Radio with CD 192 Setting the Time 183 Theft Deterrent Feature 198 Understanding Radio Reception 198 Automatic Ether Injection System 318 Automatic Transmission Fluid 280 Operation 113 Axle Two Speed Rear Axle Electric Shift Control 111 B Battery 303 Bench Seat Split 13 Brake Anti Lock Brake System ABS 208 Diesel Engine Exhaust 109 Emergencies 209 Exhaust Indicat...

Page 419: ...263 Chemical Paint Spotting 339 Child Restraints Child Restraint Systems 49 Infants and Young Children 45 Lower Anchors and Tethers for Children 57 Older Children 42 Securing a Child Restraint in a Rear Outside Seat Position 58 Securing a Child Restraint in the Center Rear Seat Position Crew Cab or Center Front Position 60 Securing a Child Restraint in the Right Front Seat Position 63 Where to Put...

Page 420: ... Procedure 404 GM Mobility Reimbursement Program 407 Reporting Safety Defects to General Motors 414 Reporting Safety Defects to the Canadian Government 414 Customer Assistance Information cont Reporting Safety Defects to the United States Government 414 Roadside Assistance Program 408 Service Publications Ordering Information 415 D Daytime Running Lamps 149 Daytime Running Lamps Indicator Light 17...

Page 421: ...ws and Other Power Options 342 Electrical System cont Underhood Fuse Block 345 Windshield Wiper Fuses 342 Engine Air Cleaner Filter 277 Alarm and Automatic Shutdown 102 Battery 303 Change Engine Oil Light 174 Check and Service Engine Soon Light 172 Checks Before Operating 107 Coolant 282 285 Coolant Heater 108 Coolant Temperature Gage 171 Diesel Engine Exhaust Brake 109 Drive Belt Routing 356 Exha...

Page 422: ...l Transmission 280 Power Steering 293 Windshield Washer 293 Fluid cont Four Wheel Drive 117 311 Front Axle 312 Front Wheel Bearings with Oil Filled Hubs 319 Fuel 247 Additives 247 Diesel Engine Fuel 248 Filling a Portable Fuel Container 262 Filling Your Tank 260 Filter 316 Filter Replacement 259 Fuels in Foreign Countries 260 Gage 179 Gasoline Octane 247 Gasoline Specifications 247 Primary Filter ...

Page 423: ...Specifications 247 Gasoline Engine Starting 95 GM Mobility Reimbursement Program 407 H Hazard Warning Flashers 140 Headlamp Wiring 341 Headlamps Bulb Replacement 314 Daytime Running Lamps 149 High Low Beam Changer 142 On Reminder 149 Heater 155 High Idle System 104 Highbeam On Light 178 Highway Hypnosis 225 Hill and Mountain Roads 226 Hood Checking Things Under 263 Latches 263 Horn 140 Hourmeter G...

Page 424: ...irbag Off 164 Airbag Readiness 163 Anti Lock Brake System Warning 170 Brake System Warning 168 Change Engine Oil 174 Charging System 165 Check Gages Warning 179 Daytime Running Lamps Indicator 178 Differential Lock Indicator 177 Engine Overspeed Warning 175 Engine Shutdown Warning 175 Exhaust Brake Indicator 176 Highbeam On 178 Low Coolant Warning 171 Low Oil Level 174 Low Washer Fluid Warning 178...

Page 425: ... 360 Maintenance Requirements 360 Part A Scheduled Maintenance Services 362 Maintenance Schedule cont Part B Owner Checks and Services 391 Part C Recommended Fluids and Lubricants 397 Part D Maintenance Record 400 Scheduled Maintenance 363 Scheduled Maintenance Supplements 363 Using 362 Your Vehicle and the Environment 360 Malfunction Indicator Light 172 Manual Transmission Fluid 280 Operation 114...

Page 426: ...ater Separator 316 Secondary Fuel Filter and Water Separator Heater 317 Other Warning Devices 140 Outlet Adjustment 158 Outlet s Accessory Power 154 Outside Convex Mirrors 133 Heated Mirrors 133 Manual Mirrors 132 Power Mirrors 132 Overspeed Warning Light 175 Owners Canadian 3 P Paint Damage 338 Parking 123 Brake 124 125 Brake Burnish Procedure 127 Over Things That Burn 129 Part A Scheduled Mainte...

Page 427: ...ing Lamps 152 Rear Axle 309 Differential Lock Control 211 Shift Motor 310 Two Speed Electric Shift Control 111 Rear Heating System 159 Rear Outside Passenger Positions Safety Belts 38 Rear Seat Operation 20 Rearview Mirrors 132 Reduced Engine Power Light 177 Remote Keyless Entry RKE System 85 Remote Keyless Entry RKE System Operation 86 Reporting Safety Defects Canadian Government 414 General Moto...

Page 428: ...ols 4 Scheduled Maintenance 363 Scheduled Maintenance Supplements 363 Seats Air Suspension Seats 13 Bucket Seats 9 Rear Seat Operation 20 Split Bench Seat 13 Securing a Child Restraint Center Rear Seat Position Crew Cab or Center Front Position 60 Rear Outside Seat Position 58 Right Front Seat Position 63 Service 244 California Proposition 65 Warning 244 Doing Your Own Work 245 Engine Fan Breakage...

Page 429: ... Tire Pressure 321 Tightening the Wheel Nuts 324 Wheel Alignment and Tire Balance 323 Wheel Loading 321 Tires cont Wheel Replacement 328 When It Is Time for New Tires 322 Tow Hooks 233 Towing Your Vehicle 237 Traction Control System TCS 212 Trailer Connections 239 Trailer Brake Hand Control Valve 210 Transmission Fluid Automatic 280 Fluid Manual 280 Service Warning Light 167 Temperature Gage 176 T...

Page 430: ...er Warning Devices 140 Safety and Symbols 4 Vehicle Damage 5 Washer Fluid Low Warning Light 178 Water Fuel 252 Water in Fuel Warning Light 180 What Fuel to Use 249 Wheels Alignment and Tire Balance 323 Front Bearings with Oil Filled Hubs 319 Loading 321 Replacement 328 Tightening the Wheel Nuts 324 Where to Put the Restraint 54 55 Windows 91 Manual 91 Power 92 Sliding Rear 92 Windshield Washer 144...

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