Page 1 2009 Chevrolet Kodiak Owner Manual Seats and Restraint System ......1-1 Service and Appearance Care ......5-1 Front Seats Service ..........1-2 ............. 5-3 Rear Seats Fuel ..........1-10 ............5-6 Safety Belts ..........1-11 Checking Things Under the Hood ....
Page 2 Safety Warnings and Symbols GENERAL MOTORS, GM, the GM Emblem, A circle with a slash CHEVROLET, the CHEVROLET Emblem, and the through it is a safety name KODIAK are registered trademarks of General symbol which means Motors Corporation.
Page 3: Vehicle Symbols
Vehicle Symbols CAUTION: The vehicle has components and labels that use symbols instead of text. Symbols are shown along with the text describing the operation or information These mean there is something that could hurt relating to a speciﬁc component, control, message, you or other people.
Page 4: Vehicle Symbol Chart
Vehicle Symbol Chart : Fuel Gage Here are some additional symbols that may be found on : Fuses the vehicle and what they mean. For more information on the symbol, refer to the index. : Headlamp High/Low-Beam Changer : Airbag Readiness Light : LATCH System Child Restraints : Air Conditioning : Malfunction Indicator Lamp...
Page 5: Seats And Restraint System
Section 1 Seats and Restraint System Front Seats ............1-2 Securing a Child Restraint in the Center Bucket Seats ..........1-2 Rear Seat Position (Crew Cab) ....1-42 Split Bench Seat (80/20 Split) ......1-6 Securing a Child Restraint in the Center Air Suspension Seats ........1-6 Front Seat Position ........1-44 Securing a Child Restraint in the Right Rear Seats .............1-10...
Page 6: Front Seats
Front Seats Bucket Seats On vehicles with bucket seats, you can adjust the seats several different ways. Fore-and-Aft Adjustment CAUTION: You can lose control of the vehicle if you try to adjust the seat while the vehicle is moving. The sudden movement could startle and confuse you, You can adjust the seat forward or rearward with the bar located under the front of the seat cushion.
Page 7 Lumbar Adjustment For more support to your lower back, turn the lumbar adjustment knob clockwise. To decrease the amount of Your seats may have this feature. lumbar support, turn the knob counterclockwise. The lumbar adjustment knob is located on the seatback, on the inboard side of the driver’s seat and on the outboard side of the...
Page 8 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.
Page 9 CAUTION: Sitting in a reclined position when your vehicle is in motion can be dangerous. Even if you buckle up, your safety belts cannot do their job when you are reclined like this. The shoulder belt cannot do its job. In a crash, you could go into it, receiving neck or other injuries.
Page 10 Split Bench Seat (80/20 Split) Fore-and-Aft Adjustment If your vehicle has a split bench seat, the passenger If your vehicle has this lever seat is not adjustable. it is located underneath the front of the driver’s seat. There is a storage area underneath the seat cushion. See Storage Areas on page 2-53.
Page 11: Height Adjustment
Height Adjustment 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 Seat Height Adjustment and pull it forward. You can choose between two Lever settings.
Page 12 Lumbar Adjustment Seatback Adjustment Your vehicle has a seatback adjustment control located on the outboard side of the seat. Lumbar Adjustment Knob If your vehicle has a lumbar adjustment knob, it is Recline the seatback by turning the control located on the inboard side of the driver’s seatback, or counterclockwise.
Page 13 Chugger-Snubber Lock-Out Feature CAUTION: If your vehicle has this feature, the handle is Sitting in a reclined position when your vehicle is located on the outboard side of the driver’s in motion can be dangerous. Even if you buckle and passenger’s seats. up, your safety belts cannot do their job when you are reclined like this.
Page 14: Rear Seats
Rear Seats To fold down the seatback, pull the strap located on the rear of the seat, while Rear Seat Operation pulling the seatback down. Folding the Rear Seat (Crew Cab) CAUTION: A safety belt that is improperly routed, not properly attached, or twisted will not provide the protection To raise a seatback, pull the nylon strap while raising needed in a crash.
Page 15: Safety Belts
Safety Belts CAUTION: Safety Belts: They Are for Everyone It is extremely dangerous to ride in a cargo area, This section of the manual describes how to use inside or outside of a vehicle. In a collision, people safety belts properly. It also describes some things not riding in these areas are more likely to be to do with safety belts.
Page 16: Why Safety Belts Work
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 When you ride in or on anything, you go as fast as it goes. Put someone on it.
Page 17 Get it up to speed. Then stop the vehicle. The rider The person keeps going until stopped by something. In does not stop. a real vehicle, it could be the windshield... 1-13...
Page 18 or the instrument panel... or the safety belts! With safety belts, you slow down as the vehicle does. You get more time to stop. You stop over more distance, and your strongest bones take the forces. That is why safety belts make such good sense. 1-14...
Page 19 Questions and Answers About Safety If I am a good driver, and I never drive far from Belts home, why should I wear safety belts? You may be an excellent driver, but if you are in a crash — even one that is not your fault — you and Will I be trapped in the vehicle after a crash if I your passenger(s) can be hurt.
Page 20: How To Wear Safety Belts Properly
How to Wear Safety Belts Properly This section is only for people of adult size. Be aware that there are special things to know about safety belts and children. And there are different rules for smaller children and infants. If a child will be riding in the vehicle, see Older Children on page 1-28 or Infants and Young Children on page 1-32.
Page 21 What is wrong with this? 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 snugly against your body. The shoulder belt is too loose.
Page 22 What is wrong with this? CAUTION: You can be seriously hurt if your lap belt is too loose. In a crash, you could slide under the lap belt and apply force on your abdomen. This could cause serious or even fatal injuries. The lap belt should be worn low and snug on the hips, just touching the thighs.
Page 23 What is wrong with this? CAUTION: You 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 on the pelvic bones. This could cause serious internal injuries.
Page 24 What is wrong with this? CAUTION: You can be seriously injured if your belt goes over an armrest like this. The belt would be much too high. In a crash, you can slide under the belt. The belt force would then be applied on the abdomen, not on the pelvic bones, and that could cause serious or fatal injuries.
Page 25 What is wrong with this? CAUTION: You can be 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.
Page 26 What is wrong with this? CAUTION: You can be seriously injured by not wearing the lap-shoulder belt properly. In a crash, you would not be restrained by the shoulder belt. Your body could move too far forward increasing the chance of head and neck injury.
Page 27 What is wrong with this? 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/retailer to ﬁx it.
Page 28 Lap-Shoulder Belt All seating positions in the vehicle have a lap-shoulder belt except for the center passenger positions (if equipped), which have a lap belt. See Lap Belt on page 1-27 for more information. The following instructions explain how to wear a lap-shoulder belt properly.
Page 29 5. To make the lap part tight, pull up on the To unlatch the belt, push the button on the buckle. shoulder belt. The belt should return to its stowed position. It may be necessary to pull stitching on the safety Before a door is closed, be sure the safety belt is out of belt through the latch plate to fully tighten the the way.
Page 30 Shoulder Belt Height Adjustment Safety Belt Use During Pregnancy The vehicle has a shoulder belt height adjuster for each Safety belts work for everyone, including pregnant seating position next to a window. women. Like all occupants, they are more likely to be seriously injured if they do not wear safety belts.
Page 31: Lap Belt
Lap Belt This part is only for the lap belt. To learn how to wear a lap-shoulder belt, see Lap-Shoulder Belt on page 1-24. You vehicle may have a center seating position. When you sit in the center front or rear seating position, you may have a lap safety belt, which has no retractor.
Page 32: Child Restraints
Safety Belt Extender Child Restraints If the safety belt will fasten around you, you should Older Children use it. But if a safety belt is not long enough, your dealer/retailer will order you an extender. When you go in to order it, take the heaviest coat you will wear, so the extender will be long enough for you.
Page 33 The manufacturer’s instructions that come with the What is the proper way to wear safety belts? booster seat, state the weight and height limitations for that booster. Use a booster seat with a lap-shoulder An older child should wear a lap-shoulder belt belt until the child passes the below ﬁt test: and get the additional restraint a shoulder belt can provide.
Page 34 CAUTION: Never do this. Never allow two children to wear the same safety belt. The safety belt can not properly spread the impact forces. In a crash, the two children can be crushed together and seriously injured. A safety belt must be used by only one person at a time. 1-30...
Page 35 CAUTION: Never do this. Never allow a child to wear the safety belt with the shoulder belt behind their back. A child can be seriously injured by not wearing the lap-shoulder belt properly. In a crash, the child would not be restrained by the shoulder belt.
Page 36: Infants And Young Children
Infants and Young Children CAUTION: Everyone in a vehicle needs protection! This includes infants and all other children. Neither the distance traveled nor the age and size of the traveler changes the Children can be seriously injured or strangled if a need, for everyone, to use safety restraints.
Page 37 CAUTION: Never do this. Never hold an infant or a child while riding in a vehicle. Due to crash forces, an infant or a child will become so heavy it is not possible to hold it during a crash. For example, in a crash at only 25 mph (40 km/h), a 12 lb (5.5 kg) infant will suddenly become a 240 lb (110 kg) force on a person’s arms.
Page 38 CAUTION: Never do this. Children who are up against, or very close to, any airbag when it inﬂates can be seriously injured or killed. Never put a rear-facing child restraint in the right front seat. Secure a rear-facing child restraint in a rear seat.
Page 39 For most basic types of child restraints, there are many different models available. When purchasing a CAUTION: child restraint, be sure it is designed to be used in a motor vehicle. If it is, the restraint will have a label saying that it meets federal motor vehicle A young child’s hip bones are still so small that safety standards.
Page 40: Child Restraint Systems
Child Restraint Systems A rear-facing infant seat (A) provides restraint with the seating surface against the back 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 booster seat (C-D) is a child restraint designed to improve the ﬁt of the vehicle’s safety belt system.
Page 41 Securing an Add-on Child Restraint in When securing an add-on child restraint, refer to the instructions that come with the restraint which may be the Vehicle on the restraint itself or in a booklet, or both, and to this manual. The child restraint instructions are important, so if they are not available, obtain a replacement copy from CAUTION: the manufacturer.
Page 42: Securing The Child Within The Child Restraint
Securing the Child Within the Child Air Suspension Seats Restraint CAUTION: CAUTION: A child restraint cannot be secured properly in an air-suspension type seat. This is because an A child can be seriously injured or killed in a crash air-suspension seat is designed to move up and if the child is not properly secured in the child down for an adult passenger.
Page 43 A label on your sun visor says, “Never put a rear-facing child seat in the front.” This is because the risk to the CAUTION: (Continued) rear-facing child is so great, if the airbag deploys. Secure rear-facing child restraints in a rear seat, CAUTION: even if the airbag is off.
Page 44 Lower Anchors and Tethers for Securing a Child Restraint in a Rear Children (LATCH) Outside Seat Position (Crew Cab) Some child restraints have a LATCH system. As part of When securing a child restraint in a rear seating the LATCH system, your child restraint may have position, study the instructions that came with your child lower attachments and/or a top tether.
Page 45 3. Push the latch plate into the buckle until it clicks. 4. Pull the rest of the shoulder belt all the way out of the retractor to set the lock. Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly if necessary.
Page 46: Crew Cab
Securing a Child Restraint in the Center Rear Seat Position (Crew Cab) This vehicle does not have top tether anchors. Some national or local laws require that top tethers be anchored. In Canada, the law requires that forward-facing child restraints have a top tether, and that the tether be attached.
Page 47 1. Make the belt as long as possible by tilting the latch 4. Push the latch plate into the buckle until it clicks. plate and pulling it along the belt. Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly 2.
Page 48: Securing A Child Restraint In The Right Front Seat Position
Securing a Child Restraint in the Securing a Child Restraint in the Center Front Seat Position Right Front Seat Position This vehicle may have airbags. A rear seat is a safer place to secure a forward-facing child restraint. See CAUTION: Where to Put the Restraint on page 1-38.
Page 49 CAUTION: CAUTION: A child in a rear-facing child restraint can be If the airbag readiness light ever comes on when seriously injured or killed if the right front you have turned off the airbag, it means that passenger airbag inﬂates. This is because the something may be wrong with the airbag system.
Page 50 Do not secure a child restraint in a position without a top tether anchor 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 strap must be anchored.
Page 51 5. Pull the rest of the shoulder belt all the way out of 6. To tighten the belt, push down on the child restraint, the retractor to set the lock. pull the shoulder portion of the belt to tighten the lap portion of the belt and feed the shoulder belt back into the retractor.
Page 52: Airbag System
Airbag System If you turned the airbag off with the switch, turn on the right front passenger airbag when you remove the child restraint from the vehicle unless the person who The vehicle may have the following airbags: will be sitting there is a member of a passenger •...
Page 53 Here are the most important things to know about the airbag system: CAUTION: CAUTION: Airbags inﬂate with great force, faster than the blink of an eye. Anyone who is up against, or very close to, any airbag when it inﬂates can be You can be severely injured or killed in a crash if seriously injured or killed.
Page 54 The system checks the airbag electrical system for malfunctions. The light tells you if there is an electrical CAUTION: problem. See Airbag Readiness Light on page 3-27 for more information. Children who are up against, or very close to, any Where Are the Airbags? airbag when it inﬂates can be seriously injured or killed.
Page 55 CAUTION: If something is between an occupant and 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...
Page 56 When Should an Airbag Inﬂate? Frontal airbags may inﬂate at different crash speeds. For example: Frontal airbags are designed to inﬂate in moderate to • If the vehicle hits a stationary object, the airbags severe frontal or near-frontal crashes to help reduce the could inﬂate at a different crash speed than if the potential for severe injuries mainly to the driver’s or right vehicle hits a moving object.
Page 57: How Does An Airbag Restrain
How Does an Airbag Restrain? Thresholds can also vary with speciﬁc vehicle design. Frontal airbags are not intended to inﬂate during vehicle In moderate to severe frontal or near frontal collisions, rollovers, rear impacts, or in many side impacts. even belted occupants can contact the steering wheel In any particular crash, no one can say whether an or the instrument panel.
Page 58 What Will You See After an Airbag CAUTION: Inﬂates? After a frontal airbag inﬂates, it quickly deﬂates, so When an airbag inﬂates, there may be dust in the quickly that some people may not even realize the airbag air. This dust could cause breathing problems for inﬂated.
Page 59 • This switch should only be turned to the off position if Your vehicle has a crash sensing and diagnostic the person in the right front passenger position is a module which records information after a member of a passenger risk group identiﬁed by crash.
Page 60 Medical Condition. A passenger has a To turn off the right front passenger frontal airbag, medical condition which, according to his or insert your ignition key into her physician: the switch, push in, and • move the switch to the off Causes the passenger airbag to pose a special risk position.
Page 61 To turn the right front passenger airbag on CAUTION: again, insert the ignition key into the switch, push in, and move the If the airbag readiness light ever comes on and switch to the on position. stays on, it means that something may be wrong with the airbag system.
Page 62 Servicing Your Airbag-Equipped Adding Equipment to Your Vehicle Airbag-Equipped Vehicle Airbags affect how the vehicle should be serviced. There are parts of the airbag system in several places Is there anything I might add to or change around the vehicle. Your dealer/retailer and the about the vehicle that could keep the airbags service manual have information about servicing the from working properly?
Page 63: Restraint System Check
Torn or frayed safety belts may not protect you in a Because I have a disability, I have to get my crash. They can rip apart under impact forces. If a belt vehicle modiﬁed. How can I ﬁnd out whether is torn or frayed, get a new one right away.
Page 64: Replacing Restraint System Parts After A Crash
Replacing Restraint System Parts If you have had a crash, do you need new belts? After a very minor crash, nothing may be necessary. After a Crash But the belt assemblies that were used during any crash may have been stressed or damaged. See your dealer/retailer to have your safety belt assemblies CAUTION: inspected or replaced.
Page 65: Table Of Contents
Section 2 Features and Controls Keys ...............2-2 Diesel Engine Exhaust Brake ......2-26 Remote Keyless Entry (RKE) System ....2-3 Automatic Transmission Operation ....2-27 Remote Keyless Entry (RKE) System Manual Transmission Operation ......2-28 Operation ...........2-4 Power Take-Off (PTO) ........2-30 Four-Wheel Drive ..........2-30 Doors and Locks ..........2-6 Parking ............2-35 Door Locks ............2-6...
Page 66: Keys
Keys CAUTION: Leaving children in a vehicle with the ignition key is dangerous for many reasons, children or others could be badly injured or even killed. They could operate the power windows or other controls or even make the vehicle move. The windows will function with the keys in the ignition and children could be seriously injured or killed if caught in the path of a closing window.
Page 67 Remote Keyless Entry (RKE) If there is a decrease in the RKE operating range, try this: System • Check the distance. The transmitter may be too far from the vehicle. Stand closer during rainy or If this vehicle has the Remote Keyless Entry (RKE) snowy weather.
Page 68: Programming Transmitters To The Vehicle
Remote Keyless Entry (RKE) Programming Transmitters to the Vehicle System Operation Only RKE transmitters programmed to the vehicle For vehicles with the Remote Keyless Entry (RKE) will work. If a transmitter is lost or stolen, a replacement System, transmitter functions work up to 30 feet (9 m) can be purchased and programmed through your away from the vehicle.
Page 69 4. Align the transmitter back together. 5. Check the operation of the transmitter. If the transmitter does not work after battery replacement, it may need to be resynchronized to the vehicle. See Resynchronization following. Resynchronization Resynchronization may be necessary due to the security method used by this system.
Page 70: Doors And Locks
Doors and Locks CAUTION: (Continued) Door Locks • Young children who get into unlocked vehicles may be unable to get out. A child can be overcome by extreme heat and can suffer CAUTION: permanent injuries or even death from heat stroke.
Page 71: Power Door Locks
Power Door Locks To lock the door from the inside, slide the manual lever on the door down. If your vehicle has power To unlock the door, door locks, press the slide the manual lever up. bottom of the power door lock switch to lock all the doors at once.
Page 72: Windows
Windows CAUTION: Leaving children, helpless adults, or pets in a vehicle with the windows closed is dangerous. 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.
Page 73: Manual Windows
Manual Windows Express-Down The driver’s window has an express-down feature. Turn the hand crank on each door to raise or lower the This allows the window to be lowered fully without window. continuously holding the switch. Press the switch down fully to initiate the express-down feature.
Page 74: Starting And Operating Your Vehicle
Starting and Operating Your • Use the lowest gear you can when you start a loaded vehicle in motion and when going up Vehicle hills to avoid overloading the engine. • Check and adjust engine and transmission ﬂuid New Vehicle Break-In levels often and be sure tires are properly inﬂated for the load you are carrying.
Page 75: Ignition Positions
Ignition Positions C (OFF): This position turns off the engine, but leaves the steering wheel unlocked. Use OFF if you must have the vehicle in motion while the engine is off. The ignition switch has ﬁve different positions. D (ON/RUN): This position can be used to operate the electrical accessories and to display some instrument panel cluster warning and indicator lights.
Page 76 Engine Starter Over-Crank Manual Transmission Protection Set the parking brake, shift to N (Neutral) and hold the clutch pedal to the ﬂoor while starting the engine. The vehicle may have an engine starter over-crank Starter Motor Operation protection system. If the starter motor overheats and shuts off due to over-cranking, the motor must cool down •...
Page 77: Starting The Engine
Starting the Engine Gasoline Engine Warm-Up 1. Without pushing the accelerator pedal, turn the When the engine starts, let it run for 20 or 30 seconds ignition key to START. When the engine starts, to warm up before putting a load on it. let go of the key.
Page 78: Starting The Diesel Engine
Manual Transmission Moisture will condense in a fuel tank that is almost empty if the engine has not run for a while, even just Move the shift lever to N (Neutral) and hold the clutch overnight under some conditions. So, it is always best to pedal to the ﬂoor while starting the engine.
Page 79 Notice: If the wait to start light stays on after If you do not have the GM Automatic Ether Injection starting the vehicle, the vehicle may not run System, do not use starting ﬂuid or you could properly. Have the vehicle serviced right away. damage the engine.
Page 80 ® Cold Weather Starting (Caterpillar 3. Turn the ignition key to OFF. If the vehicle has a two-speed axle, see Two-Speed Diesel) Rear Axle on page 2-36. Because the diesel engine uses compression ignition, it ® If you have a Caterpillar diesel engine, see the is harder to start in cold weather than a gasoline engine.
Page 81 If the Diesel Engine Will Not Start If the batteries do not have enough charge to start the engine, see Battery on page 5-61. If you have run out of fuel, see Running Out of Fuel on Be sure you have the right oil for the engine, and that page 5-17.
Page 82: Engine Alarm And Automatic Shutdown
Engine Alarm and Automatic 25 to 30 seconds of operation. Do this only if you have to, since there is a problem that can harm the engine if it is Shutdown not ﬁxed. Engine automatic shutdown, for gasoline engines, requires activation by your dealer/retailer. The check gages warning light will come on if the Notice: If you try to operate the vehicle after the system senses high engine temperature, and a low or...
Page 83: Operation
Idle Shutdown The engine will not go into idle shutdown mode if: • The Power Take-Off (PTO) equipment is operating. If the vehicle has a diesel engine it could have an See Power Take-Off (PTO) on page 2-30 for more engine idle shutdown feature.
Page 84: High Idle System
High Idle System The ENGINE SHUTDOWN WARNING LIGHT will come on and a continuous chime will alert the driver 30 seconds before the engine goes into idle shutdown High Idle System with Switch mode. The engine shutdown warning light and chime will stay on for the entire duration of the idle shutdown If the vehicle has this event to inform the driver that the engine is in idle...
Page 85 This system can be used to increase the engine idle To set a new temporary engine idle speed do the speed whenever the following conditions are met: following: • The brake pedal is not pressed. 1. Make sure all of the previously described conditions •...
Page 86: Exhaust Restrictor (Engine Warm-Up)
Exhaust Restrictor (Engine For all engines this feature is already turned on. The ® automatic quick warm-up on the DURAMAX engine Warm-Up) can be turned off and on by doing the following procedure: Exhaust Restrictor 1. Turn the ignition to ON/RUN, with the vehicle off. If the vehicle has a Isuzu 6H Diesel Engine, it may have 2.
Page 87: Engine Checks Before Operating
Engine Checks Before Operating The engine idle speed will return to normal once the following conditions are met: When you have started the engine, let it run for • Once engine coolant temperature reaches about 20 to 30 seconds before you put a load on the engine. 150°F (65°C).
Page 88 • During this warm-up period, check the warning lights The charging system light should come on when the and gages: ignition key is turned to ON/RUN or START and should go out when the engine is running above idle. • If oil pressure does not begin to rise within If the light does not go out or comes back on during 15 seconds of starting, stop the engine and ﬁnd the...
Page 89: Engine Coolant Heater
Engine Coolant Heater CAUTION: The engine coolant heater can provide easier starting and better fuel economy during engine warm-up in cold weather conditions at or below 0°F (−18°C). Vehicles Plugging the cord into an ungrounded outlet could with an engine coolant heater should be plugged cause an electrical shock.
Page 90: Diesel Engine Exhaust Brake
Diesel Engine Exhaust Brake While using the exhaust brake, the proper gear range selection is important. The exhaust brake is most effective if the gear range selected is the lowest possible If the vehicle has a Isuzu 6H Diesel Engine, it may have range that does not allow the engine rpm to go more an exhaust brake, which is located in the exhaust than 200 rpm above rated (full load) rpm.
Page 91: Automatic Transmission Operation
Automatic Transmission Operation All vehicles with automatic transmission can be started in P (Park), if equipped, or in N (Neutral). See the ® ® Allison Transmission Operator’s Manual for additional If the vehicle has an Allison ﬁve-speed or six-speed ® information.
Page 92: Manual Transmission Operation
Overdrive Defeat Manual Transmission Operation If your vehicle has this feature, you can select not to Using the Clutch shift up to ﬁfth gear. This is useful when towing or under a heavy load. When you are starting to move the vehicle, it is important to begin with the engine speed at idle.
Page 93 ® ® Eaton Fuller Five and Six-Speed • Never move the range shift lever to the LO speed gear position after HI range preselection, or Transmissions and TTC Spicer anytime the transmission is in the HI range. Seven-Speed Transmissions • Never move the range knob or lever with the shift These transmissions have gears that automatically lever in N (Neutral) while the vehicle is moving.
Page 94: Power Take-Off (Pto)
Power Take-Off (PTO) Four-Wheel Drive If the vehicle has four-wheel drive, you can send the The vehicle may have engine’s driving power to all four wheels for extra power take-off (PTO). The traction. To get the most satisfaction out of four-wheel PTO switch is located drive, you must be familiar with its operation.
Page 95 Locking Hubs If the vehicle has four-wheel drive, the transfer case knob is located to the right of the steering wheel on the instrument panel. Use this knob to shift into and out of four-wheel drive. An indicator light shows you which position the transfer Hublock Dial Location Hublock Dial case is in.
Page 96 Recommended Transfer Case Settings CAUTION: Transfer Case Settings Driving Conditions Shifting the transfer case to Neutral can cause the Normal vehicle to roll even if the transmission is in Severe P (Park). You or someone else could be injured. If Extreme you are going to leave the vehicle, set the parking brake and shift the transmission to P (Park) and...
Page 97 Shifting Into Four-Wheel High Notice: Shifting the transmission into gear before the Four-Wheel Drive Low indicator light has Turn the knob to four-wheel high. This can be done at stopped ﬂashing could damage the transfer case. 3 mph or less. The indicator light ﬂashes while shifting. To help avoid damaging the vehicle, always wait for It remains on after the shift is complete.
Page 98 Shifting Out of Four-Wheel Low Shifting Into Neutral To shift from Four-Wheel Low to Four-Wheel High or Before shifting the transfer case to N (Neutral), ﬁrst Two-Wheel High, the vehicle must be stopped or moving make sure the vehicle is parked so that it will not roll. less than 3 mph (5 km/h) with the transmission in 1.
Page 99: Parking
Shifting Out of Neutral Excessively shifting the transfer case into or out of the different modes can cause the transfer case to enter the To shift the transfer case out of N (Neutral), do the shift protection mode. This protects the transfer case from following: possible damage and only allows the transfer case to respond to one shift per 10 seconds.
Page 100: Two-Speed Rear Axle
Parking a Vehicle With the Two-Speed For better performance during off-road or under a heavy load, shift the axle into Low Range and then operate Rear Axle the transmission normally. 1. With the engine running, shift the two-speed rear For better performance on the highway, shift the axle to axle into low.
Page 101 Two-Speed Rear Axle Shift Control Shifting Operation Upshifting the Axle To shift from Low to High Range: The rear axle shift control switch for automatic and 1. Press the bottom of the switch to shift the axle manual transmissions control from Low to High. is located in the instrument 2.
Page 102: Parking Brake (With Hydraulic Brakes)
Split Upshift (Manual Transmissions Only) To downshift the axle with a transmission upshift: 1. Push the clutch. 2. Shift the Transmission to a higher gear. 3. Shift the axle control from High to Low Range. 4. Release the clutch. 5. Push the accelerator pedal until the axle shifts. Split Downshift (Manual Transmission Only) To upshift the axle with a transmission downshift:...
Page 103 Once the parking brake is applied, slowly remove your foot from the regular brake pedal, while checking to CAUTION: see if the vehicle moves. If the vehicle does start to move, press the regular brake pedal and adjust the parking brake holding force. See “Parking Brake It can be dangerous to get out of the vehicle Adjustment”...
Page 104 Parking Brake Adjustment (Hand Lever System Only) Make sure the parking brake burnish procedure has been previously followed before continuing with any park brake adjustment. See Parking Brake Burnish Procedure on page 2-43 for more information. Parking brake adjustment may be necessary after the burnish procedure or at the scheduled maintenance intervals.
Page 105: Parking Brake (With Air Brakes)
Parking Brake (With Air Brakes) Notice: Over-tightening the park brake lever can cause damage to the park brake system. Over-tightening is possible by turning the knob If the vehicle has air more than half a turn. brakes, you will have this Over-tightening is similar to driving down the road with parking brake.
Page 106 Vehicles built for use as tractors or towing vehicles have To charge a trailer’s air brake system do the following: two air brake controls. They look like this: 1. Move the vehicle into the proper position. 2. Apply the parking brake by pulling the yellow parking brake knob out.
Page 107: Parking Brake Burnish Procedure
Parking Brake Burnish Procedure CAUTION: All vehicles which have hydraulic brakes have a parking brake. It is recommended that the parking brake be burnished as part of the new vehicle break-in. The If you apply any one of the air brake parking parking brake will work best after it has been burnished controls while the vehicle is moving, the rig will following these instructions:...
Page 108: Air Suspension
Air Suspension Press the bottom of the switch to deﬂate the air suspension and lower the deck height. Press the top of the switch to return the suspension to normal deck height. The vehicle may have the Hendrickson HAS Series single-axle air suspension which is designed for An indicator light will come on and stay on whenever a single-axle on-highway use.
Page 109: Engine Exhaust
Engine Exhaust CAUTION: (Continued) • CAUTION: The vehicle’s exhaust system has been modiﬁed, damaged or improperly repaired. • There are holes or openings in the vehicle Engine exhaust contains Carbon Monoxide (CO) body from damage or after-market which cannot be seen or smelled. Exposure to CO modiﬁcations that are not completely sealed.
Page 110: Diesel Particulate Filter
Diesel Particulate Filter To clean the ﬁlter, either drive the vehicle above 30 mph (50 km/h) to activate self cleaning, or stop the vehicle and perform the manual cleaning procedure. For The vehicle has a Diesel Particulate Filter (DPF) as part self cleaning, drive until the green DPF indicator light of the exhaust system to reduce vehicle emissions.
Page 111 Notice: Extended idle should be avoided because Notice: Permanent damage can occur to the DPF the DPF system is not capable of self cleaning at or related components if the required Ultra Low idle. During extended idle operation, monitor the Sulfur Diesel (15 ppm sulfur maximum) or low ash instrument panel telltale lights and Driver Information CJ-4 engine oil is not used.
Page 112 Manual Cleaning Procedure When it is safe to do so, stop the vehicle. Perform DPF manual cleaning in a well ventilated area. DPF Manual cleaning must be performed outdoors, as follows. Once manual cleaning is started, complete the manual cleaning CAUTION: in a single operation if possible.
Page 113 4. Fully set the parking brake. 9. When both the green and the yellow or red DPF indicator lights go off, cleaning is completed. 5. Shift the transmission to P (Park) or N (Neutral). Manual cleaning is normally completed in about 6.
Page 114: Running The Vehicle While Parked
Running the Vehicle While Parked CAUTION: It is better not to park with the engine running. But if you ever have to, here are some things to know. It can be dangerous to get out of the vehicle if the automatic transmission shift lever is not fully in CAUTION: P (Park) with the parking brake ﬁrmly set.
Page 115: Mirrors
Mirrors Outside Power Mirrors If the vehicle has outside power mirrors, they can be Manual Rearview Mirror adjusted from the inside of the vehicle. Hold the inside rearview mirror in the center to move Controls for the outside it for a clearer view behind your vehicle. Adjust the power mirrors are located mirror to avoid glare from the headlamps behind you.
Page 116: Outside Convex Mirrors
Outside Convex Mirrors Outside Heated Mirrors If your vehicle has this feature, the outside rearview mirrors can be defrosted. CAUTION: The switch is located in the instrument panel A convex mirror can make things (like other switchbank. vehicles) look farther away than they really are. If you cut too sharply into the right or left lane, you could hit a vehicle.
Page 117: Storage Areas
Storage Areas Center Console Storage Your vehicle may have a center console compartment. Your vehicle includes a number of storage compartments. The back of your center bench seat may also fold forward to reveal a console compartment. Some vehicles have storage areas in the instrument panel.
Page 118 ✍ NOTES 2-54...
Page 119: Instrument Panel
Section 3 Instrument Panel Instrument Panel Overview .......3-4 Climate Controls ..........3-20 Hazard Warning Flashers ........3-6 Climate Control System .........3-20 Horn .............3-6 Outlet Adjustment .........3-22 Tilt Wheel .............3-6 Rear Heating System ........3-23 Turn Signal/Multifunction Lever ......3-7 Warning Lights, Gages, and Indicators ....3-23 Turn and Lane-Change Signals ......3-7 Instrument Panel Cluster ........3-24 Headlamp High/Low-Beam Changer ....3-8...
Page 120 Section 3 Instrument Panel Low Coolant Warning Light ......3-35 Check Gages Warning Light ......3-43 Wait to Start Light ........3-35 Fuel Gage ...........3-44 Malfunction Indicator Lamp ......3-36 Water in Fuel Warning Light ......3-45 Oil Pressure Gage ........3-38 Change Fuel Filter Warning Light ....3-45 Low Oil Level Light ........3-39 Diesel Particulate Filter Warning Light ....3-46 Change Engine Oil Light ........3-39...
Page 121 ✍ NOTES...
Page 122: Instrument Panel Overview
Instrument Panel Overview Automatic Transmission Shown, Manual Transmission Similar...
Page 123 The main components of the instrument panel are the following: A. Outlet Adjustment on page 3-22. F. Auxiliary Gages. See Warning Lights, Gages, and Indicators on page 3-23. B. Instrument Panel Cluster on page 3-24. G. Exterior Lamps on page 3-14. C.
Page 124: Hazard Warning Flashers
Hazard Warning Flashers Tilt Wheel A tilt wheel lets the steering wheel be adjusted. (Hazard Warning Flasher): Press this button located on top of the steering column, to make the front and rear turn signal lamps ﬂash on and off. This warns others that you are having trouble.
Page 125: Turn Signal/Multifunction Lever
Turn Signal/Multifunction Lever Turn and Lane-Change Signals An arrow on the instrument panel cluster ﬂashes in the direction of the turn or lane change. Move the lever all the way up or down to signal a turn. Raise or lower the lever until the arrow starts to ﬂash to signal a lane change.
Page 126: Headlamp High/Low-Beam Changer
Headlamp High/Low-Beam Changer Windshield Wipers To change the headlamps from low to high beam or The windshield wipers are high to low beam, pull the multifunction lever all the way controlled by turning the toward you, then release it. band with the wiper symbol on it.
Page 127: Windshield Washer
Windshield Washer For steady wiping at low speed, turn the band toward you to the ﬁrst solid band below the delay settings. (Washer Fluid): There is a paddle marked with the For high-speed wiping, turn the band farther, to the last solid band below the delay settings.
Page 128: Cruise Control
Cruise Control For vehicles with this feature, it is located at the end of the multifunction With cruise control, a speed of about 25 mph (40 km/h) lever. or more can be maintained without keeping your foot on the accelerator. Cruise control does not work at speeds below about 25 mph (40 km/h).
Page 129 Setting Cruise Control Resuming a Set Speed If the cruise control is set at a desired speed and then the brake is applied, this shuts off the cruise control. CAUTION: But it does not need to be reset. Once the vehicle is going about 25 mph (40 km/h) or If you leave your cruise control on when you are more, move the cruise control switch brieﬂy from not using cruise, you might hit a button and go...
Page 130 Increasing Speed While Using Cruise Reducing Speed While Using Cruise Control Control There are two ways to go to a higher speed: Press at the end of the lever until the lower speed • desired is reached, then release it. Use the accelerator pedal to get to the higher speed.
Page 131 Using Cruise Control on Hills Ending Cruise Control How well the cruise control works on hills depends upon There are four different ways to turn off the cruise the vehicles speed, load and the steepness of the hills. control: When going up steep hills, you may want to step on the •...
Page 132: Exterior Lamps
Exterior Lamps (Parking Lamps): Turns on the parking lamps, together with the following: • Marker Lamps • Taillamps • License Plate Lamps • Instrument Panel Lights (Headlamps): Turns on the headlamps, together with the previously listed lamps and lights. Change the headlamps from low to high beam by pulling the turn signal/multifunction lever toward you.
Page 133: Daytime Running Lamps (Drl)
Daytime Running Lamps (DRL) When it gets dark, the DRL indicator light is a reminder to turn the Daytime Running Lamps (DRL) can make it easier for headlamps on. others to see the front of your vehicle during the day. Fully functional daytime running lamps are required on all vehicles ﬁrst sold in Canada.
Page 134: Marker Lamps
Marker Lamps Instrument Panel Brightness For vehicles with this feature, the marker and clearance This feature controls the brightness of the instrument lamps can be manually blinked. panel lights. The thumbwheel for this feature is located to the right of The marker lamp defeat the exterior lamp control.
Page 135: Entry Lighting
Entry Lighting The delayed illumination feature allows you to enter or exit the vehicle with the lights on for about 20 seconds, after the door is closed or the ignition is cycled. Reading Lamps For vehicles with reading lamps, press the button next to the lamp to turn the lamp on or off.
Page 136: Instrument Panel Switchbank
Instrument Panel Switchbank This switchbank is located in the center of the instrument panel. : Marker Lamps on page 3-16. : Power Take-Off (PTO) on page 2-30 and High Idle System on page 2-20. : Traction Control System (TCS) on page 4-8. : Outside Heated Mirrors on page 2-52.
Page 137: Accessory Power Outlet(S)
Accessory Power Outlet(s) When adding electrical equipment, be sure to follow the proper installation instructions included with the equipment. Accessory power outlets let you plug in auxiliary electrical equipment, such as a cellular telephone. Notice: Improper use of the power outlet can cause The accessory power outlet is located on the damage not covered by the warranty.
Page 138: Climate Controls
Climate Controls Air Delivery Mode Control: Turn clockwise or counterclockwise to change the direction of the airﬂow inside the vehicle. Climate Control System To change the current mode, select one of the following: The heating, cooling, and ventilation for the vehicle can (Vent): Air is directed to the instrument panel vents.
Page 139 (Air Conditioning): For normal cooling on hot days. Outside air is cooled and directed to the instrument panel vents. (Bi-Level Air Conditioning): Air is divided between the ﬂoor and instrument panel vents. The air conditioning compressor cycles continuously in this setting as long as the outside temperature is warm enough to activate the Vehicles With Air Conditioning compressor.
Page 140: Rear Window Defogger
Rear Window Defogger Outlet Adjustment For vehicles with a rear window defogger, a warming The vehicle has air outlets on the instrument panel that grid is used to remove fog or frost from the rear window. adjust the direction and amount of airﬂow inside the vehicle.
Page 141: Rear Heating System
Rear Heating System Warning Lights, Gages, and Indicators If the vehicle has a crew cab and has a rear heater, Warning lights and gages can signal that something is the thumbwheel for this wrong before it becomes serious enough to cause feature is located on an expensive repair or replacement.
Page 142: Instrument Panel Cluster
Instrument Panel Cluster The instrument panel cluster is designed to let you know at a glance how your vehicle is running. You will know how fast you are going, about how much fuel is left and many other things you will need to drive safely and economically. Isuzu 6H Diesel Engine shown, 6.6L &...
Page 143: Speedometer And Odometer
Speedometer and Odometer Tachometer The speedometer shows the vehicle’s speed in both miles per hour (mph) and kilometers per hour (km/h). The odometer shows how far the vehicle has been driven, in either miles (used in the United States) or kilometers (used in Canada). Trip Odometer The trip odometer can tell you how far your vehicle has been driven since you last set the trip odometer to zero.
Page 144: Safety Belt Reminders
Engine Road Speed Governor Safety Belt Reminders This system controls maximum vehicle speed Safety Belt Reminder Light automatically and reduces engine power until vehicle speed gets down to maximum governed speed. When the engine is started, a light will come on for several seconds to remind people to fasten their safety The default setting for C4500 and C5500 models up to belts.
Page 145: Airbag Readiness Light
Airbag Readiness Light The airbag readiness light should ﬂash for a few seconds when you turn the ignition key to ON/RUN or START. If the light doesn’t come on then, have it If your vehicle has airbags, there is an airbag readiness ﬁxed so it will be ready to warn you if there is a problem.
Page 146: Airbag Off Light
Airbag Off Light CAUTION: If the vehicle has an airbag on-off switch, it also has a passenger airbag status indicator located in the instrument panel. If the right front passenger’s airbag is turned off for a person who is not in a risk group identiﬁed When the right front by the national government, that person will not passenger airbag is...
Page 147: Charging System Light
Charging System Light CAUTION: The charging system light may be located in the If the airbag readiness light ever comes on and instrument panel cluster, or stays on, it means that something may be wrong with the auxiliary warning with the airbag system. For example, the right lights in the center of the instrument panel.
Page 148: Voltmeter Gage
Voltmeter Gage Service Transmission Warning Light ® If your vehicle has an Allison automatic transmission, When your engine is certain transmission malfunctions will turn this light on. running, the voltmeter gage shows the charging This light is located with system voltage. the auxiliary warning lights in the center of the instrument panel.
Page 149: Range Inhibit Warning Indicator
Range Inhibit Warning Indicator Brake System Warning Light If your vehicle has an Allison 1000/2200/2300/ Your vehicle has either hydraulic or air brakes. Each 2500 series automatic transmission, a lighted bar system has different warning lights. under the current gear selected will ﬂash. Hydraulic Brake System Warning Lights If your vehicle has an Allison 3000/3500 series automatic transmission, the current gear selected on the pushbutton...
Page 150 Air Brake System Warning Light If the light comes on while driving, pull off the road and stop carefully. The pedal might be harder to push or Vehicles with air brake systems have a brake system might go the ﬂoor. It can take longer to stop. If the light warning light on the instrument panel.
Page 151: Antilock Brake System (Abs) Warning Light
Antilock Brake System (ABS) When the warning light comes on while you are driving, you should drive only as far as the nearest point of Warning Light safety and then stop the vehicle. Here is a very important thing for you to know: This light will come on brieﬂy when you start the CAUTION:...
Page 152: Trailer Antilock Brake System Warning Light
Trailer Antilock Brake System Engine Coolant Temperature Gage Warning Light This gage shows the engine coolant If your vehicle is connected temperature. If the gage to a trailer with antilock pointer moves into the brakes, this light should red area, your engine come on brieﬂy, as a coolant might have check, when you turn on...
Page 153: Low Coolant Warning Light
Low Coolant Warning Light Wait to Start Light ® If your vehicle has the DURAMAX 6.6L diesel engine, Your vehicle has a low it will have glow plugs and an air intake heater. If your coolant warning light. vehicle has the Isuzu 6H diesel engine, it will have glow If this light comes on, the plugs and an inlet heater.
Page 154: Malfunction Indicator Lamp
Malfunction Indicator Lamp This light should come on when the ignition is on, but the engine is not running, as a check to show it is working. If it does not come on at all, have it repaired. Check Engine Light Notice: If the vehicle is continually driven with A computer system called OBD II (On-Board this light on, after a while, the emission controls...
Page 155: Emissions Inspection And Maintenance Programs
Emissions Inspection and Maintenance An emission system malfunction might be corrected by doing the following: Programs • If the vehicle has been driven through a deep Some state/provincial and local governments have or puddle of water, the vehicle’s electrical system might begin programs to inspect the emission control might be wet.
Page 156: Oil Pressure Gage
Oil Pressure Gage 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 The engine oil pressure ® Caterpillar Operation & Maintenance Manual. gage, on the lower right portion of your instrument panel cluster, shows...
Page 157: Low Oil Level Light
Low Oil Level Light Notice: Lack of proper engine oil maintenance can damage the engine. The repairs would not be covered by the vehicle warranty. Always follow the Your vehicle may have a maintenance schedule in this manual for changing low oil level light.
Page 158: Engine Overspeed Warning Light
Engine Overspeed Warning Light Transmission Temperature Gage If your vehicle has this If you have an automatic light, it will come on if transmission and this gage, your engine is operating it is located above the at too many revolutions per switchbank in the center of minute (rpm).
Page 159: Exhaust Brake Indicator Light
Exhaust Brake Indicator Light Differential Lock Indicator Light For vehicles with an If your vehicle has exhaust brake, this light is this feature, this light is located above the located in the center of climate controls. the instrument panel. The light is on when the rear differential lock system is in use.
Page 160: Reduced Engine Power Light
Reduced Engine Power Light Highbeam On Light If the check engine and This light comes on when reduced engine power the high-beam headlamps lights are on, the electronic are in use. throttle control may be disabled. A noticeable change in the vehicle’s performance may See Headlamp High/Low-Beam Changer on page 3-8 also occur.
Page 161: Low Washer Fluid Warning Light
Low Washer Fluid Warning Light Check Gages Warning Light This light is located above This light will come on the climate controls in the brieﬂy when the engine is center of the instrument started. panel. This light will come on when your vehicle is low on If this light comes on and stays on while you are driving.
Page 162: Fuel Gage
Fuel Gage Here are four concerns of some operators. None of these shows a problem with your fuel gage: • The gage moves a little when you turn a corner or Your fuel gage is located on the right side of your speed up.
Page 163: Water In Fuel Warning Light
Water in Fuel Warning Light Change Fuel Filter Warning Light This light is located above For vehicles with this light, the climate controls in the it is located in the center of center of the instrument the instrument panel. panel. ®...
Page 164: Diesel Particulate Filter Warning Light
Diesel Particulate Filter Warning Air Filter Restriction Indicator Light If your vehicle has this feature, the gage is located Your vehicle may have two above the switchbank in Diesel Particulate Filter the center of the instrument (DPF) Warning lights. panel. It monitors the engine air ﬁlter.
Page 165: Air Pressure Gage
Air Pressure Gage The bottom yellow pointer shows the pressure available for the front secondary system, while the top white pointer shows pressure for the rear primary system. If your vehicle has air There should be no more than 4 psi (28 kPa) difference brakes, the air pressure showing between the systems.
Page 166: Audio System(S)
Audio System(s) Notice: Contact your dealer/retailer before adding any equipment. If the vehicle came without a radio, the wiring provisions Adding audio or communication equipment could for a radio and an antenna were installed at the interfere with the operation of the vehicle’s engine, assembly plant, so that if you want, a radio can be radio, or other systems, and could damage them.
Page 167: Radio(S)
Radio(s) Playing the Radio PWR (Power): Press to turn the system on and off. VOL (Volume): Turn clockwise or counterclockwise to increase or to decrease the volume. RCL (Recall): Press to switch the display between the radio station frequency and the time. When the ignition is off, press to display the time.
Page 168: Setting Preset Stations
Setting Preset Stations To adjust bass or treble to the middle position, select BAS or TRE. Then press and hold the AUDIO button for Up to 18 stations (six FM1, six FM2, and six AM), can more than two seconds until a beep sounds. B and a be programmed on the six numbered pushbuttons, zero or T and a zero displays.
Page 169: Playing A Cd
Playing a CD To adjust balance or fade to the middle position, select BAL or FAD. Then press and hold AUDIO for more than Insert a CD partway into the slot, label side up. The two seconds until a beep sounds. B (balance) and a zero player pulls it in and the CD should begin playing.
Page 170 Care of Your CDs Care of Your CD Player If playing a CD-R, the sound quality can be reduced Do not add any label to a CD, it could get caught in the due to CD-R quality, the method of recording, the quality CD player.
Page 171 1 PREV (Previous): Press to go to the beginning of the RCL (Recall): Press this to see the current track current track if more than eight seconds have played. number or how long the current track has been playing. The track number displays. If this pushbutton is held or AM FM: Press to listen to the radio when a CD is pressed more than once, the player continues moving playing.
Page 172: Playing A Cassette Tape
If the CD is not playing correctly, for any other reason, Cassette tape adapter kits for portable CD players try a known good CD. works in the cassette tape player. See “CD Adapter Kits” later for more information. If any error occurs repeatedly or if an error cannot be corrected, contact your dealer/retailer.
Page 173 2 NEXT: The tape must have at least three seconds of SEEK : The tape must have at least three seconds silence between each selection for next to work. Press of silence between each selection for seek to work. The this pushbutton to go to the next selection on the tape.
Page 174 Care of the Cassette Tape Player The cut tape detection feature of the cassette tape player may identify the cleaning cassette as a damaged tape. A tape player that is not cleaned regularly can cause To prevent the cleaning cassette from being ejected, reduced sound quality, ruined cassettes, or a damaged use the following steps: mechanism.
Page 175: Theft-Deterrent Feature
Cassette Tape Messages CD Adapter Kits It is possible to use a portable CD player adapter kit ERR (Error): If the player detects a tight or broken with the cassette tape player after deactivating the tape, this message displays and the player ejects the tight/loose tape sensor feature on the tape player.
Page 176: Radio Reception
Radio Reception Fixed Mast Antenna Frequency interference and static can occur during The ﬁxed mast antenna can withstand most car washes normal radio reception if items such as cell phone without being damaged as long as it is securely attached chargers, vehicle convenience accessories, and external to the base.
Page 177: Driving Your Vehicle
Section 4 Driving Your Vehicle Your Driving, the Road, and the Vehicle ....4-2 Loss of Control ..........4-12 Driving for Better Fuel Economy .......4-2 Driving at Night ..........4-13 Defensive Driving ...........4-2 Driving in Rain and on Wet Roads ....4-14 Drunk Driving ..........4-3 Highway Hypnosis ........4-15 Control of a Vehicle ........4-3 Hill and Mountain Roads ........4-16...
Page 178: Your Driving, The Road, And The Vehicle
Your Driving, the Road, and Defensive Driving the Vehicle Defensive driving means “always expect the unexpected.” The ﬁrst step in driving defensively is to wear your safety belt — See Safety Belts: They Are for Driving for Better Fuel Economy Everyone on page 1-11.
Page 179: Drunk Driving
Drunk Driving 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. CAUTION: The obvious way to eliminate the leading highway safety problem is for people never to drink alcohol and Drinking and then driving is very dangerous.
Page 180: Braking
Braking traffic and allowing realistic following distances eliminates a lot of unnecessary braking. That means better braking and longer brake life. See Brake System Warning Light on page 3-31. If the engine ever stops while the vehicle is being driven, Braking action involves perception time and reaction brake normally but do not pump the brakes.
Page 181: Antilock Brake System (Abs)
Antilock Brake System (ABS) ABS can change the brake pressure to each wheel, as required, faster than any driver could. This can help the driver steer around the obstacle while braking hard. This vehicle has the Antilock Brake System (ABS), an advanced electronic braking system that helps prevent a As the brakes are applied, the computer keeps braking skid.
Page 182: Trailer Brake Hand Control Valve
Trailer Brake Hand Control Valve You can apply the trailer brakes a little or apply them all the way if you have to. Use this control only when you are driving. Do not use it for parking or to hold the If your vehicle has this feature, the control is mounted rig on a hill.
Page 183: Rear Axle Differential Lock Control
Rear Axle Differential Lock Control 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). If the vehicle has a Turn on this control only while the wheels are controlled traction or not spinning freely.
Page 184: Traction Control System (Tcs)
Traction Control System (TCS) When the light in the top of the TCS button is on, TCS is off and will not limit wheel spin. Adjust your driving accordingly. The vehicle may have a traction control system that limits wheel spin. This is especially useful in slippery road The light in the top of the TCS button will come on if conditions.
Page 185: Steering
Steering To turn the system on or off, press the traction control button located on Power Steering the instrument panel. If power steering assist is lost because the engine stops or the system is not functioning, the vehicle can be steered but it will take more effort.
Page 186: Steering In Emergencies
Steering in Emergencies There are times when steering can be more effective than braking. For example, you come over a hill and ﬁnd a truck stopped in your lane, or a car suddenly pulls out from nowhere, or a child darts out from between parked cars and stops right in front of you.
Page 187: Off-Road Recovery
Off-Road Recovery Passing The vehicle’s right wheels can drop off the edge of a Passing another vehicle on a two-lane road can be road onto the shoulder while driving. dangerous. To reduce the risk of danger while passing: • A vehicle like yours takes a longer time to reach passing speed, so you will need a longer stretch of clear road ahead than you would with a passenger car.
Page 188: Loss Of Control
Loss of Control Of course, traction is reduced when water, snow, ice, gravel, or other material is on the road. For safety, slow down and adjust your driving to these conditions. It is Let us review what driving experts say about what important to slow down on slippery surfaces because happens when the three control systems —...
Page 189: Driving At Night
Driving at Night • When tired, pull off the road. • Do not wear sunglasses. Night driving is more dangerous than day driving because • some drivers are likely to be impaired — by alcohol or Avoid staring directly into approaching headlamps. drugs, with night vision problems, or by fatigue.
Page 190: Driving In Rain And On Wet Roads
Driving in Rain and on Wet Roads CAUTION: (Continued) Rain and wet roads can reduce vehicle traction and affect your ability to stop and accelerate. Always After driving through a large puddle of water or a drive slower in these types of driving conditions and avoid driving through large puddles and car/vehicle wash, lightly apply the brake pedal until deep-standing or ﬂowing water.
Page 191: Highway Hypnosis
Hydroplaning Highway Hypnosis Hydroplaning is dangerous. Water can build up under Always be alert and pay attention to your surroundings your vehicle’s tires so they actually ride on the while driving. If you become tired or sleepy, ﬁnd a water. This can happen if the road is wet enough and safe place to park your vehicle and rest.
Page 192: Hill And Mountain Roads
Hill and Mountain Roads CAUTION: Driving on steep hills or through mountains is different than driving on ﬂat or rolling terrain. Tips for driving in these conditions include: Coasting downhill in N (Neutral) or with the ignition • off is dangerous. The brakes will have to do all the Keep the vehicle serviced and in good shape.
Page 193: Winter Driving
Winter Driving If the vehicle has the Traction Control System (TCS) on page 4-8, it improves the ability to accelerate on slippery roads, but slow down and adjust your driving to Driving on Snow or Ice the road conditions. When driving through deep snow, turn off the traction control system to help maintain Drive carefully when there is snow or ice between the vehicle motion at lower speeds.
Page 194 Blizzard Conditions CAUTION: (Continued) Being stuck in snow can be in a serious situation. Stay with the vehicle unless there is help nearby. If possible, • Open a window about two inches (5 cm) on use the Roadside Assistance Program on page 7-5. the side of the vehicle that is away from the To get help and keep everyone in the vehicle safe: wind to bring in fresh air.
Page 195: If Your Vehicle Is Stuck In Sand, Mud, Ice, Or Snow
Repeat this until help arrives but only when you feel really uncomfortable from the cold. Moving about CAUTION: to keep warm also helps. If it takes some time for help to arrive, now and then If you let your vehicle’s tires spin at high speed, when you run the engine, push the accelerator they can explode, and you or others could be pedal slightly so the engine runs faster than the idle...
Page 196: Tow Hooks
Tow Hooks CAUTION: These hooks, when used, are under a lot of force. Always pull the vehicle straight out. Never pull on the hooks at a sideways angle. The hooks could break off and you or others could be injured from the chain or cable snapping back.
Page 197 The Certiﬁcation label also tells you the maximum Notice Overloading your vehicle may cause weight for the front and rear axles, called the Gross Axle damage. Repairs would not be covered by your Weight Rating (GAWR). To ﬁnd out the actual loads warranty.
Page 198: Adding A Snow Plow Or Similar Equipment
Adding a Snow Plow or Similar CAUTION: Equipment If you will be installing a snow plow on your vehicle, we On some vehicles that have certain front mounted recommend that the vehicle have the snow plow equipment, such as a snow plow, it may be prep package (RPO ANQ).
Page 199: Towing
Towing The tow operator can release the brakes manually by using the following steps. Then the vehicle can be towed with all wheels or only the rear wheels on the ground. Towing Your Vehicle 1. Block the wheels of the vehicle. Consult your dealer/retailer or a professional towing service to have the vehicle towed.
Page 200 3. Remove the rubber 6. Turn the stud nut cap from the rear of clockwise several turns the chamber. to release the brakes. Follow the same procedure to release the other brake or brakes. 4. Put the release stud, nut and ﬂat washer into the 7.
Page 201: Trailer Connections
Trailer Connections Trailer Connections (C7/C8 Models Only) Heavy-Duty Trailer Wiring Package If the vehicle has these trailer connections, they are The vehicle may be equipped with an eight-wire trailer located at the rear of the cab for a tractor and at the rear towing harness.
Page 202 ✍ NOTES 4-26...
Page 203: Service And Appearance Care
Section 5 Service and Appearance Care Service ............5-3 Engine Oil Life System (DURAMAX/Isuzu Accessories and Modiﬁcations ......5-3 Diesel Engines) .........5-36 California Proposition 65 Warning .....5-4 Engine Oil Life System (Caterpillar California Perchlorate Materials Requirements ..5-4 Diesel Engine) ..........5-38 Doing Your Own Service Work ......5-5 Engine Air Cleaner/Filter ........5-38 Engine Fan Breakage ........5-6 Automatic Transmission Fluid ......5-42...
Page 204 Section 5 Service and Appearance Care Windshield Wiper Blade Replacement ....5-71 Cleaning Exterior Lamps/Lenses .....5-90 Finish Care ..........5-90 Other Service Items ........5-72 Windshield and Wiper Blades ......5-91 Fuel Filter ............5-72 Aluminum or Chrome-Plated Wheels Primary Fuel Filter and Water Separator ..5-73 and Trim ..........5-92 Secondary Fuel Filter and Water Separator/ Tires ............5-92...
Page 205: Service
Service Accessories and Modiﬁcations Adding non-dealer accessories to the vehicle can affect For service and parts needs, visit your dealer/retailer. its performance and safety. Such things as airbags, You will receive genuine GM parts and GM-trained and braking, stability, ride and handling, emissions systems, supported service people.
Page 206: California Proposition 65 Warning
Aftermarket Engine Performance California Proposition 65 Warning Enhancement Products and Most motor vehicles, including this one, contain and/or Modiﬁcations emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Some aftermarket engine performance products and Engine exhaust, many parts and systems (including modiﬁcations promise a way to increase the horsepower some inside the vehicle), many ﬂuids, and some...
Page 207: Doing Your Own Service Work
Doing Your Own Service Work If doing some of your own service work, use the proper service manual. It tells you much more about how to service the vehicle than this manual can. To order the proper service manual, see Service Publications CAUTION: Ordering Information on page 7-10.
Page 208: Engine Fan Breakage
Engine Fan Breakage Fuel For diesel engine vehicles, see Diesel Engine Fuel on CAUTION: page 5-8. For vehicles with gasoline engines, please read this. Changing the Fan Drive Ratio or Engine Governed Use of the recommended fuel is an important part of the Speed: proper maintenance of this vehicle.
Page 209: Gasoline Speciﬁcations
Gasoline Speciﬁcations Also, your dealer/retailer has additives that will help correct and prevent most deposit-related problems. At a minimum, gasoline should meet ASTM speciﬁcation Gasolines containing oxygenates, such as ethers and D 4814 in the United States or CAN/CGSB-3.5 or 3.511 in ethanol, and reformulated gasolines might be available in Canada.
Page 210: Diesel Engine Fuel
Diesel Engine Fuel What Fuel to Use ® ® For the Caterpillar diesel, see the Caterpillar Notice: Use of diesel fuel other than Ultra Low Operation & Maintenance Manual for information Sulfur Diesel (15 ppm sulfur maximum) or engine oil concerning fuel usage.
Page 211 In the United States, for best results use No. 2-D diesel Because of the cleansing properties of biodiesel, fuel year-round (above and below freezing conditions) as switching from straight diesel to a biodiesel blend can oil companies blend No. 2-D fuel to address climate prematurely restrict the fuel ﬁlter with normal deposits in differences.
Page 212 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 might notice Notice: Use of diesel fuel other than Ultra Low Sulfur Diesel (15 ppm sulfur maximum) or engine oil some power and fuel economy loss.
Page 213: Very Cold Weather Operation
Very Cold Weather Operation Notice: If there is water in the diesel fuel and the weather is warm or humid, fungus and bacteria can grow in the fuel. They can damage the fuel system. Follow the instructions listed previously under the A diesel fuel biocide can be used to sterilize the heading “What Fuel to Use.”...
Page 214 Water In Fuel Light Notice: Driving when this warning indicator is on, can damage the fuel injection system and the engine. Problem Recommended Action If the indicator comes on right after a refuel, it means Light comes on Drain water from the fuel water was pumped into the fuel tank.
Page 215 4. Open the drain valve 6. Install the fuel cap. by turning two to three 7. Start the engine and let it run for a few minutes. turns. When fuel If the engine stalls, the fuel system may need to empties from the valve, be primed.
Page 216 ® Priming the 6.6L Duramax Diesel Engine Air can get into the fuel lines if any of the following happen: ® If the vehicle is equipped with the 6.6L Duramax diesel • The vehicle runs out of fuel. engine, it has a priming pump which is part of the engine mounted fuel ﬁlter.
Page 217 5. Open the fuel ﬁlter vent 7. Operate the priming pump until a small amount of valve by turning the fuel seeps from the vent valve. When fuel is seen, screw counterclockwise the ﬁlter is full of fuel and the system should be several full turns.
Page 218 ® Priming the 7.8L Duramax Diesel Engine 4. Make sure the fuel ﬁlter is cool to the touch. 5. Use a clean cloth to remove dirt and oil from the ® If the vehicle is equipped with the 7.8L Duramax diesel fuel ﬁlter head and breather valve.
Page 219: Running Out Of Fuel
Running Out of Fuel 2. Follow the fuel priming procedure earlier in this section to prime the fuel ﬁlter. If the diesel engine stalls and you think that you have 3. Close the air bleed valve. run out of fuel, do this to restart the engine: 4.
Page 220: Fuel Filter Replacement
Fuel Filter Replacement If the vehicle has the 6.6L engine, the fuel ﬁlter is located in the engine compartment on the driver side of the vehicle. If the vehicle has either the 7.2L or 7.8L engine, If you want to change the diesel engine fuel ﬁlter the fuel ﬁlters are located in the engine compartment yourself, here is how to do it: on the driver side of the vehicle, and on the driver side...
Page 221: Fuels In Foreign Countries
4. Install the new ﬁlter element. To reset the Fuel Filter Change light: 5. Reinstall and tighten the ﬁlter container and 1. Turn the ignition key to ON/RUN with the engine off reconnect the water sensor wire to the ﬁlter. 2.
Page 222: Filling The Tank
Filling the Tank CAUTION: Fuel vapor is highly ﬂammable. It burns violently, and that can cause very bad injuries. Do not smoke if you are near fuel or refueling the vehicle. Keep sparks, ﬂames and smoking materials away from fuel. The fuel cap can be on either or both sides of the vehicle depending on option content.
Page 223 If the vehicle has dual tanks, ﬁll the driver side tank, or forward tank, ﬁrst. The fuel gage will give better CAUTION: readings this way. The gage will show the total fuel left in both tanks. If you get fuel on yourself and then something If the vehicle is a C4/C5 model and has dual tanks, the ignites it, you could be badly burned.
Page 224: Filling A Portable Fuel Container
Filling a Portable Fuel Container Checking Things Under the Hood CAUTION: CAUTION: Never ﬁll a portable fuel container while it is in the vehicle. Static electricity discharge from the Things that burn can get on hot engine parts and container can ignite the fuel vapor. You can be start a ﬁre.
Page 225: Hood Latches
Hood Latches Then take the hand hold and pull the hood forward. When you tilt the hood far enough, there are cables that To tilt the hood forward, pull back and up on each of the will support it. When you close the hood, make sure hood latches, located above the wheel wells on both both latches are secured.
Page 226: Engine Oil (Duramax Diesel Engine)
Engine Oil (DURAMAX Diesel In order to get an accurate reading, the engine should be at normal operating temperature, so that the oil Engine) is warm, and the vehicle must be on level ground. Checking Engine Oil 1. If the engine is at normal operating temperature and the oil is warm, turn off the engine and allow at It is a good idea to check the engine oil level every time least ﬁve minutes for the oil to drain back into the...
Page 227 2. Pull out the dipstick and clean it with a paper towel Add oil at the engine oil ﬁll or a cloth, then push it back in all the way. cap in the engine compartment. Install and 3. Remove the dipstick again, keeping the tip down, fully tighten the ﬁll cap and check the oil level.
Page 228 What Kind of Engine Oil to Use • CJ-4 Oils designated as API CJ-4 are required for the Look for three things: vehicle. The CJ-4 designation can appear either alone or in combination with other American Petroleum Institute (API) designations, such as API CJ-4/SL. These letters show API levels of quality.
Page 229: Engine Oil (Caterpillar Diesel Engine)
• Engine Oil Additives American Petroleum Institute (API) symbol This doughnut-shaped logo Do not add anything to the oil. The recommended oils (symbol) is used on most with the API service symbol are all you need for oil containers to help you good performance and engine protection.
Page 230: Engine Oil (Isuzu Diesel Engine)
Engine Oil (Isuzu Diesel Engine) 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. Checking Engine Oil 1. If the engine is at normal operating temperature and It is a good idea to check the engine oil level every time the oil is warm, turn off the engine and allow at you get fuel.
Page 231 When to Add Engine Oil This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities and Notice: Do not add too much oil. Keep the oil level Speciﬁcations on page 5-102. between the ADD (C) and FULL (B) marks on the Add oil at the engine oil ﬁll dipstick.
Page 232 What Kind of Engine Oil to Use • CJ-4 Oils designated as API CJ-4 are required for the Look for three things: vehicle. The CJ-4 designation can appear either alone or in combination with other American Petroleum Institute (API) designations, such as API CJ-4/SL. These letters show API levels of quality.
Page 233 • Engine Oil Additives American Petroleum Institute (API) symbol This doughnut-shaped logo Do not add anything to the oil. The recommended oils (symbol) is used on most with the API service symbol are all you need for oil containers to help you good performance and engine protection.
Page 234: Engine Oil (Gasoline Engine)
Engine Oil (Gasoline Engine) Checking Engine Oil It is a good idea to check the engine oil every time you If the low oil light appears get fuel. In order to get an accurate reading, the oil on the instrument cluster, must be warm and the vehicle must be on level ground.
Page 235 When to Add Engine Oil 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...
Page 236: Cold Temperature Operation
What Kind of Engine Oil to Use • American Petroleum Institute (API) starburst symbol Oils meeting these Look for three things: requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certiﬁed by the American Petroleum Institute (API).
Page 237: Engine Oil Life System (Gasoline Engine)
Engine Oil Additives / Engine Oil Engine Oil Light on page 3-39. Change the oil as soon as possible within the next 600 miles (1 000 km). It Flushes is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change Do not add anything to the oil.
Page 238: Engine Oil Life System (Duramax/Isuzu Diesel Engines)
Engine Oil Life System To reset the change engine oil light: 1. Turn the ignition key to ON/RUN with the (DURAMAX/Isuzu Diesel Engines) engine off. When to Change Engine Oil 2. Fully press and release the accelerator pedal slowly three times within 10 seconds. If the vehicle has the Engine Oil Life System, it has a If the change engine oil light ﬂashes for computer system that indicates when to change...
Page 239 If the system is ever reset accidentally, the oil must be If the change engine oil light comes back on when the changed at 15,000 miles (24 000 km), or 150 hours vehicle is started, the Engine Oil Life System has of engine operation, whichever occurs ﬁrst, since the last not reset.
Page 240: Engine Oil Life System (Caterpillar Diesel Engine)
Engine Oil Life System (Caterpillar Engine Air Cleaner/Filter Diesel Engine) How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and ﬁlter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required.
Page 241 When to Inspect the Engine Air How to Inspect the Engine Air Cleaner/Filters Cleaner/Filter (Duramax Diesel 6.6L Engine) 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.
Page 242 How to Inspect the Engine Air Cleaner/ To inspect the engine air cleaner/ﬁlter: 1. Disconnect the air Filters (Gas V8 8.1L, Caterpillar 7.2L and compressor hose by Isuzu 7.8L Diesel Engines) pinching the connector ring to release the connector lock. CAUTION: Operating the engine with the air cleaner/ﬁlter off can cause you or others to be burned.
Page 243 Hood Inlet Seal If the vehicle is being used in heavy snow conditions or for snow plowing, there is a possibility of snow and ice build up in the inlet to the air cleaner, which can block airﬂow to the engine and affect impacting engine performance.
Page 244: Automatic Transmission Fluid
Automatic Transmission Fluid Manual Transmission Fluid When to Check When to Check A good time to check your automatic transmission ﬂuid A good time to have it checked is when the engine oil is level is when the engine oil is checked. See your checked.
Page 245: How To Add Fluid
How to Add Fluid Cooling System To add transmission ﬂuid, do the following: When you decide it is safe to lift the hood, here is what you will see: 1. Remove the ﬁller plug. 2. Add ﬂuid at the ﬁller plug hole. Add only enough ﬂuid to bring the ﬂuid level up to the bottom of the ﬁll opening.
Page 246: How To Add Coolant To The Coolant
The coolant level should If there seems to be no leak, start the engine again. The be at the FULL COLD engine cooling fan speed should increase when idle mark or higher. If it is not, speed is doubled by pushing the accelerator pedal down. you may have a leak at If it does not, your vehicle needs service.
Page 247 If no coolant is visible in the surge tank, add coolant as follows: CAUTION: CAUTION: Adding only plain water to the cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant Steam and scalding liquids from a hot cooling mixture will.
Page 248 CAUTION: You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine. 1. You can remove the coolant surge tank pressure cap when the cooling system,...
Page 249: Engine Coolant (Caterpillar Diesel Engines)
Engine Coolant (Caterpillar Diesel 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...
Page 250: Engine Overheating
Engine Overheating CAUTION: (Continued) You will ﬁnd an engine coolant temperature gage, as well as a low coolant warning light, on your vehicle’s If you keep driving when your engine is overheated, instrument panel. See Engine Coolant Temperature Gage on page 3-34 and Low Coolant Warning Light on the liquids in it can catch ﬁre.
Page 251: Engine Fan Noise
Engine Fan Noise If you get the overheat warning with no sign of steam, try this for a minute or so: Your vehicle has a clutched engine cooling fan. When 1. In heavy traffic, let the engine idle in N (Neutral) the clutch is engaged, the fan spins faster to provide while stopped.
Page 252: How To Check Power Steering Fluid
How To Check Power Steering Fluid What to Use Check your power steering ﬂuid only when the engine is To determine what kind of ﬂuid to use, see Part C: warm. If the engine is not warm, you probably will not Recommended Fluids and Lubricants on page 6-31.
Page 253 Adding Washer Fluid Notice: • When using concentrated washer ﬂuid, follow Open the cap with the the manufacturer’s instructions for adding washer symbol on it. water. Add washer ﬂuid until • Do not mix water with ready-to-use washer ﬂuid. the tank is full. Water can cause the solution to freeze and damage your washer ﬂuid tank and other parts of the washer system.
Page 254: Brakes
Brakes CAUTION: Brake Fluid Do not add brake ﬂuid before checking the level or If the vehicle has hydraulic there could be too much brake ﬂuid. Brake ﬂuid brakes, there is a brake master cylinder in the could spill on the hot engine and it can catch ﬁre. engine compartment on the You could be burned and the vehicle could be driver side of the vehicle.
Page 255 The ﬂuid level should be even with the bottom ring of CAUTION: the ﬁller opening. If it is low, add enough ﬂuid to ﬁll the reservoir to the proper With the wrong kind of ﬂuid in the brake hydraulic level. system, the brakes might not work well.
Page 256: Brake Adjustment
Four-Wheel Disc Brakes Brake Adjustment (Hydraulic Only) Every brake stop, the brakes adjust for wear. The vehicle has four-wheel disc brakes. Brake Adjustment on Air Braked Vehicles Some driving conditions or climates can cause a brake The vehicle has automatic slack adjusters. Every squeal when the brakes are ﬁrst applied or lightly brake stop, the brakes automatically adjust for wear.
Page 257: Replacing Brake System Parts
Replacing Brake System Parts Hydraulic Brake Pads Brake pad lining life will vary depending on The braking system on a vehicle is complex. Its many vehicle application, working environment, equipment parts have to be of top quality and work well together if maintenance, and style of driving.
Page 258: Air Dryer
Air Brake Systems Air Dryer If the vehicle has air brakes, it is important to get rid of If the vehicle has air brakes, it has an air dryer mounted moisture in the system. Moisture will damage the system on the passenger side frame rail. This collects and if it is not removed daily.
Page 259 Electric Air Compressor Clutch Pedal Free Travel The vehicle might have an electric air compressor. If the vehicle has a V8 engine and a manual This compressor is used to run options that require transmission, the clutch needs adjustment when pedal pressurized air, such as an air horn or air seat.
Page 260 Single Axle Models Item Number Item Remarks Brake Camshaft** One ﬁtting each (apply sparingly). Steering Column Slip Joint* One ﬁtting. Steering Drag Link Ends One ﬁtting each end. 5-58...
Page 261 Item Number Item Remarks Pivot Points and Hinges Apply chassis lubricant. Pivot Points and Hinges Apply chassis lubricant. Slack Adjuster** One ﬁtting. Brake Cam Roller Pins at interface of pin Apply engine oil. and shoe** One ﬁtting each side, lower bushing. Front Steering Knuckles (Hand-operated grease gun only.) Hand-pack upper bearing.
Page 262 Tandem Axle Models Item Number Item Remarks Brake Camshafts One ﬁtting each. One ﬁtting each joint. Lubricate with GM Propshaft U-Joint Part No. 1051344, Wheel Bearing Lubricant. Fill to level of Rear Axles ﬁller plug. Apply engine oil Brake Shoe at pin to shoe Roller Pins joint only.
Page 263: Battery
Battery Vehicle Storage This vehicle has two or more maintenance free batteries. When it is time for a new battery, see your dealer/retailer CAUTION: for one that has the replacement number shown on the original battery’s label. Batteries have acid that can burn you and gas that Warning: Battery posts, terminals, and related accessories contain lead and lead compounds, can explode.
Page 264: Jump Starting
Jump Starting Notice: Ignoring these steps could result in costly damage to the vehicle that would not be covered by the warranty. If the vehicle’s battery (or batteries) has run down, you may want to use another vehicle and some jumper Trying to start the vehicle by pushing or pulling it cables to start your vehicle.
Page 265 2. Get the vehicles close enough so the jumper cables 4. Open the hood on the other vehicle and locate the can reach, but be sure the vehicles are not touching positive (+) and the negative (−) terminal locations each other. If they are, it could cause a ground on that vehicle.
Page 266 CAUTION: CAUTION: Using a match near a battery can cause battery Fans or other moving engine parts can injure you gas to explode. People have been hurt doing this, badly. Keep your hands away from moving parts and some have been blinded. Use a ﬂashlight if once the engine is running.
Page 267 6. Connect the red 9. Connect the other end of the negative (−) cable at positive (+) cable to the least 18 inches (45 cm) away from the dead battery, positive (+) terminal of but not near engine parts that move. The electrical the dead battery.
Page 268 Notice: If the jumper cables are connected or To disconnect the jumper cables from both vehicles, do removed in the wrong order, electrical shorting may the following: occur and damage the vehicle. The repairs would 1. Disconnect the black negative (−) cable from the not be covered by your warranty.
Page 269: Rear Axle
Rear Axle How to Check Lubricant When to Check and 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 6-5. 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.
Page 270: Rear Axle Shift Motor
Rear Axle Shift Motor How to Check Lubricant 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.
Page 271: Front Axle
When to Change Lubricant How to Check Lubricant Refer to the Maintenance Schedule to determine how often to change the lubricant. See Scheduled Maintenance on page 6-5. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Part C: Recommended Fluids and Lubricants on page 6-31.
Page 272: Noise Control System
Noise Control System Among those acts presumed to constitute tampering are the acts listed below. Insulation: Tampering with Noise Control • Removal of the noise shields or any underhood System Prohibited insulation. Engine: The following information relates to compliance with federal noise emission standards for vehicles with a •...
Page 273: Bulb Replacement
Bulb Replacement Here’s how to remove the wiper blade: It is recommended that all bulbs be replaced by your dealer/retailer. Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking. See “Wiper Blade Check”...
Page 274: Other Service Items
Other Service Items Fuel Filter Fuel Filter/Pressure Regulator (Gasoline Engines) The steel fuel ﬁlter/pressure regulator is located near the engine compartment on the driver’s side frame rail. If your vehicle has a rear steel fuel tank, the fuel ﬁlter/pressure regulator is located near the rear fuel tank, on the driver’s side frame rail.
Page 275: Primary Fuel Filter And Water Separator
Primary Fuel Filter and Water Secondary Fuel Filter and Heater Separator Your vehicle may have this fuel ﬁlter and fuel heater. It is mounted on the left side of the engine. Your vehicle may have this spin-on ﬁlter. It is located on the driver’s side frame rail.
Page 276: Secondary Fuel Filter And Water Separator/Heater (Caterpillar Diesel)
Secondary Fuel Filter and Water It has a metal drain bowl at the bottom. Occasionally, check the bowl for any water or particles. Separator/Heater (Caterpillar Diesel) To check or drain the bowl, do the following: • Shut off the engine. ®...
Page 277: Front Wheel Bearings With Oil-Filled Hubs
Front Wheel Bearings with If your vehicle has oil-ﬁlled hubs, occasionally check to Oil-Filled Hubs see if they have enough oil. You can tell if there is oil Notice: If you drive your vehicle through deep water there by using the circular that is higher than the front or rear axle, water may gage on the sight glass.
Page 278: Tires
Tires CAUTION: (Continued) Your new vehicle comes with high-quality tires made by a leading tire manufacturer. If you ever • Underinﬂated tires pose the same danger have questions about your tire warranty and where as overloaded tires. The resulting accident to obtain service, see your vehicle Warranty booklet could cause serious injury.
Page 279: Inﬂation - Tire Pressure
Inﬂation - Tire Pressure When to Check Check your tires once a month or more. Tires need the correct amount of air pressure to operate effectively. The Certiﬁcation or Tire Information label Also, check the tire pressure of the spare tire if your shows the correct inﬂation pressures for your tires vehicle has one.
Page 280: Wheel Loading
Wheel Loading When It Is Time for New Tires Wheels are stamped with a maximum load and cold Various factors, such as maintenance, temperatures, inﬂation rating. Be sure you do not exceed these limits. driving speeds, vehicle loading, and road conditions, inﬂuence when you need new tires.
Page 281: Buying New Tires
If your vehicle has four-wheel drive, the axle differentials, propshafts, and transfer case may be damaged if tires CAUTION: of different sizes, brands or tread types are installed on the front and rear axles. That damage would not be covered under your warranty. Mixing tires could cause you to lose control while driving.
Page 282: Wheel Alignment And Tire Balance
Wheel Alignment and Tire Balance Tightening the Wheel Nuts The wheels on your vehicle were aligned at the factory to give you the longest tire life and best overall CAUTION: performance. Proper front wheel alignment must be maintained in Wheel nuts that are not tight can work loose. If all order to ensure efficient steering, good directional stability, and prevent abnormal tire wear.
Page 283 Hub-Piloted Wheels, 8-Hole or 10-Hole First, use these pictures to decide what kind of wheels you have. The studs and nuts used with these wheels have right-hand threads. 1. With intermittent pilot pads, position a pad at 12 o’clock to center the wheel and reduce run-out. 2.
Page 284 6. Tighten the nuts to 400 lb ft (542 Y ) if an 8-hole stud or 480 lb ft (650 Y) if a 10-hole stud, using the following diagrams. 10-Hole (Front) 10-Hole (Rear) CAUTION: 8-Hole Never use oil or grease on studs or the threads of the wheel nuts.
Page 285 CAUTION: CAUTION: If wheel studs are damaged, they can break. If all Rust or dirt on a wheel, or on the parts to which it is fastened, can make wheel nuts the studs on a wheel broke, the wheel could come become loose after a time.
Page 286: Wheel Replacement
Wheel Replacement CAUTION: Replace any wheel that is bent, cracked, or badly rusted or corroded. If wheel nuts keep coming loose, replace the wheel, wheel bolts, and wheel nuts. If the wheel A leaking wheel could fail without warning. A leaks air, replace it.
Page 287: If A Tire Goes Flat
If a Tire Goes Flat Using wheels and tires with higher load-carrying limits than the original wheels and tires does not change the Gross Axle Weight Rating (GAWR) or the Gross It is unusual for a tire to blowout while you are driving, Vehicle Weight Rating (GVWR) of your vehicle.
Page 288 If a tire goes ﬂat, avoid further tire and wheel damage by driving slowly to a level place and turn on your CAUTION: hazard warning ﬂashers. See Hazard Warning Flashers on page 3-6. If you try to put air back into a tire that has run ﬂat, even a tire that was extremely low on air, the CAUTION: tire can have a sudden air-out.
Page 289: Appearance Care
Appearance Care surfaces for which they were not intended. Use glass cleaner only on glass. Remove any accidental over-spray from other surfaces immediately. To prevent over-spray, Interior Cleaning apply cleaner directly to the cleaning cloth. Notice: Using abrasive cleaners when cleaning The vehicle’s interior will continue to look its best if it is glass surfaces on the vehicle, could scratch cleaned often.
Page 290: Fabric/Carpet
Fabric/Carpet Do not clean the vehicle using: • A knife or any other sharp object to remove a soil Use a vacuum cleaner with a soft brush attachment from any interior surface. frequently to remove dust and loose dirt. A canister •...
Page 291: Instrument Panel, Vinyl, And Other Plastic Surfaces
If any of the soil remains, a commercial fabric cleaner Some commercial products may increase gloss on the or spot lifter may be necessary. When a commercial instrument panel. The increase in gloss may cause upholstery cleaner or spot lifter is to be used, test annoying reﬂections in the windshield and even make it a small hidden area for colorfastness ﬁrst.
Page 292: Washing Your Vehicle
Washing Your Vehicle High pressure car washes may cause water to enter the vehicle. Avoid using high pressure washes closer than 12 inches (30 cm) to the surface of the vehicle. The best way to preserve the vehicle’s ﬁnish is to keep Use of power washers exceeding 1,200 psi (8 274 kPa) it clean by washing it often.
Page 293: Windshield And Wiper Blades
Windshield and Wiper Blades Notice: Machine compounding or aggressive polishing on a basecoat/clearcoat paint ﬁnish may damage it. Use only non-abrasive waxes and Clean the outside of the windshield with glass cleaner. polishes that are made for a basecoat/clearcoat Clean the rubber blades using a lint free cloth or paper paint ﬁnish on the vehicle.
Page 294: Aluminum Or Chrome-Plated Wheels And Trim
Aluminum or Chrome-Plated Wheels Notice: Using chrome polish on aluminum wheels could damage the wheels. The repairs would not and Trim be covered by the warranty. Use chrome polish on chrome wheels only. The vehicle may be equipped with either aluminum or Use chrome polish only on chrome-plated wheels, but chrome-plated wheels.
Page 295: Sheet Metal Damage
Sheet Metal Damage Underbody Maintenance If the vehicle is damaged and requires sheet metal Chemicals used for ice and snow removal and dust repair or replacement, make sure the body repair shop control can collect on the underbody. If these are not applies anti-corrosion material to parts repaired or removed, corrosion and rust can develop on the replaced to restore corrosion protection.
Page 296: Vehicle Identiﬁcation
Vehicle Identiﬁcation Engine Identiﬁcation The eighth character in the VIN is the engine code. This code helps identify the vehicle’s engine, speciﬁcations, Vehicle Identiﬁcation Number (VIN) and replacement parts. See “Engine Speciﬁcations” under Capacities and Speciﬁcations on page 5-102 for your vehicle’s engine code.
Page 297: Electrical System
Electrical System Windshield Wiper Fuses The windshield wiper motor is protected by a circuit Add-On Electrical Equipment breaker inside the motor and a circuit breaker or fuse in the fuse block. If the motor overheats, the wipers will stop until the motor cools. If the overload is caused by Notice: Do not add anything electrical to the an electrical problem, be sure to get it ﬁxed.
Page 298: Power Windows And Other Power Options
Power Windows and Other Power Instrument Panel Fuse Block Options There are two instrument panel fuse blocks located behind the instrument panel on the passenger side of Circuit breakers in the fuse panel protect the power the vehicle. windows and other power accessories. When the current Be sure to replace fuses with fuses of the same rating.
Page 299 Fuse Usage Fuse Usage Stoplamps Courtesy Lamps Not Used Warning Lights, Gages and Indicators Parking Lamps Starter Powertrain Control Module Rear Axle/Four-Wheel-Drive Auxiliary Wiring Trailer Turn Signals/Hazard Warning Heater/Air Conditioning Flashers Hazard Warning Flashers Radio/Chime Power Post Daytime Running Lamps 5-97...
Page 300 Fuse Usage Fuse Usage Airbag System RADIO Radio Exterior/Interior Lamps Blank Not Used Parking Brake Blank Not Used Accessory Power PWR WNDW Power Windows Ignition 4 Sidemarker Lamps Relay Usage Turn Signal/Backup Lamps Engine Control Unit/Power Take-Off ECU/PTO* *Diesel 7.8 Duramax Transmission C4/C5 Brake Lamps, Hydraulics/Air Brake...
Page 301: Underhood Fuse Block
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 side of the vehicle. To access the fuse blocks, gently squeeze both sides of the cover to unlatch the tabs at the top.
Page 302 Fuse Usage Fuse Usage PCM-B Powertrain Control Module NOTE 4 Electronic Control Module (LF6) Transmissions (LF8) STUD A Spare ENG 4 Engine 4 (LMM/LF6/LF8) STUD B Spare ENG 2 Engine 2 (L18/LMM) HTD FUEL Heated Fuel (LMM) Relay Usage BLANK Not Used NOTE 1 LMM/L18 Fuel Pump Relay...
Page 303 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 C4/C5 Electric Brake, NOTE C6/C7/C8 Brake Lamps Secondary Underhood Fuse Block 5-101...
Page 304: Capacities And Speciﬁcations
Capacities and Speciﬁcations The following approximate capacities are given in English and metric conversions. See Part C: Recommended Fluids and Lubricants on page 6-31 for more information. Capacities Application English Metric For the air conditioning system refrigerant charge amount, see the refrigerant caution label located Air Conditioning Refrigerant R134a under the hood.
Page 305 Capacities Application English Metric Cooling System – C6/C7/C8 Manual Transmission 7.2L L6 Engine 30.4 qt 28.8 L 7.2L L6 Engine with A/C and Increased Cooling 33.9 qt 32.1 L Isuzu 6H Engine (207–275 hp) 32.7 qt 31.0 L Isuzu 6H Engine (207–275 hp) with A/C and Increased 35.9 qt 34.0 L Cooling...
Page 306 Capacities Application English Metric Fuel Capacity – C4/C5 Models Standard (Mid-Mounted) 25 gal 94.6 L Optional (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) 60 gal 227.1 L...
Page 307 Capacities Application English Metric Front 4WD Axle (G38) 7.0 pt 3.6 L Rear Axle – Single Speed 80 (GL4) 10.0 pt 4.7 L 19060D (HPM), 19060S (HPK), 21060D (HPN), 31.0 pt 14.7 L 21060S (HPP), 22060S (HPG) 23090S (HPT) 42.5 pt 20.1 L 23105D (HNB), 23105S (HNA) 51.0 pt...
Page 308 Capacities Application English Metric Rear Axle – Two-Speed 19060T (HPL), 22060T (HPH) 38.0 pt 18.0 L 21060T (H15) 38.0 pt 18.0 L 23082T (H25) 44.0 pt 20.8 L 26080T (GJ4) 44.0 pt 20.8 L Transfer Case (Four-Wheel Drive) 4.0 pt 1.9 L Transmission Fluid, Automatic 3000 RDS and EVS, and 3500 RDS and EVS with PTO...
Page 309 Capacities Application English Metric Transmission Fluid, Manual ES052-7, ES066-7 22.0 pt 10.4 L FS5205A 12.5 pt 5.9 L FSO8406, FS6305A, FS6305B, FS6406, FS5406A 19.5 pt 9.2 L FS4205A, FS4205B 11.5 pt 5.4 L RT6609 12.0 pt 5.7 L RT8709 26.0 pt 12.3 L RT8908LL 28.0 pt...
Page 310: Normal Maintenance Replacement Parts
Normal Maintenance Replacement Parts Maintenance Replacement Parts Replacement parts identiﬁed by name, part number, or speciﬁcation can be obtained from your dealer. Part GM Part Number ACDelco Part Number Air Compressor Filter 88915425 A507CF Haldex compressor (8.1L Engine Only) Engine Air Cleaner/Filter 6.6L V8 (C4/C5 Models) 19152817 A3102C...
Page 311 Part GM Part Number ACDelco Part Number Fuel Filter 6.6L V8 98017645 TP1298B 7.2L L6 — 1R-0751 Isuzu 6H 98026037 — 8.1L V8 (C4/C5 with NG6/NK1 or U-Haul) 15807649 — 8.1L V8 (C4/C5 with all other fuel tanks) 10376257 — 8.1L V8 (All C6/C7/C8) 10370247 —...
Page 312: Engine Drive Belt Routing
Engine Drive Belt Routing 8.1L V8 Engine (C6,C7,C8) 8.1L V8 Engine (C4, C5) A. Air Conditioning Compressor. B. Air Brake Compressor. A. Air Conditioning Compressor. B. Dual Generators. 5-110...
Page 313 6.6L V8 Duramax Diesel Engine Isuzu 6H Diesel Engine A. Dual Generators. A. Air Conditioning Compressor. 5-111...
Page 314 7.2L I6 Caterpillar Diesel Engine A. Air Conditioning Compressor. 5-112...
Page 315 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Scheduled Maintenance ........6-5 Introduction ...........6-2 Part B: Owner Checks and Services ....6-26 Maintenance Requirements ......6-2 At Each Fuel Fill ..........6-26 Your Vehicle and the Environment ....6-2 At Least Twice a Year ........6-27 How This Section is Organized ......6-3 At Least Once a Year ........6-30 Part A: Scheduled Maintenance Services ...6-4 Part C: Recommended Fluids and...
Page 316: Maintenance Schedule
Maintenance Schedule Maintenance Requirements Maintenance intervals, checks, inspections and Introduction recommended ﬂuids and lubricants as prescribed in this manual are necessary to keep this vehicle in good Important: Keep engine oil at the proper level and working condition. Any damage caused by failure to change as recommended.
Page 317: How This Section Is Organized
How This Section is Organized To purchase service information, see Service Publications Ordering Information on page 7-10. This maintenance schedule is divided into four parts: “Part B: Owner Checks and Services” tells what should be checked and when. It also explains what can “Part A: Scheduled Maintenance Services”...
Page 318: Part A: Scheduled Maintenance Services
Part A: Scheduled Maintenance The proper ﬂuids and lubricants to use are listed in Part C. Make sure whoever services the vehicle uses Services these. All parts should be replaced and all necessary repairs done before you or anyone else drives the In this part are scheduled maintenance services which vehicle.
Page 319: Scheduled Maintenance
Scheduled Maintenance 100 Miles (160 km) ❑ Wheel stud nut service. (36) The services shown in this schedule up to 100,000 miles (166 000 km) should be repeated after 100,000 miles 1,000 Miles (1 600 km) (166 000 km) at the same intervals for the life of ❑...
Page 320 ❑ Check air brake relay valve operation and check for ❑ Gasoline Engine: Inspect engine air cleaner ﬁlter. leaks (or every month, or every 300 hours, whichever If necessary, replace the ﬁlter. If vehicle is driven in occurs ﬁrst). dusty/dirty conditions, inspect ﬁlter at every engine oil change.
Page 321 ❑ Air brake service (or every 6 months, whichever 22,500 Miles (36 000 km) occurs ﬁrst). (32) ❑ Gasoline Engine Only: Check engine oil life system. If ❑ Air brake automatic slack adjuster service (or every engine oil and ﬁlter are changed, reset system. See 500 hours, whichever occurs ﬁrst).
Page 322 ❑ Air brake service (or every 6 months, whichever 24,000 Miles (40 000 km) occurs ﬁrst). (32) ❑ Lubricate U-joints (or every 6 months, whichever ❑ Air brake automatic slack adjuster service (or every occurs ﬁrst). 500 hours, whichever occurs ﬁrst). (33) 30,000 Miles (48 000 km) ❑...
Page 323 ❑ Diesel Engine: Inspect engine air cleaner ﬁlter change ❑ Air brake service (or every 6 months, whichever indicator. If necessary, replace the ﬁlter. If vehicle is occurs ﬁrst). (32) driven in dusty/dirty conditions, inspect ﬁlter change ❑ Air brake automatic slack adjuster service (or every indicator at every engine oil change.
Page 324 37,500 Miles (60 000 km) 45,000 Miles (72 000 km) ❑ Gasoline Engine Only: Check engine oil life system. If ❑ Gasoline Engine Only: Check engine oil life system. engine oil and ﬁlter are changed, reset system. See If engine oil and ﬁlter are changed, reset system. See “Engine Oil (Gasoline Engine)”...
Page 325 ❑ Cooling system service. Clean the cooling system ﬁller ❑ Clean air brake application valve (or every 3 months, cap with clean water, clean the core, pressure test the or every 300 hours, whichever occurs ﬁrst). Lubricate cap and the system for proper pressure capability, and linkage.
Page 326 ❑ Air brake automatic slack adjuster service (or every 48,000 Miles (75 000 km) 500 hours, whichever occurs ﬁrst). (33) ❑ Lubricate U-joints (or every 6 months, whichever ❑ Check air brake relay valve operation and check for occurs ﬁrst). leaks (or every month, or every 300 hours, whichever 50,000 Miles (80 000 km) occurs ﬁrst).
Page 327 ❑ Gasoline Engine: Inspect engine air cleaner ﬁlter. ❑ Wheels and tires service. (14) If necessary, replace the ﬁlter. If vehicle is driven in ❑ Isuzu Diesel Engine Only: Adjust valve lash (or every dusty/dirty conditions, inspect ﬁlter at every engine oil 2,625 hours of engine operation, whichever occurs change.
Page 328 ❑ Thermostatically controlled engine cooling fan ❑ Hydraulic brake service (or every 6 months, whichever service. (3) (19) occurs ﬁrst). (6) (36) ❑ Shields and underhood insulation service. (3) (4) (20) ❑ Parking brake service (or every 6 months, whichever occurs ﬁrst).
Page 329 ❑ Diesel Engine: Inspect engine air cleaner ﬁlter change 72,000 Miles (115 000 km) indicator. If necessary, replace the ﬁlter. If vehicle is ❑ Lubricate U-joints (or every 6 months, whichever driven in dusty/dirty conditions, inspect ﬁlter change occurs ﬁrst). indicator at every engine oil change.
Page 330 ❑ Clean air brake application valve (or every 3 months, 82,500 Miles (132 000 km) or every 300 hours, whichever occurs ﬁrst). Lubricate ❑ Gasoline Engine Only: Check engine oil life system. linkage. If engine oil and ﬁlter are changed, reset system. See ❑...
Page 331 ❑ Cooling system service. Clean the cooling system ﬁller 90,000 Miles (144 000 km) cap with clean water, clean the core, pressure test the ❑ Gasoline Engine Only: Check engine oil life system. cap and the system for proper pressure capability, and If engine oil and ﬁlter are changed, reset system.
Page 332 ❑ Air brake automatic slack adjuster service (or every ❑ Evaporative Control System service, if equipped, (or 500 hours, whichever occurs ﬁrst). (33) every 24 months, whichever occurs ﬁrst). (2) (24) † ❑ Check air brake relay valve operation and check for ❑...
Page 333 ❑ Air brake automatic slack adjuster service (or every ❑ Four-wheel drive only: Transfer case service. (30) 500 hours, whichever occurs ﬁrst). (33) ❑ Rear axle service — Eaton ® ® ® , Rockwell , Spicer axles ❑ Check air brake relay valve operation and check for (or every 12 months, whichever occurs ﬁrst).
Page 334 150,000 Miles (240 000 km) 300,000 Miles (480 000 km) ❑ Cooling system service (or every 60 months since ❑ Rear axle service — Eaton ® ® ® , Rockwell , Spicer last service, whichever occurs ﬁrst). (2) (29) axles (or every 12 months, whichever occurs ﬁrst).
Page 335 (4) = Applies to vehicles sold in the United States and is Remember to reset the Engine Oil Life System recommended for vehicles sold in Canada. whenever the oil is changed. For more information, see Engine Oil Life System (Gasoline Engine) on page 5-35 (5) = Check ﬂuidlevel in brake master cylinder, power or Engine Oil Life System (DURAMAX/Isuzu Diesel steering pump, front and rear axles, transmission, and...
Page 336 (11) = Chassis Lubrication Service: Lubricate all grease (12) = Check steering system: ﬁttings in front suspension, front axle, and steering • Look for damaged, loose, or missing parts. Inspect linkage. Do not lubricate kingpin bushings with air the steering linkage relay rod and tie rod ends for pressure equipment;...
Page 337 (14) = Adjust tire pressures as indicated on the (19) = With the engine off and below normal operating Certiﬁcation or Tire Information label for optimum tire temperature, check to see that the thermostatically life. See Tires on page 5-76 for further details. controlled engine cooling fan can be rotated by hand on Check tires for excessive or abnormal wear or damage.
Page 338 (24) = Evaporative Control System Service, if equipped: (30) = Change the lubricant. See Part C: Recommended Check all fuel and vapor lines and hoses for proper Fluids and Lubricants on page 6-31. connections and correct routing (or every 24 months, (31) = Front axle service: Re-pack upper kingpin roller whichever occurs ﬁrst).
Page 339 • (36) = Tighten the wheel stud nuts to the speciﬁed torque Replace the air compressor ﬁlter element, mounted values at 100 miles (160 km). Thereafter, tighten them on the air compressor. For remote air compressor 1,000 miles (1 600 km) after each time the wheel is intake service, refer to engine air cleaner ﬁlter removed.
Page 340: Part B: Owner Checks And Services
Part B: Owner Checks and Services Check the engine oil level and add the proper oil if necessary. See Engine Oil (DURAMAX Diesel Engine) on page 5-24 or Engine Oil (Caterpillar Diesel Engine) These owner checks and services should be performed on page 5-27 or Engine Oil (Isuzu Diesel Engine) on at the intervals speciﬁed to help ensure vehicle page 5-28 or Engine Oil (Gasoline Engine) on page 5-32.
Page 341: At Least Twice A Year
At Least Twice a Year Parking Brake Check Park on a fairly steep hill and hold the vehicle with the Wiper Blade Check parking brake only. This checks holding ability. See Parking Brake (With Hydraulic Brakes) on page 2-38 or Inspect wiper blades for wear, cracking, or Parking Brake (With Air Brakes) on page 2-41.
Page 342: Exhaust System Inspection
Automatic Transmission Shift Indicator Exhaust System Inspection Check Be alert for any changes in the sound of the exhaust system or any smell of fumes. These are signs the Check that the indicator points to the gear chosen. system may be leaking. Have it checked and/or repaired Steering Check at once.
Page 343 Mirrors and Sun Visors Check Glass, Mirrors, Lamps, and/or Reﬂectors Condition Check Check that friction joints hold mirrors and sun visors in place. Look for broken, scratched, dirty, or damaged glass, mirrors, lamps, or reﬂectors that could reduce the view Seat Adjuster Check or visibility or cause injury.
Page 344: At Least Once A Year
Fluid Leaks Check At Least Once a Year Check for fuel, coolant, oil, or other ﬂuid leaks by Key Lock Cylinders Service looking at the surface beneath the vehicle after it has been parked for awhile. Lubricate the key lock cylinders with the lubricant speciﬁed in Part C.
Page 345: Part C: Recommended Fluids And Lubricants
Part C: Recommended Fluids and Usage Fluid/Lubricant Lubricants ® Engine Coolant See the Caterpillar Operation & ® (Caterpillar Maintenance Manual for engine Diesel Engine) coolant recommendations. Fluids and lubricants identiﬁed below by name, part number, or speciﬁcation can be obtained from your Engine Coolant 50/50 mixture of clean, drinkable (Gasoline...
Page 346 Usage Fluid/Lubricant Usage Fluid/Lubricant Multi-Purpose Lubricant, Superlube SAE 75W-90 Synthetic Axle Key Lock (GM Part No. U.S. 12346241, Rear Axle and Lubricant for Medium Duty Trucks Cylinders in Canada 10953474). Rear Hubs (GM Part No. U.S. 89021675, in Canada 10953512). Chassis Lubricant (GM Part No.
Page 347: Part D: Maintenance Record
Part D: Maintenance Record After the scheduled services are performed, 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. Miles/km Or Maintenance Record Date...
Page 348 Miles/km Or Maintenance Record Date Serviced By Hours 6-34...
Page 349 Miles/km Or Maintenance Record Date Serviced By Hours 6-35...
Page 350 Miles/km Or Maintenance Record Date Serviced By Hours 6-36...
Page 351: Customer Assistance Information
Section 7 Customer Assistance Information Customer Assistance and Information ....7-2 Vehicle Data Recording and Privacy ....7-11 Customer Satisfaction Procedure ......7-2 Vehicle Data Recording and Privacy Customer Assistance for Text Telephone (Isuzu 7.8L L6 Engine) .......7-11 (TTY) Users ..........7-4 Event Data Recorders Customer Assistance Offices ......7-4 (Isuzu 7.8L L6 Engine) .......7-12 ®...
Page 352: Customer Assistance And Information
1-800-263-3777 (English), or 1-800-263-7854 (French). Your satisfaction and goodwill are important to your dealer and to Chevrolet. Normally, any concerns with the We encourage you to call the toll-free number in order to give your inquiry prompt attention. Have the...
Page 353 STEP THREE: Both General Motors and your dealer You may contact the BBB Auto Line Program using the are committed to making sure you are completely toll-free telephone number or write them at the following satisﬁed with your new vehicle. However, if you continue address: to remain unsatisﬁed after following the procedure BBB Auto Line Program...
Page 354: Customer Assistance For Text Telephone (Tty) Users
To assist customers who are deaf, hard of hearing, or 1908 Colonel Sam Drive speech-impaired and who use Text Telephones (TTYs), Oshawa, Ontario L1H 8P7 Chevrolet has TTY equipment available at its Customer 1-800-263-3777 (English) Assistance Center. Any TTY user in the U.S. can 1-800-263-7854 (French)
Page 355: Gm Mobility Reimbursement Program
GM Mobility Reimbursement Roadside Assistance Program Program GM Medium Duty truck’s Roadside Assistance provides stranded owner/operators with towing service for disabled GM Medium Duty trucks, during the base and/or engine warranty period, to the nearest authorized GM Medium Duty dealer. This service combines the efforts of trained telephone representatives with a network of GM Medium Duty truck services.
Page 356: Collision Damage Repair
Collision Damage Repair vehicle’s originally designed appearance and safety performance, however, the history of these parts is not known. Such parts are not covered by your GM New If your vehicle is involved in a collision and it is damaged, Vehicle Limited Warranty, and any related failures have the damage repaired by a qualiﬁed technician using are not covered by that warranty.
Page 357: Insuring Your Vehicle
Insuring Your Vehicle If a Crash Occurs Protect your investment in your GM vehicle with Here is what to do if you are involved in a crash. comprehensive and collision insurance coverage. There • Check to make sure that you are all right. If you are signiﬁcant differences in the quality of coverage are uninjured, make sure that no one else in your afforded by various insurance policy terms.
Page 358 • Managing the Vehicle Damage Repair Gather the important information you will need from the other driver. Things like name, address, phone Process number, driver’s license number, vehicle license plate, vehicle make, model and model year, Vehicle In the event that your vehicle requires damage repairs, Identiﬁcation Number (VIN), insurance company and GM recommends that you take an active role in its repair.
Page 359: Reporting Safety Defects
Reporting Safety Defects Reporting Safety Defects to the Canadian Government Reporting Safety Defects to the If you live in Canada, and you believe that your United States Government vehicle has a safety defect, notify Transport Canada immediately, in addition to notifying General Motors of If you believe that your vehicle has a defect which Canada Limited.
Page 360: Service Publications Ordering Information
Service Publications Ordering Owner Information Information Owner publications are written speciﬁcally for owners and intended to provide basic operational information Service Manuals about the vehicle. The owner manual includes the Maintenance Schedule for all models. Service Manuals have the diagnosis and repair In-Portfolio: Includes a Portfolio, Owner Manual, and information on engines, transmission, axle suspension, Warranty Booklet.
Page 361: Vehicle Data Recording And Privacy
ORDER TOLL FREE: 1-800-551-4123 Vehicle Data Recording and Monday-Friday 8:00 AM - 6:00 PM Privacy Eastern Time For Credit Card Orders Only Vehicle Data Recording and Privacy (VISA-MasterCard-Discover), visit Helm, Inc. on the World Wide Web at: helminc.com (Isuzu 7.8L L6 Engine) Or you can write to: Your GM vehicle has a number of sophisticated Helm, Incorporated...
Page 362: Event Data Recorders (Isuzu 7.8L L6 Engine)
Event Data Recorders Important: EDR data is recorded by your vehicle only if a non-trivial crash situation occurs; no data is recorded (Isuzu 7.8L L6 Engine) by the EDR under normal driving conditions and no personal data (e.g., name, gender, age, and crash This vehicle has an Event Data Recorder (EDR).
Page 363: Onstar ® (Isuzu 7.8L L6 Engine)
® OnStar (Isuzu 7.8L L6 Engine) Radio Frequency Identiﬁcation (RFID) (Isuzu 7.8L L6 Engine) If your vehicle has OnStar and you subscribe to the OnStar services, please refer to the OnStar Terms and RFID technology is used in some vehicles for functions Conditions for information on data collection and use.
Page 364 ✍ NOTES 7-14...
Page 365 Antenna, Fixed Mast ........3-58 Antilock Brake System (ABS) ......4-5 Accessories and Modiﬁcations ......5-3 Antilock Brake, System Warning Light ....3-33 Accessory Power Outlets ......... 3-19 Antilock Brakes, Trailer System Adding a Snow Plow or Similar Equipment ..4-22 Warning Light ..........
Page 366 Audio System(s) ..........3-49 Automatic Transmission California Perchlorate Materials Fluid ............5-42 Requirements ..........5-4 Operation ........... 2-27 California Proposition 65 Warning ....... 5-4 Capacities and Speciﬁcations ......5-102 Carbon Monoxide ........2-45, 4-17 Care of Battery ............5-61 Safety Belts ..........5-89 Bench Seat, Split ..........
Page 367 Child Restraints (cont.) Coolant Securing a Child Restraint in the Center Engine ............5-47 Rear Seat Position ........1-42 Engine Temperature Gage ......3-34 Securing a Child Restraint in the Right Low Warning Light ........3-35 Front Seat Position ........1-44 Surge Tank Pressure Cap ......
Page 368 Diesel Engine ..........2-26 Engine Alarm and Automatic Shutdown ... 2-18 EDR ............. 7-11 Exhaust Restrictor ........2-22 Electrical System Fuel ............5-8 Add-On Equipment ........5-95 High Idle System ......... 2-20 Fuses and Circuit Breakers ......5-96 Starting ............2-14 Fusible Links ..........
Page 369 Engine (cont.) Front Axle ............5-69 Overheating ..........5-48 Front Wheel Bearings with Overspeed Warning Light ......3-40 Oil-Filled Hubs ..........5-75 Reduced Power Light ........3-42 Fuel ............... 5-6 Shutdown Warning Light ....... 3-40 Additives ............5-7 Speed Limiter ..........3-25 Change Filter Warning Light ......
Page 370 Heater ............3-20 Engine Coolant ........... 2-25 Gage High Idle System ..........2-20 Air Pressure ..........3-47 Highbeam On Light ......... 3-42 Check Gages Warning Light ......3-43 Highway Hypnosis ........... 4-15 Engine Coolant Temperature ......3-34 Hill and Mountain Roads ........4-16 Filter Minder ..........
Page 371 Light (cont.) Engine Shutdown Warning ......3-40 Keyless Entry System ........2-3 Exhaust Brake Indicator ........ 3-41 Keys ............... 2-2 Highbeam On ..........3-42 Low Coolant Warning ........3-35 Low Oil Level ..........3-39 Low Washer Fluid Warning ......3-43 Power Take-Off ...........
Page 372 Maintenance, Replacement Parts ..... 5-108 Navigation System, Privacy ......7-13 Maintenance Schedule New Vehicle Break-In ........2-10 At Each Fuel Fill ......... 6-26 Noise Control System, Tampering ...... 5-70 At Least Once a Year ........6-30 At Least Twice a Year ........6-27 How This Section is Organized .......
Page 373 Outside Power Take-Off (PTO) ........2-30 Convex Mirrors ..........2-52 Privacy ............7-11 Heated Mirrors ..........2-52 Event Data Recorders ........7-12 Manual Mirrors ..........2-51 Navigation System ........7-13 Power Mirrors ..........2-51 OnStar ............7-13 Overspeed Warning Light ......... 3-40 Radio Frequency Identiﬁcation .......
Page 374 Reporting Safety Defects Seats Canadian Government ........7-9 Air Suspension Seats ........1-6 General Motors ..........7-9 Bucket Seats ..........1-2 United States Government ......7-9 Rear Seat Operation ........1-10 Restraint System Check Split Bench Seat ........... 1-6 Checking the Restraint Systems ....1-59 Securing a Child Restraint Replacing Restraint System Parts After a Center Front Seat Position ......
Page 375 Starting the Gasoline Engine ......2-12 Tires (cont.) Steering ............4-9 Wheel Alignment and Tire Balance ....5-80 Steering Wheel, Tilt Wheel ......... 3-6 Wheel Loading ..........5-78 Storage Areas ..........2-53 Wheel Replacement ........5-84 Center Console Storage Area ......2-53 When It Is Time for New Tires ......
Page 376 Wheels Alignment and Tire Balance ......5-80 Vehicle Front Bearings with Oil-Filled Hubs ....5-75 Control ............4-3 Loading ............5-78 Loading ............4-20 Replacement ..........5-84 Running While Parked ........2-50 Tightening the Wheel Nuts ......5-80 Symbols ............iii Where to Put the Restraint .......

Chevrolet 2009 Kodiak Owner's Manual

Section 2 Features and Controls

Keys

Mirrors

Storage Areas

Section 3 Instrument Panel

Instrument Panel Overview

Climate Controls

Warning Lights, Gages, and Indicators

Audio System(S)

Section 4 Driving Your Vehicle

Your Driving, the Road, and the Vehicle

Towing

Section 5 Service and Appearance Care

Service

Fuel

Checking Things under the Hood

Rear Axle

Four-Wheel Drive

Front Axle

Noise Control System

Windshield Wiper Blade Replacement

Bulb Replacement

Other Service Items

Tires

Appearance Care

Vehicle Identiﬁcation

Electrical System

Capacities and Speciﬁcations

Normal Maintenance Replacement Parts

Quick Links

Chapters

Related Manuals for Chevrolet 2009 Kodiak

Summary of Contents for Chevrolet 2009 Kodiak