Page 1: Table Of Contents
2004 Chevrolet Kodiak Owner Manual Seats and Restraint Systems ......1-1 Service and Appearance Care ......5-1 Front Seats ..........1-2 Service ............. 5-3 Rear Seats Fuel ..........1-7 ............5-6 Safety Belts Checking Things Under the Hood ..........1-8 ....
Page 2: Canadian Owners
Detroit, MI 48207 GENERAL MOTORS, GM, the GM Emblem, How to Use This Manual CHEVROLET, and the CHEVROLET Emblem are registered trademarks of General Motors Corporation. Many people read their owner’s manual from beginning to end when they ﬁrst receive their new vehicle. If...
Page 3 Safety Warnings and Symbols You will also ﬁnd a circle with a slash through it in this book. This safety You will ﬁnd a number of safety cautions in this book. symbol means “Don’t,” We use a box and the word CAUTION to tell you about “Don’t do this”...
Page 4: Vehicle Symbols
Vehicle Damage Warnings Vehicle Symbols Also, in this book you will ﬁnd these notices: Your vehicle has components and labels that use symbols instead of text. Symbols, used on your vehicle, Notice: These mean there is something that could are shown along with the text describing the operation damage your vehicle.
Page 5 These are some examples of symbols you may ﬁnd on your vehicle:...
Page 6: Model Reference
Model Reference C4E042 C5E042 C6E042 C7E042 This manual contains information which covers C8E042 conventional cab models as shown. Most models are unﬁnished from the factory. C4C042 C5C042 C4V042 C5V042 C4U042 C5U042 C6C042 C7C042 C8E064 C8C042 C6V042 C7V042 C8V042 C8C064 C8V064 Since C-series models delivered from the factory are ﬁnished in a variety of ways by a number of companies, you will probably ﬁnd other manuals in your ﬁnished...
Page 7: Seats And Restraint Systems
Section 1 Seats and Restraint Systems Front Seats ............1-2 Top Strap ............1-38 Manual Seats ..........1-2 Securing a Child Restraint in a Rear Outside Reclining Seatbacks ........1-4 Seat Position (Crew Cab Models) ....1-39 Split Bench Seat ..........1-6 Securing a Child Restraint in the Center Air Suspension Seats ........1-6 Rear Seat Position (Crew Cab) or Center...
Page 8: Front Seats
Front Seats Manual Seats Bucket Seats 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, or make you push a pedal when If your vehicle has bucket seats, you can adjust them you don’t want to.
Page 9 Seatback Adjustment CAUTION: The seatback adjustment knob is located on the If the seatback isn’t locked, it could move inboard side of the driver’s and passenger’s seat forward in a sudden stop or crash. That could cushions. cause injury to the person sitting there. Always press rearward on the seatback to be sure it is locked.
Page 10 Fore-and-Aft Adjustment Reclining Seatbacks The fore-and-aft adjustment lever is located underneath the seat, in the front. If your vehicle has standard, non-suspension bucket To slide the seat forward or rearward, move the lever seats, you can recline the seatbacks. The lever is toward the driver’s door.
Page 11 CAUTION: Sitting in a reclined position when your vehicle is in motion can be dangerous. Even if you buckle up, your safety belts can’t do their job when you’re reclined like this. The shoulder belt can’t do its job because it won’t be against your body.
Page 12: Air Suspension Seats
Split Bench Seat The seat cushion can also be raised or lowered. The seat cushion height If your vehicle has a split bench seat, your seat is not adjustment handle is adjustable. located underneath the front of the seat. Air Suspension Seats Your vehicle may have a low-back or high-back air suspension seat.
Page 13: Rear Seats
Chugger-Snubber Lock-Out Feature CAUTION: If your vehicle has this feature, the handle is located on the outboard A safety belt that is improperly routed, not side of the driver’s properly attached, or twisted won’t provide the and passenger’s seats. protection needed in a crash. The person wearing the belt could be seriously injured.
Page 14: Safety Belts
To fold down the seatback, pull this nylon strap CAUTION: located on the rear of the seat, while pulling the seatback down. Don’t let anyone ride where he or she can’t wear a safety belt properly. If you are in a crash and you’re not wearing a safety belt, your injuries can be much worse.
Page 15 Your vehicle has a light Why Safety Belts Work that comes on as a reminder to buckle up. Aren’t safety belts for kids? Yes. And they’re for adult truckers, and anyone else who rides in your vehicle. See Safety Belt Reminder Light on page 3-26. In most states and in all Canadian provinces, the law says to wear safety belts.
Page 16 If the vehicle hits something, it stops – right then. But Then something will stop them. It could be the nothing stops the people. They keep moving. windshield. 1-10...
Page 17 Or it could be the instrument panel. With belts, you slow down as the vehicle does. You get more time to stop. Now, what if you and your passengers were to give that big vehicle a chance to deal with the force of the You stop over more distance, and your strongest bones impact, instead of you? take the forces.
Page 18 Questions and Answers About If I’m a good driver, and I never drive far from home, why should I wear safety belts? Safety Belts You may be an excellent driver, but if you’re in an accident – even one that isn’t your fault – you and Won’t I be trapped in the vehicle after an your passengers can be hurt.
Page 19: How To Wear Safety Belts Properly
How to Wear Safety Belts Properly Driver Position This part is only for people of adult size. This part describes the driver’s restraint system. Be aware that there are special things to know about Lap-Shoulder Belt safety belts and children. And there are different rules for smaller children and babies.
Page 20 3. Pick up the latch plate and pull the belt across you. The lap part of the belt should be worn low and snug on Don’t let it get twisted. The shoulder belt may lock if the hips, just touching the thighs. In a crash, this you pull the belt across you very quickly.
Page 21: Shoulder Belt Height Adjuster
Shoulder Belt Height Adjuster To move it down, push in at the top of the arrows and move the height adjuster to the desired position. Before you begin to drive, move the shoulder belt You can move the adjuster up just by pushing up on the adjuster to the height that is right for you.
Page 22 What’s 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 against your body. The shoulder belt is too loose. It won’t give nearly as much protection this way.
Page 23 What’s 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 at the pelvic bones.
Page 24 What’s 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 at the abdomen, not at the pelvic bones, and that could cause serious or fatal injuries.
Page 25 What’s 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 aren’t as strong as shoulder bones.
Page 26 What’s wrong with this? CAUTION: You can be seriously injured by a twisted belt. In a crash, you wouldn’t have the full width of the belt to spread impact forces. If a belt is twisted, make it straight so it can work properly, or ask your dealer to ﬁx it.
Page 27: Safety Belt Use During Pregnancy
To unlatch the belt, just push the button on the buckle. A pregnant woman should wear a lap-shoulder belt, and The belt should go back out of the way. the lap portion should be worn as low as possible, Before you close the door, be sure the belt is out of the below the rounding, throughout the pregnancy.
Page 28: Right Front Passenger Position
Right Front Passenger Position Lap Belt If your vehicle has a front bench seat, someone can sit To learn how to wear the right front passenger’s safety in the center position. If your vehicle is a crew cab belt properly, see Driver Position on page 1-13. model, someone can also sit in the center rear position.
Page 29: Rear Seat Passengers
Rear Seat Passengers It is very important for rear seat passengers to buckle up! Accident statistics show that unbelted people in the rear seat are hurt more often in crashes than those who are wearing safety belts. Rear passengers who are not safety belted can be thrown out of the vehicle in a crash.
Page 30 Lap-Shoulder Belt 2. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. The positions next to the windows have lap-shoulder When the shoulder belt is pulled out all the way, belts.
Page 31 The safety belt locks if there is a sudden stop or a crash, or if you pull the belt very quickly out of the retractor. Each position next to the windows has a shoulder belt height adjuster. See “Shoulder Belt Height Adjuster” under Driver Position on page 1-13.
Page 32: Safety Belt Extender
Safety Belt Extender If the vehicle’s safety belt will fasten around you, you should use it. But if a safety belt isn’t long enough to fasten, your dealer will order you an extender. It’s free. When you go in to order it, take the heaviest coat you will wear, so the extender will be long enough for you.
Page 33: Child Restraints
Child Restraints What is the proper way to wear safety belts? If possible, an older child should wear a Older Children lap-shoulder belt and get the additional restraint a shoulder belt can provide. The shoulder belt should not cross the face or neck. The lap belt should ﬁt snugly below the hips, just touching the top of the thighs.
Page 34 CAUTION: Never do this. Here two children are wearing the same belt. The belt can’t properly spread the impact forces. In a crash, the two children can be crushed together and seriously injured. A belt must be used by only one person at a time. What if a child is wearing a lap-shoulder belt, but the child is so small that the shoulder belt is very close to the child’s face or neck?
Page 35: Infants And Young Children
CAUTION: Never do this. Here a child is sitting in a seat that has a lap-shoulder belt, but the shoulder part is behind the child. If the child wears the belt in this way, in a crash the child might slide under the belt.
Page 36 Every time infants and young children ride in vehicles, they should have the protection provided by appropriate CAUTION: restraints. Young children should not use the vehicle’s adult safety belts alone, unless there is no other choice. Instead, they need to use a child restraint. People should never hold a baby in their arms while riding in a vehicle.
Page 37 CAUTION: Children who are up against, or very close to, any air bag when it inﬂates can be seriously injured or killed. Air bags plus lap-shoulder belts offer outstanding protection for adults and older children, but not for young children and infants.
Page 38 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 The body structure of a young child is quite safety standards.
Page 39: Child Restraint Systems
Child Restraint Systems A rear-facing infant seat (B) provides restraint with the seating surface against the back of the infant. The harness system holds the infant in place and, in a crash, An infant car bed (A), a special bed made for use in a acts to keep the infant positioned in the restraint.
Page 40 A forward-facing child seat (C-E) provides restraint for A booster seat (F-G) is a child restraint designed to the child’s body with the harness and also sometimes improve the ﬁt of the vehicle’s safety belt system. Some with surfaces such as T-shaped or shelf-like shields. booster seats have a shoulder belt positioner, and some high-back booster seats have a ﬁve-point harness.
Page 41 When choosing a child restraint, be sure the child How do child restraints work? restraint is designed to be used in a vehicle. If it is, it will have a label saying that it meets federal motor A child restraint system is any device designed for vehicle safety standards.
Page 42 CAUTION: CAUTION: A child restraint cannot be secured properly in A child in a rear-facing child restraint can be seriously injured or killed if the passenger’s air an air-suspension type seat. This is because bag inﬂates. This is because the back of the an air-suspension seat is designed to move up rear-facing child restraint would be very close and down for an adult passenger.
Page 43 Where to Put the Restraint CAUTION: (Crew Cab Models) Accident statistics show that children are safer if they A child in a rear-facing child restraint can be are restrained in the rear rather than the front seat. We seriously injured or killed if the right front recommend that child restraints be secured in a rear passenger’s air bag inﬂates.
Page 44: Top Strap
If your vehicle has an air-suspension seat in the right Top Strap front passenger’s position, do not secure a child restraint there. Here is why: Some child restraints have a top strap, or “top tether,” which can help hold the child restraint during a crash.
Page 45 Securing a Child Restraint in a Rear 1. Put the restraint on the seat. 2. Pick up the latch plate, and run the lap and shoulder Outside Seat Position (Crew Cab portions of the vehicle’s safety belt through or Models) around the restraint.
Page 46 4. Pull the rest of the shoulder belt all the way out of 5. To tighten the belt, feed the shoulder belt back into the retractor to set the lock. the retractor while you push down on the child restraint. If you’re using a forward-facing child restraint, you may ﬁnd it helpful to use your knee to push down on the child restraint as you tighten the belt.
Page 47 To remove the child restraint, just unbuckle the vehicle’s Be sure to follow the instructions that came with the safety belt and let it go back all the way. The safety child restraint. Secure the child in the child restraint belt will move freely again and be ready to work for an when and as the instructions say.
Page 48 1. Make the belt as long as possible by tilting the latch 4. Buckle the belt. Make sure the release button is plate and pulling it along the belt. positioned so you would be able to unbuckle the safety belt quickly if you ever had to. 2.
Page 49: Securing A Child Restraint In The Right Front Seat Position
To remove the child restraint, just unbuckle the vehicle’s safety belt. It will be ready to work for an adult or CAUTION: large child passenger. Securing a Child Restraint in the A child restraint cannot be secured properly in an air-suspension type seat. This is because Right Front Seat Position an air-suspension seat is designed to move up and down for an adult passenger.
Page 50 A rear seat is a safer place to secure a forward-facing child restraint. Never put a rear-facing child restraint CAUTION: (Continued) in the right front passenger’s seat unless the air bag is off. Here is why: If you secure a forward-facing child restraint in the right front static seat or right front bench CAUTION: seat, always move the passenger seat as far...
Page 51 CAUTION: If the air bag readiness light ever comes on when you have turned off the air bag, it means that something may be wrong with the air bag system. The right front passenger’s air bag could inﬂate even though the switch is off. If this ever happens, don’t let anyone whom the national government has identiﬁed as a member of a passenger air bag risk group sit...
Page 52 Secure the child in the child restraint when and as the instructions say. 1. If your vehicle has a right front passenger’s air bag see Air Bag Off Switch on page 1-55. If your vehicle has a right front passenger’s air bag and your child restraint is forward-facing, always move the seat as far back as it will go before securing it in this seat.
Page 53 5. Pull the rest of the shoulder belt all the way out of 6. To tighten the belt, feed the shoulder belt back into the retractor to set the lock. the retractor while you push down on the child restraint. If you are using a forward-facing child restraint, you may ﬁnd it helpful to use your knee to push down on the child restraint as you tighten the belt.
Page 54: Air Bag System
To remove the child restraint, just unbuckle the vehicle’s Air Bag System safety belt and let it go back all the way. The safety belt will move freely again and be ready to work for an This part explains the air bag system. adult or larger child passenger.
Page 55 If it says AIR BAG on the middle part of the steering wheel, but it doesn’t say AIR BAG on the instrument panel in front of the right front passenger’s seat, your vehicle has an air bag for the driver only. If it says AIR BAG on the middle part of the steering wheel, but there is no right front passenger seat, your vehicle has an air bag for the driver only.
Page 56 Here are the most important things to know about the air bag system: CAUTION: (Continued) protection in frontal crashes than more CAUTION: forceful air bags have provided in the past. Everyone in your vehicle should wear a safety You can be severely injured or killed in a crash belt properly —...
Page 57 If your vehicle has an air bag for the right front There is an air bag passenger, please read this: readiness light on the instrument panel, which shows the air bag symbol. CAUTION: Anyone who is up against, or very close to, any air bag when it inﬂates can be seriously The system checks the air bag electrical system for injured or killed.
Page 58: Where Are The Air Bags
Where Are the Air Bags? The right front passenger’s air bag is in the instrument panel on the passenger’s side. The driver’s air bag is in the middle of the steering wheel. 1-52...
Page 59: How Does An Air Bag Restrain
What Makes an Air Bag Inﬂate? CAUTION: In an impact of sufficient severity, the air bag sensing system detects that the vehicle is in a crash. The sensing system triggers a release of gas from the If something is between an occupant and an inﬂator, which inﬂates the air bag.
Page 60 What Will You See After an CAUTION: (Continued) Air Bag Inﬂates? the vehicle should get out as soon as it is safe After an air bag inﬂates, it quickly deﬂates, so quickly that some people may not even realize the air bag to do so.
Page 61: Air Bag Off Switch
• Air Bag Off Switch Your vehicle is equipped with a crash sensing and diagnostic module, which records information If your vehicle has a right front passenger air bag, it has about the air bag system. The module records a switch on the instrument panel that you can use to information about the readiness of the system, when turn off the right front passenger’s air bag.
Page 62 Infant. An infant (less than 1 year old) must ride in the front seat because: • my vehicle has no rear seat; • my vehicle has a rear seat too small to accommodate a rear-facing infant seat; or • the infant has a medical condition which, according to the infant’s physician, makes it necessary for the infant to ride in the front seat so that the driver can constantly monitor the child’s condition.
Page 63 Medical Condition. A passenger has a medical condition which, according to his or her physician: • causes the passenger air bag to pose a special risk for the passenger; and • makes the potential harm from the passenger air bag in a crash greater than the potential harm from turning off the air bag and allowing the passenger, even if belted, to hit the dashboard or windshield in a crash.
Page 64 CAUTION: If the air bag readiness light ever comes on when you have turned off the air bag, it means that something may be wrong with the air bag system. The right front passenger’s air bag could inﬂate even though the switch is off. If this ever happens, don’t let anyone whom the national government has identiﬁed as a member of a passenger air bag risk group sit...
Page 65 United States Canada To turn the right front passenger’s air bag on again, insert your ignition key into the switch, push in, and move the switch to the on position. 1-59...
Page 66 Servicing Your Air Bag-Equipped CAUTION: Vehicle Air bags affect how your vehicle should be serviced. For up to 10 minutes after the ignition key is There are parts of the air bag system in several places turned off and the battery is disconnected, an around your vehicle.
Page 67: Restraint System Check
Adding Equipment to Your Air Restraint System Check Bag-Equipped Vehicle Checking Your Restraint Systems If I add a push bumper or a bicycle rack to the Now and then, make sure the safety belt reminder light front of my vehicle, will it keep the air bags and all your belts, buckles, latch plates, retractors from working properly? and anchorages are working properly.
Page 68: Replacing Restraint System Parts After A Crash
Replacing Restraint System Parts If you’ve had a crash, do you need new belts? After a very minor collision, nothing may be necessary. After a Crash But if the belts were stretched, as they would be if worn during a more severe crash, then you need new parts.
Page 69: Features And Controls
Section 2 Features and Controls Keys ...............2-2 Engine Checks Before Operating ....2-22 Remote Keyless Entry System ......2-3 Engine Coolant Heater ........2-23 Remote Keyless Entry System Operation ...2-4 Diesel Engine Exhaust Brake ......2-25 Two-Speed Rear Axle Electric Shift Control ..2-26 Doors and Locks ..........2-6 Automatic Transmission Operation ....2-28 Door Locks ............2-6 Manual Transmission Operation ......2-30...
Page 70: Keys
Keys CAUTION: Leaving children in a vehicle with the ignition key is dangerous for many reasons. They could operate the power windows or other controls or even make the vehicle move. The children or others could be badly injured or even killed.
Page 71 Your vehicle has one Remote Keyless Entry System double-sided key for the ignition and all door locks. If equipped, the keyless entry system operates on a radio frequency subject to Federal Communications Commission (FCC) Rules and with Industry Canada. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1.
Page 72: Remote Keyless Entry System Operation
At times you may notice a decrease in range. This is Remote Keyless Entry System normal for any remote keyless entry system. If the Operation transmitter does not work or if you have to stand closer to your vehicle for the transmitter to work, try this: If your vehicle has this feature, you can lock and unlock •...
Page 73: Battery Replacement
Matching Transmitter(s) to Your 1. Insert a thin object, such as a coin, into the slot between the covers of the transmitter near the Vehicle key ring hole. Remove the bottom by twisting the object. Each remote keyless entry transmitter is coded to prevent another transmitter from unlocking your vehicle.
Page 74: Doors And Locks
Resynchronization Doors and Locks Resynchronization may be necessary due to the security method used by this system. The transmitter Door Locks does not send the same signal twice to the receiver. The receiver will not respond to a signal it has been sent previously.
Page 75: Power Door Locks
There are several ways to lock and unlock your vehicle. Power Door Locks If your vehicle is equipped with keyless entry, you can use your transmitter to lock or unlock your vehicle. If your vehicle has power See “Remote Keyless Entry System Operation” door locks, press the earlier in this section.
Page 76: 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 77: Power Windows
Power Windows If your vehicle is a crew cab model with power windows, there will be switches located on the rear doors as well. If your vehicle is equipped with power windows, the switches are located on each of the side doors. Your power windows will work when the ignition has The driver’s door also has a switch for the passenger’s been turned to ACCESSORY or RUN.
Page 78: Theft-Deterrent Systems
Express-Down Feature Sliding Rear Window The driver’s window also has an express-down feature To open the sliding rear window, pull the latch toward that allows the window to be lowered without holding the driver’s side of the vehicle. down the switch. Press and hold the rear of the window To close the window, slide the window toward the switch labeled AUTO for one second to activate the passenger’s side of the vehicle.
Page 79: Starting And Operating Your Vehicle
Starting and Operating Your • Avoid making hard stops for the ﬁrst 200 miles (322 km) or so. During this time your new Vehicle brake linings are not yet broken in. Hard stops with new linings can mean premature wear and earlier replacement.
Page 80: Ignition Positions
Ignition Positions C (OFF): This position lets you turn off the engine but still turn the steering wheel. It doesn’t lock the With your key in the ignition switch, you can turn it to steering wheel like LOCK. Use OFF if you must have ﬁve different positions.
Page 81 Automatic Transmission Starting Your Engine 1. Without pushing the accelerator pedal, turn your Set the parking brake and move your shift lever to ignition key to START. When the engine starts, let NEUTRAL (N) or PARK (P) if so equipped. Your engine go of the key.
Page 82 Gasoline Engine Warm-Up While your engine is idling before you turn it off, you can make a list of any operational or handling concerns When you’ve started your engine, let it run for to give to responsible maintenance personnel so 20 or 30 seconds to warm up before you put a load on they can handle them right away.
Page 83 Restarting the Diesel Engine While Cold Weather Starting ® Moving (Automatic Transmission) (Caterpillar Diesel) If you have to restart the engine while the vehicle is Because the diesel engine uses compression ignition, it moving, you’ll ﬁrst have to shift the automatic is harder to start in cold weather than a gasoline transmission to NEUTRAL (N).
Page 84: Engine Alarm And Automatic Shutdown
Diesel Engine Warm-Up If the system senses low engine coolant, the ﬁve beat per second alarm and the low coolant warning light Several factors affect how quickly your diesel engine will come on. warms up. These can include outside temperature, The ﬁve beats per second tone alarm means that your engine load, idle time and your vehicle’s option content.
Page 85 Automatic High Idle System Manual High Idle System (Diesel Engines) If your vehicle has this The automatic high idle feature will engage whenever feature, the manual high you start your vehicle and the engine is below the preset idle switch is located in the operating temperature.
Page 86 The manual high idle feature is activated by pressing The exhaust restrictor operates: the switch on the instrument panel. When the switch is • while the engine is running. pressed again, or any of the previous conditions are • while the vehicle is not moving. not met, manual high idle will be deactivated.
Page 87 Starting Your DURAMAX™ Diesel Starting Your Engine Engine 1. Turn your ignition key to RUN. Observe the wait to start light. See Wait to Start Your diesel engine starts differently than a gasoline Indicator on page 3-36. (This light may not come on engine.
Page 88 If you’re trying to start your engine after you’ve run out If you experience longer cranking times, notice an of fuel, see Running Out of Fuel on page 5-15. unusual amount of exhaust smoke or are at higher altitudes (over 7,000 ft. or 2 135 m), you may use your When your engine is cold, let it run for a few minutes engine coolant heater.
Page 89 If your batteries don’t have enough charge to start your Elevated Idle/Exhaust Restrictor engine, see Battery on page 5-55. If your vehicle is equipped with the RPO LLY engine, it Be sure you have the right oil for your engine, and that has a cold temperature high idle and exhaust restrictor you’ve changed the oil at the proper times.
Page 90: Engine Checks Before Operating
When the engine is started, it will slowly ramp up to the Engine Checks Before Operating high idle speed after a delay of a few seconds up to about two minutes. For this method to work properly When you’ve started your engine, let it run for there must be no throttle or brake pedal faults, and the 20 to 30 seconds before you put a load on the engine.
Page 91: Engine Coolant Heater
• Notice: For diesel engines, don’t allow the engine If you have air brakes, the dual-needle air pressure to operate at low idle for more than ﬁve minutes. gage should read at least 115 psi (790 kPa) for This can cause low engine operating temperatures both service systems before you try to move which can affect engine operation and reduce the vehicle.
Page 92: To Use The Engine Coolant Heater
To Use the Engine Coolant Heater 4. Before starting the engine, be sure to unplug the cord. 1. Turn off the engine. How long should you keep the coolant heater plugged 2. Find the plug-in receptacle located under the in? The answer depends on the outside temperature. driver’s door.
Page 93 Diesel Engine Exhaust Brake There is an indicator light on the instrument panel similar to the symbol on the switch, that will come on when the exhaust brake is active. See Exhaust The exhaust brake is available on vehicles equipped Brake Indicator Light on page 3-40 for more information.
Page 94 Two-Speed Rear Axle Electric The two-speed axle should be in low when you park the vehicle. You’ll need to engage the transmission, even Shift Control move the vehicle a little, to be sure the axle is in the low range. Then apply the parking brake, shift into If your vehicle is equipped with this feature, you’ll ﬁnd a NEUTRAL and shut off the engine.
Page 95 Air Shift Control (Automatic To shift up from low to high, press the top of the rear axle shift control switch and press down on the Transmission) accelerator. When you shift the axle from high to low, press the bottom of the switch, release the accelerator The rear axle shift control and then quickly press it down again.
Page 96 Rear Air Suspension Dump Control Automatic Transmission Operation If your vehicle is equipped with the Hendrickson HAS We build vehicles with ﬁve and six-speed automatic Series single-axle air suspension, you have this control. transmissions. This part of the manual covers the basics The air suspension dump control allows the operator of these.
Page 97 Overdrive Defeat CAUTION: If your vehicle has this feature, you can select not to shift up to ﬁfth gear. This is useful when towing or under a heavy load. It can be dangerous to get out of your vehicle without the parking brake ﬁrmly set. Your The overdrive defeat vehicle can roll.
Page 98: Manual Transmission Operation
® ® Manual Transmission Operation Eaton Fuller Five and Six-Speed Transmissions and TTC Spicer Using the Clutch Seven-Speed Transmissions When you are starting to move the vehicle, it is These transmissions have gears that automatically important to begin with the engine speed at idle. Then synchronize when you shift up or down (except start to engage the clutch and listen for an engine speed FIRST (1) gear on the ﬁve-speed and seven-speed...
Page 99 ZF Six-Speed Transmission FIRST (1): With the vehicle at a stop, release the brake, press the clutch pedal and shift into FIRST (1). Then, slowly let up on the clutch pedal as you press the Here’s how to operate your accelerator pedal.
Page 100 NEUTRAL: Use this position when you start or idle • Never move the range knob or lever with the shift your engine. lever in neutral while the vehicle is moving. • Never make a range shift while moving in REVERSE (R): To back up, press the clutch pedal. Wait for the vehicle to stop moving and then, shift REVERSE (R).
Page 101: Hydraulic Brakes
Parking Hydraulic Brakes If your vehicle has hydraulic brakes, it has either a parking brake foot pedal or hand lever. If you have the CAUTION: parking brake foot pedal, it is located below the instrument panel to the left of the steering column. If you don’t park your vehicle properly, it can roll.
Page 102 To set the hand lever parking brake, hold the regular Notice: Driving with the parking brake on can brake pedal down with your right foot. Pull up on damage the transmission and brake system parts. the handle with your right hand, until it stops. Verify that the parking brake is fully released and the brake warning light is off before driving.
Page 103 Air Brake Vehicles built for use as tractors or towing vehicles have two air brake controls. They look like this: CAUTION: When the yellow SYSTEM PARK and the red TRAILER AIR SUPPLY knobs are both pushed in, your rig will be free to move. It could strike someone or something.
Page 104 After a few minutes, the trailer system should be fully If the air pressure drops to 35 to 45 psi (241 to 310 kPa), charged. When it is, the air pressure gage will show the yellow park brake knob will automatically pop out about 125 to 135 psi (862 to 931 kPa).
Page 105: Parking Over Things That Burn
Parking Over Things That Burn Engine Exhaust CAUTION: Engine exhaust can kill. It contains the gas carbon monoxide (CO), which you can not see or smell. It can cause unconsciousness and death. You might have exhaust coming in if: • Your exhaust system sounds strange or different.
Page 106: Running Your Engine While You Are Parked
Running Your Engine While You CAUTION: Are Parked It is better not to park with the engine running. But if It can be dangerous to get out of your vehicle you ever have to, here are some things to know. if the shift lever is not fully in PARK (P) with the parking brake ﬁrmly set.
Page 107: Mirrors
Mirrors CAUTION: Manual Rearview Mirror It can be dangerous to get out of your vehicle If your vehicle has this feature, pull the tab under the without the parking brake ﬁrmly set. Your mirror toward you to reduce glare from headlamps vehicle can roll.
Page 108 Outside Power Mirrors Outside Convex Mirrors If you have outside power mirrors, they can be adjusted Your vehicle has convex mirrors on the lower quarter of from the inside of the vehicle. both the driver’s and passenger’s side rearview mirrors. A convex mirror’s surface is curved so you can The control for this see more from the driver’s seat.
Page 109: Storage Areas
Outside Heated Mirrors Storage Areas If your vehicle has this feature, your outside rearview Your vehicle includes a number of storage mirrors can be defrosted. compartments. Some vehicles have storage areas in the instrument The switch for this feature panel. Another small storage area may be located is located in the instrument overhead.
Page 110 Center Console Storage Area To expose the storage compartment, pull the strap to release the seatback. Then fold the seatback forward. Your vehicle may have a center console compartment To open the storage compartment, press the release between the bucket or suspension seats. button and lift the lid rearward.
Page 111: Instrument Panel
Section 3 Instrument Panel Instrument Panel Overview .......3-4 Charging System Light ........3-30 Hazard Warning Flashers ........3-5 Voltmeter Gage ..........3-30 Other Warning Devices ........3-6 Service Transmission Warning Light ....3-31 Horn .............3-6 Range Inhibit Warning Indicator ......3-31 Tilt Wheel .............3-7 Brake System Warning Light ......3-31 Turn Signal/Multifunction Lever ......3-7 Parking Brake Warning Light ......3-34 Exterior Lamps ..........3-13...
Page 112 Section 3 Instrument Panel Low Washer Fluid Warning Light .....3-42 Radio with Cassette ........3-48 Check Gages Warning Light ......3-42 Radio with CD ..........3-53 Fuel Gage ...........3-42 Theft-Deterrent Feature (Non-RDS Radios) ..3-57 Water in Fuel Warning Light ......3-43 Radio Reception ...........3-57 Air Filter Restriction Indicator ......3-44 Care of Your Cassette Tape Player ....3-57 Air Pressure Gage ........3-44...
Page 113 NOTES...
Page 114 Instrument Panel Overview...
Page 115: Warning Lights, Gages, And Indicators
A. Air Outlets. See Outlet Adjustment on page 3-22. Hazard Warning Flashers B. Instrument Panel Cluster. See Instrument Panel Cluster on page 3-24. C. Shift Lever. See Starting Your Gasoline Engine on page 2-12, Starting Your Diesel Engine on page 2-14 and Starting Your DURAMAX™...
Page 116 Your hazard warning Other Warning Devices ﬂashers button is located on top of the steering If you carry reﬂective triangles, you can set one up at column. the side of the road behind your vehicle in the recommended manner per Federal Motor Carrier Safety Regulation (FMCSR) Section 392.22, to warn others.
Page 117: Tilt Wheel
Tilt Wheel Turn Signal/Multifunction Lever A tilt wheel allows you to adjust the steering wheel before you drive. You can raise it to the highest level to give your legs more room when you exit and enter the vehicle. The lever that allows you to tilt the steering wheel is located on the left side of the steering column.
Page 118: Windshield Wipers
Turn and Lane-Change Signals Headlamp High/Low-Beam Changer The turn signal has two upward (for right) and two To change the headlamps from low to high beam or high downward (for left) positions. These positions allow you to low beam, pull the multifunction lever all the way to signal a turn or a lane change.
Page 119: Windshield Washer
Heavy snow or ice can overload your wipers. The (Mist): For a single wiping cycle, turn the band to windshield wiper motor is protected from overload by a this symbol. Hold it there until the wipers start, then circuit breaker and a fuse. If the motor overheats let go.
Page 120 Cruise Control With cruise control, you can maintain a speed of about 30 mph (48 km/h) or more without keeping your foot on the accelerator. Cruise control does not work If your vehicle has this at speeds below about 30 mph (48 km/h). feature, it is located at the end of the multifunction If you have an automatic transmission and you apply...
Page 121 Setting Cruise Control Once you’re going about 30 mph (48 km/h) or more, you can move the cruise control switch brieﬂy from on to resume/accelerate. CAUTION: The vehicle will return to your chosen speed and stay there. If you hold the switch at resume/accelerate, the vehicle If you leave your cruise control on when you will keep going faster until you release the switch or are not using cruise, you might hit a button...
Page 122 Reducing Speed While Using Cruise Ending Cruise Control Control There are four different ways to turn off the cruise control: Press in the button at the end of the lever until you reach the lower speed you want, then release it. •...
Page 123: Exterior Lamps
Exterior Lamps (Parking Lamps): Turning the control to this position turns on the parking lamps, together with the following: • Marker Lamps • Taillamps • License Plate Lamps • Instrument Panel Lights (Headlamps): Turning the control to this position turns on the headlamps, together with the previously listed lamps and lights.
Page 124: Daytime Running Lamps
Daytime Running Lamps To idle your vehicle with the DRL off, set the parking brake. The DRL will stay off until you release the Daytime Running Lamps (DRL) can make it easier for parking brake. others to see the front of your vehicle during the As with any vehicle, you should turn on the regular day.
Page 125: Interior Lamps
Interior Lamps Instrument Panel Brightness Control This feature controls the brightness of the instrument panel lights. The thumbwheel for this feature is located to the right of the exterior lamp control. Turn the thumbwheel up to brighten the lights. When the thumbwheel is moved to the ﬁrst position, the radio display and transmission selection display will go to full intensity.
Page 126: Illuminated Entry
Illuminated Entry Instrument Panel Switchbank The delayed illumination feature will allow you to enter or exit your vehicle with the lights on for about 20 seconds, after the door is closed or the ignition is cycled. Reading Lamps If your vehicle has reading lamps, press the button next to the lamp to turn the lamp on or off.
Page 127: Accessory Power Outlets
This switchbank is located in the center of the instrument (Differential Lock Control Switch): See Rear panel. Axle Differential Lock Control on page 4-10. (Marker Lamp Defeat Switch): See “Marker Lamp (Air Bag Off Switch): See Air Bag Off Switch Defeat Switch”...
Page 128: Ashtrays And Cigarette Lighter
Certain electrical accessories may not be compatible Ashtrays and Cigarette Lighter with the accessory power outlet and could result in blown vehicle or adapter fuses. If you experience a Your vehicle may have an ashtray and a cigarette problem, see your dealer for additional information lighter located in the center ﬂoor console.
Page 129: Climate Controls
Climate Controls (Bi-Level): This mode directs half of the air to the instrument panel vents, then directs the remaining air to the ﬂoor vents. Cooler air is directed to the upper Climate Control System vents and warmer air to the ﬂoor vents. With these systems, you can control the heating, (Floor): This mode directs most of the air to the cooling and ventilation for your vehicle.
Page 130: Defogging And Defrosting
If your vehicle has air conditioning, the controls will look (Air Conditioning): This setting is used for normal like this: cooling on hot days. It cools outside air and directs it through the instrument panel vents. (Bi-Level Air Conditioning): This setting divides airﬂow between the ﬂoor vents and instrument panel vents.
Page 131: Rear Window Defogger
Turn the mode knob on the right of the climate control Be sure to clear as much snow from the rear window as panel to select the defog or defrost mode. possible. (Defog): With this setting, the outside air comes out Press this button which is located near the fan of both the ﬂoor and defroster outlets.
Page 132 Outlet Adjustment Operation Tips • Keep the hood and front air inlets free of ice, snow, Your vehicle has air outlets or any other obstruction (such as leaves). The on the instrument panel heater and defroster will work far better, reducing that allow you to adjust the the chance of fogging the inside of your windows.
Page 133 Rear Heating System Warning lights and gages can signal that something is wrong before it becomes serious enough to cause an expensive repair or replacement. Paying attention to If your vehicle has a rear your warning lights and gages could also save you heater, the thumbwheel for or others from injury.
Page 134: Instrument Panel Cluster
Instrument Panel Cluster Your instrument panel cluster is designed to let you know at a glance how your vehicle is running. You’ll know how fast your going, about how much fuel is left and many other things you’ll need to drive safely and economically. United States Diesel Engine shown, Canada and Gasoline Engine similar 3-24...
Page 135: Speedometer And Odometer
Speedometer and Odometer Engine Speed Limiting All engines have electronic engine speed limiting. Your speedometer lets you see your speed in both The engine limited speeds range between miles per hour (mph) and kilometers per hour (km/h). 2,900 and 4,400 rpm depending on engine Your odometer shows how far your vehicle has option content.
Page 136: Safety Belt Reminder Tone
Tachometer Safety Belt Reminder Light When the key is turned to RUN or START, a light will come on for several seconds to remind people to fasten their safety belts. The safety belt light will also come on and stay on for several seconds.
Page 137: Air Bag Readiness Light
Air Bag Readiness Light The air bag readiness light should ﬂash for a few seconds when you turn the ignition key to RUN or START. If the light doesn’t come on then, have it ﬁxed If your vehicle has air bags, there is an air bag readiness so it will be ready to warn you if there is a problem.
Page 138: Air Bag Off Light
Air Bag Off Light If your vehicle is equipped with an air bag off switch, when you turn the right front passenger’s air bag off, this light will come on and stay on to remind you that the air bag has been turned off. This light will go off when you turn the air bag back on again.
Page 139 CAUTION: CAUTION: If the right front passenger’s air bag is turned If the air bag readiness light ever comes on off for a person who isn’t in a risk group when you have turned off the air bag, it means identiﬁed by the national government, that that something may be wrong with the air bag person won’t have the extra protection of an...
Page 140: Charging System Light
Charging System Light Voltmeter Gage The charging system light When your engine is may be located in the running, the voltmeter instrument panel cluster, or gage shows the charging with the auxiliary warning system voltage. lights in the center of the instrument panel.
Page 141: Service Transmission Warning Light
Service Transmission Warning Light Range Inhibit Warning Indicator If your vehicle has an Allison automatic transmission, If your vehicle has an Allison certain transmission malfunctions will turn this light on. 1000/2000/2200/2400 series automatic transmission, a lighted bar under the current gear selected will ﬂash. This light is located with If your vehicle has an Allison MD automatic the auxiliary warning lights...
Page 142 Hydraulic Brake System If the service brakes soon warning light comes on, it Warning Lights means there is something wrong in the brake Vehicles with hydraulic brake systems have two brake system. system warning lights on the instrument panel. If the BRAKE warning light comes on, it means that the ﬂuid level in the master When this light comes on, you will also hear a warning...
Page 143 Air Brake System Warning Light CAUTION: Vehicles with air brake systems have a brake system warning light on the instrument panel. If the LOW AIR warning light comes on and the warning tone sounds, the vehicle can stop suddenly and without further warning. This is because the parking brake will come on if the pressure falls below 35 to 45 psi (240 to 310 kPa).
Page 144: Parking Brake Warning Light
Parking Brake Warning Light Anti-Lock Brake System Warning Light Your vehicle has a brake warning light. When the With the anti-lock brake ignition is on, this light will system, this light will come come on when you set on when you start your your parking brake.
Page 145: Engine Coolant Temperature Gage
Trailer Anti-Lock Brake System Engine Coolant Temperature Gage Warning Light If your vehicle is connected to a trailer with anti-lock brakes, this light should come on brieﬂy, as a check, when you turn on the ignition. When this light comes on and stays on, it means there United States Canada is something wrong in the trailer anti-lock brake...
Page 146: Low Coolant Warning Light
Low Coolant Warning Light Wait to Start Indicator If your vehicle has the DURAMAX™ 6600, you will have You have a low coolant glow plugs. If your vehicle has the DURAMAX™ 7800, warning light. If this light you will have glow plugs and an inlet heater. If your comes on, your system is ®...
Page 147: Malfunction Indicator Lamp
Malfunction Indicator Lamp Oil Pressure Gage Service Engine Soon Light If this light comes on or ﬂashes while you are driving, two things may happen. First, you will not notice any difference in engine United States Canada performance, but your tail pipe emissions may increase. Second, your engine may not run properly or may The engine oil pressure gage, on the lower right portion stall without warning.
Page 148: Low Oil Level Light
A reading in the low pressure zone may be caused by a Low Oil Level Light dangerously low oil level or other problem. ® If you have a Caterpillar diesel engine, also see your This light should come on ® Caterpillar Operation &...
Page 149: Change Engine Oil Light
Change Engine Oil Light Engine Overspeed Warning Light If your vehicle has this The change engine oil light light, it will come on if your should come on brieﬂy as engine is operating at a bulb check when you too many revolutions per start the engine.
Page 150: Transmission Temperature Gage
Transmission Temperature Gage Exhaust Brake Indicator Light If your vehicle is equipped If you have an automatic with an exhaust brake, you transmission, this gage is will have this light, located above the located above the comfort switchbank in the center of controls in the center of the instrument panel.
Page 151: Reduced Engine Power Light
Reduced Engine Power Light Daytime Running Lamps Indicator Light If the check engine and reduced engine power This light is located on the lights are on, the throttle instrument panel cluster. It may be disabled, and goes on whenever the a noticeable reduction in Daytime Running Lamps the vehicle’s performance...
Page 152: Low Washer Fluid Warning Light
Low Washer Fluid Warning Light When the check gages light comes on, you will also hear a warning tone. The tone and the light will stay activated until the problem is corrected. This light will come on This light may also come on if your vehicle is equipped when your vehicle is low with the optional automatic engine shutdown system on windshield washer ﬂuid.
Page 153: Water In Fuel Warning Light
If your vehicle has dual fuel tanks, the reading on the Water in Fuel Warning Light gage is the total fuel left in both tanks. Here are four concerns of some operators. None of If your vehicle is equipped these shows a problem with your fuel gage: with a diesel engine, you may have this light.
Page 154: Air Filter Restriction Indicator
Air Filter Restriction Indicator Air Pressure Gage If your vehicle has this If your vehicle has air feature, the gage is brakes, the air pressure located above the gage is located above the switchbank in the center of switchbank in the center the instrument panel.
Page 155: Hourmeter Gage
Hourmeter Gage Your vehicle’s systems may interfere with the operation of sound equipment that has been added improperly. The instrument panel cluster displays the accumulated engine run time hours using the reconﬁgurable So, before adding sound equipment, check with odometer VF display. The engine run time hours your dealer and be sure to check federal rules displays only when the ignition is in the OFF or ACC covering mobile radio and telephone units.
Page 156: Am-Fm Radio
AM-FM Radio Finding a Station AM FM: Press this button to switch between FM1, FM2, or AM. The display will show your selection. TUNE: Turn this knob to select radio stations. SEEK : Press the right or the left arrow to go to the next or to the previous station and stay there.
Page 157 Setting Preset Stations To adjust both tone controls and both speaker controls to the middle position, end out of audio by waiting The six numbered pushbuttons let you return to for the display to change to the time display. Then press your favorite stations.
Page 158: Radio With Cassette
To adjust both tone controls and both speaker controls Radio with Cassette to the middle position, end out of audio by waiting for the display to change to the time display. Then press and hold AUDIO for more than two seconds until you hear a beep.
Page 159 Finding a Station Setting Preset Stations The six numbered pushbuttons let you return to AM FM: Press this button to switch between AM, FM1 your favorite stations. You can set up to 18 stations and FM2. The display will show your selection. (six AM, six FM1 and six FM2) by performing the TUNE: Turn this knob to choose radio stations.
Page 160 To adjust both tone controls and both speaker controls Radio Messages to the middle position, end out of audio by waiting for the display to change to the clock display. Then CAL (Calibration): Your audio system has been press and hold AUDIO for more than two seconds until calibrated for your vehicle from the factory.
Page 161 If an error appears on the display, see “Cassette Tape 3 REV (Reverse): Press this pushbutton to reverse the Messages” later in this section. tape rapidly. FR will appear on the display. Press it again to return to playing the tape. The radio will play 1 PREV (Previous): Your tape must have at least three while the tape reverses.
Page 162: Cd Adapter Kits
CD Adapter Kits SEEK : The right arrow is the same as the NEXT pushbutton, and the left arrow is the same as the It is possible to use a portable CD player adapter kit PREV pushbutton. If the arrows are held or pressed with your cassette tape player after deactivating more than once, the player will continue moving forward the tight/loose tape sensor feature on your tape player.
Page 163: Radio With Cd
Radio with CD Finding a Station AM FM: Press this button to switch between AM, FM1 and FM2. The display will show your selection. TUNE: Turn this knob to choose radio stations. SEEK : Press the right or the left arrow to seek to the next or to the previous station and stay there.
Page 164 Setting Preset Stations To adjust both tone controls and both speaker controls to the middle position, end out of audio mode by The six numbered pushbuttons let you return to waiting for the display to change to the time display. your favorite stations.
Page 165: Playing A Compact Disc
Radio Messages Do not add paper labels to discs, they could get caught in the CD player. CAL (Calibrated): Your audio system has been Do not play 3 inch discs without a standard calibrated for your vehicle from the factory. If CAL adapter disc.
Page 166: Compact Disc Messages
5 RDM (Random): Press this pushbutton to hear the Compact Disc Messages tracks in random, rather than sequential, order. RND will If the disc comes out, it could be for one of the following appear on the display. Press this pushbutton again to reasons: turn off random play.
Page 167: Theft-Deterrent Feature (Non-Rds Radios)
Theft-Deterrent Feature Care of Your Cassette Tape Player (Non-RDS Radios) A tape player that is not cleaned regularly can cause reduced sound quality, ruined cassettes or a damaged ® THEFTLOCK is designed to discourage theft of your mechanism. Cassette tapes should be stored in their radio.
Page 168 The cut tape detection feature of your cassette tape You may also choose a non-scrubbing action, wet-type player may identify the cleaning cassette as a damaged cleaner which uses a cassette with a fabric belt to tape. To prevent the cleaning cassette from being clean the tape head.
Page 169: Care Of Your Cds
Care of Your CDs Chime Level Adjustment Handle CDs carefully. Store them in their original cases The radio is the vehicle chime producer. The chime is or other protective cases and away from direct produced from the driver’s side front door speakers. sunlight and dust.
Page 170 NOTES 3-60...
Page 171 Section 4 Driving Your Vehicle Your Driving, the Road, and Your Vehicle ..4-2 Driving in Rain and on Wet Roads ....4-18 Defensive Driving ...........4-2 City Driving ..........4-21 Drunken Driving ..........4-2 Freeway Driving ...........4-22 Control of a Vehicle ........4-5 Highway Hypnosis ........4-23 Braking ............4-6 Hill and Mountain Roads ........4-23 Trailer Brake Hand Control Valve ......4-9...
Page 172: Your Driving, The Road, And Your Vehicle
Your Driving, the Road, and proper defensive driving more difficult and can even cause a collision, with resulting injury. Ask a passenger to Your Vehicle help do things like this, or pull off the road in a safe place to do them yourself. These simple defensive driving techniques could save your life.
Page 173 Many adults — by some estimates, nearly half the adult same BAC by drinking three 4 ounce (120 ml) glasses population — choose never to drink alcohol, so they of wine or three mixed drinks if each had 1-1/2 ounces never drive after drinking.
Page 174 There is a gender difference, too. Women generally But the ability to drive is affected well below a BAC of have a lower relative percentage of body water 0.10 percent. Research shows that the driving skills than men. Since alcohol is carried in body water, this of many people are impaired at a BAC approaching means that a woman generally will reach a higher BAC 0.05 percent, and that the effects are worse at night.
Page 175: Control Of A Vehicle
There is something else about drinking and driving that Control of a Vehicle many people do not know. Medical research shows that alcohol in a person’s system can make crash You have three systems that make your vehicle go injuries worse, especially injuries to the brain, spinal where you want it to go.
Page 176: Braking
Braking with the traffic and allow realistic following distances, you will eliminate a lot of unnecessary braking. That means better braking and longer brake life. Braking action involves perception time and reaction time. If your engine ever stops while you are driving, brake normally but do not pump your brakes.
Page 177 Anti-lock Brake System (ABS) Your vehicle has anti-lock brakes. ABS is an advanced electronic braking system that will help prevent a braking skid. When you start your engine and begin to drive away, your anti-lock brake system will check itself. You may hear a momentary motor or clicking noise while this test is going on.
Page 178: Braking In Emergencies
The anti-lock system can change the brake pressure Remember: Anti-lock does not change the time you faster than any driver could. The computer is need to get your foot up to the brake pedal or always programmed to make the most of available tire and road decrease stopping distance.
Page 179: Trailer Brake Hand Control Valve
Trailer Brake Hand Control Valve CAUTION: If your vehicle has this feature, the control is mounted on the ﬂoor console. Using the trailer brake hand control for parking This feature lets you apply or for holding the vehicle on a hill may not the trailer brakes without keep the vehicle from rolling.
Page 180: Inter-Axle Differential Lock Control
Inter-Axle Differential Lock Control Rear Axle Differential Lock Control If you vehicle has this If your vehicle has a feature, the switch is controlled traction or located in the center of the locking differential axle, the instrument panel. switch is located in the center of the instrument panel.
Page 181: Traction Control System (Tcs)
Traction Control System (TCS) The traction control system automatically comes on whenever you start your vehicle. To limit wheel spin, especially in slippery road conditions, you should Your vehicle may have a traction control system that always leave the system on. But you can turn the limits wheel spin.
Page 182: Steering
Steering The traction you can get in a curve depends on the condition of your tires and the road surface, the angle at which the curve is banked, and your speed. While Power Steering you are in a curve, speed is the one factor you can control.
Page 183: 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 184: Off-Road Recovery
Off-Road Recovery Passing You may ﬁnd that your right wheels have dropped off The driver of a vehicle about to pass another on a the edge of a road onto the shoulder while you are two-lane highway waits for just the right moment, driving.
Page 185 • • Watch for traffic signs, pavement markings and If other cars are lined up to pass a slow vehicle, lines. If you can see a sign up ahead that might wait your turn. But take care that someone is indicate a turn or an intersection, delay your pass.
Page 186: Loss Of Control
Loss of Control If you have the Traction Control System, remember: It helps avoid only the acceleration skid. If you do not have this system, or if the system is off, then an acceleration Let us review what driving experts say about what skid is also best handled by easing your foot off the happens when the three control systems (brakes, accelerator pedal.
Page 187: Driving At Night
Driving at Night Here are some tips on night driving. • Drive defensively. • Do not drink and drive. • Since you can not see as well, you may need to slow down and keep more space between you and other vehicles. •...
Page 188: Driving In Rain And On Wet Roads
You can be temporarily blinded by approaching Driving in Rain and on Wet Roads headlamps. It can take a second or two, or even several seconds, for your eyes to readjust to the dark. When you are faced with severe glare (as from a driver who does not lower the high beams, or a vehicle with misaimed headlamps), slow down a little.
Page 189 The heavier the rain, the harder it is to see. Even if your Driving too fast through large water puddles or even windshield wiper blades are in good shape, a heavy going through some vehicle washes can cause rain can make it harder to see road signs and problems, too.
Page 190: Driving Through Flowing Water
Hydroplaning Driving Through Flowing Water Hydroplaning is dangerous. So much water can build up under your tires that they can actually ride on the CAUTION: water. This can happen if the road is wet enough and you are going fast enough. When your vehicle is hydroplaning, it has little or no contact with the road.
Page 191: City Driving
• One of the biggest problems with city streets is the Besides slowing down, allow some extra following amount of traffic on them. You will want to watch out for distance. And be especially careful when you what the other drivers are doing and pay attention to pass another vehicle.
Page 192: Freeway Driving
Freeway Driving At the entrance, there is usually a ramp that leads to the freeway. If you have a clear view of the freeway as you drive along the entrance ramp, you should begin to check traffic. Try to determine where you expect to blend with the ﬂow.
Page 193: Hill And Mountain Roads
Highway Hypnosis Hill and Mountain Roads Is there actually such a condition as “highway hypnosis”? Or is it just plain falling asleep at the wheel? Call it highway hypnosis, lack of awareness, or whatever. When you drive the vehicle for a long distance, there is something about an easy stretch of road with the same scenery, along with the hum of the tires on the road, the drone of the engine, and the rush of the wind...
Page 194 Here are some tips that can make your drive through steep country safer: CAUTION: • Keep the vehicle in good shape. Check all ﬂuid levels and also the brakes, tires, cooling system Coasting downhill in NEUTRAL (N) or with the and transmission.
Page 195: Winter Driving
Winter Driving Here are some tips for winter driving: • Be sure the vehicle is in good shape for winter. • You may want to put winter emergency supplies in your vehicle. Also see Tires on page 5-68. Include an ice scraper, a small brush or broom, a supply of windshield washer ﬂuid, a rag, some winter outer clothing, a small shovel, a ﬂashlight, a red cloth and reﬂective warning triangles.
Page 196: Driving On Snow Or Ice
Driving on Snow or Ice What is the worst time for this? “Wet ice.” Very cold snow or ice can be slick and hard to drive on. But wet Most of the time, those places where your tires meet ice can be even more trouble because it may offer the road probably have good traction.
Page 197: If You Are Caught In A Blizzard
Unless you have the anti-lock braking system, you will If You Are Caught in a Blizzard want to brake very gently, too. If you do have anti-lock, see Braking on page 4-6. This system improves your vehicle’s stability when you make a hard stop on a slippery road.
Page 198 • Put on extra clothing or wrap a blanket around you. If you have no blankets or extra clothing, make CAUTION: body insulators from newspapers, burlap bags, rags, ﬂoor mats — anything you can wrap around yourself or tuck under your clothing to keep warm. Snow can trap exhaust gases under your vehicle.
Page 199: If You Are Stuck: In Sand, Mud, Ice Or Snow
If you have a diesel engine, you may have to run it at a higher speed to get enough heat. CAUTION: Then, shut the engine off and close the window almost all the way to preserve the heat. Start the engine If you let your tires spin at high speed, they again and repeat this only when you feel really can explode, and you or others could be...
Page 200: Rocking Your Vehicle To Get It Out
Rocking Your Vehicle To Get It Out Using the Tow Hooks First, turn your steering wheel left and right. That will clear the area around your front wheels. If your vehicle has traction control, you should turn the traction control system off. See Traction Control System (TCS) on page 4-11.
Page 201: Towing
Towing Towing Your Vehicle Consult your dealer or a professional towing service if you need to have your disabled vehicle towed. See Roadside Assistance Program on page 7-4. Releasing Air-Operated Parking Brakes If your vehicle has air brakes, you could have a special towing problem.
Page 202 3. Remove the rubber cap from the rear of the chamber. 4. Put the release stud, nut and ﬂat washer into the 2. Remove the release stud and nut from the side of chamber. the brake chamber. Some chambers have studs 5.
Page 203: Loading Your Vehicle
6. Turn the stud nut Loading Your Vehicle clockwise several turns to release the brakes. There is a GVW Rating label on your vehicle that shows Follow the same how much weight it may properly carry. It also shows procedure to release the size of your original tires and the inﬂation pressures the other brake.
Page 204 The GVW Rating label is provided by the ﬁnal Notice: Overloading your vehicle may cause manufacturer and should be on the door or door jamb. It damage. Repairs would not be covered by your also tells you the maximum weights for the front and rear warranty.
Page 205: Trailer Connections (C4/C5 Models Only)
Trailer Connections The eight-wire harness contains the following trailer circuits: (C4/C5 Models Only) • Yellow: Left Stop/Turn Signal Heavy-Duty Trailer Wiring Package • Dark Green: Right Stop/Turn Signal • Brown: Taillamps Your vehicle may be equipped with an eight-wire trailer towing harness.
Page 206: Power Take-Off (Pto)
Trailer Connections Power Take-Off (PTO) (C7/C8 Models Only) If your vehicle is equipped If your vehicle has these trailer connections, they are for the addition of a PTO, located at the rear of the cab for a tractor and at the rear this factory installed of the chassis when towing a trailer.
Page 207 Section 5 Service and Appearance Care Service ............5-3 Engine Coolant (Gas and Doing Your Own Service Work ......5-4 DURAMAX™ engines) ........5-32 ® Two Safety Cautions about Engine Fan Engine Coolant (Caterpillar Diesel Engines) ..5-35 Breakage ...........5-5 Coolant Surge Tank Pressure Cap ....5-35 Engine Overheating ........5-36 Fuel ..............5-6 Cooling System ..........5-38...
Page 208 Section 5 Service and Appearance Care Automatic Ether Injection System ....5-66 Finish Damage ..........5-83 Front Wheel Bearings with Oil-Filled Hubs ..5-67 Underbody Maintenance ........5-83 Air Conditioning System .........5-67 Chemical Paint Spotting .........5-83 Vehicle Care/Appearance Materials ....5-84 Tires ..............5-68 Inﬂation - Tire Pressure .........5-68 Vehicle Identiﬁcation ........5-85 Rims and Wheels .........5-69 Vehicle Identiﬁcation Number (VIN) ....5-85...
Page 209: Service
Service California Proposition 65 Warning Most motor vehicles, including this one, contain and/or Your dealer knows your vehicle best and wants you to emit chemicals known to the State of California to be happy with it. We hope you will go to your dealer cause cancer and birth defects or other reproductive for all your service needs.
Page 210: Doing Your Own Service Work
Doing Your Own Service Work CAUTION: If you want to do some of your own service work, you will want to use the proper service manual. It tells you much more about how to service your vehicle than You can be injured and your vehicle could be this manual can.
Page 211: Two Safety Cautions About Engine Fan
Two Safety Cautions about Engine CAUTION: (Continued) Fan Breakage Winter Fronts, Grille Covers or Obstructions CAUTION: Winter Fronts, grille covers or other add-on equipment causing obstructions in front orbehind the fan should not be used on this Changing the Fan Drive Ratio or Engine vehicle.
Page 212: Fuel
Fuel Gasoline Speciﬁcations It is recommended that gasoline meet speciﬁcations If your vehicle has a diesel engine, see Diesel Engine which were developed by automobile manufacturers Fuel on page 5-8. around the world and contained in the World-Wide Fuel For vehicles with gasoline engines, please read this. Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org.
Page 213: Additives
Additives Notice: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel To provide cleaner air, all gasolines in the United States system and also damage the plastic and rubber are now required to contain additives that will help parts.
Page 214: Diesel Engine Fuel
Diesel Engine Fuel What Fuel to Use ® ® For the Caterpillar diesel, see the Caterpillar In the United States, for best results use Number 2–D Operation & Maintenance Manual for information diesel fuel year-round (above and below freezing concerning fuel usage. conditions) as oil companies blend Number 2–D fuel to address climate differences.
Page 215 Biodiesel is produced from vegetable oils or animal fat What Fuel to Use in Canada that have been chemically modiﬁed to reduce the Canadian fuels are blended for seasonal changes. possibility of damage to your fuel system and engine. Diesel Type “A” fuel is blended for better cold weather Higher concentration (i.e., greater than B5) starting (below 0°F or −18°C);...
Page 216: Very Cold Weather Operation
It is acceptable to use diesel fuel containing up to 5% Water in Fuel biodiesel (B5), but the ﬁnal blended fuel must meet the same speciﬁcation, CAN/CGSB—3.517–2000 (Low Sulfur Diesel) in Canada, as other fuels used in your CAUTION: vehicle, and the biodiesel used for making this fuel must meet the ASTM D6751–02 speciﬁcation.
Page 217 Sometimes, water can be pumped into your fuel tank Water In Fuel Light Chart (cont’d) along with your diesel fuel. This can happen if a service Problem Recommended Action station doesn’t regularly inspect and clean its fuel Drain fuel ﬁlter tanks, or if it gets contaminated fuel from its suppliers.
Page 218 To drain water, do the following: 5. Remove the fuel-resistant container and properly dispose of the contaminated fuel. To ﬁnd out how 1. Stop and park the vehicle in a safe place. Turn off to properly dispose of contaminated diesel fuel, see the engine and apply the parking brake.
Page 219 Fuel Priming If one or more of the above occur, it is very likely that air has entered your fuel system and that you will need In order for the DURAMAX™ diesel engine fuel system to prime the fuel system before operating the vehicle. to work properly, the fuel lines must be full of fuel Air in the fuel lines will not harm the engine or the and contain no air.
Page 220 3. Make sure the fuel lines are properly connected 6. Repeatedly push down and the fuel ﬁlter is cool enough to touch. on the fuel ﬁlter primer pump with the palm 4. Remove any dirt from the fuel ﬁlter head and vent of your hand.
Page 221: Running Out Of Fuel
Running Out of Fuel 4. Turn the ignition key to START for 10 to 15 seconds at a time until your engine starts. If the engine tries to run, but does not run smoothly, If the diesel engine stalls and you think that you’ve run increase the rpm a little using the accelerator pedal.
Page 222: Fuels In Foreign Countries
The fuel ﬁlter is located in the engine compartment on 4. Install the new ﬁlter element. the passenger’s side of the vehicle, or on the driver’s 5. Reinstall and tighten the ﬁlter container and side frame rail in front of the fuel tank. reconnect the water sensor wire to the ﬁlter.
Page 223: Filling Your Tank
Filling Your Tank To take off the cap, turn it slowly to the left (counterclockwise). CAUTION: If you get fuel on yourself and then something ignites it, you could be badly burned. Fuel can spray out on you if you open the fuel cap too quickly.
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 your vehicle. Static electricity discharge from Things that burn can get on hot engine parts the container can ignite the gasoline vapor. and start a ﬁre.
Page 225: Hood Latches
Hood Latches Then take the hand hold and pull the hood forward. To tilt the hood forward, pull back and up on each of the hood latches, located above the wheel wells on both sides of the vehicle. 5-19...
Page 226: Engine Oil
® Engine Oil (Caterpillar Diesel Engine) ® See your Caterpillar Operation & Maintenance Manual for information on oil quality and viscosities as well as the temperature range chart. Engine Oil (Gasoline Engine) If the low oil light appears on the instrument cluster, it means you need to check your engine oil level right away.
Page 227 Checking Engine Oil It is a good idea to check your engine oil every time you get fuel. In order to get an accurate reading, the oil must be warm and the vehicle must be on level ground. The engine oil dipstick is located in the engine compartment on the driver’s side of the vehicle.
Page 228 The engine oil ﬁll cap is located near the engine oil dipstick in the engine compartment, on the driver’s side of the vehicle. Be sure to add enough oil to put the level somewhere in the proper operating range in the cross-hatched area. Push the dipstick all the way back in when you are through.
Page 229 • Notice: Use only engine oil identiﬁed as meeting SAE 5W-30 GM Standard GM6094M and showing the American As shown in the viscosity chart, SAE 5W-30 is best Petroleum Institute Certiﬁed For Gasoline Engines for your vehicle. However, if it is going to be 0°F starburst symbol.
Page 230 When to Change Engine Oil (GM Oil How to Reset the Change Engine Oil Light Life System) The GM Oil Life System calculates when to change your engine oil and ﬁlter based on vehicle use. Anytime Your vehicle has a computer system that lets you know your oil is changed, reset the system so it can when to change the engine oil and ﬁlter.
Page 231 What to Do with Used Oil Engine Oil (DURAMAX™ Diesel) Used engine oil contains certain elements that may be Checking Engine Oil unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean It is a good idea to check your engine oil level every your skin and nails with soap and water, or a good time you get fuel.
Page 232 Turn off the engine and give the oil at least ﬁve minutes to drain back into the oil pan. With a cool engine, allow 30 minutes. If you don’t, the oil dipstick might not show the actual level. Pull out the dipstick and clean it with a paper towel or a cloth, then push it back in all the way.
Page 233 When to Add Engine Oil If the oil is at or below the cross-hatched area at the tip of the dipstick for the 6.6L V8 (LB7/LLY) engines, then you will need to add at least two quarts of oil. If the oil is at or below the A mark for the 7.8L L6 (LG4) engine, then you will need to add at least one quart of oil.
Page 234 What Kind of Engine Oil to Use • SAE 15W-40 As shown in the viscosity chart, SAE 15W-40 is Look for these two things: best for your vehicle. However, you can use • CI-4 or CH-4 SAE 10W-30 at temperatures above 0°F (−18°C). When it is very cold, below 0°F (−18°C), you should Oils designated as API CI-4 or CH-4 are use SAE 5W-40 to improve cold starting.
Page 235: When To Change Engine Oil
Engine Oil Additives Do not add anything to your oil. The recommended oils with the API service symbol are all you will need for good performance and engine protection. When to Change Engine Oil Change engine oil and ﬁlter every 10,000 miles (16 000 km) or every 12 months, whichever occurs ﬁrst.
Page 236: Engine Air Cleaner/Filter
Engine Air Cleaner/Filter When to Inspect the Engine Air Cleaner/Filter The engine air cleaner/ﬁlter is located in the center of If your vehicle has a ﬁlter the engine compartment. change indicator, inspect the air cleaner/ﬁlter change indicator at every oil change and replace the ﬁlter when the indicator tells you to.
Page 237: Automatic Transmission Fluid
To inspect the air cleaner/ﬁlter, remove the ﬁlter from Automatic Transmission Fluid the vehicle and lightly shake ﬁlter to release loose dust and dirt. If the ﬁlter remains “caked” with dirt, a new When to Check ﬁlter is required. A good time to have it checked is when the engine oil is checked.
Page 238: Manual Transmission Fluid
Manual Transmission Fluid How to Add Fluid Refer to the Maintenance Schedule to determine how Here’s how to add ﬂuid. Refer to the Maintenance often to check the lubricant and when to change it. See Schedule to determine the proper ﬂuid to use. See Part Scheduled Maintenance on page 6-5.
Page 239 The following explains your cooling system and how to add coolant when it is low. If you have a problem CAUTION: with engine overheating, see Engine Overheating on page 5-36. Adding only plain water to your cooling A 50/50 mixture of clean, drinkable water and ®...
Page 240: Checking Coolant
Checking Coolant CAUTION: Turning the surge tank pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly. Never turn the surge tank pressure cap — even a little — when the engine and radiator are hot.
Page 241: Coolant Surge Tank Pressure Cap
Adding Coolant Coolant Surge Tank Pressure Cap ® If you need more coolant, add the proper DEX-COOL The surge tank pressure coolant mixture at the surge tank, but only when the cap is located in the engine is cool. engine compartment, on the driver’s side of the vehicle.
Page 242: Engine Overheating
Engine Overheating CAUTION: You will ﬁnd a coolant temperature warning gage on your vehicle’s instrument panel, as well as a low coolant warning light. Your vehicle also has a check gages Steam from an overheated engine can burn warning light on the instrument panel. you badly, even if you just open the hood.
Page 243: If No Steam Is Coming From Your Engine
If No Steam Is Coming From Your 2. Turn on your heater to full hot at the highest fan speed and open the window as necessary. Engine 3. If climbing a hill, downshift to raise engine and fan An overheat warning, along with a low coolant light, can speeds.
Page 244: Cooling System
Cooling System The coolant level should be at COLD FILL or higher. If it isn’t, you may When you decide it’s safe to lift the hood, here’s what have a leak at the you’ll see: pressure cap or in the radiator hoses, heater hoses, radiator, water pump or somewhere else...
Page 245: How To Add Coolant To The Coolant Surge Tank
If there seems to be no leak, start the engine again. How to Add Coolant to the Coolant The engine cooling fan speed should increase when idle Surge Tank speed is doubled by pushing the accelerator pedal down. If it doesn’t, your vehicle needs service. Turn off If you haven’t found a problem yet, check to see if the engine.
Page 246 If no coolant is visible in the surge tank, add coolant as follows: CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the coolant surge tank pressure cap —...
Page 247 CAUTION: CAUTION: Adding only plain water to your cooling You can be burned if you spill coolant on hot system can be dangerous. Plain water, or engine parts. Coolant contains ethylene glycol some other liquid such as alcohol, can boil and it will burn if the engine parts are hot before the proper coolant mixture will.
Page 248 3. Then ﬁll the coolant surge tank with the proper 4. With the coolant surge tank pressure cap off, start mixture, to the FULL mark. the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine cooling fan.
Page 249: Engine Fan Noise
5. Then replace the transmission slipping or making extra shifts. It is merely pressure cap. Be sure the cooling system functioning properly. The fan will the pressure cap is slow down when additional cooling is not required and hand-tight and the clutch disengages.
Page 250: Windshield Washer Fluid
If your power steering ﬂuid level is low, this can cause Windshield Washer Fluid the brake or service brake soon warning lights to come on. In addition, the steering effort and emergency What to Use brake distance could increase. When you need windshield washer ﬂuid, be sure to read If either light remains on after you have added power the manufacturer’s instructions before use.
Page 251 The windshield washer Notice: reservoir is located in the • When using concentrated washer ﬂuid, follow engine compartment the manufacturer’s instructions for adding on the driver’s side of the water. vehicle. • Do not mix water with ready-to-use washer ﬂuid. Water can cause the solution to freeze and damage your washer ﬂuid tank and other parts of the washer system.
Page 252: Brakes
Brakes CAUTION: Brake Fluid Do not add brake ﬂuid before you check the level. If you do, you could get too much brake ﬂuid. Brake ﬂuid could spill on the hot engine and it can catch ﬁre. You could be burned and your vehicle could be damaged.
Page 253 Checking Brake Fluid (Hydro Max System) Checking Brake Fluid (Hydro Boost System) Apply the brake pedal several times with the ignition off. Then clean one of the reservoir caps and the area Apply the brake pedal several times with the ignition off. around the cap, and remove it.
Page 254 What to Add Notice: • Using the wrong ﬂuid can badly damage brake Use the proper ﬂuid listed in your Maintenance system parts. For example, just a few drops of Schedule. Use new brake ﬂuid from a sealed mineral-based oil, such as engine oil, in your container only.
Page 255: Brake Adjustment
Four-Wheel Disc Brakes Brake Adjustment (Hydraulic Only) Every time you make a brake stop, your brakes adjust for wear. Your vehicle has four-wheel disc brakes. Replacing Brake System Parts Some driving conditions or climates may cause a brake squeal when the brakes are ﬁrst applied or lightly The braking system on a vehicle is complex.
Page 256: Air Dryer
Air Brake Systems Moisture Ejector If your vehicle has air brakes, it is important to get rid of If you have air brakes with a moisture ejector, the valve moisture in your system. Moisture will damage your automatically ejects moisture from the reserve tank system if it is not removed daily.
Page 257 Electric Air Compressor Clutch Pedal Free Travel Your vehicle may have an electric air compressor. This If you have a manual transmission, your clutch will need compressor is used to run options that require adjustment when pedal free travel gets down to about pressurized air, such as air horn, air seat, exhaust 1/4 inch (32 mm), as measured at the clutch pedal pad.
Page 258 Single Axle Models 5-52...
Page 259 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. Pivot Points and Hinges Apply chassis lubricant. Pivot Points and Hinges Apply chassis lubricant. Slack Adjuster** One ﬁtting.
Page 260 Item Number Item Remarks Release Bearing, Clutch Cross Shaft Two ﬁttings, apply chassis lubricant. Clutch Release Fork Two ﬁttings. * Applies to some vehicles. ** Applies to air brakes only. $ Applies to hydraulic brakes only. Tandem Axle Models Item Number Item Remarks...
Page 261: Battery
Battery CAUTION: Your new vehicle comes with one or more maintenance ® free ACDelco batteries. When it is time for a new battery, be sure it has the replacement number shown Batteries have acid that can burn you and gas on the original battery’s label.
Page 262: Jump Starting
Jump Starting Notice: If the other vehicle’s system is not a 12-volt system with a negative ground, both vehicles can If your battery (or batteries) has run down, you may be damaged. Only use vehicles with 12-volt systems want to use another vehicle and some jumper cables to with negative grounds to jump start your vehicle.
Page 263 3. Turn off the ignition on both vehicles. Unplug You will not need to access your battery (or unnecessary accessories plugged into the cigarette batteries) for jump starting. The remote positive (+) lighter or accessory power outlets. Turn off the terminal is for that purpose.
Page 264 6. Connect the red positive (+) cable to the CAUTION: positive (+) terminal of the dead battery. Use a remote Fans or other moving engine parts can injure positive (+) terminal you badly. Keep your hands away from moving if the vehicle parts once the engine is running.
Page 265 8. Now connect the black negative (−) cable to the negative (−) terminal of the good battery. Use a remote negative (−) terminal if the vehicle has one. Don’t let the other end touch anything until the next step. The other end of the negative (−) cable 9.
Page 266 Notice: If the jumper cables are removed in the To disconnect the jumper cables from both vehicles, do wrong order, electrical shorting may occur and the following: damage the vehicle. The repairs would not be 1. Disconnect the black negative (−) cable from the covered by your warranty.
Page 267: Rear Axle
Rear Axle What to Use Refer to the Maintenance Schedule to determine what When to Check and Change Lubricant kind of lubricant to use. See Part C: Recommended Refer to the Maintenance Schedule to determine Fluids and Lubricants on page 6-29. how often to check the lubricant and when to change it.
Page 268: Noise Control System
Noise Control System 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Tampering with Noise Control Among those acts presumed to constitute tampering are the acts listed below. System Prohibited Insulation: The following information relates to compliance with...
Page 269: Bulb Replacement
Bulb Replacement Here’s how to remove the Shephard’s Hook type: Replacement Bulbs ® It is recommended that you use an ACDelco type bulb whenever you need to replace one. If you need a bulb replaced, contact your dealer. Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking.
Page 270: Other Service Items
Other Service Items Fuel Filter Fuel Filter (Gasoline Engines) 2. Push the release lever and slide the wiper assembly toward the driver’s side of the vehicle. 3. Install a new blade by reversing Steps 1 and 2. The steel fuel ﬁlter is located near the engine compartment on the driver’s side of the vehicle.
Page 271: Primary Fuel Filter And Water Separator
Fuel Filter (Diesel Engines) It has a clear plastic drain bowl at the bottom. Check the drain bowl occasionally for any water or particles. If you have a diesel engine, your fuel ﬁlter is located in To drain the bowl, do the following: the engine compartment on the driver’s side of the vehicle, or along the driver’s side frame rail.
Page 272: Secondary Fuel Filter And Water
Secondary Fuel Filter and Water Automatic Ether Injection System Separator/Heater ® If you have a Caterpillar diesel engine, you may ® If you have a Caterpillar have this feature. The diesel engine, you may ether cylinder is located in also have this spin-on ﬁlter the engine compartment and fuel separator/heater.
Page 273: Front Wheel Bearings With Oil-Filled Hubs
6. Install a new gasket whenever you take out the If there isn’t, clean the rubber ﬁll plug in the center of cylinder. Use only one gasket and spread a light the glass, and then remove it. Be careful not to ﬁlm of clean oil on it before installation.
Page 274: Tires
Underinﬂated tires pose the same danger about your tire warranty and where to obtain service, as overloaded tires. The resulting accident see your Chevrolet Warranty booklet for details. could cause serious injury. Check all tires frequently to maintain the recommended pressure.
Page 275: Rims And Wheels
Notice: Don’t let anyone tell you that underinﬂation How to Check or overinﬂation is all right. It’s not. If your tires Use a good quality pocket-type gage to check tire don’t have enough air (underinﬂation), you can get pressure. You can’t tell if your tires are properly inﬂated the following: simply by looking at them.
Page 276: When It Is Time For New Tires
See Tightening the Wheel Nuts on page 5-71 for wheel • The tire has a bump, bulge or split. nut tightening information and proper torque values. • The tire has a puncture, cut or other damage that can’t be repaired well because of the size or location of the damage.
Page 277: Tightening The Wheel Nuts
Proper front wheel alignment must be maintained in First, use these pictures to decide what kind of wheels order to ensure efficient steering, good directional you have. stability, and prevent abnormal tire wear. If you notice unusual tire wear or your vehicle is pulling one way or the other, the alignment may need to be reset.
Page 278 3. Put on the wheel nuts. 4. Finger-tighten the nuts. 5. Oil the surfaces between the nuts and washers. Do not oil the studs or the threads of the nut. 6. Tighten the nuts to 400 lb-ft (542 N-m) if an 8-hole stud or 480 lb-ft (650 N-m) if a 10-hole stud, using the following diagrams.
Page 279 CAUTION: CAUTION: If wheel studs are damaged, they can break. If Rust or dirt on a wheel, or on the parts to all the studs on a wheel broke, the wheel could which it is fastened, can make wheel nuts come off and cause a crash.
Page 280: 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. If the wheel leaks air, replace it. Without the correct wheel, you may not be able to stop properly, and you could have other Your dealer will know the kind of wheel you need.
Page 281: Used Replacement Wheels
Used Replacement Wheels If a Tire Goes Flat It’s unusual for a tire to “blow out” while you’re driving, especially if you maintain your tires properly. If air CAUTION: goes out of a tire, it’s much more likely to leak out slowly.
Page 282: Changing A Flat Tire
Changing a Flat Tire CAUTION: Your truck, when new, did not include tire changing equipment or a place to store a tire in the vehicle. Few drivers of these vehicles have the necessary equipment Your vehicle, when new, did not include tire aboard to be able to change a ﬂat tire safely.
Page 283: Cleaning The Inside Of Your Vehicle
Never use these to clean your vehicle: Cleaning the Inside of Your Vehicle • Gasoline Use a vacuum cleaner often to get rid of dust and • Benzene loose dirt. Wipe vinyl, leather, plastic and painted surfaces with a clean, damp cloth. •...
Page 284: Using Cleaner On Fabric
Using Cleaner on Fabric 3. If an odor lingers after cleaning vomit or urine, treat the area with a water/baking soda solution: 1. Vacuum and brush the area to remove any 1 teaspoon (5 ml) of baking soda to 1 cup (250 ml) loose dirt.
Page 285: Cleaning The Top Of The Instrument Panel
Cleaning the Top of the Care of Safety Belts Instrument Panel Keep belts clean and dry. Use only mild soap and water to clean the top surfaces of the instrument panel. Sprays containing silicones CAUTION: or waxes may cause annoying reﬂections in the windshield and even make it difficult to see through the windshield under certain conditions.
Page 286: Cleaning The Outside Of Your Vehicle
Cleaning the Outside of Your Cleaning Exterior Lamps/Lenses Vehicle Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. The paint ﬁnish on your vehicle provides beauty, depth Follow instructions under “Washing Your Vehicle.” of color, gloss retention and durability.
Page 287: Windshield And Wiper Blades
Foreign materials such as calcium chloride and other Windshield and Wiper Blades salts, ice melting agents, road oil and tar, tree sap, bird If the windshield is not clear after using the windshield droppings, chemicals from industrial chimneys, etc., washer, or if the wiper blade chatters when running, can damage your vehicle’s ﬁnish if they remain wax, sap or other material may be on the blade or on painted surfaces.
Page 288: Sheet Metal Damage
Aluminum or Chrome-Plated Wheels Tires Your vehicle may be equipped with either aluminum or To clean your tires, use a stiff brush with tire cleaner. chrome-plated wheels. Notice: Using petroleum-based tire dressing Keep your wheels clean using a soft clean cloth with products on your vehicle may damage the paint mild soap and water.
Page 289: Finish Damage
Finish Damage Chemical Paint Spotting Any stone chips, fractures or deep scratches in the Some weather and atmospheric conditions can create a ﬁnish should be repaired right away. Bare metal chemical fallout. Airborne pollutants can fall upon and will corrode quickly and may develop into major repair attack painted surfaces on your vehicle.
Page 290: Vehicle Care/Appearance Materials
Vehicle Care/Appearance Materials Vehicle Care/Appearance Materials (cont’d) See your GM dealer for more information on purchasing Description Usage the following products. Removes swirl marks, ﬁne Swirl Remover Polish scratches and other light Vehicle Care/Appearance Materials surface contamination. Description Usage Removes light scratches and Cleaner Wax Polishing Cloth Interior and exterior polishing...
Page 291: Vehicle Identiﬁcation
Vehicle Identiﬁcation Service Statement One of these statements is on your GVW Rating label. Vehicle Identiﬁcation Number (VIN) Here is what each one means. TRUCK SERVICE: A vehicle made to carry property or special equipment. It is made for uniform frame loading.
Page 292: Service Parts Identiﬁcation Label
Service Parts Identiﬁcation Label Electrical System You’ll ﬁnd this label in a location determined by the body Add-On Electrical Equipment manufacturer. It’s very helpful if you ever need to order parts. On this label is: Notice: Don’t add anything electrical to your •...
Page 293: Windshield Wiper Fuses
Windshield Wiper Fuses Power Windows and Other Power Options The windshield wiper motor is protected by a circuit breaker inside the motor and a circuit breaker or fuse in Circuit breakers in the fuse panel protect the power the fuse block. If the motor overheats, the wipers will windows and other power accessories.
Page 294: Instrument Panel Fuse Block
Instrument Panel Fuse Block There are two instrument panel fuse blocks located behind the instrument panel on the passenger’s side of the vehicle. Be sure to replace fuses with fuses of the same rating. Do not use fuses of higher amperage than those indicated on the fuse block.
Page 295 Fuse Usage Relay Usage RH PARK LP Right-hand Parking Lamps MARKER LP Sidemarker and Clearance Lamps HTD FUEL LB7/LG4 Heated Fuel LH PARK LP Left-hand Parking Lamps RADIO U Radio AIR HTR LG4 Air Heater PWR WINDOW Power Windows ECU MAINTAIN LG4 Electronic Control Unit BRAKE ISO Brake Warning Lamp Daytime Running Lamps...
Page 296 Circuit Breaker Usage Power Post Courtesy Lamps Warning Lights, Gages and Indicators Crank Rear Axle Trailer Turn Signals/Hazard Warning Flashers Radio/Chime Daytime Running Lamps Air Bag System Exterior/Interior Lamps Parking Brake Accessory Power Fuse Block 2 Ignition Sidemarker Lamps Turn Signal/Backup Lamps Circuit Breaker Usage Transmission Stoplamps...
Page 297: 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 uses blade-type fuses. Both underhood fuse blocks are located in the engine compartment, on the passenger’s side of the vehicle.
Page 298 Relay Usage Fuse Usage Power Take-Off BLANK Empty BLANK Empty REVERSE Reverse NEUTRAL A/C COMP Air Conditioning Compressor Neutral Start START ABS 1 Anti-Lock Brake System 1 ABS 2 Anti-Lock Brake System 2 ABS 3 Anti-Lock Brake System 3 Fuse Usage ENGINE Engine...
Page 299: Capacities And Speciﬁcations
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 Comfort Control System NOTE C4/C5 Electric Brake, C6/C7/C8 Brake Lamps Secondary Underhood Fuse Block Capacities and Speciﬁcations Capacities and Speciﬁcations Engine 7.2L L6 HEUI Fuel System...
Page 300 Cooling System Capacity The following approximate capacities are given in English and metric conversions. Please refer to Part C: Recommended Fluids and Lubricants on page 6-29 for more information. Capacities Application English Metric C4/C5 Models 8.1L with manual transmission 30.1 quarts 28.5 liters 8.1L with automatic transmission 29.8 quarts...
Page 301 Capacities Application English Metric 7.2L 175–230 hp engine with manual transmission, air 33.0 quarts 31.2 liters conditioning and increased cooling 7.2L 175–210 hp engine with automatic transmission 31.4 quarts 29.7 liters 7.8L 250–275 hp engine with manual transmission 34.9 quarts 33.0 liters 7.8L 250–275 hp engine with manual transmission, air 35.4 quarts...
Page 302 Engine Oil with Filter Capacity Capacities Application English Metric 7.2L** 30.0 quarts 28.4 liters* 8.1** 6.5 quarts 6.1 liters 7.8L** 23.8 quarts 22.5 liters 6.6L** 14.6 quarts 13.8 liters *Additional oil is required with auxiliary oil ﬁlter systems. Make sure to add enough extra oil to ﬁll the auxiliary oil ﬁlter system.
Page 303 Fuel Tank Capacity (cont’d) Capacities Application English Metric C6/C7/C8 Models Standard 50 gallons 189.2 liters Optional 35 gallons 132.4 liters Optional 50 gallons 189.2 liters Optional† 70 gallons 264.8 liters Optional** 75 gallons 283.8 liters Optional& 100 gallons 378.5 liters *One 25-gallon (94.6 L) tank and one 15-gallon (56.8 L) tank †Two 35-gallon (132.4 L) tanks **One 25-gallon (94.6 L) tank and one 50-gallon (189.2 L) tank...
Page 304 Transmission Fluid Capacity For manual transmissions, the correct ﬂuid level is to the bottom of the ﬂuid ﬁll plug opening. The ﬂuid capacity will vary, due to the angle of the transmission, with the vehicle. For automatic transmissions, see the Allison Automatic Transmission Operator’s Manual for ﬂuid check and maintenance information.
Page 305 Rear Axle Lubricant Capacity Capacities Application English Metric Single Speed Axle 10.0 pints 4.7 liters S135 26.0 pints 12.3 liters 19060S 31.0 pints 14.7 liters 21060D 31.0 pints 14.7 liters 21060S 31.0 pints 14.7 liters S150 28.0 pints 13.0 liters 23090S 40.0 pints 19.0 liters...
Page 306: Normal Maintenance Replacement Parts
Rear Axle Lubricant Capacity (cont’d) Capacities Application English Metric DSH44 (front) 32.0 pints 15.1 liters RSH44 (rear) 31.0 pints 14.7 liters DS404, DS404P (front) 32.0 pints 15.1 liters RS404 (rear) 31.0 pints 14.7 liters Normal Maintenance Replacement Parts ® Allison Transmission External Filters ®...
Page 307 ® Part Engine GM Part ACDelco Part Other Part (RPO Code) Number Number Numbers Engine Air Cleaner/Filter 6.6L (LB7/LLY) (C4/C5 Models) 88937527 — — 6.6L (LB7/LLY) (C6/C7/C8 Models) 88937548*** — — 7.2L (LG5) — — Donaldson P522606 7.8L (LG4) (C4/C5 Models) 8837527 —...
Page 308 ® Part Engine GM Part ACDelco Part Other Part (RPO Code) Number Number Numbers Pressure Caps 6.6L (LB7/LLY) 15075118 — — 7.2L (LG5) — — — 7.8L (LG4) 15075118 — — 8.1L (L18) 15997145 — — Secondary Fuel Filter 6.6L (LB7/LLY) —...
Page 309: Engine Drive Belt Routing
Engine Drive Belt Routing 8.1L Engine DURAMAX™ Diesel Engine Caterpillar Diesel Engine 5-103...
Page 310 NOTES 5-104...
Page 311 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Scheduled Maintenance ........6-5 Introduction ...........6-2 Part B: Owner Checks and Services ....6-24 Maintenance Requirements ......6-2 At Each Fuel Fill ..........6-24 Your Vehicle and the Environment ....6-2 At Least Twice a Year ........6-25 How This Section is Organized ......6-3 At Least Once a Year ........6-28 Part A: Scheduled Maintenance Services ...6-4 Part C: Recommended Fluids and Lubricants ..6-29...
Page 312: 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 your vehicle in good Important: Keep engine oil at the proper level and working condition. Any damage caused by failure change as recommended.
Page 313: How This Section Is Organized
How This Section is Organized If you want to get the service information, see Service Publications Ordering Information on page 7-7. This maintenance schedule is divided into four parts: “Part B: Owner Checks and Services”: tells you what should be checked and when. It also explains what Part A: Scheduled Maintenance Services”: explains you can easily do to keep your vehicle in good condition.
Page 314: 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 your 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 315: Scheduled Maintenance
Scheduled Maintenance 7,500 Miles (12 000 km) Gasoline Engine Only: Check Oil Life System. If The services shown in this schedule up to 100,000 miles engine oil and ﬁlter are changed, reset system. See (166 000 km) should be repeated after 100,000 miles “Engine Oil (Gasoline Engine)”...
Page 316 10,000 Miles (16 000 km) Exhaust system service (or every 6 months, whichever occurs ﬁrst). (3) (4) (17) DURAMAX™ Diesel Only: Change engine oil Wheels and tires service. (15) and ﬁlter (or every 12 months, whichever occurs Hydraulic brake service (or every 6 months, ﬁrst).
Page 317 20,000 Miles (32 000 km) Wheels and tires service. (15) Hydraulic brake service (or every 6 months, whichever DURAMAX™ Diesel Only: Change engine oil occurs ﬁrst). (7) (46) and ﬁlter (or every 12 months, whichever occurs Parking brake service (or every 6 months, whichever ﬁrst).
Page 318 30,000 Miles (48 000 km) Hydraulic brake service (or every 6 months, whichever occurs ﬁrst). (7) (46) Gasoline Engine Only: Check Oil Life System. If Parking brake service (or every 6 months, whichever engine oil and ﬁlter are changed, reset system. See occurs ﬁrst).
Page 319 37,500 Miles (60 000 km) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever Gasoline Engine Only: Check Oil Life System. If occurs ﬁrst). engine oil and ﬁlter are changed, reset system. See Clean air brake application valve (or every 3 months, “Engine Oil (Gasoline Engine)”...
Page 320 45,000 Miles (72 000 km) Inspect door hinge pins and bushings and replace as necessary. Gasoline Engine Only: Check Oil Life System. If Steering system service. (13) engine oil and ﬁlter are changed, reset system. See Front and rear suspension service. (14) “Engine Oil (Gasoline Engine)”...
Page 321 Trailer brake hand control valve service (or every Check ﬂuid levels (or every 3 months, whichever 3 months, or every 900 hours, whichever occurs occurs ﬁrst). (1) (6) ﬁrst). (42) Chassis lubrication service (or every 6 months, Thermostatically controlled engine cooling fan whichever occurs ﬁrst).(12) service.
Page 322 60,000 Miles (96 000 km) Steering system service. (13) Front and rear suspension service. (14) Gasoline Engine Only: Check Oil Life System. Spring-to-axle U-bolts and shackle bolts service. (16) If engine oil and ﬁlter are changed, reset system. See “Engine Oil (Gasoline Engine)” in the Index. (3) (9) Exhaust system service (or every 6 months, whichever occurs ﬁrst).
Page 323 C600, C700 and C800 Gasoline Engines Only: Wheels and tires service. (15) Engine drive belts service (or every 12 months, Hydraulic brake service (or every 6 months, whichever whichever occurs ﬁrst). (18) occurs ﬁrst). (7) (46) Thermostatically controlled engine cooling fan Parking brake service (or every 6 months, whichever service.
Page 324 70,000 Miles (112 000 km) Wheels and tires service. (15) Hydraulic brake service (or every 6 months, whichever DURAMAX™ Diesel Only: Change engine oil occurs ﬁrst). (7) (46) and ﬁlter (or every 12 months, whichever occurs Parking brake service (or every 6 months, whichever ﬁrst).
Page 325 80,000 Miles (128 000 km) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever DURAMAX™ Diesel Only: Change engine oil occurs ﬁrst). and ﬁlter (or every 12 months, whichever occurs Clean air brake application valve (or every 3 months, ﬁrst).
Page 326 Gasoline Engine: Replace engine air cleaner ﬁlter. Inspect door hinge pins and bushings and replace as Diesel Engine: Inspect engine air cleaner ﬁlter necessary. change indicator. If necessary, replace the ﬁlter. If Wheels and tires service. (15) vehicle is driven in dusty/dirty conditions, inspect ﬁlter Hydraulic brake service (or every 6 months, change indicator at every engine oil change.
Page 327 Thermostatically controlled engine cooling fan Air brake automatic slack adjuster service (or every service. (4) (20) 500 hours, whichever occurs ﬁrst). (40) Shields and underhood insulation service. (4) (5) (21) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever Rear axle air shift motor service.
Page 328 Replace power steering reservoir ﬁlter element (or 150,000 Miles (240 000 km) every 24 months, whichever occurs ﬁrst). Cooling system service (or every 60 months since Front axle service. (38) last service, whichever occurs ﬁrst). (3) (35) Rear axle service – Eaton, Rockwell, Spicer Axles Diesel Engine Only: Inspect engine drive belt;...
Page 329 300,000 Miles (480 000 km) (6) = Check ﬂuid level in brake master cylinder, power steering pump, axle, transmission and hydraulic Remove, disassemble, clean and inspect the air spring parking brake pump (if equipped). A low ﬂuid brake air dryer (or every 3 years, or 10,800 hours, level in the brake master cylinder can indicate whichever occurs ﬁrst).
Page 330 (11) = Inspect rear axle air shift motor for ﬂuid leaks. linkage more often when operating under dusty or Remove plug to check ﬂuid level. Inspect air lines muddy conditions and in excessive off-road use. and hoses for proper hook-up, binding, leaks, etc. Frequently power-washed vehicles will require more Inspect at 1,000 miles (1 600 km) and 22,500 miles frequent lubrication.
Page 331 (14) = Check front and rear suspension. Look for (18) = Check all gasoline engine drive belts for cracks, damaged, loose or missing parts or parts showing signs fraying and wear. Replace as needed. of wear or lack of lubrication. Replace parts as (20) = With the engine off and below normal operating needed.
Page 332 (24) = Check the air intake system installation to see (32) = Inspect Electronic Vacuum Regulator Valve that gaskets are seated properly and all hose (EVRV) ﬁlter for excessive contamination or plugging. If connections, fasteners and other components are tight. needed, clean ﬁlter with solution of soap and water, Tighten connections and fasteners or replace parts let dry and install.
Page 333 (39) = Air brake service: • Remove, disassemble, clean and inspect the safety valve, standard brake chambers, quick release • Inspect brake lines and hoses for proper hook-up, valves, quick release/double check valve binding, leaks, cracks, chaﬁng, etc. Inspect drum combinations, parking brake control valve, double brake linings for wear or cracks.
Page 334: Part B: Owner Checks And Services
Part B: Owner Checks and Services Engine Coolant Level Check ® Check the engine coolant level and add DEX-COOL Listed in this part are owner checks and services coolant mixture if necessary. See “Engine Coolant” which should be performed at the intervals speciﬁed to in the Index for further details.
Page 335: At Least Twice A Year
At Least Twice a Year Weatherstrip Lubrication Silicone grease on weatherstrips will make them last Restraint System Check longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth. During very cold, Make sure the safety belt reminder light (if equipped) damp weather more frequent application may be and all your belts, buckles, latch plates, retractors required.
Page 336: Starter Switch Check
Starter Switch Check Steering Check Be alert for any changes in steering action, abnormal front tire wear or steering wheel position. An inspection CAUTION: or service is needed when the steering wheel is harder to turn or has too much free play, or if there are strange sounds when turning or parking.
Page 337: Exhaust System Check
Exhaust System Check Lamps Check Be alert for any changes in the sound of the exhaust Check panel lighting, warning lights, indicator lights and system or any smell of fumes. These are signs the interior lamps. On the outside, check: license plate system may be leaking.
Page 338: At Least Once A Year
Hood Latches Check Engine Cover Check Check that the hood closes ﬁrmly. Check for broken, Check that the cab’s engine cover and seal (if equipped) damaged, loose or missing parts that might prevent tight are not torn or damaged. Be sure that the cover is latching.
Page 339: Part C: Recommended Fluids And Lubricants
Part C: Recommended Fluids and Usage Fluid/Lubricant ® Lubricants Engine Oil See the Caterpillar Operation & ® (Caterpillar Maintenance Manual for engine oil Diesel Engine) recommendations. Fluids and lubricants identiﬁed below by name, part ® Engine Coolant See the Caterpillar Operation &...
Page 340 Usage Fluid/Lubricant Usage Fluid/Lubricant Manual Front Wheel SAE 75W-90 Synthetic Axle Synthetic Manual Transmission Fluid Transmission Bearing Grease Lubricant for Medium Duty Trucks (GM Part No. U.S. 12345724, in (Except ZF with Oil Filled (GM Part No. U.S. 12345841, in Canada 10953510).
Page 341: 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. Odometer Date Serviced By...
Page 342 Odometer Date Serviced By Maintenance Record Reading 6-32...
Page 343 Section 7 Customer Assistance and Information Customer Assistance and Information ....7-2 Reporting Safety Defects ........7-6 Customer Satisfaction Procedure ......7-2 Reporting Safety Defects to the United States Online Owner Center ........7-3 Government ..........7-6 Customer Assistance for Text Telephone Reporting Safety Defects to the Canadian (TTY) Users ..........7-3 Government ..........7-7 Customer Assistance Offices ......7-3...
Page 344: Customer Assistance And Information
Communication Centre in Oshawa by calling Your satisfaction and goodwill are important to 1-800-263-3777 (English) or 1-800-263-7854 (French). your dealer and to Chevrolet. Normally, any concerns We encourage you to call the toll-free number in with the sales transaction or the operation of your order to give your inquiry prompt attention.
Page 345: Online Owner Center
If a U.S. customer wishes • Find GM dealers for service nationwide. to write to Chevrolet, the letter should be addressed to • Chevrolet Medium Duty Truck’s Customer Assistance Receive special promotions and privileges only Center.
Page 346: Roadside Assistance Program
United States All Overseas Locations GM Medium Duty Truck Please contact the local General Motors Business Unit. Customer Assistance Center Mexico, Central America and P.O. Box 44947 Detroit, MI 48244 Caribbean Islands/Countries (Except 1-800-TO-CHEVY (1-800-862-4389) Puerto Rico and U.S. Virgin Islands) 1-800-833-2438 (For Text Telephone devices (TTYs)) Roadside Assistance: 1-800-TO-CHEVY General Motors de Mexico, S.
Page 347: Vehicle Data Collection And Event Data Records
Just dial GM Medium Duty Truck Roadside Assistance In a crash or near crash event, computer systems, such at 1-800-862-4389 to reach a qualiﬁed representative as the Air Bag Sensing and Diagnostic Module (SDM) who can assist you in a repair or arrange a tow. We also in your vehicle may record information about the provide dealer information at no charge, such as condition of the vehicle and how it was operated, such...
Page 348: Reporting Safety Defects
In addition, once GM collects or receives data, GM may Reporting Safety Defects • use the data for GM research needs, • Reporting Safety Defects to the make it available for research where appropriate conﬁdentiality is to be maintained and need is United States Government shown, or •...
Page 349: Reporting Safety Defects To The Canadian Government
Reporting Safety Defects to the In Canada, please call us at 1-800-263-3777 (English) or 1-800-263-7854 (French). Or, write Canadian Government General Motors of Canada Limited Customer Communication Centre, 163-005 If you live in Canada, and you believe that your vehicle 1908 Colonel Sam Drive has a safety defect, you should immediately notify Oshawa, Ontario L1H 8P7...
Page 350: Service Bulletins
Service Bulletins Current and Past Model Order Forms Service Bulletins give technical service information Service Publications are available for current and needed to knowledgeably service General Motors cars past model GM vehicles. To request an order form, and trucks. Each bulletin contains instructions to please specify year and model name of the vehicle.
Page 351 Air Connections ..........4-36 Air Dryer ............5-50 Accessory Power Outlets ......... 3-17 Air Pressure Gage .......... 3-44 Adding Equipment to Your Air Bag-Equipped Air Shift Control (Automatic Transmission) ..2-27 Vehicle ............1-61 Air Suspension ..........2-27 Adding Washer Fluid ........5-44 Air Suspension Seats ........
Page 352 Audio System(s) ..........3-45 Brake AM-FM Radio ..........3-46 Diesel Engine Exhaust ......... 2-25 Care of Your Cassette Tape Player ....3-57 Exhaust Indicator Light ......... 3-40 Care of Your CD Player ....... 3-59 Parking Warning Light ........3-34 Care of Your CDs ........3-59 System Warning Light ........
Page 353 Care of Child Restraints (cont.) Safety Belts ..........5-79 Securing a Child Restraint in the Right Your Cassette Tape Player ......3-57 Front Seat Position ........1-43 Your CD Player ........... 3-59 Top Strap ........... 1-38 Your CDs ........... 3-59 Where to Put the Restraint ....
Page 354 Compact Disc Messages ........3-56 Defogging and Defrosting ......... 3-20 Control of a Vehicle .......... 4-5 Defroster Check ..........6-27 Coolant Diesel Engine Engine Temperature Gage ......3-35 Exhaust Brake ..........2-25 Heater, Engine ..........2-23 Fuel ............5-8 Low Warning Light ........3-36 Starting ............
Page 355 Driving on Snow or Ice ........4-26 Engine (cont.) Driving Through Deep Standing Water ....4-20 Checks Before Operating ......2-22 Driving Through Flowing Water ......4-20 Coolant ..........5-32, 5-35 Dual Tire Operation ......... 5-69 Coolant Heater ..........2-23 Coolant Temperature Gage ......
Page 356 Exhaust Restrictor (Diesel Engines) ....2-18 Four-Wheel and Six-Wheel Drum Brakes Exhaust System Check ........6-27 (Air Only) ........... 5-49 Express-Down Feature ........2-10 Four-Wheel Disc Brakes Extender, Safety Belt ........1-26 (Hydraulic Only) .......... 5-49 Exterior Lamps ..........3-13 Front Wheel Bearings with Oil-Filled Hubs ..
Page 357 Headlamps On Reminder ......... 3-13 Heavy-Duty Trailer Wiring Package ....4-35 Gage Height Adjustment ..........1-6 Air Pressure ..........3-44 ® High Idle System (Caterpillar Diesel and Check Gages Warning Light ......3-42 Gasoline Engines) ........2-16 Engine Coolant Temperature ......3-35 Highway Hypnosis ...........
Page 358 If No Steam Is Coming From Your Engine ..5-37 Key Lock Cylinders Service ......6-28 If Steam Is Coming From Your Engine ....5-36 Keyless Entry System ........2-3 If You Are Caught in a Blizzard ......4-27 Keys ............... 2-2 If You Are Stuck in Sand, Mud, Ice or Snow ..
Page 359 Light (cont.) Differential Lock Indicator ......3-40 Maintenance, Normal Replacement Parts ..5-100 Engine Overspeed Warning ......3-39 Maintenance Schedule Engine Shutdown Warning ......3-39 At Each Fuel Fill ......... 6-24 Exhaust Brake Indicator ........ 3-40 At Least Once a Year ........6-28 Low Coolant Warning ........
Page 360 Matching Transmitter(s) to Your Vehicle ....2-5 Mexico, Central America and Caribbean Change Engine Oil Light ....... 3-39 Islands/Countries (Except Puerto Rico and Engine ..........5-20, 5-25 U.S. Virgin Islands) ........7-4 Low Oil Level Light ........3-38 Mirrors Pressure Gage ..........3-37 Manual Rearview Mirror ........
Page 361 Parking ............2-33 Questions and Answers About Safety Belts ..1-12 Brake Warning Light ........3-34 Over Things That Burn ......... 2-37 Parking Brake Check ........6-25 Part A - Scheduled Maintenance Services .... 6-4 Radio Messages ......3-48, 3-50, 3-55 Part B - Owner Checks and Services ....
Page 362 Rear Seat Outside Passenger Positions Restraint Systems (Crew Cab Models) ........1-23 Checking ............ 1-61 Rear Seat Passengers, Safety Belts ....1-23 Replacing Parts ........... 1-62 Rear Wheel Park Brake Burnish Procedure ..2-34 Resynchronization ..........2-6 Rear Window Defogger ........3-21 Right Front Passenger Position, Safety Belts ..
Page 363 Safety Belts (cont.) Service Bulletins ..........7-8 Safety Belt Extender ........1-26 Service Engine Soon Light ....... 3-37 Safety Belt Use During Pregnancy ....1-21 Service Manuals ..........7-7 Safety Belts Are for Everyone ......1-8 Servicing Your Air Bag-Equipped Vehicle .... 1-60 Safety Warnings and Symbols ......
Page 364 Storage Areas ..........2-41 Traction Center Console Storage Area ......2-42 Control System (TCS) ........4-11 Stuck in Sand, Mud, Ice or Snow ...... 4-29 Tractor Protection (Breakaway) Valve Check ..6-28 Sun Visors ............. 2-10 Trailer Switchbanks, Instrument Panel ......3-16 Connections ..........
Page 365 United States ........... 7-4 Warnings Used Replacement Wheels ......5-75 Hazard Warning Flashers ....... 3-5 Using Cleaner on Fabric ........5-78 Other Warning Devices ........3-6 Using the Clutch ..........2-30 Safety and Symbols ......... iii Using the Tow Hooks ........4-30 Vehicle Damage ..........
Page 366 When to Check and Change Fluid ..... 5-61 Windshield Wiper When to Check and Change Lubricant ....5-61 Blade Replacement ........5-63 When to Inspect the Engine Air Fuses ............5-87 Cleaner/Filter ..........5-30 Windshield Wipers ..........3-8 Where to Put the Restraint ....... 1-35, 1-37 Windshield Wipers and Washers Check .....

Chevrolet kodiak 2004 Owner's Manual

Table of Contents

Seats and Restraint Systems

Features and Controls

Section 3 Instrument Panel

Instrument Panel

Driving Your Vehicle

Section 4 Driving Your Vehicle

Your Driving, the Road, and Your Vehicle

Towing

Section 5 Service and Appearance Care

Service

Fuel

Checking Things under the Hood

Rear Axle

Noise Control System

Bulb Replacement

Windshield Wiper Blade Replacement

Other Service Items

Tires

Appearance Care

Vehicle Identiﬁcation

Electrical System

Capacities and Speciﬁcations

Normal Maintenance Replacement Parts

Section 6 Maintenance Schedule

Quick Links

Chapters

Related Manuals for Chevrolet kodiak 2004

Summary of Contents for Chevrolet kodiak 2004