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Chevrolet GMC 2002 Owner's Manual Supplement

6.5l diesel supplement
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  • Page 2 The 2002 GM 6.5L Diesel Engine Owner’s Manual Supplement for Trucks Features and Controls This section explains how to start and operate your vehicle. Problems on the Road This section tells what to do if you have a problem while driving, such as an overheated engine, etc. Service and Appearance Care Here the manual tells you how to keep your vehicle running properly.
  • Page 3 Copyright 2002 General Motors Corporation. All Rights Reserved. General Motors, GM, GMC, CHEVROLET, SIERRA and the corresponding emblem SAVANA and CHEVY EXPRESS are registered trademarks of General Motors Corporation. Part No. 15061585 A First Edition...

  • Page 4: Table Of Contents

    Section 2 Features and Controls Here you can learn about starting your diesel engine. Also explained are the instrument panel clusters and the warning systems that tell you if everything is working properly and what to do if you have a problem. Use this section along with the information in Section 2 of your owner’s manual.

  • Page 5: Starting Your Diesel Engine

    Starting Your Diesel Engine Starting Your Engine 1. Turn your ignition key to RUN. Your diesel engine starts differently than a gasoline engine. Observe the WAIT TO START light. (This light may not come on if the engine is hot.) Automatic Transmission 2.
  • Page 6 3. If the engine does not start after 15 seconds of Cold Weather Starting (Diesel Engine) cranking, turn the ignition key to OFF. Wait The following tips will help you get good starting in one minute for the starter to cool, then try the cold weather.

  • Page 7: Engine Coolant Heater (If Equipped)

    If Your Diesel Engine Won’t Start Be sure you are using the proper fuel for existing weather conditions. See “Diesel Fuel Requirements If you’ve run out of fuel, look at “Running Out of Fuel.” and Fuel System” in the Index. See “Diesel Fuel Requirements and Fuel System”...
  • Page 8 In very cold weather, 0 _ F ( 18 _ C) or colder, the engine 4. Before starting the engine, be sure to unplug and coolant heater can help. You’ll get easier starting and store the cord as it was before to keep it away from better fuel economy during engine warm up.

  • Page 9: Instrument Panel Cluster

    Instrument Panel Cluster 3500HD model United States version shown, Canada similar...
  • Page 10 Full Size Van model United States version shown, Canada similar Your instrument panel cluster is designed to let you know at a glance how your vehicle is running. You’ll know how fast you’re going, about how much fuel you have and many other things you’ll need to know to drive safely and economically.
  • Page 11 Speedometer and Odometer Tachometer (3500HD) Your speedometer lets you see your speed in both Your tachometer displays the engine speed in miles per hour (mph) and kilometers per hour (km/h). revolutions per minute (rpm). Your odometer shows how far your vehicle has been driven, in either miles (used in the United States) or NOTICE: kilometers (used in Canada).

  • Page 12: Warning Lights, Gages And Indicators

    Warning Lights, Gages and Indicators Please follow this manual’s advice. Waiting to do repairs can be costly and even dangerous. So please get to This part describes the warning lights and gages that know your warning lights and gages. They’re a big help. may be on your vehicle.

  • Page 13: Malfunction Indicator Lamp

    Malfunction Indicator Lamp NOTICE: (Service Engine Soon Light) Your vehicle is equipped If you keep driving your vehicle with this light with a computer which on, after a while, your emission controls may not monitors operation of the work as well, your fuel economy may not be as fuel, timing and emission good and your engine may not run as smoothly.
  • Page 14 If the Light Comes On Emissions Inspection and Maintenance Programs This light should come on, as a check to show you it is Some state/provincial and local governments have or may working, when the ignition is on and the engine is not begin programs to inspect the emission control equipment running.

  • Page 15: Water In Fuel Light

    Water in Fuel Light Service Throttle Soon Light On diesel engines, a computer monitors the operation of the electronic accelerator. 3500HD Full Size Van As a check to show you it’s working, this light comes on This light will come on to warn you if there is water in for a few seconds after the ignition is turned on.

  • Page 16: Wait To Start Light

    Wait To Start Light Fuel Gage 3500HD Full Size Van Your diesel engine has a glow plug system to aid in starting your vehicle. 3500HD Full Size Van An instrument panel WAIT TO START light shows that the system is functioning properly and tells you when The fuel gage, when the ignition is on, tells you the engine is ready to be started.
  • Page 17 Listed are four situations you may experience with your The gage moves a little when you turn a corner or fuel gage: speed up. At the gas station, the fuel pump shuts off before the The gage doesn’t go back to empty when you turn gage reads full.
  • Page 18 Section 5 Problems on the Road Here you’ll find out what to do about some problems that can occur on the road. Use this section along with the information in Section 5 of your owner’s manual. Engine Overheating Cooling System If Steam Is Coming From Your Engine How to Add Coolant to the Coolant If No Steam Is Coming From Your Engine...
  • Page 19 Engine Overheating CAUTION: You will find a coolant temperature gage and low coolant light on your vehicle’s instrument panel. Steam from an overheated engine can burn you If Steam Is Coming From Your Engine badly, even if you just open the hood. Stay away from the engine if you see or hear steam coming from it.
  • Page 20 If No Steam Is Coming From Your Engine 3. If you’re in a traffic jam, shift to NEUTRAL (N); otherwise, shift to the highest gear while driving: An overheat warning, along with a low coolant light, DRIVE (D) (Full Size Van models) or, can indicate a serious problem.
  • Page 21 Cooling System When you decide it’s safe to lift the hood, here’s what you’ll see: Full Size Van Models A. Coolant Surge Tank B. Engine Cooling Fan(s) 3500HD Models If the coolant inside the coolant surge tank is boiling, don’t do anything else until it cools down. A.
  • Page 22 When the engine is cold, the coolant level should be at or above the COLD mark for 3500HD models, or at or above the FULL COLD line for Full Size Van models. If it isn’t, you may have a leak at the pressure cap or in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system.
  • Page 23 How to Add Coolant to the Coolant NOTICE: Surge Tank Engine damage from running your engine NOTICE: without coolant isn’t covered by your warranty. The diesel engine has a specific coolant fill procedure. Failure to follow this procedure NOTICE: could cause your engine to overheat and be severely damaged.
  • Page 24 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 even a little they can come...
  • Page 25 NOTICE: CAUTION: In cold weather, water can freeze and crack the Adding only plain water to your cooling system engine, radiator, heater core and other parts. can be dangerous. Plain water, or some other So use the recommended coolant. liquid such as alcohol, can boil before the proper coolant mixture will.
  • Page 26 1. Park the vehicle on a Then keep turning level surface. You can the cap, but now remove the coolant push down as you surge tank pressure turn it. Remove the cap when the cooling pressure cap. system, including the coolant surge tank pressure cap and upper radiator hose,...
  • Page 27 5. Close the bleed valve. CAUTION: 6. Rinse or wipe the spilled coolant from the engine and compartment. You can be burned if you spill coolant on hot 7. Then fill the coolant engine parts. Coolant contains ethylene glycol, surge tank with the and it will burn if the engine parts are hot proper mixture, to the enough.
  • Page 28 3500HD Full Size Van Models 8. With the coolant surge tank pressure cap off, start the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine cooling fan(s). By this time, the coolant level inside the coolant surge tank may be lower.
  • Page 29 3500HD Models Full Size Van Models 9. Then replace the pressure cap. Be sure the arrows on the pressure cap line up like this. 5-12...
  • Page 30 Section 6 Service and Appearance Care Here you will find information about the care of your vehicle. This section begins with service and diesel fuel information, and then it shows how to check important fluid and lubricant levels. There is also technical information about your vehicle.

  • Page 31: Diesel Fuel Requirements And Fuel System

    Diesel Fuel Requirements and Diesel Engine Fuel Fuel System NOTICE: Some states and provinces have restrictions on the purchase of diesel fuel for light duty vehicles and require you to buy permits or pay special taxes. Diesel fuel or fuel additives not recommended Some of these restrictions apply only to residents, in this manual could damage your fuel system and others apply to both residents and visitors.
  • Page 32 What Fuel to Use If there are questions about the fuel you are using, please contact your fuel supplier. In the United States, for best results use Number 2 Diesel fuel may foam when you fill your tank. This can diesel fuel year round (above and below freezing cause the automatic pump nozzle to shut off, even...
  • Page 33 What Fuel to Use in Canada Very Cold Weather Operation Canadian fuels are blended for seasonal changes. Follow the instructions listed previously under the Diesel Type “A” fuel is blended for better cold weather heading “What Fuel to Use.” starting (below 0 _ F or 18 _ C);...
  • Page 34 It also should come on NOTICE: briefly when you start your engine, as a check. If it doesn’t, have it fixed If there is water in your diesel fuel and the so it will be there to let weather is warm or humid, fungus and bacteria you know if you ever do can grow in the fuel.
  • Page 35 Water In Fuel Light Chart Problem Recommended Action At temperatures Drain fuel filter immediately. If no Problem Recommended Action below freezing water can be drained water may Light comes Drain water from fuel filter. (Full Size Van). be frozen in fuel filter or fuel on intermittently.
  • Page 36 To drain water in 3500HD models: 4. With the engine off, open the water drain valve two to three turns. The valve is located to the left 1. Stop and park the vehicle in a safe place. of the engine oil fill cap, when standing in front of Turn off the engine and apply the parking brake.
  • Page 37 To drain water in full size van models: 6. Close the water drain valve. 1. Stop and park the vehicle in a safe place. 7. Remove the hose and container and properly dispose Turn off the engine and apply the parking brake. of the contaminated fuel.
  • Page 38 Running Out of Fuel (Diesel Engines) If the engine stalls and you think that you’ve run out of fuel, do this: Full Size Van Models First, open the fuel filter air bleed valve. Briefly crank the engine and have someone watch the bleed valve. If air comes out of the bleed valve, then you are 3500HD Models probably out of fuel.
  • Page 39 3. Close the air bleed valve. CAUTION: 4. Turn the ignition key to START for 10 to 15 seconds at a time until your engine starts. (If the vehicle starts but runs roughly, press down slightly on the Diesel fuel is flammable. It could start a fire if it accelerator pedal.) gets on hot engine parts.
  • Page 40 Fuel Filter Replacement (3500HD Models) Your vehicle’s engine should be off until the end of the following procedure. The fuel filter is located at the rear of the engine. To access the filter, remove the engine cover. See “Engine Compartment Overview” in the Index for more information on location.
  • Page 41 5. Line up the widest slot 8. With the air bleed valve open, turn your ignition in the top of the new key to START for 10 to15 seconds. Wait one element with the widest minute for your starter to cool. Do this until you key on the top of the can see clear fuel coming from the air bleed valve.
  • Page 42 6. Loosen and remove the ring nut from the top of the filter head. 7. Pull the element straight down and remove any dirt from the element sealing surface. 4. First drain the filter using the water drain valve and open the air purge valve to let air in.
  • Page 43 9. Remove the shipping plug from the bottom of the 12. Reinstall and tighten the ring nut until the new filter. alignment arrow on the ring nut aligns with the arrow on the filter. A click should be heard when 10.

  • Page 44: Filling Your Tank

    Filling Your Tank Filling a Portable Fuel Container For full size van models, the fuel cap is located behind a hinged door on the driver’s side of your vehicle. CAUTION: For 3500HD models, the fuel cap can be located on either or both sides of your vehicle depending on vehicle Never fill a portable fuel container while it is in content.
  • Page 45 Engine Compartment Overview When you open the hood on the 3500HD, you’ll see: A. Battery F. Automatic Transmission K. Engine Oil Dipstick Dipstick (If Equipped) B. Engine Air Cleaner/Filter L. Power Steering Fluid Reservoir G. Water Drain Valve C. Surge Tank Pressure Cap M.
  • Page 46 When you open the hood on the Full Size Van, you’ll see the following: A. Battery E. Engine Oil Fill Cap I. Brake Fluid Reservoir B. Surge Tank Pressure Cap F. Engine Cooling Fan J. Windshield Washer Fluid Reservoir C. Automatic Transmission Dipstick G.

  • Page 47: Engine Oil (Diesel Engines)

    Engine Oil (Diesel Engines) The engine oil dipstick has a yellow ring handle. The engine oil dipstick on the 3500HD is located on Checking Engine Oil the driver’s side of the engine compartment. The engine oil dipstick on the full size van is located at the center It’s a good idea to check your engine oil level every time of the engine compartment.
  • Page 48 When to Add Engine Oil If the oil is at or below the ADD line, then you’ll need to add at least one quart of oil. But you must use the right kind. This part explains what kind of oil to use. For engine oil crankcase capacity, see “Capacities and Specifications”...
  • Page 49 What Kind of Engine Oil to Use SAE 15W As shown in the viscosity chart, SAE 15W Look for these two things: is best for your vehicle. However, you can use SAE 4 or CG 30 if it’s going to be colder than 32 F (0 before your next oil change.
  • Page 50 Engine Oil Additives Don’t 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 If any one of these is true for you, use the short trip/city maintenance schedule: Most trips are less than 5 miles (8 km).

  • Page 51: Engine Air Cleaner/Filter

    If none of them is true, use the long trip/highway Engine Air Cleaner/Filter maintenance schedule. Change the oil and filter every To avoid the possibility of unfiltered air being drawn 7,500 miles (12 500 km) or 12 months whichever into the engine, make sure the engine air cleaner/filter occurs first.
  • Page 52 The air cleaner assembly has an indicator that lets you know when the air filter is dirty and needs to be serviced. The indicator is located between the air cleaner and the turbocharger. See “Engine Compartment Overview” in the Index for more information on location.
  • Page 53 2. Clean the filter sealing surface of the duct, the interior of the filter housing and the cover. 4. Install the duct and the filter into the air cleaner housing. Make sure that the duct fits properly into the housing. Align the tab on the duct with the notch 3.
  • Page 54 On full size van models, 1. To access the engine air cleaner/ filter, remove the the engine air cleaner/filter three air cleaner assembly bolts. is located under the 2. Then loosen the screw on the air intake hose clamp. hood at the center of the 3.

  • Page 55: Automatic Transmission Fluid

    Automatic Transmission Fluid Wait at least 30 minutes before checking the transmission fluid level if you have been driving: When to Check and Change When outside temperatures are above 90 F (32 A good time to check your automatic transmission At high speed for quite a while.
  • Page 56 Checking the Fluid Level Then, without shutting off the engine, follow these steps: Prepare your vehicle as follows: Park your vehicle on a level place. Keep the engine running. With the parking brake applied, place the shift lever in PARK (P). With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range.
  • Page 57 1. Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel. 2. Push it back in all the way, wait three seconds and then pull it back out again. Full Size Van Models The transmission dipstick has a red handle.
  • Page 58 How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission fluid to use. See “Recommended Fluids and Lubricants” in the Owner’s Manual. Add fluid only after checking the transmission fluid while it is hot. (A cold check is used only as a reference.) If the fluid level is low, add only enough of the proper fluid to bring the level up to the HOT area for a hot check.

  • Page 59: Engine Coolant

    Engine Coolant NOTICE: The cooling system in your vehicle is filled with COOL R engine coolant. This coolant is designed When adding coolant, it is important that you to remain in your vehicle for 5 years or 150,000 miles COOL R (silicate use only DEX free) coolant.
  • Page 60 What to Use NOTICE: Use a mixture of one half clean, drinkable water and half DEX COOL coolant which won’t damage If you use an improper coolant mixture, your aluminum parts. If you use this coolant mixture, you engine could overheat and be badly damaged. don’t need to add anything else.
  • Page 61 Checking Coolant On 3500HD models, the coolant surge tank is located on the passenger’s side at the rear corner of the engine compartment. Full Size Van 3500HD On full size van models, the coolant surge tank is located near the center of the engine compartment. See “Engine Compartment Overview”...
  • Page 62 Adding Coolant CAUTION: If you need more coolant, add the proper DEX COOL coolant mixture at the surge tank, but only when the engine is cool. If the surge tank is empty, see “Engine Turning the surge tank pressure cap when the Overheating”...

  • Page 63: Surge Tank Pressure Cap

    Surge Tank Pressure Cap NOTICE: The surge tank pressure cap must be tightly installed Your surge tank pressure cap is a unique with the arrows on the cap 15 psi (105 kPa) pressure type cap for use lined up with the top tube with surge tank cooling systems only.

  • Page 64: Specification Charts

    Specification Charts Engine Oil Capacity Engine Engine oil with filter change Engine Identification 6.5 L 8.0 quarts (7.5 L) Engine 6.5L Type All quantities are approximate. After refill, the level MUST be checked as outlined under “Engine Oil VIN Code And Filter Recommendations”...
  • Page 65 Service Replacement Part and Filter Recommendations Full Size Van 3500HD Engine 6.5L Engine 6.5L Oil Filter PF1218* Oil Filter PF1218* Engine Air A917C* Air Cleaner** A1300C* Cleaner/Filter** Fuel Filter TP1256* Fuel Filter TP1263* Surge Tank Cap RC33* Surge Tank Cap RC33* ** For operation in extremely dirty or dusty ** For operation in extremely dirty or dusty...

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