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Chevrolet B7 2001 Owner's Manual

Medium duty b7 chassis
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Summary of Contents for Chevrolet B7 2001

  • Page 2 This section tells you when to perform vehicle maintenance and what fluids and lubricants to use. Customer Assistance Information This section tells you how to contact Chevrolet for assistance and how to get service and owner publications. It also gives you information on “Reporting Safety Defects” on page 6 Index Here’s an alphabetical listing of almost every subject in this manual.
  • Page 3 We support voluntary technician certification. GENERAL MOTORS, GM, the GM Emblem, CHEVROLET and the CHEVROLET Emblem are registered trademarks of General Motors Corporation. This manual includes the latest information at the time it was printed. We reserve the right to make changes after that time without further notice.
  • Page 4 How to Use this Manual Safety Warnings and Symbols Many people read their owner’s manual from beginning You will find a number of safety cautions in this book. to end when they first receive their new vehicle. If you We use a box and the word CAUTION to tell you do this, it will help you learn about the features and about things that could hurt you if you were to ignore controls for your vehicle.
  • Page 5 You will also find a circle In the notice area, we tell you about something that can with a slash through it in damage your vehicle. Many times, this damage would this book. This safety not be covered by your warranty, and it could be costly. symbol means “Don’t,”...
  • Page 6 Vehicle Symbols These are some of the symbols you may find on your vehicle. Also see “Warning Lights and Gages” in the Index. For example, These symbols These symbols These symbols These symbols Here are some these symbols are important for have to do with are on some of are used on...
  • Page 7 Model Reference Since B7 Chassis models delivered from the factory are finished in a variety of ways by a number of This manual contains information which covers the companies, you’ll probably find other manuals in your B7 Chassis models as shown. Most models are finished vehicle.
  • Page 8 Section 1 Features and Controls Here you can learn about the many standard and optional features on your vehicle, and information on starting, shifting and braking. Also explained are the instrument panel and the warning systems that tell you if everything is working properly and what to do if you have a problem.
  • Page 9 Keys When a new vehicle is delivered, the dealership removes the plugs from the keys, and gives them to the first owner. Each plug has a code on it that tells your dealer or a CAUTION: qualified locksmith how to make extra keys. Keep the plugs in a safe place.
  • Page 10 New Vehicle “Break In” NOTICE: (Continued) Avoid making hard stops for the first NOTICE: 200 miles (322 km) or so. During this time your new brake linings aren’t yet broken Your vehicle doesn’t need an elaborate in. Hard stops with new linings can mean “break in.”...
  • Page 11 Ignition Positions Engine Starter Over Crank Protection (If Equipped) Use your ignition key to start your vehicle. You can Some vehicles have an engine starter over crank turn the ignition switch to protection system. This system includes a built four different positions. temperature limiting switch to prevent internal damage to the starter.
  • Page 12 Manual Transmission Starting Your Engine Set the parking brake, shift your gear selector to 1. Without pushing the accelerator pedal, turn your NEUTRAL and hold the clutch pedal to the floor while ignition key to START. When the engine starts, let starting the engine.
  • Page 13 Restarting the Gasoline Engine While NOTICE: Moving (Automatic Transmission) If you have to restart the engine while the vehicle is Your engine is designed to work with the moving, you’ll first have to shift the automatic electronics in your vehicle. If you add electrical transmission to NEUTRAL (N).
  • Page 14 Starting Your Diesel Engine Restarting the Diesel Engine While Moving (Automatic Transmission) If you have a Caterpillar diesel engine, also refer to your Caterpillar Diesel Engine Operation & Maintenance If you have to restart the engine while the vehicle is Manual for starting procedure.
  • Page 15 Cold Weather Starting If It Won’t Start In Cold Weather: (Caterpillar R Diesel) Be sure the fuel filter is properly serviced. If water in the primary or secondary filter has frozen, the engine Because the diesel engine uses compression ignition, it will not start.
  • Page 16 Diesel Engine Warm-Up Engine Alarm and Automatic Shutdown (Option) Several factors affect how quickly your diesel engine warms up. These can include outside temperature, Your CHECK GAGES light will come on if the system engine load, idle time and your vehicle’s option content. senses high engine temperature or low engine oil Your vehicle may be equipped with some features that pressure.
  • Page 17 Manual Fast Idle System (Caterpillar R Diesel and Fast Idle System (Electronically Controlled Gasoline Engines) Caterpillar Diesel and Gasoline Engines) The manual fast idle switch If your vehicle is equipped with an electronically is located on the lower controlled diesel engine, it has both automatic and portion of the instrument manual fast idle capabilities.
  • Page 18 The manual fast idle feature is activated by pressing the Radiator Shutters (If Equipped) switch on the instrument panel. When the switch is Radiator shutters aid engine warm up by blocking the pressed again, or any of the previous conditions are not airflow through the radiator and charge air cooler to met, manual fast idle will be deactivated.
  • Page 19 Engine Checks Before Operating The charging system light should come on when the ignition key is turned to ON or START and When you’ve started your engine, let it run for 20 to should go out when the engine is running above idle. 30 seconds before you put a load on the engine.
  • Page 20 Engine Coolant Heater (If Equipped) NOTICE: If your vehicle is equipped with this feature, the plug Don’t allow the engine to operate at low idle for receptacle is located behind more than five minutes. This can cause low the front bumper as shown, engine operating temperatures which can affect or in the component box engine operation and reduce engine life.
  • Page 21 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. in? The answer depends on the outside temperature. Above 32 _ F (0 _ C), the coolant heater is not required.
  • Page 22 Diesel Engine Exhaust Brake The accelerator and clutch pedals must be released in order for the exhaust brake to engage. Whenever the The exhaust brake is available on vehicles equipped EXHAUST BRAKE switch is in ON, the light in the with a diesel engine and air brakes (or an air switch will be on.
  • Page 23 Speed Rear Axle Electric Shift When the switch is up, the rear axle is in the high range. Push it down to switch to the low range. Control (If Equipped) Air Shift Control (If Equipped) If your vehicle is equipped with this feature, you’ll find a label (or labels) that show how to use it on the If your vehicle has a manual transmission and this headliner above the windshield or in another place near...
  • Page 24 The two speed axle should be in LOW when you park Automatic Transmission Operation the vehicle. You’ll need to engage the transmission, even moving the vehicle a little, to be sure the axle is in the low range. Then apply the parking brake, shift into NEUTRAL (N) and shut off the engine.
  • Page 25 On the headliner in front of and above the driver, or in some other place near the driver, you will see a label CAUTION: that describes important operating facts about the automatic transmission in your vehicle. Make sure you It can be dangerous to get out of your vehicle follow the directions on this label.
  • Page 26 Automatic Transmission Third Gear Hold Double-Clutching (If Equipped) You must use the “double clutching” method when you shift an unsynchronized gear set. Disengage the clutch, If your vehicle is equipped with this feature, your range shift to NEUTRAL and engage the clutch. When selector has a “2 3”...
  • Page 27 Parking Hydraulic Brakes If your vehicle has hydraulic brakes, it has a parking brake lever. The lever is located below the instrument CAUTION: panel cluster to the left of the steering column. Propshaft Brake Burnish Procedure If you don’t park your vehicle properly, it can It is recommended that the propshaft mounted parking roll.
  • Page 28 Lever Operated Parking Brake To apply the parking brake, place the transmission in (If Equipped) NEUTRAL (N) and pull the lever all the way up. The PARK BRAKE light will CAUTION: illuminate when the parking brake is applied. It will take a few seconds for the parking brake to fully apply, and even longer when it is cold outside.
  • Page 29 To release the parking Air Brake (If Equipped) brake, first push down the regular brake pedal. Then, push down the release catch CAUTION: and lower the parking brake lever all the way down. When the yellow SYSTEM PARK knob is pushed in, your vehicle will be free to move.
  • Page 30 If your vehicle has air brakes, the parking brake control will be located on the instrument panel to the right of the CAUTION: steering column. To apply the parking brake, If your vehicle is left in gear, the engine can pull this knob toward you.
  • Page 31 Engine Exhaust Running Your Engine While You’re Parked (Automatic Transmission) It’s better not to park with the engine running. But if you CAUTION: ever have to, here are some things to know. Engine exhaust can kill. It contains the gas carbon monoxide (CO), which you can’t see or CAUTION: smell.
  • Page 32 CAUTION: CAUTION: It can be dangerous to get out of your vehicle if It can be dangerous to get out of your vehicle the shift lever is not fully in PARK (P) with the without the parking brake firmly set. Your parking brake firmly set.
  • Page 33 Horn Turn and Lane Change Signals The turn signal has two upward (for right) and two Sound the horn by firmly pressing the pad in the center downward (for left) positions. These positions allow you of the steering wheel. to signal a turn or a lane change. Turn Signal Lever To signal a turn, move the lever all the way up or down.
  • Page 34 As you signal a turn or a lane change, if the arrows don’t flash Exterior Lamps but just stay on, check the turn signal flasher and circuit breaker. See “Fuses and Circuit Breakers” in the Index. Headlamps If a bulb is burned out, replace it to help avoid an accident. If the arrows don’t go on at all when you signal a turn, check the circuit breaker and for burned out bulbs.
  • Page 35 Push the switch marked “P” to turn on the following: The DRL system will make your low beam headlamps come on at reduced brightness in daylight when the Parking Lamps following conditions are met: Marker Lamps The ignition is on, Taillamps the headlamp switch is off and Instrument Panel Lights...
  • Page 36 Instrument Panel Cluster Gasoline engine shown, diesel engine 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 is left, and many other things you’ll need to know to drive safely and economically.
  • Page 37 Speedometer and Odometer You may wonder what happens if your vehicle needs a new odometer installed. If the new odometer can be set Your speedometer lets you see your speed in both to the mileage total of the old odometer, then it must be. miles per hour (mph) and kilometers per hour (km/h).
  • Page 38 Engine Road Speed Governor Warning Lights, Gages and Indicators This system controls maximum vehicle speed automatically and reduces engine power until vehicle This part describes the warning lights and gages that speed gets down to a maximum governed speed may be on your vehicle. The pictures will help you (which depends on your vehicle’s option content).
  • Page 39 When one of the warning lights comes on and stays on The charging system light is when you are driving, or when one of the gages shows located in the center of the there may be a problem, check the section that tells you instrument panel cluster just what to do about it.
  • Page 40 Voltmeter You can only drive for a short time with the reading in either warning zone. If you must drive, turn off all When your engine is not unnecessary accessories. running, but the ignition is Readings in either warning zone indicate a possible on (in START), this gage problem in the electrical system.
  • Page 41 Brake System Warning Light If the AUX BRAKE warning light comes on, Your vehicle has either hydraulic or air brakes. it means that there is Each system has different warning lights. something wrong in the auxiliary brake system. Hydraulic Brake System Warning Lights Vehicles with hydraulic systems have two brake system warning lights on the instrument panel.
  • Page 42 When this warning light comes on, you will also hear a warning tone. If the warning light and tone come on CAUTION: while you are driving, you should drive only as far as the nearest point of safety and then stop the vehicle. Your brake system may not be working properly Here’s a very important thing for you to know: if a brake system warning light is on.
  • Page 43 Parking Brake Warning Light Parking Brake Indicator Light This light turns on as a Vehicles with hydraulic or check when the engine is air brakes have a parking first started and any time the brake indicator light. When system needs adjustment. the ignition is on, this light will come on when you set your parking brake.
  • Page 44 Anti-Lock Brake System Warning Light Engine Coolant Temperature Gage With the anti lock brake system, this light will come on when you start your engine and it may stay on for several seconds. That’s normal. If the light stays on, or comes on when you’re driving, your vehicle needs service.
  • Page 45 Transmission Temperature Gage (If Equipped) Low Coolant Warning Light If you have an automatic You have a LOW transmission and this COOLANT warning gage, it is located to the light. If this light comes right of the dash mounted on, your system is low on shift lever.
  • Page 46 Manual Fast Idle Indicator Light Intake Heater Indicator Light (If Equipped) (Diesel Engines) If your vehicle is equipped This light on the instrument with an electronically panel cluster will come on controlled diesel engine or when the intake heater is gasoline engine, you may on and the ignition key is have this indicator light.
  • Page 47 Malfunction Indicator Lamp This light should come on when the ignition is on, but the engine is not running, as a check to show you it is (Service Engine Soon Light) working. If it does not come on at all, have it repaired. If your vehicle is equipped with either a gasoline engine or an electronically controlled diesel engine, you will NOTICE:...
  • Page 48 Engine Oil Pressure Gage A reading in the low pressure zone may be caused by a dangerously low oil level or another problem. If you have a Caterpillar diesel engine, also see your Caterpillar Operation & Maintenance Manual. CAUTION: Don’t keep driving if the oil pressure is low. If you do, your engine can become so hot that it catches fire.
  • Page 49 Change Oil Light (If Equipped) Engine Overspeed Warning Light (Gasoline Engines) The CHANGE OIL light should come on briefly as a If your vehicle has a bulb check when you start gasoline engine, you’ll have the engine. If the light this light.
  • Page 50 Daytime Running Lamps (DRL) Indicator Check Gages Indicator Light Light (If Equipped) This light will come on as you’re starting the engine, The DRL indicator light is just as a check. located near the upper center of the instrument panel cluster. It goes on whenever the Daytime Running Lamps (DRL) are on.
  • Page 51 Fuel Gage When the ignition is on, your fuel gage lets you know about how much fuel you have left. When the gage first shows empty, you’ll still have a little fuel left, but you should get more fuel soon. Here are four concerns of some operators.
  • Page 52 Reduced Engine Power Warning Light Air Pressure Gage (If Equipped) If the SERVICE ENGINE If your vehicle has air SOON and REDUCED brakes, this gage located on ENGINE POWER lights are the instrument panel cluster on, a noticeable reduction in shows the air pressure for the vehicle’s performance both your front and rear...
  • Page 53 Hourmeter Gage (If Equipped) Ammeter Gage (If Equipped) This gage is located on your This gage, located on the instrument panel cluster. It lower right portion of the shows the total engine instrument panel cluster, operating time. shows how much charge the battery is getting when the engine is running.

  • Page 54: Table Of Contents

    Section 2 Your Driving and the Road Here you’ll find information about driving on different kinds of roads and in varying weather conditions. We’ve also included many other useful tips on driving. Defensive Driving Driving in Rain and on Wet Roads Drunken Driving City Driving Control of a Vehicle...

  • Page 55: Defensive Driving

    Defensive driving really means “be ready for anything.” On city streets, rural roads or freeways, it means “always expect the unexpected.” Assume that pedestrians or other drivers are going to be careless and make mistakes. Anticipate what they might do. Be ready for their mistakes. Rear end collisions are about the most preventable of accidents.

  • Page 56: Drunken Driving

    Drunken Driving Many adults by some estimates, nearly half the adult population choose never to drink alcohol, Death and injury associated with drinking and driving is so they never drive after drinking. For persons under 21, a national tragedy. It’s the number one contributor to it’s against the law in every U.S.
  • Page 57 According to the American Medical Association, a It’s the amount of alcohol that counts. For example, lb. (82 kg) person who drinks three 12 ounce if the same person drank three double martinis (355 ml) bottles of beer in an hour will end up with a (3 ounces or 90 ml of liquor each) within an hour, BAC of about 0.06 percent.
  • Page 58 But the ability to drive is affected well below a BAC There’s something else about drinking and driving that of 0.10 percent. Research shows that the driving skills many people don’t know. Medical research shows that of many people are impaired at a BAC approaching alcohol in a person’s system can make crash injuries 0.05 percent, and that the effects are worse at worse, especially injuries to the brain, spinal cord or...

  • Page 59: Control Of A Vehicle

    Control of a Vehicle Braking You have three systems that make your vehicle go where Braking action involves perception time and you want it to go. They are the brakes, the steering and reaction time. the accelerator. All three systems have to do their work First, you have to decide to push on the brake pedal.
  • Page 60 Avoid needless heavy braking. Some people drive Hydraulic Brake Systems in spurts heavy acceleration followed by heavy If your engine stops running, or if your primary brake braking rather than keeping pace with traffic. system stops working, your vehicle has a reserve power This is a mistake.
  • Page 61 Anti-Lock Brakes (ABS) Your vehicle has anti lock brakes (ABS). 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 62 The anti lock system can change the brake Remember: Anti lock doesn’t change the time you need pressure faster than any driver could. The computer is to get your foot up to the brake pedal or always decrease programmed to make the most of available tire and road stopping distance.

  • Page 63: Steering

    Steering If there’s no traction, inertia will keep the vehicle going in the same direction. If you’ve ever tried to steer a Power Steering vehicle on wet ice, you’ll understand this. If you lose power steering assist because the engine The traction you can get in a curve depends on stops or the system is not functioning, you can steer the condition of your tires and the road surface,...
  • Page 64 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 65: Off - Road Recovery

    Road Recovery Passing You may find that your right wheels have dropped off the The driver of a vehicle about to pass another on a edge of a road onto the shoulder while you’re driving. lane highway waits for just the right moment, accelerates, moves around the vehicle ahead, then goes back into the right lane again.
  • Page 66 Watch for traffic signs, pavement markings and lines. If other cars are lined up to pass a slow vehicle, wait If you can see a sign up ahead that might indicate a your turn. But take care that someone isn’t trying to turn or an intersection, delay your pass.

  • Page 67: Loss Of Control

    Loss of Control If your vehicle starts to slide, ease your foot off the accelerator pedal and quickly steer the way you want Let’s review what driving experts say about what happens the vehicle to go. If you start steering quickly enough, when the three control systems (brakes, steering and your vehicle may straighten out.

  • Page 68: Driving At Night

    Driving at Night No one can see as well at night as in the daytime. But as we get older these differences increase. A 50 year Night driving is more dangerous than day driving. driver may require at least twice as much light to see the One reason is that some drivers are likely to be same thing at night as a 20 year...

  • Page 69: Driving In Rain And On Wet Roads

    Remember that your headlamps light up far less of a It’s wise to keep your wiping equipment in good roadway when you are in a turn or curve. Keep your shape and keep your windshield washer tank filled eyes moving; that way, it’s easier to pick out dimly with washer fluid.
  • Page 70 Hydroplaning Driving Through Deep Standing Water Hydroplaning is dangerous. So much water can build up under your tires that they can actually ride on the water. NOTICE: This can happen if the road is wet enough and you’re going fast enough. When your vehicle is hydroplaning, If you drive too quickly through deep puddles it has little or no contact with the road.
  • Page 71 Driving Through Flowing Water Some Other Rainy Weather Tips Turn on your low beam headlamps and your marker and clearance lamps, if your vehicle has them CAUTION: just your parking lamps to help make you more visible to others. Flowing or rushing water creates strong forces. Besides slowing down, allow some extra following If you try to drive through flowing water, as you distance.

  • Page 72: City Driving

    City Driving Freeway Driving One of the biggest problems with city streets is the amount of traffic on them. You’ll want to watch out for what the other drivers are doing and pay attention to traffic signals. Here are ways to increase your safety in city driving: Know the best way to get to where you are going.
  • Page 73 The most important advice on freeway driving is: Keep Before changing lanes, check your mirrors. Then use up with traffic and keep to the right. Drive at the same your turn signal. speed most of the other drivers are driving. Too fast or Once you are moving on the freeway, make certain you slow driving breaks a smooth traffic flow.

  • Page 74: Before Leaving On A Long Trip

    Before Leaving on a Long Trip Here are some things you can check before a trip: Windshield Washer Fluid: Is the reservoir full? Make sure you’re ready. Try to be well rested. If you Are all windows clean inside and outside? must start when you’re not fresh such as after a day’s work...

  • Page 75: Highway Hypnosis

    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 against the...
  • Page 76 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. These parts can work hard on ignition off is dangerous.

  • Page 77: Winter Driving

    Winter Driving freezing (32 F; 0 C) and freezing rain begins to fall. Try to avoid driving on wet ice until salt and sand crews Here are some tips for winter driving: can get there. Be sure the vehicle is in good shape for winter. Whatever the condition smooth ice, packed, blowing You may want to put winter emergency supplies...
  • Page 78 If You’re Caught in a Blizzard Tie a red cloth to your mirror arm to alert police that you’ve been stopped by the snow. Put on extra clothing or wrap a blanket around you. If you have no blankets or extra clothing, make body insulators from newspapers, burlap bags, rags, floor mats anything you can wrap around yourself or...

  • Page 79: Loading Your Vehicle

    Run your engine only as long as you must. This saves Loading Your Vehicle fuel. When you run the engine, make it go a little faster than just idle. That is, push the accelerator slightly. This uses less fuel for the heat that you get and it keeps the battery (or batteries) charged.
  • Page 80 The Certification/Tire label also tells you the maximum Ask your dealer to help you load your vehicle the weights for the front and rear axles, called Gross Axle right way. Weight Rating (GAWR). To find out the actual loads on your front and rear axles, you need to go to a weigh NOTICE: station and weigh your vehicle.
  • Page 81 Section 3 Problems on the Road Here you’ll find what to do about some problems that can occur on the road. Hazard Warning Flashers Cooling System (Diesel Engine) Other Warning Devices Engine Fan Noise Jump Starting If a Tire Goes Flat Towing Your Vehicle Changing a Flat Tire Engine Overheating...

  • Page 82: Hazard Warning Flashers

    Hazard Warning Flashers The knob for your flashers is on the lower right side of the instrument panel. Pull the knob out to make your Your hazard warning flashers let you warn others. They front and rear turn signal lamps flash on and off. also let police know you have a problem.

  • Page 83: Jump Starting

    Jump Starting NOTICE: If your battery (or batteries) has run down, you may want to use another vehicle and some jumper cables Ignoring these steps could result in costly damage to start your vehicle. Please use the following steps to to your vehicle that wouldn’t be covered by do it safely.
  • Page 84 1. Check the other vehicle. It must have a 12 volt 4. Locate the batteries on each vehicle. Find the battery with a negative ground system. positive (+) and negative ( ) terminals on each battery. NOTICE: CAUTION: If the other system isn’t a 12 volt system with a Using a match near a battery can cause battery negative ground, both vehicles can be damaged.
  • Page 85 5. Check that the jumper cables don’t have loose or 6. Connect the red missing insulation. If they do, you could get a shock. positive (+) cable to The vehicles could be damaged, too. the positive (+) terminal of the vehicle with the Before you connect the cables, here are some basic dead battery.
  • Page 86 8. Now connect the black 9. Attach the cable at least negative ( ) cable to 8 inches (45 cm) away the good battery’s from the dead battery, negative ( ) terminal. but not near engine parts that move. The electrical connection is just as good there, but the chance of sparks...
  • Page 87 To disconnect the jumper cables from both vehicles, do the following: 1. Disconnect the black negative ( ) cable from the heavy, unpainted metal engine part on the vehicle that had the dead battery. 2. Disconnect the black negative ( ) cable from the negative ( ) terminal on the vehicle with the...

  • Page 88: Towing Your Vehicle

    Towing Your Vehicle Consult your dealer or a professional towing service if you need to have your vehicle towed. They can provide the right equipment and know how to tow it without CAUTION: damage. See “Roadside Assistance” in the Index. Before you do anything, turn on the hazard warning To help avoid serious personal injury to you flashers (if they have not been damaged).
  • Page 89 Towing Your Vehicle From the Front Towing the Vehicle with the Front Bumper Removed (Front Wheels Off the Ground) 1. Remove the front bumper. 2. Connect and lock the lift chains to the front axle, Before Towing outside of the spring anchor plates as shown. Block the rear wheels of the disabled vehicle.
  • Page 90 4. Connect lift chains to the tow bar and raise the tow Towing the Vehicle with the Front Bumper Installed bar until lift chain slack has been taken up and the 1. Connect and lock the lift chains to the front axle, outside hardwood beam is fully seated against the spring of the spring anchor plates as previously shown.
  • Page 91 4. Remove the remaining slack in the lift chains. The tow bar swing arm should rest against the 2 x 2 x 40 hardwood board as shown. A. Rubber Pad E. Hardwood Beam B. Hardwood Board F. Bumper C. Shackle Bracket G.
  • Page 92 Single Drive Rear Axle Before Towing Disconnect the propshaft at the rear axle. Secure the Block the wheels of the disabled vehicle. On vehicles propshaft to the frame or crossmember. with air brakes, release the emergency brake system by compressing the brake chamber springs as outlined in After Towing this section.
  • Page 93 Towing Your Vehicle From the Rear The tow operator can release the brakes manually by using the following steps. Then your vehicle can be towed with (Rear Wheels Off the Ground) all wheels or just the rear wheels on the ground. Before Towing 1.
  • Page 94 3. Remove the rubber 6. Using a wrench, turn cap from the rear the stud nut clockwise of the chamber. several turns to release the brakes. Follow the same procedure to release the other brake. 4. Put the release stud, nut and flat washer into 7.

  • Page 95: Engine Overheating

    Engine Overheating CAUTION: (Continued) You will find a coolant temperature warning gage located on your vehicle’s instrument panel cluster, as If you keep driving when your engine is well as a LOW COOLANT warning light, if you have a overheated, the liquids in it can catch fire. You or diesel engine.
  • Page 96 If No Steam Is Coming From Your Engine If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about If you get an engine overheat warning but see or hear no 10 minutes. If the warning doesn’t come back on, steam, the problem may not be too serious.

  • Page 97: Cooling System (Gasoline Engine)

    Cooling System (Gasoline Engine) When the engine is cold, the coolant level should be When you decide it’s safe to lift the hood, here’s what at the COLD LEVEL mark. you’ll see: If it isn’t, you may have a leak in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system.
  • Page 98 How to Add Coolant to the Coolant NOTICE: Recovery Tank If you haven’t found a problem yet, but the coolant level Engine damage from running your engine isn’t at or above the COLD LEVEL mark, add a 50/50 without coolant isn’t covered by your warranty. mixture of clean, drinkable water and DEX COOL engine coolant at the coolant recovery tank.
  • Page 99 NOTICE: CAUTION: In cold weather, water can freeze and crack the You can be burned if you spill coolant on hot engine, radiator, heater core and other parts. engine parts. Coolant contains ethylene glycol Use the recommended coolant and the proper and it will burn if the engine parts are hot coolant mixture.
  • Page 100 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 radiator pressure cap even a little they can come out at high speed. Never turn the cap when the cooling system, including the radiator pressure cap, is hot.
  • Page 101 How to Add Coolant to the Radiator 2. Then keep turning the pressure cap, but 1. You can remove the now push down as radiator pressure cap you turn it. Remove when the cooling the pressure cap. system, including the radiator pressure cap and upper radiator hose, is no longer hot.
  • Page 102 5. Put the cap back on the coolant recovery tank, but 7. By this time, the coolant level inside the radiator leave the radiator pressure cap off. filler neck may be lower. If the level is lower, add more of the proper DEX COOL coolant mixture through the filler neck until the level reaches the...

  • Page 103: Cooling System (Diesel Engine)

    Cooling System (Diesel Engine) If the coolant inside the coolant surge tank is boiling, don’t do anything else until it cools down. When you decide it’s safe to lift the hood, here’s what you’ll see: The coolant level should be at COLD ADD or higher.
  • Page 104 How to Add Coolant to the Coolant CAUTION: Surge Tank If you haven’t found a problem yet, but the coolant level Heater and radiator hoses, and other engine isn’t at the COLD FULL mark, add a 50/50 mixture of clean, drinkable water and coolant at the coolant parts, can be very hot.
  • Page 105 CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid like alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you wouldn’t get the overheat warning.
  • Page 106 NOTICE: In cold weather, water can freeze and crack the engine, radiator, heater core and other parts. So use the recommended coolant. CAUTION: You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot 1.
  • Page 107 2. Then keep turning the cap, but now push down as 3. Then fill the coolant surge tank with the proper you turn it. Remove the pressure cap. coolant mixture, up to the COLD FULL mark. 3-27...
  • Page 108 4. 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 fan. By this time, the coolant level inside the coolant surge tank may be lower.

  • Page 109: Engine Fan Noise

    Engine Fan Noise If a Tire Goes Flat Your vehicle has a clutched engine cooling fan. It’s unusual for a tire to “blow out” while you’re driving, When the clutch is engaged, the fan spins faster to especially if you maintain your tires properly. If air goes provide more air to cool the engine.

  • Page 110: Changing A Flat Tire

    Changing a Flat Tire CAUTION: Your truck, when new, included no tire changing equipment and no place to store a tire in the vehicle. Few drivers of these vehicles have the necessary Your vehicle, when new, included no tire equipment aboard to be able to change a flat tire safely. changing equipment and no place to store a tire For example, you have to have a truck jack that can lift in the vehicle.
  • Page 111 Rocking Your Vehicle To Get It Out CAUTION: First, turn your steering wheel left and right. That will clear the area around your front wheels. Then shift back and forth between REVERSE (R) and a forward gear If you let your tires spin at high speed, they can (or with a manual transmission, between FIRST (1) or explode, and you or others could be injured.
  • Page 112 Section 4 Service Here you will find information about the care of your vehicle. This section begins with service and fuel information, and then it shows how to check important fluid and lubricant levels. There is also technical information about your vehicle.
  • Page 113 Service Doing Your Own Service Work If you want to do some of your own service work, you’ll Your dealer knows your vehicle best and wants you to want to use the proper service manual. It tells you much be happy with it. We hope you’ll go to your dealer for more about how to service your vehicle than this manual all your service needs.
  • Page 114 CAUTION: (Continued) CAUTION: (Continued) Be sure to use the proper nuts, bolts and rotating, the flying pieces can cause severe injury other fasteners. “English” and “metric” to anyone such as a service technician who is fasteners can be easily confused. If you use nearby.
  • Page 115 Fuel (Gasoline Engine) In Canada, look for the “Auto Makers’ Choice” If your vehicle has a diesel engine, see “Diesel Engine label on the fuel pump. Fuel” in this section. For vehicles with gasoline engines, please read this. Use regular unleaded gasoline rated at 87 octane or higher. It is recommended that the gasoline meet specifications which were developed by the American Automobile Manufacturers Association (AAMA) and endorsed by the...
  • Page 116 If you’re using fuel rated at 87 octane or higher and you To provide cleaner air, all gasolines in the United States hear heavy knocking, your engine needs service. But are now required to contain additives that will help don’t worry if you hear a little pinging noise when prevent deposits from forming in your engine and fuel you’re accelerating or driving up a hill.
  • Page 117 Diesel Fuel Requirements and NOTICE: Fuel System Diesel Engine Fuel If there is water in your diesel fuel and the weather is warm or humid, fungus and bacteria See your Caterpillar Diesel Engine Operation & can grow in the fuel. They can damage your fuel Maintenance Manual for information concerning system.
  • Page 118 Fuels in Foreign Countries Filling Your Tank (Gasoline Engines) If you plan on driving in another country outside the CAUTION: United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not Fuel vapor is highly flammable.
  • Page 119 Filling a Portable Fuel Container CAUTION: CAUTION: Gasoline Engine Vehicles: If you get gasoline on you and then something ignites it, you could be Never fill a portable fuel container while it is in badly burned. Gasoline can spray out on you if your vehicle.
  • Page 120 Checking Things Under the Hood Then take the hand holds and pull the hood forward. When you tilt the hood forward far enough, To tilt the complete hood forward, pull out on each of spring cushioned cables will support it. the hood latch handles to release the locks.
  • Page 121 CAUTION: Things that burn can get on hot engine parts and start a fire. These include liquids like fuel, oil, coolant, brake fluid, windshield washer and other fluids, and plastic or rubber. You or others could be burned. Be careful not to drop or spill things that will burn onto a hot engine.
  • Page 122 Engine Oil (Gasoline Engine) Turn off the engine and give the oil several minutes to drain back into the oil pan. If you don’t, the oil dipstick Checking Engine Oil might not show the actual level. Pull out the dipstick and clean it with a paper towel or It’s a good idea to check your engine oil every time you cloth, then push it back in all the way.
  • Page 123 When to Add Engine Oil What Kind of Engine Oil to Use If the oil is at or below the ADD line, then you’ll need Oils recommended for your vehicle can be identified by to add at least one quart of oil. But you must use the looking for the starburst symbol.
  • Page 124 As in the chart shown previously, SAE 5W 30 is best for your vehicle. However, you can use SAE 10W 30 if it’s going to be 0 C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils, such as SAE 20W NOTICE: Use only engine oil with the American Petroleum...
  • Page 125 Engine Oil Additives The system won’t detect dust in the oil. So, if you drive in a dusty area, be sure to change your oil and Don’t add anything to your oil. The recommended oils filter every 3,000 miles (5 000 km) or sooner. with the starburst symbol are all you will need for good Remember to reset the CHANGE OIL light whenever performance and engine protection.
  • Page 126 What to Do with Used Oil Engine Air Cleaner Filter Restriction Indicator (Gasoline Engine) Did you know that used engine oil contains certain elements that may be unhealthy for your skin and could Your engine has an indicator that lets you know when even cause cancer? Don’t let used oil stay on your skin the air filter is dirty and needs to be serviced.
  • Page 127 Engine Air Filter Restriction Engine Air Cleaner/Filter Indicator (Diesel Engines) Your GM Maintenance Schedule says when to replace the air filter. Your engine has an indicator that lets you know when the air cleaner filter is dirty and needs to be serviced. The air filter restriction indicator is located below the air cleaner on the driver’s side of the engine.
  • Page 128 NOTICE: CAUTION: Gasoline Engines Only: If the air cleaner/filter is Gasoline Engines Only: Operating the engine off, a backfire can cause a damaging engine fire. with the air cleaner/filter off can cause you or And, dirt can easily get into your engine, which others to be burned.
  • Page 129 Automatic Transmission Fluid Automatic Transmission External Filter Your automatic transmission spin on type filter requires When to Check periodic replacement. It is mounted just behind the A good time to have it checked is when the engine oil is radiator on the outside of the passenger’s side frame rail. checked.
  • Page 130 How to Check and What to Use Rear Axle Your Eaton Fuller Manual Transmission Operator’s When to Check and Change Lubricant Manual also shows how to check the manual Refer to the Maintenance Schedule to determine how transmission fluid and what fluid to use. often to check the lubricant and when to change it.
  • Page 131 What to Use A 50/50 mixture of clean, drinkable water and COOL coolant will: Refer to the Maintenance Schedule to determine what Give freezing protection down to kind of lubricant to use. See “Recommended Fluids and Lubricants” in the Maintenance Schedule. Give boiling protection up to 252 F (122 Engine Coolant (Gasoline Engine)
  • Page 132 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 133 Checking Coolant Surge Tank (Caterpillar Diesel Engines) When your engine is cold, the coolant level should be at Coolant Recovery Tank (Gasoline Engines) the COLD level, or a little higher, on the coolant recovery tank with the gasoline engine, or at the COLD FULL mark, visible through the surge tank, with the diesel engine.
  • Page 134 If this light comes on and Add coolant mixture at the recovery tank or the surge stays on, it means you’re tank, but be careful not to spill it. low on engine coolant. CAUTION: You can be burned if you spill coolant on hot engine parts.
  • Page 135 Radiator Pressure Cap Surge Tank Pressure Cap (Gasoline Engine) (Diesel Engine) Be sure the arrows on the The surge tank pressure cap cap line up with the must be tightly installed overflow tube on the with the arrows on the cap filler neck.
  • Page 136 Heater Hose Shut Off Valve Power Steering Fluid See your Maintenance Schedule for when to check your If you have a gasoline power steering fluid. engine, your vehicle is equipped with two shut How To Check Power Steering Fluid valves. One is located on Check your power steering fluid only when the engine is the radiator and one on the warm.
  • Page 137 What to Use Brakes To determine what kind of fluid to use, see Brake Fluid “Recommended Fluids and Lubricants” in the Index. If your vehicle has hydraulic brakes, there’s NOTICE: a brake master cylinder. Refer to the Maintenance When adding power steering fluid or making a Schedule to determine when complete fluid change, always use the proper to check your brake fluid.
  • Page 138 Checking Brake Fluid CAUTION: Apply the brake pedal several times with the ignition off. Then clean one of the reservoir caps and the area around the cap, and remove it. The fluid level should be With the wrong kind of fluid in your brake even with the bottom ring of the filler opening.
  • Page 139 Brake Pedal Travel Air Brake Systems (If Equipped) See your dealer if the brake pedal does not return to If you have air brakes, it is important to get rid of normal height, or if there is a rapid increase in pedal moisture in the system.
  • Page 140 Air Dryer (If Equipped) If your vehicle has air brakes, it may have an air dryer. This collects and removes dirt, moisture or other foreign matter from the air prior to entering the brake system. It is mounted on the left frame rail. If your dryer is a Bendix Westinghouse, it has a filter that you need to change at intervals.
  • Page 141 Chassis Lubrication 4-30...
  • Page 142 ITEM ITEM REMARKS Brake Camshaft One fitting each (apply sparingly). For caliper rails, Brake Caliper Rails$ apply Aero Shell #5 Lubricant. Steering Column Slip Joint** One fitting. Steering Drag Link Ends One fitting each end. One fitting each joint. Steering Column U joints Pivot Points and Hinges Apply chassis lubricant.
  • Page 143 ITEM ITEM REMARKS Transmission* Fill to level of filler plug. Check fluid level. Transmission Automatic*,**, Propshaft Slip Joints One fitting each joint; lubricate with GM Part No. 1051344 Wheel Bearing Lubricant. One fitting each joint (1480 and 1550 Series); lubricate with Propshaft U joints GM Part No.
  • Page 144 Battery CAUTION: Your new vehicle comes with one or more maintenance free ACDelco batteries. When it’s 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. We recommend an that can explode.
  • Page 145 Other Service Items Primary Fuel Filter and Water Separator (Option) Fuel Filter (Gasoline Engines) Your Caterpillar diesel The steel fuel filter is located in the fuel line along the engine vehicle may have inside of the driver’s side frame rail. It is strapped and this spin on filter.
  • Page 146 Secondary Fuel Filter and Water Automatic Ether Injection System Separator/Heater (Option) (If Equipped) If you have a Caterpiller If your Caterpillar diesel diesel engine, you may have engine vehicle has this this spin on filter and fuel feature, it is at the rear of separator/heater.
  • Page 147 3. Clean any dirt from the neck of the cylinder and the Front Wheel Bearings with Oil-Filled Hubs top of the valve before you take out the cylinder. (If Equipped) 4. Check the inside of the valve for any foreign matter Some vehicles have oil filled hubs.
  • Page 148 Tires CAUTION: (Continued) Your new vehicle comes with high quality tires made by a leading tire manufacturer. If you ever have questions Underinflated tires pose the same danger as about your tire warranty and where to obtain service, see overloaded tires. The resulting accident your GM Warranty booklet for details.
  • Page 149 Inflation -- Tire Pressure NOTICE: (Continued) The Certification/Tire label, which is provided by the final body manufacturer, shows the correct inflation If your tires have too much air (overinflation), pressures for your tires when they’re cold. “Cold” you can get the following: means your vehicle has been sitting for at least Unusual wear three hours or driven no more than 1 mile (1.6 km).
  • Page 150 Rims and Wheels The outer tire on a dual wheel setup generally wears faster than the inner tire. Your tires will wear more Rims and wheels are stamped with a maximum load and evenly and last longer if you rotate the tires periodically. cold inflation rating.
  • Page 151 When It’s Time for New Tires When you replace tires, make sure they are the same size, load range, speed rating and construction type Replace your tires when the tread depth is down to (bias, bias belted or radial) as your original tires. 1/8 of an inch (3.2 mm) for the front tires, or 1/16 of an inch (1.6 mm) for a rear tire.
  • Page 152 Tightening the Wheel Nuts CAUTION: Wheel nuts that are not tight can work loose. If all the nuts on a wheel come off, the wheel can come off the vehicle, causing a serious crash. All wheel nuts must be properly tightened. Follow the rules in this section to be sure they are.
  • Page 153 Then, follow the steps below for the wheels you have. 5. Oil the surfaces between the nuts and washers as CAUTION: shown. Do not oil the studs or the threads of the nut. Never use oil or grease on studs or nuts. If you do, the nuts might come loose.
  • Page 154 CAUTION: (Continued) could collapse in operation. Replace any wheel if its stud holes have become larger or distorted in any way. Inspect hubs and hub piloted wheels for damage. Because of loose running wheels, piloting pad damage may occur and require replacement of the entire hub, for proper centering of the wheels.
  • Page 155 How Often to Check CAUTION: Wheel tightness is so important you should have a technician check nut tightness on all wheels, with a torque wrench, every 1,000 miles (1 600 km). Without the correct wheel, you may not be able to stop properly, and you could have other Wheel Replacement problems like a tire air...
  • Page 156 Appearance Care NOTICE: Remember, cleaning products can be hazardous. Some are toxic. Others can burst into flame if you strike a The wrong wheel can cause trouble in bearing match or get them on a hot part of the vehicle. Some are life, brake cooling, speedometer/odometer dangerous if you breathe their fumes in a closed space.
  • Page 157 Don’t use any of these unless this manual says you can. Cleaning Tires In many uses, these will damage your vehicle: To clean your tires, use a stiff brush with a tire cleaner. Alcohol Laundry Soap NOTICE: Bleach Reducing Agents When applying a tire dressing always take care to wipe off any overspray or splash from all painted Care of Safety Belts...
  • Page 158 Finish Damage Underbody Maintenance Any stone chips, fractures or deep scratches in the finish Chemicals used for ice and snow removal and dust should be repaired right away. Bare metal will corrode control can collect on the underbody. If these are not quickly and may develop into a major repair expense.
  • Page 159 Vehicle Identification Number (VIN) Service Statement One of these statements is on your Certification/Tire label. Here is what each one means. MAX. VERT. CG The highest allowable vertical center of gravity, at the highest allowable GVWR. It’s measured from level ground in inches. SCHOOL BUS A bus for purposes that include carrying students to and from school or related events,...
  • Page 160 Electrical System Headlamp Wiring The headlamp wiring is protected by a circuit breaker in the Add-On Electrical Equipment lamp switch. An electrical overload will cause the lamps to go on and off, or in some cases to remain off. If this happens, have your headlamp wiring checked right away.
  • Page 161 Fusible Links 1-Way Power Feed A fusible link is a short piece of wire several gage sizes This terminal feed, located just below the instrument smaller than the circuit it protects. It will melt in an panel attached to the left cowl support, lets the body overload situation, opening the circuit.
  • Page 162 Fuses and Circuit Breakers You can remove circuit breakers with a fuse extractor. If you have one, you will find it attached to the inside of The wiring circuits in your vehicle are protected from the cover. short circuits by a combination of circuit breakers, Be sure to use the correct circuit breaker.
  • Page 163 Gasoline Engines Diesel Engines 4-52...
  • Page 164 Maxi Fuse Block Circuit Breaker Circuits Protected This block uses blade type fuses. The block is under the STOP LP Stoplamps instrument panel on the passenger’s side. Just to the left IGN 1 Ignition Switch and right of it are the relay centers. CHASSIS Air Dryer (Gasoline Engines) HORNS...
  • Page 165 To access the maxi fuse block, remove the screws that Capacities and Specifications secure the long dash panel to the right of the automatic transmission shifter. Remove the panel to expose the Engine Identification and Data maxi fuse block and relay center. Engine RPO Locate the label attached to the cowl directly under the Engine Type...
  • Page 166 Crankcase Capacity Fuel Tank Capacity Model U.S. Gallons (Liters) Capacities (volumes) shown are normal refill. Add oil as indicated when the oil filter element is changed. R.H. Mount (Standard) ....60.0 (227.1) Capacities given are approximate keep level within...
  • Page 167 Rear Axle Lubricant Capacity Normal Maintenance Axle Type Lubricant, Pints (Liters) Replacement Parts 19060S ......28.0 (13.0) Allison Transmission External Filters 21060S...
  • Page 168 Service Replacement Part and Filter Recommendations Replacement part numbers listed in this section are based on the latest information available at the time of printing, and are subject to change. If a part listed in this manual is not the same as the part used in your vehicle when it was built, or if you have any questions, please contact your GM Truck dealer.
  • Page 169 Section 5 Scheduled Maintenance Services This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety, dependability and emission control performance. Introduction Part C: Recommended Fluids and Lubricants Part A: Scheduled Maintenance Services Part D: Maintenance Record Part B: Owner Checks and Services...
  • Page 170 Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance can even affect the quality of the air we breathe. Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle.
  • Page 171 How This Section is Organized “Part B: Owner Checks and Services” tells you what should be checked and when. It also explains This maintenance schedule is divided into four parts: what you can easily do to help keep your vehicle in good condition.
  • Page 172 Part A: Scheduled The proper fluids and lubricants to use are listed in Part C. Make sure whoever services your vehicle uses Maintenance Services these. All parts should be replaced and all necessary repairs done before you or anyone else drives Using Your Maintenance Schedule the vehicle.
  • Page 173 Scheduled Maintenance 1,000 Miles (1 600 km) Wheel stud nut service. (46) The services shown in this schedule up to 100,000 miles (166 000 km) should be performed after 100,000 miles 3,000 Miles (5 000 km) (166 000 km) at the same intervals. The services shown Check Oil Life Monitor.
  • Page 174 9,000 Miles (15 000 km) Clutch pedal free travel service. (10) Thermostatically controlled engine cooling Check Oil Life Monitor. If engine oil and filter fan service. (4)(20) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Shields and underhood insulation service. (4)(5)(21) Check fluid levels (or every 3 months, Check air brake relay valve operation and check whichever occurs first).
  • Page 175 18,000 Miles (30 000 km) 21,000 Miles (35 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 176 24,000 Miles (40 000 km) (Continued) 30,000 Miles (50 000 km) Engine drive belts service (or every 12 months, Check Oil Life Monitor. If engine oil and filter whichever occurs first). (18) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Clutch pedal free travel service.
  • Page 177 Hydraulic parking brake service (or every 6 months, Hydraulic brake caliper service (or every 6 months, whichever occurs first). (8) whichever occurs first). (22) Clutch pedal free travel service. (10) Hydraulic parking brake service (or every 6 months, whichever occurs first). (8) Air brake automatic slack adjuster service (or every 500 hours, whichever occurs first).
  • Page 178 42,000 Miles (70 000 km) Spring axle U bolts and shackle bolts service. (16) Check Oil Life Monitor. If engine oil and filter Exhaust system service (or every 6 months, are changed, reset monitor. See “Engine Oil” whichever occurs first). (3)(4)(17) in the Index.
  • Page 179 Engine drive belts service (or every 12 months, 54,000 Miles (90 000 km) whichever occurs first). (18) Check Oil Life Monitor. If engine oil and filter Clutch pedal free travel service. (10) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Thermostatically controlled engine cooling fan service.
  • Page 180 57,000 Miles (95 000 km) Exhaust system service (or every 6 months, whichever occurs first). (3)(4)(17) Check Oil Life Monitor. If engine oil and filter Air brake service (or every 6 months, are changed, reset monitor. See “Engine Oil” whichever occurs first). (39) in the Index.
  • Page 181 63,000 Miles (105 000 km) 69,000 Miles (115 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 182 72,000 Miles (120 000 km) (Continued) Clean air brake application valve (or every 3 months, or every 300 hours, whichever occurs first); Hydraulic parking brake service (or every 6 months, lubricate linkage. whichever occurs first). (8) Air brake chamber service (or every 2 months, Engine drive belts service (or every 12 months, whichever occurs first).
  • Page 183 78,000 Miles (130 000 km) 84,000 Miles (140 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 184 87,000 Miles (145 000 km) Exhaust system service (or every 6 months, whichever occurs first). (3)(4)(17) Check Oil Life Monitor. If engine oil and filter Air brake service (or every 6 months, are changed, reset monitor. See “Engine Oil” whichever occurs first). (39) in the Index.
  • Page 185 96,000 Miles (160 000 km) Thermostatically controlled engine cooling fan service. (4)(20) Check Oil Life Monitor. If engine oil and filter Shields and underhood insulation service. (4)(5)(21) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Air intake system service (or every 24 months, whichever occurs first).
  • Page 186 100,000 Miles (166 000 km) 200,000 Miles (320 000 km) Change power steering fluid (or every 24 months, Remove, disassemble, clean and inspect the air brake whichever occurs first). (13) trailer supply valve (or every 2 years, or 7,200 hours, whichever occurs first).
  • Page 187 Footnotes (7) = Inspect brake lines and hoses for proper hook binding, leaks, cracks, chafing, etc. Inspect disc brake = The U.S. Environmental Protection Agency or the pads for wear and rotors for surface condition. Check California Air Resources Board has determined that the brake pedal for excessive free play or travel (or every failure to perform this maintenance item will not nullify 6 months, whichever occurs first) and have serviced if...
  • Page 188 (10) = Check clutch pedal for free travel. Press pedal (13) = Check steering system: by hand until resistance is felt. Free travel should be Look for damaged, loose or missing parts. maintained at 1.5 to 2 inches (38 to 51 mm) measured Also look for parts showing signs of wear or lack at the clutch pedal pad.
  • Page 189 (16) = Check spring axle U bolts and shackle bolts (23) = Wheel bearing service: for proper torque. See the service manual for torque Grease type Clean, inspect and lubricate with the sequence and specifications. When parts are replaced, proper wheel bearing grease at designated intervals the torque must be checked and adjusted more often or when hubs are removed.
  • Page 190 pressure cap. For Caterpillar R diesel engines, (27) = Replace air cleaner filter (or every 24 months, whichever occurs first). Replace filter more often if always refer to the Caterpillar Diesel Engine driving in dusty conditions. Ask your dealer for the Operation &...
  • Page 191 Inspect air parking brake chamber for leaks and (46) = Tighten the wheel stud nuts to the specified damage. Inspect lines and hoses for leaks, cracks, torque values at 1,000 miles (1 600 km). Thereafter, chafing, etc. Also check all attachments for tighten them 1,000 miles (1 600 km) after each time the tightness, wear or damage.
  • Page 192 Part B: Owner Checks and Services At Each Fuel Fill It is important for you or a service station attendant Listed in this part are owner checks and services which to perform these underhood checks at each fuel fill. should be performed at the intervals specified to help ensure the safety, dependability and emission control Engine Oil Level Check performance of your vehicle.
  • Page 193 At Least Twice a Year Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen. Parking Brake Check Park on a fairly steep hill and hold the vehicle with the Steering Check parking brake only. This checks holding ability. Be alert for any changes in steering action, abnormal Starter Switch Check front tire wear or steering wheel position.
  • Page 194 Engine Cooling System Service Underbody Inspection Inspect the hoses and have them replaced if they are Corrosive materials used for ice, snow removal and dust cracked, swollen or deteriorated. Inspect all pipes, control can collect on the underbody. If these materials fittings and clamps;...
  • Page 195 Part C: Recommended Fluids USAGE FLUID/LUBRICANT and Lubricants Engine Coolant 50/50 mixture of clean, (GM Gasoline NOTE: Fluids and lubricants identified below by name, drinkable water and use only Engine) part number or specification may be obtained from GM Goodwrench COOL your dealer.
  • Page 196 USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Exhaust Brake High Temperature Grease (GM Chassis Chassis Lubricant (GM Part Ball Joint Lubrication No. 12377985 or equivalent) or Part No. 1051344 or equivalent) Cap Lubricant lubricant meeting requirements of or NLGI #3 consistency. NLGI # 2, Category LB or GC Spring DEXRON III Automatic...
  • Page 197 Part D: Maintenance Record After the scheduled services are performed, enter the date, odometer reading and services performed on the maintenance record charts provided here. Any additional information from “Owner Checks and Services” can be added on the following record pages. Also, you should retain all maintenance receipts. Your owner information portfolio is a convenient place to store them.
  • Page 198 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 5-30...
  • Page 199 Section 6 Customer Assistance Information Here you will find out how to contact Chevrolet if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects. Customer Satisfaction Procedure Reporting Safety Defects to the United...
  • Page 200 Customer Satisfaction Procedure Your satisfaction and goodwill are important to your dealer and to Chevrolet. Normally, any concerns with the sales transaction or the operation of your vehicle will be resolved by your dealer’s sales or service departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur.
  • Page 201 Customer number for assistance. If a U.S. customer wishes to write Assistance Representative: to Chevrolet, the letter should be addressed to Chevrolet Vehicle Identification Number (This is available Medium Duty Truck’s Customer Assistance Center.
  • Page 202 Canada Mexico, Central America and Caribbean Islands/Countries (Except Puerto Rico and General Motors of Canada Limited U.S. Virgin Islands) Customer Communication Centre, 163-005 1908 Colonel Sam Drive General Motors de Mexico, S. de R.L. de C.V. Oshawa, Ontario L1H 8P7 Customer Assistance Center Paseo de la Reforma # 2740 1-800-263-3777 (English)
  • Page 203 REPORTING SAFETY REPORTING SAFETY DEFECTS TO DEFECTS TO THE UNITED THE CANADIAN GOVERNMENT STATES GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify If you believe that your vehicle has a defect which could Transport Canada, in addition to notifying General cause a crash or could cause injury or death, you should Motors of Canada Limited.
  • Page 204 1908 Colonel Sam Drive us. Please call us at 1 8782, or write: Oshawa, Ontario L1H 8P7 Chevrolet Medium Duty Truck Customer Assistance Center P.O. Box 33172 Detroit, MI 48232 5172...
  • Page 205 2001 CHEVROLET SERVICE PUBLICATIONS ORDERING INFORMATION The following publications covering the operation and servicing of your vehicle can be purchased by filling out the Service Publication Order Form in this book and mailing it in with your check, money order, or credit card information to Helm, Incorporated (address below.)
  • Page 206 Orders will be mailed within 10 days of receipt. Please allow adequate time for postal ORDER TOLL FREE service. If further information is needed, write to the address shown below or call (NOTE: For Credit Card Holders Only) 1-800-551-4123. Material cannot be returned for credit without packing slip with return 1-800-551-4123 information within 30 days of delivery.

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