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2006 Chevrolet Kodiak Owner Manual
Seats and Restraint Systems ........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-8
Safety Belts
.............................................. 1-9
Child Restraints
....................................... 1-28
Airbag System
......................................... 1-50
Restraint System Check
Features and Controls ..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................. 2-8
Starting and Operating Your Vehicle
Mirrors
.................................................... 2-47
Storage Areas
......................................... 2-49
Instrument Panel ............................................. 3-1
Instrument Panel Overview
Climate Controls
...................................... 3-20
Warning Lights, Gages, and Indicators
Audio System(s)
....................................... 3-48
Driving Your Vehicle ....................................... 4-1
Your Driving, the Road, and Your Vehicle
Towing
................................................... 4-37
............................ 1-62
........... 2-11
.......................... 3-4
........ 3-25
..... 4-2
Service and Appearance Care .......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-6
Checking Things Under the Hood
Rear Axle
............................................... 5-64
Four-Wheel Drive
..................................... 5-65
Front Axle
............................................... 5-66
Noise Control System
Bulb Replacement
Windshield Wiper Blade Replacement
Other Service Items
Tires
...................................................... 5-74
Appearance Care
..................................... 5-83
Vehicle Identification
Electrical System
...................................... 5-92
Capacities and Specifications
Normal Maintenance Replacement Parts
Maintenance Schedule ..................................... 6-1
Maintenance Schedule
Customer Assistance and Information .............. 7-1
Customer Assistance and Information
Reporting Safety Defects
Index ................................................................ 1
M
............... 5-22
............................... 5-67
.................................... 5-68
......... 5-69
.................................. 5-70
................................. 5-91
..................... 5-99
..... 5-104
................................ 6-2
........... 7-2
........................... 7-10

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Summary of Contents for Chevrolet Kodiak 2006

  • Page 1 2006 Chevrolet Kodiak Owner Manual Seats and Restraint Systems ......1-1 Service and Appearance Care ......5-1 Front Seats Service ..........1-2 ............. 5-3 Rear Seats Fuel ..........1-8 ............5-6 Safety Belts ..........1-9 Checking Things Under the Hood ....
  • Page 2: How To Use This Manual

    P.O. Box 07130 Detroit, MI 48207 GENERAL MOTORS, GM, the GM Emblem, How to Use This Manual CHEVROLET, the CHEVROLET Emblem, and the name KODIAK are registered trademarks of General Many people read the owner manual from beginning to Motors Corporation.
  • Page 3 Safety Warnings and Symbols In the caution area, we tell you what the hazard is. Then we tell you what to do to help avoid or reduce the hazard. Please read these cautions. If you do not, There are a number of safety cautions in this book. We you or others could be hurt.
  • Page 4: Vehicle Symbols

    Vehicle Damage Warnings Vehicle Symbols Also, in this manual you will find these notices: The vehicle has components and labels that use symbols instead of text. Symbols are shown along with Notice: These mean there is something that could the text describing the operation or information damage your vehicle.
  • Page 5 These are some examples of symbols that may be found on the vehicle:...
  • Page 6 NOTES...
  • Page 7: Seats And Restraint Systems

    Section 1 Seats and Restraint Systems Front Seats ............1-2 Where to Put the Restraint Bucket Seats ..........1-2 (Crew Cab Models) ........1-40 Split Bench Seat (80/20 Split) ......1-6 Lower Anchors and Tethers for Children Air Suspension Seats ........1-6 (LATCH) ..........1-41 Securing a Child Restraint in a Rear Seats ............1-8 Rear Outside Seat Position Rear Seat Operation ........1-8...
  • Page 8: Front Seats

    Front Seats The fore-and-aft adjustment lever is located underneath the Bucket Seats front of the driver’s seat. If your vehicle has bucket seats, you can adjust the seats several different ways. Fore-and-Aft Adjustment CAUTION: To slide the seat forward or rearward, move the lever toward the outboard side of the seat.
  • Page 9: Lumbar Adjustment

    Lumbar Adjustment Seatback Adjustment Your seats may have this feature. Your vehicle will have one of the following seatback reclining mechanisms. The lumbar adjustment knob is located on the seatback, on the inboard CAUTION: side of the driver’s seat and on the outboard side of the You can lose control of the vehicle if you try to passenger’s seat.
  • Page 10 CAUTION: If the seatback is not locked, it could move forward in a sudden stop or crash. That could cause injury to the person sitting there. Always push and pull on the seatback to be sure it is locked. If your vehicle has this If your vehicle has this lever, it is located on the knob, it is located on the outboard side of the driver’s and passenger’s seat...
  • Page 11 To return the seatback to an upright position, do the following: CAUTION: 1. Lift the lever fully without applying pressure to the seatback and the seatback will return to the upright Sitting in a reclined position when your vehicle position. is in motion can be dangerous.
  • Page 12: Height Adjustment

    Split Bench Seat (80/20 Split) Height Adjustment If your vehicle has a split bench seat, the passenger The suspension seat seat is not adjustable. height adjustment lever is located on the front There is a storage area underneath the seat cushion. inboard side of the seat.
  • Page 13 Chugger-Snubber Lock-Out Feature The seat cushion height adjustment handle is located underneath the If your vehicle has this front of the seat. feature, the handle is located on the outboard side of the driver’s and passenger’s seats. To adjust the height of the cushion, lift the handle up and pull it forward.
  • Page 14: Rear Seats

    Rear Seats Notice: Folding a rear seat with the safety belts still fastened may cause damage to the seat or the safety belts. Always unbuckle the safety belts Rear Seat Operation and return them to their normal stowed position before folding a rear seat. Folding the Rear Seat (Crew Cab) The rear bench seat on the crew cab can be folded down to provide more cargo space.
  • Page 15: Safety Belts

    Safety Belts To raise a seatback, pull the nylon strap while raising the seatback until it locks upright. Safety Belts: They Are for Everyone CAUTION: This part of the manual tells you how to use safety belts properly. It also tells you some things you should not do with safety belts.
  • Page 16 Your vehicle has a light that comes on as a CAUTION: reminder to buckle up. See Safety Belt Reminder Light on page 3-28. It is extremely dangerous to ride in a cargo area, inside or outside of a vehicle. In a collision, people riding in these areas are more likely to be seriously injured or killed.
  • Page 17: Why Safety Belts Work

    Why Safety Belts Work A few crashes are mild, and some crashes can be so serious that even buckled up, a person would not survive. But most crashes are in between. In many of Aren’t safety belts for kids? them, people who buckle up can survive and sometimes walk away.
  • Page 18 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. 1-12...
  • Page 19 Or it could be the instrument panel. With safety 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 20: Questions And Answers About Safety Belts

    Questions and Answers About If I am 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 are in an accident — even one that is not your fault — you Will I be trapped in the vehicle after an accident and your passengers can be hurt.
  • Page 21: Driver Position

    Driver Position The shoulder belt may lock if you pull the belt across you very quickly. If this happens, let the belt go back slightly to unlock it. Then pull the belt Lap-Shoulder Belt across you more slowly. The driver has a lap-shoulder belt. Here is how to wear 4.
  • Page 22 6. To make the lap part tight, pull up on the shoulder belt. The lap part of the belt should be worn low and snug on the hips, just touching the thighs. In a crash, this applies force to the strong pelvic bones. And you would be less likely to slide under the lap belt.
  • Page 23 What is wrong with this? CAUTION: You can be seriously hurt if your shoulder belt is too loose. In a crash, you would move forward too much, which could increase injury. The shoulder belt should fit against your body. The shoulder belt is too loose. It will not give nearly as much protection this way.
  • Page 24 What is wrong with this? CAUTION: You can be seriously injured if your belt is buckled in the wrong place like this. In a crash, the belt would go up over your abdomen. The belt forces would be there, not at the pelvic bones.
  • Page 25 What is wrong with this? CAUTION: You can be seriously injured if your belt goes over an armrest like this. The belt would be much too high. In a crash, you can slide under the belt. The belt force would then be applied at the abdomen, not at the pelvic bones, and that could cause serious or fatal injuries.
  • Page 26 What is wrong with this? CAUTION: You can be seriously injured if you wear the shoulder belt under your arm. In a crash, your body would move too far forward, which would increase the chance of head and neck injury. Also, the belt would apply too much force to the ribs, which are not as strong as shoulder bones.
  • Page 27 What is wrong with this? CAUTION: You can be seriously injured by a twisted belt. In a crash, you would not have the full width of the belt to spread impact forces. If a belt is twisted, make it straight so it can work properly, or ask your dealer to fix it.
  • Page 28: Shoulder Belt Height Adjustment

    Shoulder Belt Height Adjustment Before you begin to drive, move the shoulder belt height adjuster to the height that is right for you. Adjust the height so that the shoulder portion of the belt is centered on your shoulder. The belt should be away from your face and neck, but not falling off your shoulder.
  • Page 29: Safety Belt Use During Pregnancy

    Safety Belt Use During Pregnancy The best way to protect the fetus is to protect the mother. When a safety belt is worn properly, it is more likely that the fetus will not be hurt in a crash. For Safety belts work for everyone, including pregnant pregnant women, as for anyone, the key to making women.
  • Page 30: Center Passenger Position

    Center Passenger Position Lap Belt If your vehicle has a front bench seat, someone can sit in the center position. If your vehicle is a crew cab, someone can also sit in the center rear position. To make the belt shorter, pull its free end as shown until the belt is snug.
  • Page 31: Crew Cab

    Rear Outside Passenger Positions Lap-Shoulder Belt (Crew Cab) The positions next to the windows have lap-shoulder belts. Here is how to wear one properly. 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.
  • Page 32 2. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. When the shoulder belt is pulled out all the way, it will lock. If it does, let it go back all the way and start again.
  • Page 33 The safety belt locks if there is a sudden stop or a crash, or if you pull the belt very quickly out of the retractor. Each position next to the windows has a shoulder belt height adjuster. See Shoulder Belt Height Adjustment on page 1-22.
  • Page 34: Safety Belt Extender

    Safety Belt Extender Child Restraints If the vehicle’s safety belt will fasten around you, you Older Children should use it. But if a safety belt is not long enough, your dealer will order you an extender. It is 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 35 What is the proper way to wear safety belts? If possible, an older child should wear a 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 36 What if a child is wearing a lap-shoulder belt, but the child is so small that the shoulder belt CAUTION: is very close to the child’s face or neck? Move the child toward the center of the vehicle, but Never do this. be sure that the shoulder belt still is on the child’s Here a child is sitting in a seat that has a shoulder, so that in a crash the child’s upper...
  • Page 37: Infants And Young Children

    Infants and Young Children Everyone in a vehicle needs protection! This includes infants and all other children. Neither the distance traveled nor the age and size of the traveler changes the need, for everyone, to use safety restraints. In fact, the law in every state in the United States and in every Canadian province says children up to some age must be restrained while in a vehicle.
  • Page 38 What are the different types of add-on child restraints? Add-on child restraints, which are purchased by the vehicle’s owner, are available in four basic types. Selection of a particular restraint should take into consideration not only the child’s weight, height, and age but also whether or not the restraint will be compatible with the motor vehicle in which it will be used.
  • Page 39 CAUTION: CAUTION: Newborn infants need complete support, The body structure of a young child is quite including support for the head and neck. unlike that of an adult or older child, for whom This is necessary because a newborn infant’s the safety belts are designed.
  • Page 40: 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 41 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 42 Securing an Add-on Child Restraint in How Should I Use a Child Restraint? the Vehicle A child restraint system is any device designed for use in a motor vehicle to restrain, seat, or position children. A built-in child restraint system is a CAUTION: permanent part of the motor vehicle.
  • Page 43: Securing The Child Within The Child Restraint

    When securing an add-on child restraint, refer to the A T-shaped shield has shoulder straps that are attached instructions that come with the restraint which may be on to a flat pad which rests low against the child’s body. the restraint itself or in a booklet, or both, and to this A shelf- or armrest-type shield has straps that are manual.
  • Page 44: Where To Put The Restraint

    Where to Put the Restraint If your vehicle is a regular cab model with a static seat in the right front passenger’s position, or if it has a (Regular Cab Models) bench seat, the child restraint must be secured properly in the right front passenger’s seat.
  • Page 45 Unless the passenger’s airbag has been turned off, never put a rear-facing child restraint in this vehicle. CAUTION: (Continued) Here is why: Even though the airbag off switch is designed CAUTION: to turn off the passenger’s frontal airbag, no system is fail-safe, and no one can guarantee that an airbag will not deploy under some A child in a rear-facing child restraint can be unusual circumstance, even though it is turned...
  • Page 46: Crew Cab Models

    Where to Put the Restraint Unless the passenger’s airbag has been turned off, never put a rear-facing child restraint in this vehicle. (Crew Cab Models) Here is why: Accident statistics show that children are safer if they are restrained in the rear rather than the front seat. We CAUTION: recommend that child restraints be secured in a rear seat position, including an infant riding in a rear-facing...
  • Page 47: Lower Anchors And Tethers For Children (Latch)

    Lower Anchors and Tethers for CAUTION: (Continued) Children (LATCH) Some child restraints have a LATCH system. As part of If you need to secure a forward-facing child the LATCH system, your child restraint may have restraint in the right front static seat or right lower attachments and/or a top tether.
  • Page 48: Securing A Child Restraint In A Rear Outside Seat Position

    Securing a Child Restraint in a Rear Outside Seat Position (Crew Cab Models) There are no top tether anchors in the rear outside seat positions. Do not secure a child seat in these positions if a national or local law requires that the top tether be anchored, or if the instructions that come with the child restraint say that the top tether must be anchored.
  • Page 49 4. Pull the rest of the shoulder belt all the way out of 5. To tighten the belt, push down on the child restraint, the retractor to set the lock. pull the shoulder portion of the belt to tighten the lap portion of the belt and feed the shoulder belt back into the retractor.
  • Page 50 Securing a Child Restraint in the CAUTION: Center Rear Seat Position (Crew Cab) or Center Front Position A child in a child restraint in the center front There are no top tether anchors in these positions. seat can be badly injured or killed by the right Do not secure a child seat in these positions if a national front passenger airbag if it inflates.
  • Page 51 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 52: Securing A Child Restraint In The Right Front Seat Position

    Securing a Child Restraint in the If your vehicle has a right front passenger’s airbag, there is a switch on the instrument panel that you can Right Front Seat Position use to turn off the right front passenger’s airbag when you need to secure a child restraint in the right Do not use a child restraint with an air suspension seat.
  • Page 53 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 airbag is off. Here is why: If you need to secure a forward-facing child restraint in the right front static seat or the CAUTION: right front bench seat, always move the...
  • Page 54 You will be using the lap-shoulder belt. Be sure to follow the instructions that came with the child restraint. Secure the child in the child restraint when and as the instructions say. 1. If your vehicle has a right front passenger’s airbag see Airbag Off Switch on page 1-58.
  • Page 55 5. Pull the rest of the shoulder belt all the way out of 6. To tighten the belt, push down on the child restraint, the retractor to set the lock. pull the shoulder portion of the belt to tighten the lap portion of the belt and feed the shoulder belt back into the retractor.
  • Page 56: Airbag System

    Airbag System If you were using a child restraint in a vehicle equipped with a right front passenger’s airbag, turn on the right front passenger’s airbag when you remove the child restraint from the vehicle unless the person who will be sitting there is a member of a passenger airbag risk group.
  • Page 57 If it says AIR BAG on the middle part of the steering wheel, but it does not say AIR BAG on the instrument panel in front of the right front passenger’s seat, your vehicle has an airbag 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 airbag for the driver only.
  • Page 58 Frontal airbags are designed to help reduce the risk of injury from the force of an inflating airbag. But these CAUTION: (Continued) airbags must inflate very quickly to do their job and comply with federal regulations. And, for some unrestrained occupants, airbags Here are the most important things to know about the may provide less protection in frontal crashes airbag system:...
  • Page 59 If your vehicle has an airbag for the right front There is an airbag passenger, please read this: readiness light on the instrument panel, which shows the airbag symbol. CAUTION: Anyone who is up against, or very close to, any airbag when it inflates can be seriously The system checks the airbag electrical system for injured or killed.
  • Page 60: Where Are The Airbags

    Where Are the Airbags? The right front passenger’s airbag is in the instrument panel on the passenger’s side. The driver’s airbag is in the middle of the steering wheel. 1-54...
  • Page 61: When Should An Airbag Inflate

    Whether your frontal airbags will or should deploy is not based on how fast your vehicle is traveling. It depends CAUTION: largely on what you hit, the direction of the impact and how quickly your vehicle slows down. (The threshold level can vary, however, with specific vehicle If something is between an occupant and an design, so that it can be somewhat above or below airbag, the bag might not inflate properly or it...
  • Page 62: How Does An Airbag Restrain

    How Does an Airbag Restrain? The frontal airbags are not intended to inflate during vehicle rollovers, rear impacts, or in many side impacts. In moderate to severe frontal or near-frontal collisions, In any particular crash, no one can say whether an even belted occupants can contact the steering wheel or airbag should have inflated simply because of the the instrument panel.
  • Page 63 The parts of the airbag that come into contact with you In many crashes severe enough to inflate an airbag, may be warm, but not too hot to touch. There will be windshields are broken by vehicle deformation. some smoke and dust coming from the vents in the Additional windshield breakage may also occur from the deflated airbags.
  • Page 64: Airbag Off Switch

    Airbag Off Switch Infant. An infant (less than 1 year old) must ride in the front seat because: If your vehicle has a right front passenger airbag, it has • my vehicle has no rear seat; a switch on the instrument panel that you can use to turn off the right front passenger’s airbag.
  • Page 65 Medical Condition. A passenger has a medical condition which, according to his or her physician: • causes the passenger airbag to pose a special risk for the passenger; and • makes the potential harm from the passenger airbag in a crash greater than the potential harm from turning off the airbag and allowing the passenger, even if belted, to hit the dashboard or windshield in a crash.
  • Page 66 The airbag off light will come on to let you know that the right front passenger’s airbag is off. The light will stay on to remind you that the airbag is off. The right front passenger’s airbag will remain off until you turn it back on.
  • Page 67: Servicing Your Airbag-Equipped Vehicle

    Servicing Your Airbag-Equipped Adding Equipment to Your Vehicle Airbag-Equipped Vehicle Airbags affect how your vehicle should be serviced. There are parts of the airbag system in several places Is there anything I might add to the front of the around your vehicle. You do not want the system to vehicle that could keep the airbags from inflate while someone is working on your vehicle.
  • Page 68: Restraint System Check

    Restraint System Check Because I have a disability, I have to get my vehicle modified. How can I find out whether this will affect my airbag system? Checking the Restraint Systems Changing or moving any parts of the front seats, Now and then, make sure the safety belt reminder light safety belts, the airbag sensing and diagnostic and all your belts, buckles, latch plates, retractors...
  • Page 69: Replacing Restraint System Parts After A Crash

    Replacing Restraint System Parts If belts are cut or damaged, replace them. Collision damage also may mean you will need to have safety belt After a Crash or seat parts repaired or replaced. New parts and repairs may be necessary even if the belt was not being used at the time of the collision.
  • Page 70 NOTES 1-64...
  • Page 71: Table Of Contents

    Section 2 Features and Controls Keys ...............2-2 Two-Speed Rear Axle Electric Shift Control ..2-28 Remote Keyless Entry System ......2-3 Air Shift Control (Automatic Transmission) ..2-29 Remote Keyless Entry System Operation ...2-4 Automatic Transmission Operation ....2-30 Manual Transmission Operation ......2-31 Doors and Locks ..........2-6 Power Take-Off (PTO) ........2-35 Door Locks ............2-6 Four-Wheel Drive ..........2-35...
  • Page 72: 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 73 Remote Keyless Entry System Your vehicle has one double-sided key for the ignition and all door locks. If the vehicle has the keyless entry system, it 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.
  • Page 74: Remote Keyless Entry System Operation

    Remote Keyless Entry System At times you may notice a decrease in range. This is 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 75: Battery Replacement

    Matching Transmitter(s) to Your Vehicle Notice: When replacing the battery, use care not to touch any of the circuitry. Static from your body Each remote keyless entry transmitter is coded to transferred to these surfaces may damage the prevent another transmitter from unlocking your vehicle. transmitter.
  • Page 76: 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 77: Power Door Locks

    Power Door Locks There are several ways to lock and unlock your vehicle. 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 on door locks, press the page 2-4.
  • Page 78: 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 79: Power Windows

    Manual Windows Turn the hand crank on each door to raise or lower the window. Power Windows If your vehicle has power windows, the switches for all windows are located on the driver’s door. Crew Cab Switches In addition, each passenger door has a switch for their own Press the rearward part of the switch to lower the...
  • Page 80: Sliding Rear Window

    Express-Down Sliding Rear Window The driver’s window has an express-down feature. To open the sliding rear window, pull the latch toward This allows the window to be lowered fully without the driver’s side of the vehicle. continuously holding the switch. Press the switch down To close the window, slide the window toward the fully to initiate the express-down feature.
  • Page 81: New Vehicle Break-In

    Starting and Operating • Avoid making hard stops for the first 200 miles (322 km) or so. During this time your new Your Vehicle brake linings are not yet broken in. Hard stops with new linings can mean premature wear and earlier replacement.
  • Page 82: Ignition Positions

    Ignition Positions B (LOCK): This position locks your ignition, steering wheel and transmission. It is a theft-deterrent feature. You will only be able to remove your key when the With your key in the ignition switch, you can turn it to ignition is turned to LOCK.
  • Page 83: Starter Motor Operation

    Starting the Gasoline Engine Starter Motor Operation • The starter motor will disengage if you release the The 8th digit of your Vehicle Identification Number (VIN) key or the engine reaches a predetermined engine shows the code letter for your engine. Use this number to speed.
  • Page 84: Starting Your Engine

    Starting Your Engine Gasoline Engine Warm-Up 1. Without pushing the accelerator pedal, turn your When you have started your engine, let it run for ignition key to START. When the engine starts, let 20 or 30 seconds to warm up before you put a load on go of the key.
  • Page 85: Starting The Diesel Engine

    Automatic Transmission While your engine is idling and before you turn it off, you can make a list of any operational or handling Move your shift lever to PARK (P) or NEUTRAL (N). concerns to give to responsible maintenance personnel Your engine will not start in any other position —...
  • Page 86 Starting Your Engine Notice: If the wait to start light stays on after starting your vehicle, your vehicle may not run 1. Turn your ignition key to RUN. properly. Have your vehicle serviced right away. Observe the wait to start light. See Wait to Start 3.
  • Page 87 Cold Weather Starting The following tips will help you get good starting in cold weather. ® If your vehicle has the DURAMAX Diesel Engine, the • Use the recommended engine oil when the outside following notice applies: temperature drops below freezing. See Engine Oil ®...
  • Page 88 Cold Weather Starting Stopping the Diesel Engine ® (Caterpillar Diesel) 1. Set the parking brake and shift to NEUTRAL (N) or PARK (P). Because the diesel engine uses compression ignition, it 2. Turn the ignition key to OFF. is harder to start in cold weather than a gasoline engine. The air intake heater and use of the proper engine oil, If your vehicle has a two-speed axle, see optional engine coolant heaters and optional ether...
  • Page 89 If Your Diesel Engine Will Not Start Be sure you have the right oil for your engine, and that you have changed the oil at the proper times. If you If you have run out of fuel, see Running Out of Fuel on use the wrong oil, your engine may be harder to start.
  • Page 90: Engine Alarm And Automatic Shutdown

    Engine Alarm and Automatic Do this only if you have to, since there is a problem that can harm the engine if it is not fixed. Engine automatic Shutdown shutdown, for gasoline engines, requires activation by your dealer. Your check gages warning light will come on if the Notice: If you try to operate the vehicle after the system senses high engine temperature or low engine engine automatically shuts down, you may damage...
  • Page 91: High Idle System

    High Idle System The manual high idle feature is activated by pressing the switch on the instrument panel. When the switch is pressed again, or any of the previous conditions are High Idle System with Switch not met, manual high idle will be deactivated. The manual high idle has been preset at the factory.
  • Page 92: Exhaust Restrictor (Engine Warm-Up)

    Automatic High Idle System Exhaust Restrictor (Engine Warm-Up) The automatic high idle feature will engage whenever you start your vehicle and the engine is below the preset Exhaust Restrictor operating temperature. This will help decrease engine warm-up time. ® ® If your vehicle has a DURAMAX 7800 or Caterpillar ®...
  • Page 93 For all engines this feature is already turned on. The The engine idle speed will return to normal once the ® automatic quick warm-up on the DURAMAX engine following conditions are met: can be turned off and on by doing the following •...
  • Page 94: Engine Checks Before Operating

    Engine Checks Before Operating During this warm-up period, check your warning lights and gages: When you have started your engine, let it run for • If oil pressure does not begin to rise within 20 to 30 seconds before you put a load on the engine. 15 seconds of starting, stop the engine and find the But do not leave the vehicle while the engine is running.
  • Page 95 • Notice: Do not allow the engine to operate at low The charging system light should come on when idle for more than five minutes. This can cause the ignition key is turned to RUN or START and low engine operating temperatures which can affect should go out when the engine is running above engine operation and reduce engine life.
  • Page 96: Engine Coolant Heater

    Engine Coolant Heater CAUTION: Your vehicle may be equipped with this feature. In very cold weather, 0°F (–18°C) or colder, the engine Plugging the cord into an ungrounded outlet coolant heater can help. You will get easier starting could cause an electrical shock. Also, the and better fuel economy during engine warm-up.
  • Page 97: Diesel Engine Exhaust Brake

    Diesel Engine Exhaust Brake When using the exhaust brake, the proper gear range selection is important. The exhaust brake will be ® ® most effective if the gear range selected is the lowest If your vehicle has a DURAMAX 7800 or Caterpillar possible range that does not allow the engine rpm to go diesel engine, it may have an exhaust brake, which more than 200 rpm above rated (full load) rpm.
  • Page 98: Two-Speed Rear Axle Electric Shift Control

    Two-Speed Rear Axle Electric Shift The two-speed axle should be in the up position or low range when you park the vehicle. You will need to Control engage the transmission and move the vehicle a little to assure the axle is in the low range. Then apply the If your vehicle has this feature, you will find a label on parking brake, shift into NEUTRAL and shut off the headliner above the windshield or in another...
  • Page 99: Air Shift Control (Automatic Transmission)

    Air Shift Control To shift up from low to high range while driving, press the bottom of the rear axle shift control switch as you are (Automatic Transmission) releasing the accelerator pedal. After the shift has occurred, apply the accelerator as desired. The rear axle shift control To shift from high to low range while driving, press the switch for an automatic...
  • Page 100: Automatic Transmission Operation

    Automatic Transmission Operation CAUTION: ® We build vehicles with Allison five and six-speed automatic transmissions. This part of the manual covers the basics of these. With these transmissions, you It can be dangerous to get out of your vehicle ® will find another Allison manual in your vehicle that without the parking brake firmly set.
  • Page 101: Manual Transmission Operation

    Overdrive Defeat Manual Transmission Operation If your vehicle has this feature, you can select not to Using the Clutch shift up to fifth gear. This is useful when towing or under a heavy load. When you are starting to move the vehicle, it is important to begin with the engine speed at idle.
  • Page 102 ® ® Eaton Fuller Five and Six-Speed ZF Six-Speed Transmission Transmissions and TTC Spicer Here is how to operate your transmission. Seven-Speed Transmissions This six-speed pattern is These transmissions have gears that automatically unique to GM manual synchronize when you shift up or down (except transmissions.
  • Page 103 FIRST (1): With the vehicle at a stop, release the THIRD (3): Press the clutch pedal and upshift into brake, press the clutch pedal and shift into FIRST (1). THIRD (3). Then, slowly let up on the clutch pedal as Then, slowly let up on the clutch pedal as you press the you press the accelerator pedal.
  • Page 104 ® ® Eaton Fuller Nine and Ten-Speed Clutch Brake (Vehicles with Non-Synchronized Manual Non-Synchronized Transmission) Transmissions A clutch brake is used to stop transmission input shaft rotation so that FIRST (1) or REVERSE (R) gear If your vehicle has one of these transmissions the selection can be initiated when the vehicle is at a engine rpm and road speed must match when upshifting standstill and the engine is idling.
  • Page 105: Power Take-Off (Pto)

    Power Take-Off (PTO) Four-Wheel Drive If your vehicle has four-wheel drive, you can send your If your vehicle is equipped engine’s driving power to all four wheels for extra for the addition of a PTO, traction. To get the most satisfaction out of four-wheel this factory installed drive, you must be familiar with its operation.
  • Page 106 Locking Hubs If your vehicle is equipped with four-wheel drive, the transfer case knob is located to the right of the steering wheel on the instrument panel. Use this knob to shift into and out of four-wheel drive. An indicator light will show you which position the Hublock Dial Location Hublock Dial transfer case is in.
  • Page 107 Recommended Transfer Case Settings (Four-Wheel Low): This setting sends maximum power to all four wheels. You might choose Four-Wheel Transfer Case Settings Driving Conditions Low if you are driving off-road in deep sand, deep mud, and climbing or descending steep hills. Be sure the front wheel hubs are locked when you want to drive Normal in Four-Wheel Low.
  • Page 108 Shifting Into Four-Wheel High If you turn the knob to Four-Wheel Low when your vehicle is in gear and/or moving, the Four-Wheel Low Turn the knob to four-wheel high. This can be done at indicator light will flash for 30 seconds and not complete 3 mph or less and when you are shifting out of the shift unless your vehicle is moving less than Four-Wheel Low.
  • Page 109: Shifting Out Of Neutral

    Shifting Out of NEUTRAL If the knob is turned to Four-Wheel High or Two-Wheel High when your vehicle is in gear and/or moving, the To shift the transfer case out of NEUTRAL, do the Four-Wheel High or Two-Wheel high indicator light following: will flash for 30 seconds.
  • Page 110: Parking

    Parking Hydraulic Brakes (Parking Brake Operation) CAUTION: If your vehicle has hydraulic brakes, it has either a parking brake foot pedal or hand lever. If you have the parking brake foot pedal, it is located below the If you do not park your vehicle properly, it can instrument panel to the left of the steering column.
  • Page 111: Propshaft Brake Burnish Procedure

    Propshaft Brake Burnish Procedure To set the foot pedal parking brake, hold the regular brake pedal down with your right foot. Push down the parking brake pedal with your left foot. It is recommended that the propshaft-mounted parking brake be burnished as part of the new vehicle break-in. To set the hand lever parking brake, hold the regular The parking brake will work best after it has been brake pedal down with your right foot.
  • Page 112: Air Brake

    Rear Wheel Park Brake Burnish Air Brake Procedure If your vehicle has air It is recommended that the rear wheel mounted parking brakes, you will have this brake be burnished as part of the new vehicle parking brake. It is break-in.
  • Page 113 Vehicles built for use as tractors or towing vehicles have To charge a trailer’s air brake system do the following: two air brake controls. They look like this: 1. Move your vehicle into the proper position. 2. Apply the parking brake by pulling the yellow parking brake knob out.
  • Page 114: Air Suspension

    Air Suspension For driving with a trailer, the yellow and red, if equipped, knobs must be pushed in. When you are not pulling a trailer, the red trailer air supply knob must be pulled out. Your vehicle may have the Hendrickson HAS Series single-axle air suspension which is designed for a single-axle on-highway use.
  • Page 115: 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 cannot see or smell. It can cause unconsciousness and death. You might have exhaust coming in if: • Your exhaust system sounds strange or different.
  • Page 116: Running The Engine While Parked

    Running the Engine While Parked CAUTION: It is better not to park with the engine running. But if you ever have to, here are some things to know. It can be dangerous to get out of your vehicle if the automatic transmission shift lever is not CAUTION: fully in PARK (P) with the parking brake firmly set.
  • Page 117: Mirrors

    Mirrors Outside Power Mirrors If you have outside power mirrors, they can be adjusted Manual Rearview Mirror from the inside of the vehicle. If your vehicle has this feature, pull the tab under the The control for this mirror toward you to reduce glare from headlamps feature is located on the behind you after dark.
  • Page 118: Outside Convex Mirrors

    Outside Convex Mirrors Outside Heated Mirrors If your vehicle has this feature, your outside rearview mirrors can be defrosted. CAUTION: The switch for this feature is located in the instrument A convex mirror can make things (like other panel switchbank. vehicles) look farther away than they really are.
  • Page 119: Storage Areas

    Storage Areas Center Console Storage Area Your vehicle may have a center console compartment if Your vehicle includes a number of storage you have the bucket or suspension seats. compartments. The back of your center bench seat may also fold Some vehicles have storage areas in the instrument forward to reveal a console compartment.
  • Page 120 NOTES 2-50...
  • Page 121: Instrument Panel Overview

    Section 3 Instrument Panel Instrument Panel Overview .......3-4 Climate Controls ..........3-20 Hazard Warning Flashers ........3-6 Climate Control System .........3-20 Other Warning Devices ........3-6 Outlet Adjustment .........3-24 Horn .............3-6 Rear Heating System ........3-24 Tilt Wheel .............3-7 Warning Lights, Gages, and Indicators ....3-25 Turn Signal/Multifunction Lever ......3-7 Instrument Panel Cluster ........3-26 Turn and Lane-Change Signals ......3-8...
  • Page 122: Audio System(S)

    Section 3 Instrument Panel Low Coolant Warning Light ......3-37 Fuel Gage ...........3-45 Wait to Start Indicator (Diesel Engine) .....3-37 Water in Fuel Warning Light ......3-46 Malfunction Indicator Lamp ......3-38 Air Filter Restriction Indicator ......3-46 Oil Pressure Gage ........3-38 Air Pressure Gage ........3-47 Low Oil Level Light ........3-39 Hourmeter Gage ...........3-47 Change Engine Oil Light ........3-40...
  • Page 123 NOTES...
  • Page 124: Instrument Panel Overview

    Instrument Panel Overview Automatic Transmission Shown...
  • Page 125 A. Air Outlets. See Outlet Adjustment on page 3-24. H. Turn Signal/Multifunction Lever. See Turn Signal/Multifunction Lever on page 3-7. B. Instrument Panel Cluster. See Instrument Panel Cluster on page 3-26. I. Hazard Warning Flashers Button. See Hazard Warning Flashers on page 3-6. C.
  • Page 126: Hazard Warning Flashers

    Hazard Warning Flashers Other Warning Devices The hazard warning flashers warn others. They also let If you carry reflective triangles, you can set them up at police know you have a problem. Your front and rear the side of the road about 300 feet (100 m) behind turn signal lamps will flash on and off.
  • Page 127: 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 128: Turn And Lane-Change Signals

    Turn and Lane-Change Signals As you signal a turn or a lane change, if the arrows don’t flash but just stay on, check the turn signal flasher and circuit breaker. See Fuses and Circuit Breakers The turn signal has two upward (for right) and on page 5-93.
  • Page 129: Windshield Wipers

    Windshield Wipers For steady wiping at low speed, turn the band toward you to the first solid band below the delay settings. You control the windshield For high-speed wiping, turn the band farther, to the last wipers by turning the solid band below the delay settings.
  • Page 130: Windshield Washer

    Windshield Washer Cruise Control (Washer Fluid): There is a paddle marked with the If your vehicle has this feature, it is located windshield washer symbol at the top of the multifunction at the end of the lever. To spray washer fluid on the windshield, press multifunction lever.
  • Page 131: Setting Cruise Control

    Setting 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 at speeds below about 30 mph (48 km/h). CAUTION: If you have an automatic transmission and you apply your brakes, the cruise control will shut off.
  • Page 132: Resuming A Set Speed

    Resuming a Set Speed Increasing Speed While Using Cruise Control Suppose you set your cruise control at a desired speed and then you apply the brake. This, of course, shuts There are two ways to go to a higher speed: off the cruise control.
  • Page 133 Passing Another Vehicle While Using Ending Cruise Control Cruise Control There are four different ways to turn off the cruise control: Use the accelerator pedal to increase your speed. • When you take your foot off the pedal, your vehicle will Step lightly on the brake pedal (manual and slow down to the cruise control speed you set earlier.
  • Page 134: 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 135: Headlamps On Reminder

    Headlamps on Reminder When the DRL are on, only your headlamps will be on. The taillamps, sidemarker and other lamps won’t be on. Your instrument panel won’t be lit up either. If you have this system, a tone will sound when your headlamps and/or parking lamps are turned on and your When it begins to get dark, ignition is in LOCK or ACCESSORY.
  • Page 136: Marker Lamps

    Marker Lamps Instrument Panel Brightness If your vehicle has this feature, you can manually blink This feature controls the brightness of the instrument the marker and clearance lamps. panel lights. The thumbwheel for this feature is located to the right of The marker lamp defeat the exterior lamp control.
  • Page 137: Entry Lighting

    You can use the dome override button to set the dome If the dome override button is pushed in, the dome lamps to automatically come on when a door is lamps will not come on. Use this feature when you want open, or to remain off.
  • Page 138: Instrument Panel Switchbank

    Instrument Panel Switchbank This switchbank is located in the center of the instrument panel. (Marker Lamp Defeat Switch): See Marker Lamps on page 3-16. (Manual High Idle Switch): See High Idle System on page 2-21. (Traction Control Switch): See Traction Control System (TCS) on page 4-12.
  • Page 139: Accessory Power Outlet(S)

    Notice: Leaving electrical equipment on for (Exhaust Brake Switch): See Diesel Engine extended periods will drain the battery. Always turn Exhaust Brake on page 2-27. off electrical equipment when not in use and do not plug in equipment that exceeds the maximum (Differential Lock Control Switch): See Rear amperage rating.
  • Page 140: Ashtray And Cigarette Lighter

    Ashtray(s) and Cigarette Lighter Climate Controls Your vehicle may have an ashtray and a cigarette lighter Climate Control System located in the center floor console. To open the removable ashtray, flip open the top. With these systems, you can control the heating, Notice: If you put papers, pins, or other flammable cooling and ventilation for your vehicle.
  • Page 141 To change the current mode, select one of the following: The mode knob can also be used to select the defrost mode. For more information, see “Defogging and (Off): This setting turns the system off. Defrosting” later in this section. (Vent): This mode directs air to the instrument (Fan): Turn the left knob clockwise or panel vents.
  • Page 142: 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 143: Rear Window Defogger

    Press this button which is (Defog): With this setting, the outside air comes out located near the fan of both the floor and defroster outlets. Adjust the control to turn the rear temperature knob for warmer or cooler air. The air window defogger on or off.
  • Page 144: Outlet Adjustment

    Outlet Adjustment Rear Heating System Your vehicle has air outlets on the instrument panel that If you have a crew cab allow you to adjust the direction and amount of airflow and your vehicle has a inside the vehicle. rear heater, the Move the lever on the outlet up or down to direct the thumbwheel for this airflow.
  • Page 145: Warning Lights, Gages, And Indicators

    Warning Lights, Gages, and Warning lights come on when there may be or is a problem with one of your vehicle’s functions. As you Indicators will see in the details on the next few pages, some warning lights come on briefly when you start the engine This part describes the warning lights and gages that just to let you know they’re working.
  • Page 146: 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 7.8L Diesel Engine shown, Canada, 6.6L Diesel and Gasoline Engine similar 3-26...
  • Page 147: Speedometer And Odometer

    Speedometer and Odometer Tachometer Your speedometer lets you see your speed in both miles per hour (mph) and kilometers per hour (km/h). Your odometer shows how far your vehicle has been driven, in either miles (used in the United States) or kilometers (used in Canada).
  • Page 148: Engine Speed Limiter

    Engine Speed Limiter Safety Belt Reminder Light All engines have electronic engine speed limiting. When the key is turned to RUN or START, a light will The engine limited speeds range between come on for several seconds to remind people to fasten 2,900 and 4,400 rpm depending on engine their safety belts.
  • Page 149: Airbag Readiness Light

    Airbag Readiness Light The airbag readiness light should flash for a few seconds when you turn the ignition key to RUN or START. If the light doesn’t come on then, have it If your vehicle has airbags, there is an airbag readiness fixed so it will be ready to warn you if there is a problem.
  • Page 150: Airbag Off Light

    Airbag Off Light CAUTION: If your vehicle is equipped with an airbag off switch, when you turn the right front passenger’s airbag off, this light will come on and stay on to remind you that the If the right front passenger’s airbag is turned airbag has been turned off.
  • Page 151: Charging System Light

    Charging System Light CAUTION: The charging system light may be located in the If the airbag readiness light ever comes on instrument panel cluster, or when you have turned off the airbag, it means with the auxiliary warning that something may be wrong with the airbag lights in the center of the instrument panel.
  • Page 152: Voltmeter Gage

    Voltmeter Gage Service Transmission Warning Light ® If your vehicle has an Allison automatic transmission, When your engine is certain transmission malfunctions will turn this light on. running, the voltmeter gage shows the charging This light is located with system voltage. the auxiliary warning lights in the center of the instrument panel.
  • Page 153: Range Inhibit Warning Indicator

    Range Inhibit Warning Indicator Hydraulic Brake System Warning Lights If your vehicle has an Allison 1000/2200/2300/2500 series automatic transmission, a lighted bar under the Vehicles with hydraulic brake systems have two brake current gear selected will flash. system warning lights on the instrument panel. If your vehicle has an Allison 3000/3500 series If the BRAKE system automatic transmission, the current gear selected on the...
  • Page 154 Parking Brake Warning Light If the service brakes soon warning light comes on, it This light will also come on when you set the parking means there may be brake. The light will stay on if your parking brake something wrong in the does not release fully.
  • Page 155: Anti-Lock Brake System Warning Light

    Anti-Lock Brake System When the warning light comes on while you are driving, you should drive only as far as the nearest point of Warning Light safety and then stop the vehicle. Here’s a very important thing for you to know: This light will come on briefly when you start your CAUTION:...
  • Page 156: Trailer Anti-Lock Brake System Warning Light

    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 157: Low Coolant Warning Light

    Low Coolant Warning Light Wait to Start Indicator (Diesel Engine) You have a low coolant warning light. If this light ® If your vehicle has the DURAMAX 6.6L diesel engine, comes on, your system is you will have glow plugs and an air intake heater. If low on coolant and the ®...
  • Page 158: 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 159: Maintenance Schedule

    Low Oil Level Light A reading in the low pressure zone may be caused by a dangerously low oil level or other problem. ® If you have a Caterpillar diesel engine, also see your This light should come on ® Caterpillar Operation &...
  • Page 160: Change Engine Oil Light

    Change Engine Oil Light Engine Overspeed Warning Light The change engine oil light If your vehicle has this should come on briefly as light, it will come on if your a bulb check when you engine is operating at start the engine. If the light too many revolutions does not come on, have per minute (rpm).
  • Page 161: Transmission Temperature Gage

    Transmission Temperature Gage Exhaust Brake Indicator Light If you have an automatic If your vehicle is equipped transmission and this with an exhaust brake, you gage, it is located above will have this light, the switchbank in the located above the climate center of the instrument controls in the center panel.
  • Page 162: Differential Lock Indicator Light

    Differential Lock Indicator Light Reduced Engine Power Light If your vehicle has this If the check engine and feature, this light is located reduced engine power in the center of the lights are on, the electronic instrument panel. The light throttle control may be is on when the rear disabled, and a noticeable...
  • Page 163: Highbeam On Light

    Highbeam On Light Daytime Running Lamps (DRL) Indicator Light This light will come on when the high-beam This light is located on the headlamps are in use. instrument panel cluster. It goes on whenever the Daytime Running Lamps are on. See Headlamp High/Low-Beam Changer on page 3-8.
  • Page 164: Low Washer Fluid Warning Light

    Low Washer Fluid Warning Light Check Gages Warning Light This light will come on This light will come on as when your vehicle is low you’re starting the engine, on windshield washer fluid. just as a check. For more information, see Windshield Washer Fluid on If this light comes on and stays on while you are driving.
  • Page 165: Fuel Gage

    Fuel Gage Here are four concerns of some operators. None of these shows a problem with your fuel gage: • The gage moves a little when you turn a corner or Your fuel gage is located on the right side of your speed up.
  • Page 166: Water In Fuel Warning Light

    Water in Fuel Warning Light Air Filter Restriction Indicator If your vehicle has the 6.6L If your vehicle has this ® or 7.8L DURAMAX diesel feature, the gage is engine, this light will located above the come on to warn you that switchbank in the center of there is water in the the instrument panel.
  • Page 167: Air Pressure Gage

    Air Pressure Gage Hourmeter Gage To access the engine hourmeter gage, press the trip If your vehicle has air odometer button three times. brakes, the air pressure gage is located above the The instrument panel cluster displays the accumulated switchbank in the center engine run time hours using the reconfigurable of the instrument panel.
  • Page 168: Audio System(S)

    Audio System(s) CAUTION: If your vehicle came without a radio, the wiring provisions for a radio and an antenna were installed at the assembly plant, so that if you want, a radio can This system provides you with a far greater be installed at the dealer.
  • Page 169: Setting The Time

    Here are some ways in which you can help avoid Notice: The chime signals related to safety belts, distraction while driving. parking brake, and other functions of your vehicle operate through the GM radio/entertainment system. While your vehicle is parked: If that equipment is replaced or additional •...
  • Page 170: Playing The Radio

    AM-FM Radio Finding a Station AM FM: Press this button to switch between FM1, FM2, or AM. The display will show the 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 171: Setting Preset Stations

    Setting Preset Stations Setting the Tone (Bass/Treble) Up to 18 stations (six FM1, six FM2, and six AM) can be AUDIO: To adjust bass or treble, press and release programmed on the six numbered pushbuttons, by AUDIO until BAS or TRE appears on the display. Then performing the following steps: press and hold the up or the down arrow to increase or to decrease.
  • Page 172: Radio Messages

    Adjusting the Speakers (Balance/Fade) Radio Messages AUDIO: To adjust the balance between the right CAL (Calibrated): The audio system has been and the left speakers, press and release AUDIO until calibrated for your vehicle from the factory. If CAL BAL appears on the display. Then press and hold the up appears on the display it means that the radio has not or the down arrow to move the sound toward the right been configured properly for your vehicle and must...
  • Page 173: Radio With Cassette

    Radio with Cassette Finding a Station AM FM: Press this button to switch between FM1, FM2, and AM. The display will show the 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 174 Setting Preset Stations Setting the Tone (Bass/Treble) Up to 18 stations (six FM1, six FM2, and six AM) can be AUDIO: To adjust bass and treble, press and release programmed on the six numbered pushbuttons, by AUDIO until BAS or TRE appears on the display. performing the following steps: Then press and hold the up or the down arrow to increase or to decrease.
  • Page 175 Adjusting the Speakers (Balance/Fade) Radio Messages AUDIO: To adjust the balance between the right CAL (Calibration): The audio system has been and the left speakers, press and release AUDIO until calibrated for your vehicle from the factory. If CAL BAL appears on the display. Then press and hold the up appears on the display it means that the radio has not or the down arrow to move the sound toward the right been configured properly for your vehicle and must...
  • Page 176: Playing A Cassette Tape

    Playing a Cassette Tape If an error appears on the display, see “Cassette Tape Messages” later in this section. The tape player is built to work best with tapes that are 1 PREV (Previous): The tape must have at least up to 30 to 45 minutes long on each side.
  • Page 177 3 REV (Reverse): Press this pushbutton to quickly SEEK : The tape must have at least reverse the tape. FR will appear on the display. three seconds of silence between each selection The radio will play while the tape reverses. Press it for seek to work.
  • Page 178: Cassette Tape Messages

    Cassette Tape Messages CD Adapter Kits It is possible to use a portable CD player adapter kit ERR (Error): If the player detects a tight or broken with the cassette tape player after deactivating the tape, this message will appear on the display and the tight/loose tape sensor feature on the tape player.
  • Page 179 Radio with CD Finding a Station AM FM: Press this button to switch between FM1, FM2, and AM. The display will show the 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 180 Setting Preset Stations Setting the Tone (Bass/Treble) Up to 18 stations (six FM1, six FM2, and six AM), can AUDIO: To adjust the bass or the treble, press and be programmed on the six numbered pushbuttons, release the AUDIO button until BAS or TRE appears on by performing the following steps: the display.
  • Page 181 Adjusting the Speakers (Balance/Fade) Radio Messages AUDIO: To adjust the balance between the right CAL (Calibration): The audio system has been and the left speakers, press and release the AUDIO calibrated for your vehicle from the factory. If CAL button until BAL appears on the display. Then press and appears on the display it means that the radio has not hold the up or the down arrow to move the sound been configured properly for your vehicle and must...
  • Page 182: Playing A Cd

    Playing a CD If playing a CD-R, the sound quality may be reduced due to CD-R quality, the method of recording, the quality Insert a CD partway into the slot, label side up. The of the music that has been recorded, and the way the player will pull it in and the CD should begin playing.
  • Page 183 1 PREV (Previous): Press this pushbutton to go to the 6 RPT (Repeat): Press this pushbutton once to hear a beginning of the current track if more than eight seconds track over again. RPT will appear on the display. have played. The track number will appear on the display. The current track will continue to repeat.
  • Page 184: Theft-Deterrent Feature (Non-Rds Radios)

    CD Messages Theft-Deterrent Feature (Non-RDS Radios) If the CD comes out, it could be for one of the following reasons: ® THEFTLOCK is designed to discourage theft of your • It is very hot. When the temperature returns to vehicle’s radio. The feature works automatically by normal, the CD should play.
  • Page 185: Care Of The Cassette Tape Player

    Care of the Cassette Tape Player The range for most AM stations is greater than for FM, A tape player that is not cleaned regularly can cause especially at night. The longer range can cause reduced sound quality, ruined cassettes or a damaged station frequencies to interfere with each other.
  • Page 186: Care Of Your Cds

    The cut tape detection feature of the cassette tape After the player is cleaned, press and hold the eject player may identify the cleaning cassette as a damaged button for three seconds to reset the CLN indicator. The tape. To prevent the cleaning cassette from being radio will display --- to show the indicator was reset.
  • Page 187: Care Of The Cd Player

    Care of the CD Player Chime Level Adjustment The use of CD lens cleaners for CD players is not The radio is used to adjust the vehicle’s chime level. To advised, due to the risk of contaminating the internal change the volume level of the chime, press and lens of the CD optics with lubricants.
  • Page 188 NOTES 3-68...
  • Page 189: Driving Your Vehicle

    Section 4 Driving Your Vehicle Your Driving, the Road, and Your Vehicle ..4-2 Driving in Rain and on Wet Roads ....4-20 Defensive Driving ...........4-2 City Driving ..........4-23 Drunken Driving ..........4-3 Freeway Driving ...........4-24 Control of a Vehicle ........4-6 Highway Hypnosis ........4-25 Braking ............4-6 Hill and Mountain Roads ........4-26 Hydraulic Brake Systems .........4-7...
  • Page 190: Your Driving, The Road, And Your Vehicle

    Your Driving, the Road, and CAUTION: Your Vehicle Defensive driving really means “Be ready for Defensive Driving anything.” On city streets, rural roads, or expressways, it means “Always expect the The best advice anyone can give about driving is: unexpected.” Assume that pedestrians or other Drive defensively.
  • Page 191: Drunken Driving

    Drunken Driving Many adults — by some estimates, nearly half the adult population — choose never to drink alcohol, so they never drive after drinking. For persons under 21, Death and injury associated with drinking and driving is it is against the law in every U.S. state to drink alcohol. a national tragedy.
  • Page 192 According to the American Medical Association, a 180 lb It is the amount of alcohol that counts. For example, if (82 kg) person who drinks three 12 ounce (355 ml) the same person drank three double martinis (3 ounces bottles of beer in an hour will end up with a BAC or 90 ml of liquor each) within an hour, the person’s of about 0.06 percent.
  • Page 193 But the ability to drive is affected well below a BAC of There is something else about drinking and driving that 0.10 percent. Research shows that the driving skills many people do not know. Medical research shows of many people are impaired at a BAC approaching that alcohol in a person’s system can make crash 0.05 percent, and that the effects are worse at night.
  • Page 194: Control Of A Vehicle

    Control of a Vehicle Average reaction time is about three-fourths of a second. But that is only an average. It might be less with one driver and as long as two or three seconds or You have three systems that make your vehicle go more with another.
  • Page 195: Hydraulic Brake Systems

    Hydraulic Brake Systems Avoid needless heavy braking. Some people drive in spurts — heavy acceleration followed by heavy braking — rather than keeping pace with traffic. This is If your engine stops running, or if your primary brake a mistake. Your brakes may not have time to cool system stops working, your vehicle has a reserve power between hard stops.
  • Page 196: Anti-Lock Brake System (Abs)

    Anti-Lock Brake System (ABS) Your vehicle has the Anti-Lock Brake System (ABS), an advanced electronic braking system that will help prevent a braking skid. When you start your engine and begin to drive away, ABS will check itself. You may hear a momentary motor or clicking noise while this test is going on.
  • Page 197: Braking In Emergencies

    ABS can change the brake pressure faster than any Remember: ABS does not change the time you need to driver could. The computer is programmed to make the get your foot up to the brake pedal or always decrease most of available tire and road conditions. This can stopping distance.
  • Page 198: 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 199: Rear Axle Differential Lock Control

    Rear Axle Differential Lock Control Let up on the accelerator before you turn on your rear axle differential lock. If your vehicle has a Notice: Turning on the inter-axle differential lock controlled traction or while the rear wheels are spinning freely, as locking differential axle, they might on snow or ice, can damage the axle(s).
  • Page 200: Traction Control System (Tcs)

    Traction Control System (TCS) When the light in the top of the TCS button is on, the TCS is off and will not limit wheel spin. Adjust your driving accordingly. Your vehicle may have a traction control system that limits wheel spin. This is especially useful in slippery The light in the top of the TCS button will come on if the road conditions.
  • Page 201: Steering

    Steering To turn the system on or off, press the traction control button located on Power Steering the instrument panel. If you lose power steering assist because the engine stops or the system is not functioning, you can steer but it will take much more effort.
  • Page 202: Steering In Emergencies

    Steering in Emergencies The traction you can get in a curve depends on the condition of your tires and the road surface, the angle at There are times when steering can be more effective which the curve is banked, and your speed. While than braking.
  • Page 203: Off-Road Recovery

    Off-Road Recovery You may find that your right wheels have dropped off the edge of a road onto the shoulder while you are driving. An emergency like this requires close attention and a quick decision. If you are holding the steering wheel at the recommended 9 and 3 o’clock positions, you can turn it a full 180 degrees very quickly without removing either hand.
  • Page 204: Passing

    Passing • Watch for traffic signs, pavement markings and lines. If you can see a sign up ahead that might The driver of a vehicle about to pass another on a indicate a turn or an intersection, delay your pass. two-lane highway waits for just the right moment, A broken center line usually indicates it is all accelerates, moves around the vehicle ahead, then...
  • Page 205: Loss Of Control

    • Loss of Control If other cars are lined up to pass a slow vehicle, wait your turn. But take care that someone is Let us review what driving experts say about what not trying to pass you as you pull out to pass the happens when the three control systems —...
  • Page 206: Driving At Night

    A cornering skid is best handled by easing your foot off If you have the Anti-Lock Brake System (ABS), the accelerator pedal. remember: It helps avoid only the braking skid. If you do not have ABS, then in a braking skid, where the If you have the Traction Control System (TCS), wheels are no longer rolling, release enough pressure remember: It helps avoid only the acceleration skid.
  • Page 207 • You can be temporarily blinded by approaching Slow down, especially on higher speed roads. Your headlamps. It can take a second or two, or even vehicle’s headlamps can light up only so much road several seconds, for your eyes to re-adjust to the dark. ahead.
  • Page 208: Driving In Rain And On Wet Roads

    Driving in Rain and on Wet Roads It is always wise to go slower and be cautious if rain starts to fall while you are driving. The surface may get wet suddenly when your reflexes are tuned for driving on dry pavement. The heavier the rain, the harder it is to see.
  • Page 209 Hydroplaning CAUTION: Hydroplaning is dangerous. So much water can build up under your tires that they can actually ride on the water. This can happen if the road is wet enough and Wet brakes can cause accidents. They may not you are going fast enough.
  • Page 210: Driving Through Deep Standing Water

    Driving Through Deep Standing Water Some Other Rainy Weather Tips • Turn on your low-beam headlamps and your marker Notice: If you drive too quickly through deep and clearance lamps, if your vehicle has them — not puddles or standing water, water can come in just your parking lamps —...
  • Page 211: City Driving

    City Driving Here are ways to increase your safety in city driving: • Know the best way to get to where you are going. Get a city map and plan your trip into an unknown part of the city just as you would for a cross-country trip.
  • Page 212: Freeway Driving

    Freeway Driving The most important advice on freeway driving is: Keep up with traffic and keep to the right. Drive at the same speed most of the other drivers are driving. Too-fast or too-slow driving breaks a smooth traffic flow. Treat the left lane on a freeway as a passing lane.
  • Page 213: Highway Hypnosis

    Highway Hypnosis Once you are moving on the freeway, make certain you allow a reasonable following distance. Expect to move slightly slower at night. Is there actually such a condition as highway hypnosis? Or is it just plain falling asleep at the wheel? Call it When you want to leave the freeway, move to the highway hypnosis, lack of awareness, or whatever.
  • Page 214: Hill And Mountain Roads

    Hill and Mountain Roads CAUTION: If you do not shift down, your brakes could get so hot that they would not work well. You would then have poor braking or even none going down a hill. You could crash. Shift down to let your engine assist your brakes on a steep downhill slope.
  • Page 215: Winter Driving

    • Winter Driving Know how to go down hills. The most important thing to know is this: let your engine do some of the slowing down. Shift to a lower gear when you go down a steep or long hill. •...
  • Page 216: Driving On Snow Or Ice

    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. And, if you will be driving under severe conditions, include a small bag of sand, a piece of old carpet, or a couple of burlap bags to help provide traction.
  • Page 217 If you have a four-wheel-drive vehicle, shift into 4HI. Whether you have ABS or not, you will want to begin See Four-Wheel Drive on page 2-35. stopping sooner than you would on dry pavement. Without ABS, if you feel your vehicle begin to slide, let If you have the Traction Control System (TCS), it will up on the brakes a little.
  • Page 218: If You Are Caught In A Blizzard

    If You Are Caught in a Blizzard If you are stopped by heavy snow, you could be in a serious situation. You should probably stay with your vehicle unless you know for sure that you are near help and you can hike through the snow. Here are some things to do to summon help and keep yourself and your passengers safe: •...
  • Page 219 Run your engine only as long as you must. This saves fuel. When you run the engine, make it go a little CAUTION: 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 220: If Your Vehicle Is Stuck In Sand, Mud, Ice

    If Your Vehicle is Stuck in Sand, Rocking Your Vehicle to Get It Out Mud, Ice, or Snow First, turn the steering wheel left and right. That will clear the area around the front wheels. If you have a In order to free your vehicle when it is stuck, you will four-wheel-drive vehicle, shift into 4HI.
  • Page 221: Tow Hooks

    Tow Hooks If your vehicle has tow hooks, the hooks are at the front and, on some models, the rear of the vehicle. You may need to use them if you are stuck off-road and need to be pulled to some place where you can continue CAUTION: driving.
  • Page 222: Loading Your Vehicle

    Loading Your Vehicle The GVW Rating label is provided by the final manufacturer and should be on the door or door jamb. It also tells you the maximum weights for the front and There is a vehicle specific GVW Rating label on your rear axles, called Gross Axle Weight Rating (GAWR).
  • Page 223 If you put things inside your vehicle — like suitcases, tools, packages or anything else — they will go as fast CAUTION: as the vehicle goes. If you have to stop or turn quickly, or if there is a crash, they will keep going. Do not load your vehicle any heavier than the Gross Vehicle Weight Rating (GVWR), or either CAUTION:...
  • Page 224: Adding A Snow Plow Or Similar Equipment

    Adding a Snow Plow or Similar CAUTION: Equipment If you will be installing a snow plow on your vehicle, we On some vehicles that have certain front recommend that the vehicle have the snow plow mounted equipment, such as a snow plow, it prep package (RPO ANQ).
  • Page 225: 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 7-5. Releasing Air-Operated Parking Brakes If your vehicle has air brakes, you could have a special towing problem.
  • Page 226 3. Remove the rubber 6. Turn the stud nut cap from the rear of clockwise several turns the chamber. to release the brakes. Follow the same procedure to release the other brake or brakes. 4. Put the release stud, nut and flat washer into 7.
  • Page 227: Electrical Connections

    Trailer Connections Trailer Connections (C7/C8 Models Only) Heavy-Duty Trailer Wiring Package If your vehicle has these trailer connections, they are Your vehicle may be equipped with an eight-wire trailer located at the rear of the cab for a tractor and at the rear towing harness.
  • Page 228 NOTES 4-40...
  • Page 229: Service And Appearance Care

    Section 5 Service and Appearance Care Service ............5-3 Engine Air Cleaner/Filter ........5-35 California Proposition 65 Warning .....5-3 Automatic Transmission Fluid ......5-36 Doing Your Own Service Work ......5-4 Manual Transmission Fluid ......5-37 Engine Fan Breakage ........5-5 Engine Coolant ® (Gas and DURAMAX Engines) ....5-38 Fuel ..............5-6 ®...
  • Page 230 Section 5 Service and Appearance Care Other Service Items ........5-70 Cleaning Exterior Lamps/Lenses .....5-87 Fuel Filter ............5-70 Finish Care ..........5-87 Primary Fuel Filter and Water Separator ..5-71 Windshield and Wiper Blades ......5-88 Secondary Fuel Filter and Water Aluminum or Chrome-Plated Wheels ....5-89 ®...
  • Page 231: 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 232: Doing Your Own Service Work

    Doing Your Own Service Work If you want to do some of your own service work, you will want to use the proper service manual. It tells you much more about how to service your vehicle than this manual can. To order the proper service manual, CAUTION: see Service Publications Ordering Information on page 7-11.
  • Page 233: Engine Fan Breakage

    Engine Fan Breakage CAUTION: (Continued) CAUTION: Winter Fronts, Grille Covers or Obstructions: Winter Fronts, grille covers or other add-on Changing the Fan Drive Ratio or Engine equipment causing obstructions in front or Governed Speed: behind the fan should not be used on this vehicle.
  • Page 234: Fuel

    Fuel Additives To provide cleaner air, all gasolines in the United States If your vehicle has a diesel engine, see Diesel Engine are now required to contain additives that will help Fuel on page 5-7. prevent engine and fuel system deposits from forming, For vehicles with gasoline engines, please read this.
  • Page 235: Diesel Engine Fuel

    Diesel Engine Fuel 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 For the Caterpillar diesel, see the Caterpillar system and also damage the plastic and rubber Operation &...
  • Page 236: What Fuel To Use

    What Fuel to Use ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to your fuel In the United States, for best results use No. 2-D diesel system and engine.
  • Page 237 What Fuel to Use in Canada If your vehicle has the 6.6L engine, it is acceptable to use diesel fuel containing up to 5% biodiesel (B5), Canadian fuels are blended for seasonal changes. but the final blended fuel must meet the same Diesel Type “A”...
  • Page 238: Very Cold Weather Operation

    Very Cold Weather Operation Notice: If there is water in your diesel fuel and the weather is warm or humid, fungus and bacteria can grow in the fuel. They can damage your Follow the instructions listed previously under the fuel system. A diesel fuel biocide can be used to heading “What Fuel to Use.”...
  • Page 239 Water In Fuel Light Notice: If you drive when this warning indicator is on, you can damage your fuel injection system Problem Recommended Action and your engine. If the indicator comes on right after Light comes on Drain water from the you refuel, it means water was pumped into your intermittently.
  • Page 240 4. Open the drain valve 6. Install the fuel cap. by turning two to 7. Start the engine and let it run for a few minutes. If the three turns. When fuel engine stalls, the fuel system may need to be primed. empties from the While draining the water from the fuel filter, air may valve, all the water has...
  • Page 241 Fuel Priming If one or more of the above occurred, it is very likely that air has entered your fuel system and that you will ® If your vehicle has a Caterpillar diesel engine, see the need to prime the fuel system before operating the ®...
  • Page 242 ® Priming the 6.6L DURAMAX Diesel Engine 5. Open the fuel filter vent valve by turning the ® If your vehicle is equipped with the 6.6L DURAMAX screw counterclockwise diesel engine, it has a priming pump which is part of the several full turns.
  • Page 243 ® Priming the 7.8L DURAMAX Diesel Engine 6. Repeatedly push down on the fuel filter primer ® If your vehicle is equipped with the 7.8L DURAMAX pump with the palm diesel engine, use the following procedure to prime the of your hand. Let engine: the pump return upward between...
  • Page 244 6. Use the palm of your hand to repeatedly press and 9. Tighten the fuel filter breather screw (2) to the specified torque, 4.9 Y (43 in. lbs). release the plunger (1) at the top of the fuel filter priming pump. Continue until the plunger resistance 10.
  • Page 245: Running Out Of Fuel

    Running Out of Fuel 3. Close the air bleed valve. 4. Turn the ignition key to START for 10 to 15 seconds If the diesel engine stalls and you think that you have at a time until your engine starts. If the engine tries run out of fuel, do this to restart your engine: to run, but does not run smoothly, increase the rpm a little using the accelerator pedal.
  • Page 246: Fuel Filter Replacement

    Fuel Filter Replacement If your vehicle has the 6.6L engine, the fuel filter is located in the engine compartment on the driver’s side of the vehicle. If your vehicle has either the 7.2L or If you want to change the diesel engine fuel filter 7.8L engine, the fuel filters are located in the engine yourself, here is how to do it: compartment on the driver’s side of the vehicle, and on...
  • Page 247: Fuels In Foreign Countries

    Fuels in Foreign Countries 3. Remove the filter element. If there is any dirt on the filter sealing surface, clean it off. Remove and reuse the water sensor float switch located on the If you plan on driving in another country outside the bottom of the fuel filter.
  • Page 248: Filling The Tank

    Filling the Tank The fuel cap can be on either or both sides of your vehicle depending on option content. To take off the cap, turn it slowly 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 249: Filling A Portable Fuel Container

    Filling a Portable Fuel Container Notice: If you need a new fuel cap, be sure to get the right type. Your dealer can get one for you. If you get the wrong type, it may not fit properly. This may cause your malfunction indicator lamp to CAUTION: light and may damage your fuel tank and emissions system.
  • Page 250: Checking Things Under The Hood

    Checking Things Under Hood Latches the Hood 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.
  • Page 251 Then take the hand hold and pull the hood forward. When you tilt the hood far enough, the cables will support it. When you close the hood, make sure both latches are secured. 5-23...
  • Page 252: Engine Oil

    Engine Oil In order to get an accurate reading, the engine should be at normal operating temperature, so that the oil ® (Caterpillar Diesel Engine) is warm, and the vehicle must be on level ground. ® See your Caterpillar Operation & Maintenance Manual 1.
  • Page 253: When To Add Engine Oil

    This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities and Specifications on page 5-99. Notice: Do not add too much oil. If your engine has so much oil that the oil level gets above the cross-hatched area for the 6.6L V8 (LLY) engine or above the upper hole that shows the proper operating range for the 7.8L L6 (LG4) engine, your...
  • Page 254: What Kind Of Engine Oil To Use

    What Kind of Engine Oil to Use Look for these two things: • CI-4 or CH-4 Oils designated as API CI-4 or CH-4 are recommended for your vehicle. The CI-4 or CH-4 designations may appear either alone, together, or in combination with other API designations, such as API CI-4/SL.
  • Page 255: Engine Oil Additives

    • Engine Oil Additives SAE 15W-40 As shown in the viscosity chart, SAE 15W-40 is Do not add anything to your oil. The recommended oils best for your vehicle. However, you can use with the API service symbol are all you will need for SAE 10W-30 at temperatures above 0°F (−18°C).
  • Page 256: Engine Oil (Gasoline Engine)

    Engine Oil (Gasoline Engine) The engine oil dipstick is located in the engine compartment on the If the low oil light appears driver’s side of the vehicle. on the instrument cluster, it means you need to check your engine oil level right away.
  • Page 257 When to Add Engine Oil 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.
  • Page 258 What Kind of Engine Oil to Use These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American...
  • Page 259: Engine Oil Additives

    If you are in an area of extreme cold, where the When the system has calculated that oil life has been temperature falls below −20°F (−29°C), it is diminished, it will indicate that an oil change is recommended that you use either an SAE 5W-30 necessary.
  • Page 260: How To Reset The Engine Oil Life System

    How to Reset the Engine Oil What to Do with Used Oil Life System Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. The Engine Oil Life System calculates when to change Do not let used oil stay on your skin for very long.
  • Page 261: Diesel)

    Engine Oil Life System If the system is ever reset accidentally, you must change your oil at 15,000 miles (24 000 km), or ® (DURAMAX Diesel) 150 hours of engine operation, whichever occurs first, since your last oil change. Remember to reset the oil life When to Change Engine Oil system whenever the oil is changed.
  • Page 262: Diesel Engine)

    What to Do with Used Oil Engine Oil Life System ® (Caterpillar Diesel Engine) Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. How to Reset the Engine Oil Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good Life System hand cleaner.
  • Page 263: 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 an air the engine compartment. cleaner/filter change indicator, inspect the indicator at every oil change and replace the filter when the indicator tells you to.
  • Page 264: Automatic Transmission Fluid

    How to Inspect the Engine Air Automatic Transmission Fluid Cleaner/Filter When to Check Locate the filter change indicator. When the change indicator turns black or is in the red/orange change area, A good time to check your automatic transmission fluid replace the filter and reset the indicator.
  • Page 265: Manual Transmission Fluid

    Manual Transmission Fluid How to Add Fluid To add transmission fluid, do the following: When to Check 1. Remove the filler plug. A good time to have it checked is when the engine oil is 2. Add fluid at the filler plug hole. Add only enough checked.
  • Page 266: Engine Coolant

    Engine Coolant What to Use ® (Gas and DURAMAX Engines) Use a mixture of one-half clean, drinkable water and ® one-half DEX-COOL coolant which will not damage The cooling system in your vehicle is filled with aluminum parts. If you use this coolant mixture, you do ®...
  • Page 267: Checking Coolant

    If you have to add coolant more than four times a year, have your dealer check your cooling system. CAUTION: Notice: If you use extra inhibitors and/or additives in your vehicle’s cooling system, you could Turning the surge tank pressure cap when the damage your vehicle.
  • Page 268: Adding Coolant

    Adding Coolant Coolant Surge Tank Pressure Cap ® If you need more coolant, add the proper DEX-COOL The coolant surge tank pressure cap is located in coolant mixture at the surge tank, but only when the the engine compartment, on the driver’s side of the engine is cool.
  • Page 269: If Steam Is Coming From Your Engine

    If Steam Is Coming From Your Engine If No Steam Is Coming From Your Engine An overheat warning, along with a low coolant light, can CAUTION: indicate a serious problem. See Low Coolant Warning Light on page 3-37 for more information. Steam from an overheated engine can burn If you get an engine overheat warning with no low you badly, even if you just open the hood.
  • Page 270: Cooling System

    Cooling System If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about 10 minutes. ® (Gas and DURAMAX Engines) If the warning does not come back on, you can drive normally. When you decide it is safe to lift the hood, here is what If the warning continues and you have not stopped, pull you will see:...
  • Page 271 If the coolant inside the coolant surge tank is boiling, do not do anything else until it cools down. The vehicle CAUTION: (Continued) should be parked on a level surface. The coolant level should Do not run the engine if there is a leak. If you be at the FULL COLD run the engine, it could lose all coolant.
  • Page 272: How To Add Coolant To The Coolant Surge Tank

    How to Add Coolant to the Coolant If no coolant is visible in the surge tank, add coolant as follows: Surge Tank If you have not found a problem yet, check to see if CAUTION: coolant is visible in the surge tank. If coolant is visible but the coolant level is not at the FULL COLD mark or higher, add a 50/50 mixture of clean, drinkable water Steam and scalding liquids from a hot cooling...
  • Page 273 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 274 3. Fill the coolant surge tank with the proper mixture, 4. With the coolant surge tank pressure cap off, start to the FULL COLD 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 275: Power Steering Fluid

    Engine Fan Noise How To Check Power Steering Fluid Check your power steering fluid only when the engine is Your vehicle has a clutched engine cooling fan. When warm. If the engine is not warm, you probably will not the clutch is engaged, the fan spins faster to provide get an accurate reading.
  • Page 276: Windshield Washer Fluid

    Windshield Washer Fluid Notice: • When using concentrated washer fluid, follow What to Use the manufacturer’s instructions for adding water. When you need windshield washer fluid, be sure to read • Do not mix water with ready-to-use washer fluid. the manufacturer’s instructions before use. If you will Water can cause the solution to freeze and be operating your vehicle in an area where the damage your washer fluid tank and other parts...
  • Page 277: Brakes

    Brakes Checking Brake Fluid Apply the brake pedal several times with the ignition off. Brake Fluid Then clean one of the reservoir caps and the area around the cap, and remove it. If your vehicle has hydraulic brakes, there is a The fluid level should be brake master cylinder in even with the bottom ring...
  • Page 278 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 279: Brake Adjustment

    Four-Wheel Disc Brakes Brake Pedal Travel (Hydraulic Only) See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in Your vehicle has four-wheel disc brakes. pedal travel. This could be a sign of brake trouble. Some driving conditions or climates may cause a brake Brake Adjustment squeal when the brakes are first applied or lightly...
  • Page 280: Air Dryer

    Air Brake Systems Air Dryer If your vehicle has air brakes, it is important to get rid of If your vehicle has air brakes, it will have an air dryer. moisture in your system. Moisture will damage your This collects and removes dirt, moisture, or other foreign system if it is not removed daily.
  • Page 281 Electric Air Compressor Clutch Pedal Free Travel Your vehicle may have an electric air compressor. This If you have a V8 engine and a manual transmission, compressor is used to run options that require your clutch will need adjustment when pedal free travel pressurized air, such as air horn, air seat, 7.8L engine gets down to about 1/4 inch (32 mm), as measured exhaust restrictor, or 7.8L engine exhaust brake.
  • Page 282 Single Axle Models 5-54...
  • Page 283 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 284 Item Number Item Remarks Battery Terminal (except “ST” type) Keep coated with petroleum jelly. Transmission Fill to level of filler plug. Lubricate with GM Part No. 1051344 Propshaft U-Joints Wheel Bearing Lubricant. Parking Brake Clevis Pin$ Apply chassis lubricant. Parking Brake Lever Pivot*, $ Apply chassis lubricant.
  • Page 285 Tandem Axle Models Item Number Item Remarks Brake Camshafts One fitting each. One fitting each joint. Lubricate with Propshaft U-Joint GM Part No. 1051344, Wheel Bearing Lubricant Fill to level of Rear Axles filler plug. Apply engine oil at Brake Shoe pin to shoe Roller Pins joint only.
  • Page 286: Battery

    Battery Vehicle Storage If you are not going to drive your vehicle for 25 days or Your vehicle has one or more maintenance free more, remove the black, negative (−) cable from the batteries. When it is time for a new battery, be sure it battery.
  • Page 287: Jump Starting

    Jump Starting Notice: Ignoring these steps could result in costly damage to your vehicle that would not be covered by your warranty. If your vehicle’s battery (or batteries) has run down, you may want to use another vehicle and some jumper Trying to start your vehicle by pushing or pulling it cables to start your vehicle.
  • Page 288 2. Get the vehicles close enough so the jumper cables 4. Open the hood on the other vehicle and locate the can reach, but be sure the vehicles are not touching positive (+) and the negative (−) terminal locations each other. If they are, it could cause a ground on that vehicle.
  • Page 289 CAUTION: CAUTION: Using a match near a battery can cause battery Fans or other moving engine parts can injure gas to explode. People have been hurt doing you badly. Keep your hands away from moving this, and some have been blinded. Use a parts once the engine is running.
  • Page 290 6. Connect the red 8. Now connect the black negative (−) cable to the positive (+) cable to the negative (−) terminal of the good battery. Use a positive (+) terminal of remote negative (−) terminal if the vehicle has one. the dead battery.
  • Page 291 Notice: If the jumper cables are connected or To disconnect the jumper cables from both vehicles, do removed in the wrong order, electrical shorting may the following: occur and damage the vehicle. The repairs would 1. Disconnect the black negative (−) cable from the not be covered by your warranty.
  • Page 292: Rear Axle

    Rear Axle How to Check Lubricant When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See Scheduled Maintenance on page 6-5. Notice: If you drive your vehicle through deep water that is higher than the front or rear axle, water may enter the axle housing and cause the axle lubricant to break down.
  • Page 293: Transfer Case

    Rear Axle Shift Motor Four-Wheel Drive When to Check and Change Fluid Transfer Case When to Check Lubricant If you have an optional air-shift two-speed, controlled traction, or locking differential type rear axle, a good time It is not necessary to regularly check transfer case fluid to check the fluid level in the axle shift motor is when unless you suspect there is a leak or you hear an the rear axle lubricant is checked.
  • Page 294: Front Axle

    Front Axle To get an accurate reading, the vehicle should be on a level surface. When to Check Lubricant If the level is below the bottom of the fill plug hole, located on the transfer case, you’ll need to add some It is not necessary to regularly check front axle fluid lubricant.
  • Page 295: Noise Control System

    How to Check Lubricant Noise Control System Tampering with Noise Control System Prohibited The following information relates to compliance with federal noise emission standards for vehicles with a Gross Vehicle Weight Rating (GVWR) of more than 10,000 lbs (4 536 kg). The Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system during the life of your vehicle.
  • Page 296: Bulb Replacement

    Fan and Drive: Federal law prohibits the following acts or the causing thereof: • Removal of fan clutch (if equipped) or rendering 1. The removal or rendering inoperative by any clutch inoperative. person, other than for purposes of maintenance, • Removal of the fan shroud (if equipped).
  • Page 297: Windshield Wiper Blade Replacement

    Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking. See “Wiper Blade Check” under At Least Twice a Year on page 6-29 for more information. Replacement blades come in different types and are removed in different ways.
  • Page 298: Other Service Items

    Other Service Items If your vehicle has a rear steel fuel tank, the fuel filter/pressure regulator is located near the rear fuel tank, on the driver’s side frame rail. See Scheduled Fuel Filter Maintenance on page 6-5 for recommended service intervals.
  • Page 299: Primary Fuel Filter And Water Separator

    Primary Fuel Filter and Secondary Fuel Filter and Water Separator Water Separator/Heater ® (Caterpillar Diesel) If you have a diesel engine, you may have this ® If you have a Caterpillar spin-on filter. It is located diesel engine, you may on the driver’s side also have this spin-on filter frame rail.
  • Page 300: Automatic Ether Injection System (Caterpillar ® Diesel)

    Automatic Ether Injection System 3. Clean any dirt from the neck of the cylinder and the top of the valve before you take out the cylinder. ® (Caterpillar Diesel) 4. Check the inside of the valve for any foreign matter. Clean the valve as necessary.
  • Page 301: Front Wheel Bearings With Oil-Filled Hubs

    Front Wheel Bearings with If your vehicle has oil-filled hubs, occasionally check Oil-Filled Hubs to see if they have enough oil. You can tell if there Notice: If you drive your vehicle through deep is oil there by using water that is higher than the front or rear axle, water the circular gage on the may enter the axle housing and cause the axle sight glass.
  • Page 302: Air Conditioning System

    Air Conditioning System CAUTION: Every now and then, have your dealership check your air conditioning system to be sure it has not lost any cooling ability. If you think the system is not working Poorly maintained and improperly used tires properly, have your GM dealer check it out as soon are dangerous.
  • Page 303: How To Check

    Inflation - Tire Pressure When to Check Check your tires once a month or more. The GVW Rating label, which is on the driver’s door frame, shows the correct inflation pressures for Also, check the tire pressure of the spare tire your tires when they’re cold.
  • Page 304: Dual Tire Operation

    Dual Tire Operation When It Is Time for New Tires When the vehicle is new, check the wheel nut tightness Replace your tires when the tread depth is down to on all wheels with a torque wrench after your first 1/8 of an inch (3.2 mm) for the front tires, or 1/16 of an 100 miles (160 km) and then 1,000 miles (1 600 km) inch (1.6 mm) for a rear tire.
  • Page 305: Wheel Alignment And Tire Balance

    Tightening the Wheel Nuts When you replace tires, make sure they are the same size, load range, speed rating and construction type (bias, bias-belted or radial) as your original tires. If your vehicle has four-wheel drive, the axle differentials, CAUTION: propshafts and transfer case may be damaged if tires of different sizes, brands or tread types are installed on Wheel nuts that are not tight can work loose.
  • Page 306 Hub-Piloted Wheels, 8-Hole or 10-Hole First, use these pictures to decide what kind of wheels you have. The studs and nuts used with these wheels have right-hand threads. 1. With intermittent pilot pads, position a pad at 12 o’clock to center the wheel and reduce run-out. 2.
  • Page 307 6. Tighten the nuts to 400 lb ft (542 Y) if an 8-hole stud or 480 lb ft (650 Y) if a 10-hole stud, using the following diagrams. 10-Hole (Front) 10-Hole (Rear) CAUTION: 8-Hole Never use oil or grease on studs or the threads of the wheel nuts.
  • Page 308 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 309: 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 310: If A Tire Goes Flat

    Used Replacement Wheels A rear blowout, particularly on a curve, acts much like a skid and may require the same correction you would use in a skid. In any rear blowout, remove your foot from the accelerator pedal. Get the vehicle under control CAUTION: by steering the way you want the vehicle to go.
  • Page 311: Appearance Care

    Appearance Care 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 Cleaning the Inside of Your Vehicle aboard to be able to change a flat tire safely. For example, you would need a truck jack that can lift Your vehicle’s interior will continue to look its best if several thousand pounds and a torque wrench that can...
  • Page 312 Use glass cleaner only on glass. Remove any accidental Do not clean your vehicle using the following cleaners over-spray from other surfaces immediately. To prevent or techniques: over-spray, apply cleaner directly to the cleaning cloth. • Never use a knife or any other sharp object to remove a soil from any interior surface.
  • Page 313: Fabric/Carpet

    Fabric/Carpet 3. Start on the outside edge of the soil and gently rub toward the center. Continue cleaning, using a clean area of the cloth each time it becomes soiled. Use a vacuum cleaner with a soft brush attachment frequently to remove dust and loose dirt. A canister 4.
  • Page 314: Instrument Panel, Vinyl, And Other Plastic Surfaces

    Instrument Panel, Vinyl, and Care of Safety Belts Other Plastic Surfaces Keep belts clean and dry. A soft cloth dampened with water may be used to remove dust. If a more thorough cleaning is necessary, CAUTION: a clean soft cloth dampened with a mild soap solution can be used to gently remove dust and dirt.
  • Page 315: Washing Your Vehicle

    Washing Your Vehicle Cleaning Exterior Lamps/Lenses The paint finish on the vehicle provides beauty, depth of Use only lukewarm or cold water, a soft cloth and a car color, gloss retention, and durability. washing soap to clean exterior lamps and lenses. Follow instructions under Washing Your Vehicle on The best way to preserve the vehicle’s finish is to keep page 5-87.
  • Page 316: Windshield And Wiper Blades

    Windshield and Wiper Blades Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird droppings, chemicals from industrial chimneys, etc., If the windshield is not clear after using the windshield can damage your vehicle’s finish if they remain washer, or if the wiper blade chatters when running, on painted surfaces.
  • Page 317: Aluminum Or Chrome-Plated Wheels

    Aluminum or Chrome-Plated Wheels Tires The vehicle may be equipped with either aluminum or To clean the tires, use a stiff brush with tire cleaner. chrome-plated wheels. Notice: Using petroleum-based tire dressing Keep the wheels clean using a soft clean cloth with mild products on your vehicle may damage the paint soap and water.
  • Page 318: Underbody Maintenance

    Underbody Maintenance Vehicle Care/Appearance Materials Description Usage Chemicals used for ice and snow removal and dust Polishing Cloth Interior and exterior control can collect on the underbody. If these are not Wax-Treated polishing cloth. removed, corrosion and rust can develop on the underbody parts such as fuel lines, frame, floor pan, Tar and Road Oil Removes tar, road oil and...
  • Page 319: Vehicle Identification

    Vehicle Care/Appearance Materials Vehicle Identification (cont’d) Description Usage Vehicle Identification Number (VIN) Removes light scratches Cleaner Wax and protects finish. Cleans, shines and Foaming Tire Shine protects in one easy step, Low Gloss no wiping necessary. Medium foaming shampoo. Cleans and Wash Wax Concentrate lightly waxes.
  • Page 320: Service Statement

    Service Statement Service Parts Identification Label One of these statements is on your GVW Rating label. You will find this label in a location determined by the Here is what each one means. body manufacturer. It is very helpful if you ever need to order parts.
  • Page 321: Headlamp Wiring

    Headlamp Wiring The hydraulic brake booster motor feed circuit and starter circuit are protected by a fusible link. Vehicles with a diesel engine have a fusible link for the intake The headlamp wiring is protected by a circuit breaker in heater feed circuit.
  • Page 322: 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 323 Circuit Breaker Usage Fuse Usage Courtesy Lamps HTD/MIRR Heated Mirrors Warning Lights, Gages and Blank Not Used Indicators RT TRN TRLR Passenger’s Side Trailer Turn Signal Starter Blank Not Used Rear Axle/Four-Wheel-Drive LT TRN TRLR Driver’s Side Trailer Turn Signal Trailer Turn Signals/Hazard Blank Not Used...
  • Page 324: Underhood Fuse Block

    Underhood Fuse Block Fuse Usage Blank Not Used When a circuit goes out, the problem could be in either Blank Not Used the primary or secondary underhood fuse blocks. PWR WNDW Power Windows These blocks use blade-type fuses. Both underhood fuse blocks are located in the engine compartment, on the passenger’s side of the vehicle.
  • Page 325 Fuse Usage ENG 4 Engine 4 ENG 2 Engine 2 HTD FUEL Heated Fuel BLANK Not Used BLANK Not Used Emissions A/C COMP Air Conditioning Compressor ABS 1 Anti-lock Brake System 1 ABS 2 Anti-lock Brake System 2 ABS 3 Anti-lock Brake System 3 ENGINE Engine...
  • Page 326 Relay Usage LG4 Powertrain Control Valve, NOTE 1 L18 Fuel Pump, LG5 Heated Fuel IGN B Ignition STARTER Starter HORN Horn IGN A Ignition Power Take-Off/Engine Control Unit PTO/ECU* ® *Diesel 7.8L DURAMAX REVERSE Reverse NEUTRAL Neutral Start START Secondary Underhood Fuse Block Fuse Usage...
  • Page 327: Capacities And Specifications

    Capacities and Specifications The following approximate capacities are given in English and metric conversions. See Part C: Recommended Fluids and Lubricants on page 6-33 for more information. Capacities Application English Metric Air Conditioning Refrigerant R134a 2.13 lbs .97 kg Cooling System – C4/C5 Models 6.6L Automatic Transmission 27.3 qt 25.8 L...
  • Page 328 Capacities Application English Metric 7.2L 250 - 300 hp Engine 32.8 qt 31.0 L 7.2L 250 - 300 hp Engine with A/C and Increased Cooling 33.3 qt 31.5 L 7.8L 200 - 230 hp Engine 31.6 qt 29.9 L 7.8L 200 - 230 hp Engine with A/C and Increased Cooling 35.3 qt 33.4 L 7.8L 250 - 300 hp Engine...
  • Page 329 Capacities Application English Metric Fuel Capacity – C4/C5 Models Standard 25 gal 94.6 L Optional 32 gal 121.1 L Optional 35 gal 132.5 L Optional (Single Tank) 40 gal 151.4 L Optional (Dual Tanks) 40 gal 151.4 L Optional 60 gal 227.1 L Optional 80 gal...
  • Page 330 Capacities Application English Metric Front 4WD Axle (G38) and (FRX) 7.0 pt 3.6 L Rear Axle – Single Speed 80 (GL4) 8.0 pt 3.7 L 19060D (HPM), 19060S (HPK), 21060D (HPN), 21060S 31.0 pt 14.7 L (HPP), 22060S (HPG) 23090S (HPT) 42.5 pt 20.1 L 23105D (HNB), 23105S (HNA)
  • Page 331 Capacities Application English Metric 23082T (H25) 44.0 pt 20.8 L 26080T (GJ4) 44.0 pt 20.8 L Transfer Case (Four-Wheel Drive) 4.0 pt 1.9 L Transmission Fluid, Automatic 3000 RDS and EVS, and 3500 RDS and EVS 52.0 pt 24.6 L 1000 HS, RDS, MH, PTS and EVS, 2200 HS, RDS, MH, 35.0 pt 13.5 L...
  • Page 332: Normal Maintenance Replacement Parts

    Engine Specifications Engine Type ® 6.6L V8 DURAMAX Common Rail Fuel System Hydraulic/Electronic Unit Injector ® 7.2L L6 Caterpillar Fuel System ® 7.8L L6 DURAMAX Common Rail Fuel System Single Port Fuel Injector Fuel 8.1L V8 VORTEC™ System Normal Maintenance Replacement Parts Replacement parts identified by name, part number, or specification can be obtained from your dealer.
  • Page 333 ® Part GM Part Number ACDelco Part Number Engine Oil Filter 6.6L 88917036 PF2232 7.2L — 1R-1807†† 7.8L 94037791 — 8.1L 25324052 PF454 Fuel Filter 6.6L 97385488 TP1298A 7.2L — 1R-0751†† 7.8L 94392474 — 8.1L (NG6/NK1) 21998364 — 8.1L (All others) —...
  • Page 334 ® Part GM Part Number ACDelco Part Number Spark Plugs 6.6L — — 7.2L — — 7.8L — — 8.1L 12578277 41-983 Optional air filter (GM Part No. 88937548 AC Delco No. A2035C) for C6/C7/C8 Models. Fits inside standard size filter (GM Part No.
  • Page 335 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Scheduled Maintenance ........6-5 Introduction ...........6-2 Part B: Owner Checks and Services ....6-28 Maintenance Requirements ......6-2 At Each Fuel Fill ..........6-28 Your Vehicle and the Environment ....6-2 At Least Twice a Year ........6-29 How This Section is Organized ......6-3 At Least Once a Year ........6-32 Part A: Scheduled Maintenance Services ...6-4 Part C: Recommended Fluids and Lubricants ..6-33...
  • Page 336: 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 337: How This Section Is Organized

    How This Section is Organized “Part B: Owner Checks and Services” tells you what should be checked and when. It also explains what you can easily do to keep your vehicle in good condition. This maintenance schedule is divided into four parts: “Part C: Recommended Fluids and Lubricants”...
  • Page 338: 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 339: Scheduled Maintenance

    Scheduled Maintenance 100 Miles (160 km) Wheel stud nut service. (36) The services shown in this schedule up to 100,000 miles (166 000 km) should be repeated after 100,000 miles 1,000 Miles (1 600 km) (166 000 km) at the same intervals for the life of Wheel stud nut service.
  • Page 340 15,000 Miles (24 000 km) Air brake service (or every 6 months, whichever occurs first). (32) Gasoline Engine Only: Check engine oil life system. Air brake automatic slack adjuster service (or every If engine oil and filter are changed, reset system. 500 hours, whichever occurs first).
  • Page 341 Diesel Engine: Inspect engine air cleaner filter Check air brake relay valve operation and check for change indicator. If necessary, replace the filter. If leaks (or every month, or every 300 hours, whichever vehicle is driven in dusty/dirty conditions, inspect filter occurs first).
  • Page 342 Inspect door hinge pins and bushings and replace as Clean air brake application valve (or every 3 months, necessary. or every 300 hours, whichever occurs first). Lubricate linkage. Cooling system service. Clean the cooling system filter cap with clean water, clean the core, pressure Air brake chamber service (or every 2 months, test the cap and the system for proper pressure whichever occurs first).
  • Page 343 ® 30,000 Miles (48 000 km) DURAMAX Diesel Only: Replace fuel filter (or every 750 hours of engine operation, whichever Gasoline Engine Only: Check engine oil life system. occurs first). If engine oil and filter are changed, reset system. Chassis lubrication service (or every 6 months, See “Engine Oil (Gasoline Engine)”...
  • Page 344 37,500 Miles (60 000 km) Clean air brake application valve (or every 3 months, or every 300 hours, whichever occurs first). Lubricate Gasoline Engine Only: Check engine oil life system. linkage. If engine oil and filter are changed, reset system. Air brake chamber service (or every 2 months, See “Engine Oil (Gasoline Engine)”...
  • Page 345 45,000 Miles (72 000 km) Chassis lubrication service (or every 6 months, whichever occurs first). (11) Gasoline Engine Only: Check engine oil life system. Cooling system service. Clean the cooling system If engine oil and filter are changed, reset system. filler cap with clean water, clean the core, pressure See “Engine Oil (Gasoline Engine)”...
  • Page 346 48,000 Miles (75 000 km) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever ® 7.8L DURAMAX Diesel Without Engine Oil Life occurs first). System Only: Change engine oil and filter Clean air brake application valve (or every 3 months, (or every 12 months, or every 600 hours of engine or every 300 hours, whichever occurs first).
  • Page 347 60,000 Miles (96 000 km) Chassis lubrication service (or every 6 months, whichever occurs first). (11) Gasoline Engine Only: Check engine oil life system. Wheels and tires service. (14) If engine oil and filter are changed, reset system. ® DURAMAX Diesel Engine Only: Adjust valve lash See “Engine Oil (Gasoline Engine)”...
  • Page 348 Check fluid levels (or every 3 months, whichever Wheel bearing (grease type) service (and whenever occurs first). (1) (5) hubs are removed). (22) (36) Wheels and tires service. (14) Gasoline Engine: Inspect engine air cleaner filter. If Hydraulic brake service (or every 6 months, necessary, replace the filter.
  • Page 349 67,500 Miles (108 000 km) Clean air brake application valve (or every 3 months, or every 300 hours, whichever occurs first). Lubricate Gasoline Engine Only: Check engine oil life system. linkage. If engine oil and filter are changed, reset system. Air brake chamber service (or every 2 months, See “Engine Oil (Gasoline Engine)”...
  • Page 350 75,000 Miles (120 000 km) Diesel Engine: Inspect engine air cleaner filter change indicator. If necessary, replace the filter. If Gasoline Engine Only: Check engine oil life system. vehicle is driven in dusty/dirty conditions, inspect filter If engine oil and filter are changed, reset system. change indicator at every engine oil change.
  • Page 351 Clean air brake application valve (or every 3 months, Chassis lubrication service (or every 6 months, or every 300 hours, whichever occurs first). Lubricate whichever occurs first). (11) linkage. Wheels and tires service. (14) Air brake chamber service (or every 2 months, Hydraulic brake service (or every 6 months, whichever occurs first).
  • Page 352 84,000 Miles (140 000 km) Check fluid levels (or every 3 months, whichever occurs first). (1) (5) ® 7.8L DURAMAX Diesel Without Engine Oil Life Gasoline Engine: Replace engine air cleaner filter. System Only: Change engine oil and filter See Engine Air Cleaner/Filter on page 5-35 for (or every 12 months, or every 600 hours of engine more information.
  • Page 353 Replace fuel filter(s) (or every 12 months, whichever Clean air brake application valve (or every 3 months, occurs first). (2) or every 300 hours, whichever occurs first). Lubricate linkage. Steering system service. (12) Air brake chamber service (or every 2 months, Front and rear suspension service.
  • Page 354 96,000 Miles (152 000 km) Parking brake service (or every 6 months, whichever occurs first). (21) ® 7.8L DURAMAX Diesel Without Engine Oil Life Air brake service (or every 6 months, whichever System Only: Change engine oil and filter occurs first). (32) (or every 12 months, or every 600 hours of engine Air brake automatic slack adjuster service (or every operation, whichever occurs first).
  • Page 355 150,000 Miles (240 000 km) Except four-wheel drive: Front axle service. (31) Four-wheel drive only: Front axle service. (30) Cooling system service (or every 60 months since Four-wheel drive only: Transfer case service. (30) last service, whichever occurs first). (2) (29) ®...
  • Page 356 Footnotes (5) = Check fluid level in brake master cylinder, power steering pump, axle, transmission, and hydraulic † = The U.S. Environmental Protection Agency or the spring parking brake pump (if equipped). A low fluid California Air Resources Board has determined that the level in the brake master cylinder can indicate failure to perform this maintenance item will not nullify worn brake linings and should be checked accordingly.
  • Page 357 Remember to reset the Engine Oil Life System (9) = This vehicle has the Engine Oil Life System. This whenever the oil is changed. For more information, see system will show you when to change the engine oil Engine Oil Life System (Gasoline Engine) on page 5-31 and filter —...
  • Page 358 (11) = Chassis Lubrication Service: Lubricate all grease (12) = Check steering system: fittings in front suspension, front axle, and steering • Look for damaged, loose, or missing parts. Inspect linkage. DO NOT lubricate kingpin bushings with the steering linkage relay rod and tie rod ends for air pressure equipment;...
  • Page 359 (14) = Adjust tire pressures as indicated on the Gross (19) = With the engine off and below normal operating Vehicle Weight (GVW) Rating label for optimum tire life. temperature, check to see that the thermostatically See Tires on page 5-74 for further details. Check controlled engine cooling fan can be rotated by hand on tires for excessive or abnormal wear or damage.
  • Page 360 (23) = Check the air intake system installation to see (29) = Drain, flush, and refill cooling system. This that gaskets are seated properly and all hose service can be complex; you should have your dealer connections, fasteners, and other components are tight. perform this service.
  • Page 361 • (33) = Clean and lubricate air brake automatic slack Test air lines for leaks; tighten as needed. Replace adjuster. Check pushrod travel and auto adjustment compressor filter. operation. Have serviced if needed. • Inspect air parking brake chamber for leaks and (34) = Air brake chamber service: Check operation, damage.
  • Page 362: Engine Oil Level Check

    Part B: Owner Checks and Services Engine Oil Level Check Check the engine oil level and add the proper oil if Listed in this part are owner checks and services ® necessary. See Engine Oil (Caterpillar Diesel Engine) which should be performed at the intervals specified to ®...
  • Page 363: At Least Twice A Year

    Tire Inflation Check Weatherstrip Lubrication Check tire inflation cold. Make sure tires are inflated to Silicone grease on weatherstrips will make them last the pressures specified on the GVW Rating label. longer, seal better, and not stick or squeak. Apply See Loading Your Vehicle on page 4-34 and Tires on silicone grease with a clean cloth.
  • Page 364: Starter Switch Check

    Starter Switch Check Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen. CAUTION: Steering Check Be alert for any changes in steering action, abnormal When you are doing this inspection, the front tire wear or steering wheel position. An inspection vehicle could move suddenly.
  • Page 365: Exhaust System Check

    Exhaust System Check Seat Adjuster Check Be alert for any changes in the sound of the exhaust When adjusting a manual seat, be sure seat adjusters system or any smell of fumes. These are signs the latch by attempting to move the seat after latching. system may be leaking.
  • Page 366: 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 are not torn or damaged. Be sure that the cover is tight latching.
  • Page 367: Part C: Recommended Fluids And Lubricants

    Part C: Recommended Fluids Usage Fluid/Lubricant and Lubricants ® Engine Coolant See the Caterpillar Operation & ® (Caterpillar Maintenance Manual for engine Diesel Engine) coolant recommendations. Fluids and lubricants identified below by name, part number, or specification may be obtained from 50/50 mixture of clean, drinkable ®...
  • Page 368 Usage Fluid/Lubricant Usage Fluid/Lubricant Synthetic Transmission Fluid SAE 75W-90 Synthetic Axle Front Axle ® Manual approved to Allison Transmission Lubricant for Medium Duty Trucks (Four-Wheel Transmission specification TES-295 (GM Part No. U.S. 89021675, in Drive) (ZF 6-Speed) (GM Part No. U.S. 12378515, in Canada 10953512).
  • Page 369: Part D: Maintenance Record

    Part D: Maintenance Record After the scheduled services are performed, record the date, odometer reading and who performed the service, and any additional information from “Owner Checks and Services” on the following record pages. Also, you should retain all maintenance receipts. Miles/km Or Date Serviced By...
  • Page 370 Miles/km Or Date Serviced By Maintenance Record Hours 6-36...
  • Page 371 Miles/km Or Date Serviced By Maintenance Record Hours 6-37...
  • Page 372 Miles/km Or Date Serviced By Maintenance Record Hours 6-38...
  • Page 373: Customer Assistance And Information

    Section 7 Customer Assistance and Information Customer Assistance and Information ....7-2 Reporting Safety Defects ........7-10 Customer Satisfaction Procedure ......7-2 Reporting Safety Defects to the United States Customer Assistance for Text Telephone Government ..........7-10 (TTY) Users ..........7-3 Reporting Safety Defects to the Canadian Customer Assistance Offices ......7-4 Government ..........7-11 GM Mobility Reimbursement Program ....7-5...
  • Page 374: Customer Assistance And Information

    1-800-263-3777 (English) or 1-800-263-7854 Your satisfaction and goodwill are important to (French). your dealer and to Chevrolet. Normally, any concerns We encourage you to call the toll-free number in order with the sales transaction or the operation of your to give your inquiry prompt attention.
  • Page 375: Customer Assistance For Text Telephone (Tty) Users

    To assist customers who are deaf, hard of hearing, or venue for relief available to you. speech-impaired and who use Text Telephones (TTYs), Chevrolet has TTY equipment available at its Customer Assistance Center. Any TTY user can communicate with Chevrolet by dialing: 1-800-833-CHEV (2438).
  • Page 376: Customer Assistance Offices

    Customer Assistance Offices Canada — Customer Assistance General Motors of Canada Limited Chevrolet encourages customers to call the toll-free Customer Communication Centre, 163-005 number for assistance. However, if a customer wishes 1908 Colonel Sam Drive to write or e-mail, refer to the addresses below.
  • Page 377: Gm Mobility Reimbursement Program

    GM Mobility Reimbursement Roadside Assistance Program Program GM Medium Duty Truck’s Roadside Assistance provides stranded owners with towing service for disabled vehicles. This service combines the efforts of trained telephone representatives with a network of GM Medium Duty Truck’s dealer services. Just dial GM Medium Duty Truck Roadside Assistance at 1-800-862-4389 to reach a qualified representative who can assist you in a repair or arrange a tow.
  • Page 378: Vehicle Data Collection And Event Data Recorders

    Canadian Roadside Assistance Some information may be stored during regular operations to facilitate repair of detected malfunctions; In Canada, Medium Duty trucks are not eligible other information is stored only in a crash event by for Roadside Assistance services. However, computer systems, such as those commonly called owners/operators who contact Roadside Assistance event data recorders (EDR).
  • Page 379: Collision Damage Repair

    Collision Damage Repair To read this information, special equipment is needed and access to the vehicle or the device that stores the data is required. GM will not access information If your vehicle is involved in a collision and it is about a crash event or share it with others other than: damaged, have the damage repaired by a qualified technician using the proper equipment and quality...
  • Page 380: Insuring Your Vehicle

    Insuring Your Vehicle In most cases, the parts being recycled are from undamaged sections of the vehicle. A recycled original Protect your investment in your GM vehicle with equipment GM part, may be an acceptable choice comprehensive and collision insurance coverage. There to maintain your vehicle’s originally designed are significant differences in the quality of coverage appearance and safety performance, however, the...
  • Page 381 If an Accident Occurs • Gather the important information you will need from the other driver. Things like name, address, phone Here is what to do if you are involved in an accident. number, driver’s license number, vehicle license • plate, vehicle make, model and model year, Vehicle Try to relax and then check to make sure you are all Identification Number (VIN), insurance company and...
  • Page 382: Reporting Safety Defects

    Managing the Vehicle Damage Repair Reporting Safety Defects Process Reporting Safety Defects to the In the event that your vehicle requires damage repairs, GM recommends that you take an active role in its United States Government repair. If you have a pre-determined repair facility of choice, take your vehicle there, or have it towed there.
  • Page 383: Reporting Safety Defects To The Canadian Government

    Reporting Safety Defects to the Service Publications Ordering Canadian Government Information If you live in Canada, and you believe that your vehicle Service Manuals has a safety defect, you should immediately notify Transport Canada, in addition to notifying General Service Manuals have the diagnosis and repair Motors of Canada Limited.
  • Page 384: Current And Past Model Order Forms

    Owner’s Information ORDER TOLL FREE: 1-800-551-4123 Monday-Friday 8:00 AM - 6:00 PM Owner publications are written specifically for owners Eastern Time and intended to provide basic operational information about the vehicle. The owner’s manual will include For Credit Card Orders Only the Maintenance Schedule for all models.
  • Page 385 Airbag System (cont.) When Should an Airbag Inflate? ....1-55 Accessory Power Outlet(s) ....... 3-19 Where Are the Airbags? ....... 1-54 Adding a Snow Plow or Similar Equipment ..4-36 AM-FM Radio ..........3-50 Adding Equipment to Your Airbag-Equipped Antenna, Fixed Mast ........3-67 Vehicle ............
  • Page 386 Audio System(s) ..........3-48 Brake (cont.) AM-FM Radio ..........3-50 Hydraulic Systems ......... 4-7 Care of Your Cassette Tape Player ....3-65 System Warning Light ........3-33 Care of Your CD Player ....... 3-67 Trailer Hand Control Valve ......4-10 Care of Your CDs ........
  • Page 387: Checking Things Under The Hood

    Check Cleaning (cont.) Engine Light ..........3-38 Tires ............5-89 Gages Warning Light ........3-44 Underbody Maintenance ....... 5-90 Checking Things Under the Hood ...... 5-22 Washing Your Vehicle ........5-87 Chemical Paint Spotting ........5-90 Weatherstrips ..........5-86 Child Restraints Windshield and Wiper Blades ......
  • Page 388: Service Publications Ordering Information

    Customer Assistance Information (cont.) Driver Reporting Safety Defects to the Position, Safety Belt ........1-15 United States Government ......7-10 Driving Roadside Assistance Program ......7-5 At Night ............. 4-18 Service Publications Ordering Information ..7-11 City ............4-23 Defensive ............. 4-2 Drunken ............
  • Page 389 Engine Entry Lighting ..........3-17 Air Cleaner/Filter ......... 5-35 Event Data Recorders (EDR) ......7-6 Alarm and Automatic Shutdown ..... 2-20 Exhaust Brake Indicator Light ......3-41 Battery ............5-58 Exhaust Restrictor ........... 2-22 Change Engine Oil Light ....... 3-40 Extender, Safety Belt ........
  • Page 390 Fuel ............... 5-6 Additives ............5-6 Gage Diesel Engine Fuel ........5-7 Air Pressure ..........3-47 Filling a Portable Fuel Container ....5-21 Check Gages Warning Light ......3-44 Filling Your Tank .......... 5-20 Engine Coolant Temperature ......3-36 Filter ............5-70 Filter Minder ..........
  • Page 391 Hazard Warning Flashers ........3-6 Ignition Positions ..........2-12 Headlamp Wiring ..........5-93 Infants and Young Children, Restraints ....1-31 Headlamps Inflation - Tire Pressure ........5-75 Bulb Replacement ........5-68 Instrument Panel Daytime Running Lamps ....... 3-15 Overview ............. 3-4 High/Low Beam Changer ........
  • Page 392 Light (cont.) Range Inhibit Warning Indicator ..... 3-33 Lamps Reduced Engine Power ........ 3-42 Dome ............3-16 Safety Belt Reminder ........3-28 Exterior ............3-14 Safety Belt Reminder Tone ......3-28 Marker ............3-16 Service Transmission Warning ....... 3-32 Reading ............. 3-17 Trailer Anti-Lock Brake System Warning ..
  • Page 393 Maintenance Schedule (cont.) How This Section is Organized ....... 6-3 New Vehicle Break-In ........2-11 Introduction ..........6-2 Noise Control System, Tampering ...... 5-67 Maintenance Requirements ......6-2 Normal Maintenance Replacement Parts ... 5-104 Part A - Scheduled Maintenance Services ..6-4 Part B - Owner Checks and Services .....
  • Page 394 Other Warning Devices ........3-6 Power Outlet Adjustment ..........3-24 Accessory Outlet(s) ........3-19 Outlet(s), Accessory Power ....... 3-19 Door Locks ..........2-7 Outside Electrical System ......... 5-93 Convex Mirrors ..........2-48 Reduced Engine Light ........3-42 Heated Mirrors ..........2-48 Steering Fluid ..........
  • Page 395 Range Inhibit Warning Indicator ......3-33 Reading Lamps ..........3-17 Safety Belt Rear Axle ............5-64 Reminder Light ..........3-28 Differential Lock Control ....... 4-11 Reminder Tone ..........3-28 Shift Motor ..........5-65 Safety Belts Two-Speed Electric Shift Control ....2-28 Care of ............
  • Page 396 Securing a Child Restraint Storage Areas ..........2-49 Center Rear Seat Position (Crew Cab) Center Console Storage Area ......2-49 or Center Front Position ......1-44 Stuck in Sand, Mud, Ice, or Snow ..... 4-32 Rear Outside Seat Position ......1-42 Sun Visors .............
  • Page 397 Towing Your Vehicle ..........4-37 Vehicle Traction Control ............4-6 Control System (TCS) ........4-12 Damage Warnings ........... iv Trailer Loading ............4-34 Connections ..........4-39 Symbols ............iv Trailer Brake Hand Control Valve ...... 4-10 Vehicle Data Collection and Event Data Transmission Recorders ............
  • Page 398 Windows ............2-8 Manual ............2-9 Wait to Start Indicator ........3-37 Power ............2-9 Warning Lights, Gages and Indicators ....3-25 Sliding Rear ..........2-10 Warnings Windshield Hazard Warning Flashers ....... 3-6 Washer ............3-10 Other Warning Devices ........3-6 Washer Fluid ..........

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