Chevrolet KODIAK 2005 Owner's Manual

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2005 Chevrolet Kodiak Owner Manual

Seats and Restraint Systems ........................... 1-1

Front Seats

............................................... 1-2

Rear Seats

............................................... 1-8

Safety Belts

.............................................. 1-9

Child Restraints

....................................... 1-27

Airbag System

......................................... 1-48

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

.................................................... 2-45

Storage Areas

......................................... 2-47

Instrument Panel ............................................. 3-1

Instrument Panel Overview

Climate Controls

...................................... 3-20

Warning Lights, Gages, and Indicators

Audio System(s)

....................................... 3-44

Driving Your Vehicle ....................................... 4-1

Your Driving, the Road, and Your Vehicle

Towing

................................................... 4-35

............................ 1-60

........... 2-11

.......................... 3-4

........ 3-24

..... 4-2

Service and Appearance Care .......................... 5-1

Service

..................................................... 5-3

Fuel

......................................................... 5-6

Checking Things Under the Hood

Rear Axle

............................................... 5-60

Four-Wheel Drive

..................................... 5-62

Front Axle

............................................... 5-63

Noise Control System

Bulb Replacement

Windshield Wiper Blade Replacement

Other Service Items

Tires

...................................................... 5-70

Appearance Care

..................................... 5-79

Vehicle Identiﬁcation

Electrical System

...................................... 5-88

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

............... 5-20

............................... 5-64

.................................... 5-65

......... 5-65

.................................. 5-66

................................. 5-87

..................... 5-95

.... 5-100

................................ 6-2

........... 7-2

............................ 7-7

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Table of Contents

Summary of Contents for Chevrolet KODIAK 2005

Page 1: Table Of Contents
2005 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: Canadian Owners
Detroit, MI 48207 GENERAL MOTORS, GM, the GM Emblem, How to Use This Manual CHEVROLET, and the CHEVROLET Emblem are registered trademarks; and the name KODIAK is a Many people read the owner manual from beginning to trademark of General 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. 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 Manual Seats ..........1-2 (Crew Cab Models) ........1-38 Reclining Seatbacks ........1-4 Top Strap ............1-39 Split Bench Seat (80/20 Split) ......1-6 Securing a Child Restraint in a Rear Outside Air Suspension Seats ........1-6 Seat Position (Crew Cab Models) ....1-40 Securing a Child Restraint in the Center...
Page 8: Front Seats
Front Seats Manual Seats Bucket Seats CAUTION: You can lose control of the vehicle if you try to adjust the seat while the vehicle is moving. The sudden movement could startle and confuse you, or make you push a pedal when If your vehicle has bucket seats, you can adjust them you do not want to.
Page 9 Seatback Adjustment CAUTION: The seatback adjustment knob is located on the If the seatback is not locked, it could move inboard side of the driver’s and passenger’s forward in a sudden stop or crash. That could seat cushions. cause injury to the person sitting there. Always press rearward on the seatback to be sure it is locked.
Page 10 Fore-and-Aft Adjustment Reclining Seatbacks The fore-and-aft adjustment lever is located underneath the seat, in the front. If your vehicle has non-suspension bucket seats, you To slide the seat forward or rearward, move the lever can recline the seatbacks. The lever is located on toward the driver’s door.
Page 11 CAUTION: Sitting in a reclined position when your vehicle is in motion can be dangerous. Even if you buckle up, your safety belts cannot do their job when you are reclined like this. The shoulder belt cannot do its job because it will not be against your body.
Page 12: Height Adjustment
Split Bench Seat (80/20 Split) Height Adjustment The suspension seat If your vehicle has a split bench seat, your seat is height adjustment lever not adjustable. 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 can also be raised or lowered. The seat cushion height If your vehicle has this adjustment handle is feature, the handle is located underneath the located on the outboard front of the seat. side of the driver’s and passenger’s seats.
Page 14: Rear Seats
Rear Seats The rear bench seat on the crew cab can be folded down to provide more cargo space. Rear Seat Operation To fold down the seatback, pull this nylon strap Folding the Rear Seat (Crew Cab) located on the rear of the seat, while pulling the seatback down.
Page 15: Safety Belts
Safety Belts CAUTION: Safety Belts: They Are for Everyone It is extremely dangerous to ride in a cargo This part of the manual tells you how to use safety area, inside or outside of a vehicle. In a belts properly. It also tells you some things you should collision, people riding in these areas are more not do with safety belts.
Page 16: Why Safety Belts Work
Why Safety Belts Work In most states and in all Canadian provinces, the law says to wear safety belts. Here’s why: They work. You never know if you’ll be in a crash. If you do have Aren’t safety belts for kids? a crash, you don’t know if it will be a bad one.
Page 17 If the vehicle hits something, it stops – right then. Then something will stop them. It could be the But nothing stops the people. They keep moving. windshield. 1-11...
Page 18 Or it could be the instrument panel. With belts, you slow down as the vehicle does. You get more time to stop. Now, what if you and your passengers were to give that big vehicle a chance to deal with the force of the You stop over more distance, and your strongest bones impact, instead of you? take the forces.
Page 19 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 20: How To Wear Safety Belts Properly
How to Wear Safety Belts Properly This part is only for people of adult size. Be aware that there are special things to know about safety belts and children. And there are different rules for smaller children and babies. If a child will be riding in your vehicle, see Older Children on page 1-27 or Infants and Young Children on page 1-30.
Page 21 5. Move the shoulder belt height adjuster to the height that is right for you. See Shoulder Belt Height Adjustment on page 1-21. The lap part of the belt should be worn low and snug on 6. To make the lap part tight, pull down on the buckle the hips, just touching the thighs.
Page 22 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 23 What is wrong with this? CAUTION: You can be seriously injured if your belt is buckled in the wrong place like this. In a crash, the belt would go up over your abdomen. The belt forces would be there, not at the pelvic bones.
Page 24 What is wrong with this? CAUTION: You can be seriously injured if your belt goes over an armrest like this. The belt would be much too high. In a crash, you can slide under the belt. The belt force would then be applied at the abdomen, not at the pelvic bones, and that could cause serious or fatal injuries.
Page 25 What is wrong with this? CAUTION: You can be seriously injured if you wear the shoulder belt under your arm. In a crash, your body would move too far forward, which would increase the chance of head and neck injury. Also, the belt would apply too much force to the ribs, which are not as strong as shoulder bones.
Page 26 What is wrong with this? CAUTION: You can be seriously injured by 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 27: 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 28: Safety Belt Use During Pregnancy
Safety Belt Use During Pregnancy Right Front Passenger Position Safety belts work for everyone, including pregnant To learn how to wear the right front passenger’s safety women. Like all occupants, they are more likely to be belt properly, see Driver Position on page 1-14. seriously injured if they do not wear safety belts.
Page 29 When you sit in a center seating position, you have a To make the belt shorter, pull its free end as shown lap safety belt, which has no retractor. To make the belt until the belt is snug. longer, tilt the latch plate and pull it along the belt. Buckle, position and release it the same way as the lap part of a lap-shoulder belt.
Page 30: Rear Seat Passengers
Rear Seat Passengers It is very important for rear seat passengers to buckle up! Accident statistics show that unbelted people in the rear seat are hurt more often in crashes than those who are wearing safety belts. Rear passengers who are not safety belted can be thrown out of the vehicle in a crash.
Page 31 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. If the belt is not long enough, see Safety Belt Extender on page 1-26. Make sure the release button on the buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to.
Page 32: Safety Belt Extender
Safety Belt Extender Each position next to the windows has a shoulder belt height adjuster. See Shoulder Belt Height Adjustment on page 1-21. If the vehicle’s safety belt will fasten around you, you should use it. But if a safety belt is not long enough, your dealer will CAUTION: order you an extender.
Page 33: Child Restraints
Child Restraints What is the proper way to wear safety belts? If possible, an older child should wear a Older Children lap-shoulder belt and get the additional restraint a shoulder belt can provide. The shoulder belt should not cross the face or neck. The lap belt should ﬁt snugly below the hips, just touching the top of the thighs.
Page 34 CAUTION: Never do this. Here two children are wearing the same belt. The belt can not properly spread the impact forces. In a crash, the two children can be crushed together and seriously injured. A belt must be used by only one person at a time. What if a child is wearing a lap-shoulder belt, but the child is so small that the shoulder belt is very close to the child’s face or neck?
Page 35 CAUTION: Never do this. Here a child is sitting in a seat that has a lap-shoulder belt, but the shoulder part is behind the child. If the child wears the belt in this way, in a crash the child might slide under the belt.
Page 36: 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 37 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 38 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 39: Child Restraint Systems
Child Restraint Systems A rear-facing infant seat (B) provides restraint with the seating surface against the back of the infant. The harness system holds the infant in place and, An infant car bed (A), a special bed made for use in a in a crash, acts to keep the infant positioned in motor vehicle, is an infant restraint system designed the restraint.
Page 40 A forward-facing child seat (C-E) provides restraint for A booster seat (F-G) is a child restraint designed to the child’s body with the harness and also sometimes improve the ﬁt of the vehicle’s safety belt system. with surfaces such as T-shaped or shelf-like shields. Some booster seats have a shoulder belt positioner, and some high-back booster seats have a ﬁve-point harness.
Page 41 When choosing a child restraint, be sure the child How do child restraints work? restraint is designed to be used in a vehicle. If it is, it will have a label saying that it meets federal motor A child restraint system is any device designed for vehicle safety standards.
Page 42 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 43 Unless the passenger’s airbag has been turned off, never put a rear-facing child restraint in this vehicle. CAUTION: (Continued) Here is why: that an airbag will not deploy under some CAUTION: unusual circumstance, even though it is turned off. We recommend that rear-facing child restraints be transported in vehicles with a A child in a rear-facing child restraint can be rear seat that will accommodate a rear-facing...
Page 44 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. CAUTION: We recommend that child restraints be secured in a rear seat position, including an infant riding in a rear-racing...
Page 45: Top Strap
Wherever you install a child restraint, be sure to secure the child restraint properly. CAUTION: (Continued) Keep in mind that an unsecured child restraint can move around in a collision or sudden stop and injure If you need to secure a forward-facing child people in the vehicle —...
Page 46: 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 strap 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 strap be anchored, or if the instructions that come with the child restraint say that the top strap must be anchored.
Page 47 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 48 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 strap 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 49 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 50: Securing A Child Restraint In The Right Front Seat Position
Securing a Child Restraint in the A rear seat is a safer place to secure a forward-facing child restraint. Never put a rear-facing child restraint Right Front Seat Position in the right front passenger’s seat unless the airbag is off. Here is why: Do not use a child restraint with an air suspension seat.
Page 51 CAUTION: (Continued) CAUTION: If you need to secure a forward-facing child If the airbag readiness light ever comes on restraint in the right front static seat or the when you have turned off the airbag, it means right front bench seat, always move the that something may be wrong with the airbag passenger seat as far back as it will go.
Page 52 You will be using the lap-shoulder belt. See Top Strap on page 1-39 if the child restraint has one. 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.
Page 53 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 54: 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 55 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 56 Here are the most important things to know about the airbag system: CAUTION: CAUTION: Airbags inﬂate with great force, faster than the blink of an eye. If you are too close to an inﬂating airbag, as you would be if you were You can be severely injured or killed in a crash leaning forward, it could seriously injure you.
Page 57 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 58: 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. 1-52...
Page 59 It depends largely on what you hit, the direction of the impact and how quickly your vehicle slows down. CAUTION: (The threshold level can vary, however, with speciﬁc vehicle design, so that it can be somewhat above or below this range.) If something is between an occupant and an airbag, the bag might not inﬂate properly or it Airbags may inﬂate at different crash speeds.
Page 60: How Does An Airbag Restrain
What Makes an Airbag Inﬂate? What Will You See After an Airbag Inﬂates? In an impact of sufficient severity, the airbag sensing system detects that the vehicle is in a crash. After an airbag inﬂates, it quickly deﬂates, The sensing system triggers a release of gas from the so quickly that some people may not even realize inﬂator, which inﬂates the airbag.
Page 61 In many crashes severe enough to inﬂate the airbag, windshields are broken by vehicle deformation. CAUTION: Additional windshield breakage may also occur from the right front passenger airbag. • Airbags are designed to inﬂate only once. After they When an airbag inﬂates, there is dust in the inﬂate, you will need some new parts for your air.
Page 62: Airbag Off Switch
Airbag Off Switch This switch should only be turned to the off position if the person in the right front passenger’s position is a member of a passenger risk group identiﬁed by the If your vehicle has a right front passenger airbag, it has national government as follows: a switch on the instrument panel that you can use to turn off the right front passenger’s airbag.
Page 63 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 64 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 65 Servicing Your Airbag-Equipped Adding Equipment to Your Vehicle Airbag-Equipped Vehicle Airbags affect how your vehicle should be serviced. Is there anything I might add to the front of There are parts of the airbag system in several places the vehicle that could keep the airbags from around your vehicle.
Page 66: Restraint System Check
Restraint System Check Replacing Restraint System Parts After a Crash Checking the Restraint Systems CAUTION: Now and then, make sure the safety belt reminder light and all your belts, buckles, latch plates, retractors and anchorages are working properly. Look for any other A crash can damage the restraint systems in loose or damaged safety belt system parts.
Page 67: Features And Controls
Section 2 Features and Controls Keys ...............2-2 Diesel Engine Exhaust Brake ......2-25 Remote Keyless Entry System ......2-3 Two-Speed Rear Axle Electric Shift Control ..2-26 Remote Keyless Entry System Operation ...2-4 Air Shift Control (Automatic Transmission) ..2-27 Automatic Transmission Operation ....2-28 Doors and Locks ..........2-6 Manual Transmission Operation ......2-29 Door Locks ............2-6...
Page 68: 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. Do not leave the keys in a vehicle with children.
Page 69 Remote Keyless Entry System Your vehicle has one double-sided key for the ignition and all door locks. If equipped, the keyless entry system operates on a radio frequency subject to Federal Communications Commission (FCC) Rules and with Industry Canada. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1.
Page 70: 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 71: 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 72: Doors And Locks
Resynchronization Doors and Locks Resynchronization may be necessary due to the Door Locks security method used by this system. The transmitter does not send the same signal twice to the receiver. The receiver will not respond to a signal it has been sent CAUTION: previously.
Page 73: 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 If your vehicle has power can use your transmitter to lock or unlock your vehicle. door locks, press the See Remote Keyless Entry System Operation on bottom of the power door page 2-4.
Page 74: 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 75: Power Windows
Power Windows If your vehicle is a crew cab model with power windows, the driver’s door will have four switches on it that can control all of the windows. There will be switches located If your vehicle is equipped with power windows, the on the rear doors as well.
Page 76: Sliding Rear Window
Express-Down Feature Sliding Rear Window The driver’s window also has an express-down feature To open the sliding rear window, pull the latch toward that allows the window to be lowered without holding the driver’s side of the vehicle. down the switch. Press and hold the rear of the window To close the window, slide the window toward the switch labeled AUTO for one second to activate the passenger’s side of the vehicle.
Page 77: Starting And Operating Your Vehicle
Starting and Operating • Avoid making hard stops for the ﬁrst 200 miles (322 km) or so. During this time your new brake Your Vehicle linings are not yet broken in. Hard stops with new linings can mean premature wear and earlier replacement.
Page 78: Ignition Positions
Ignition Positions C (OFF): This position lets you turn off the engine but still turn the steering wheel. It does not lock the steering wheel like LOCK. Use OFF if you must have With your key in the ignition switch, you can turn it to your vehicle in motion while the engine is off.
Page 79 Automatic Transmission Starting Your Engine 1. Without pushing the accelerator pedal, turn your Set the parking brake and move your shift lever to ignition key to START. When the engine starts, NEUTRAL (N) or PARK (P), if so equipped. Your engine will not start in any other position —...
Page 80: Starting The Diesel Engine
Gasoline Engine Warm-Up While your engine is idling and before you turn it off, you can make a list of any operational or handling When you have started your engine, let it run for concerns to give to responsible maintenance personnel 20 or 30 seconds to warm up before you put a load so they can handle them right away.
Page 81 Automatic Transmission Starting Your Engine 1. Turn your ignition key to RUN. Move your shift lever to PARK (P) or NEUTRAL (N). Observe the wait to start light. See Wait to Your engine will not start in any other position — that is a safety feature.
Page 82 If you are trying to start your engine after you have run If you do not have the GM Automatic Ether Injection out of fuel, see Running Out of Fuel on page 5-15. System, do not use starting ﬂuid or you could damage your engine.
Page 83 Cold Weather Starting Diesel Engine Warm-Up ® (Caterpillar Diesel) Several factors affect how quickly your diesel engine Because the diesel engine uses compression ignition, warms up. These can include outside temperature, it is harder to start in cold weather than a gasoline engine load, idle time and your vehicle’s option content.
Page 84: Engine Alarm And Automatic Shutdown
If Your Diesel Engine Will Not Start Be sure you are using the proper fuel for existing weather conditions. See What Fuel to Use on page 5-8. If you have run out of fuel, see Running Out of Fuel on If the engine starts, runs a short time, then stops, page 5-15.
Page 85: Diesel Engines
High Idle System If the system senses low engine coolant, the ﬁve beat per second alarm and the low coolant warning light ® (Caterpillar Diesel/Gasoline Engine) will come on. The ﬁve beats per second tone alarm means that your Automatic High Idle System engine will shut down in about 25 to 30 seconds.
Page 86 Manual High Idle System The manual high idle feature is activated by pressing the switch on the instrument panel. When the switch is If your vehicle has this pressed again, or any of the previous conditions are feature, the manual high not met, manual high idle will be deactivated.
Page 87 Exhaust Restrictor If this feature is turned on when the engine is started, the green exhaust brake/restrictor light below the ® (DURAMAX Diesel) radio controls will be lit for 10 seconds. If this feature is turned on and the algorithm comes on, based upon ®...
Page 88: Engine Checks Before Operating
Engine Checks Before Operating The high idle speed will be temporarily interrupted and the engine speed will return to normal if any of the When you have started your engine, let it run for following conditions occur: 20 to 30 seconds before you put a load on the engine. •...
Page 89 • During this warm-up period, check your warning lights The charging system light should come on when and gages: the ignition key is turned to RUN or START and should go out when the engine is running above • If oil pressure does not begin to rise within idle.
Page 90: 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 91 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 is equipped with a diesel engine, possible range that does not allow the engine rpm to go it may have an exhaust brake, which is located in the more than 200 rpm above rated (full load) rpm.
Page 92 Two-Speed Rear Axle Electric When the switch is up, the rear axle is in the high range. Push the switch down to change to low range. Shift Control The two-speed axle should be in low when you park the vehicle. You will need to engage the transmission, If your vehicle is equipped with this feature, you will ﬁnd even move the vehicle a little, to be sure the axle is a label on the headliner above the windshield or in...
Page 93 Air Shift Control To shift up from low to high, press the top of the rear axle shift control switch and press down on the (Automatic Transmission) accelerator. When you shift the axle from high to low, press the bottom of the switch, release the accelerator and then quickly press it down again.
Page 94: 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 95 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 96 ® ® 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 unique to GM manual These transmissions have gears that automatically transmissions. synchronize when you shift up or down (except FIRST (1) gear on the ﬁve-speed and seven-speed transmission which is unsynchronized).
Page 97 During the ﬁrst 500 miles (805 km) of vehicle use, start THIRD (3): Press the clutch pedal and upshift into the vehicle moving in FIRST (1) gear. This allows THIRD (3). Then, slowly let up on the clutch pedal as the clutch components to wear-in properly.
Page 98 ® ® 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 99 Four-Wheel Drive Locking Hubs If your vehicle has four-wheel drive, you can send your engine’s driving power to all four wheels for extra traction. To get the most satisfaction out of four-wheel drive, you must be familiar with its operation. Read the part that follows before using four-wheel drive.
Page 100 Electronic Transfer Case An indicator light will show you which position the transfer case is in. The indicator lights will come on brieﬂy when you turn on the ignition and one will stay on. If your vehicle is equipped If the lights do not come on, you should take your with four-wheel drive, the vehicle to your dealer for service.
Page 101 ® Notice: If your vehicle has an Allison transmission (Four-Wheel Low): This setting sends maximum and you try to put the transmission in PARK (P) power to all four wheels. You might choose Four-Wheel while the transfer case is in Four-Wheel Low, Low if you are driving off-road in deep sand, deep mud, the transmission may not go into PARK (P) and and climbing or descending steep hills.
Page 102 Shifting Into Four-Wheel Low Shifting Out of Four-Wheel Low To shift to Four-Wheel Low, the vehicle’s engine must To shift from four-wheel low to Four-Wheel High or be running and the vehicle must be stopped or Two-Wheel High, your vehicle must be stopped moving less than 3 mph (5 km/h) with the transmission or moving less than 3 mph (5 km/h) with the in NEUTRAL (N).
Page 103 Shifting Into NEUTRAL Shifting Out of NEUTRAL Before shifting the transfer case to NEUTRAL, ﬁrst To shift the transfer case out of NEUTRAL, do the make sure the vehicle is parked so that it will not roll. following: 1. Set the parking brake and apply the regular 1.
Page 104: Hydraulic Brakes
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 105: Propshaft Brake Burnish Procedure
To set the hand lever parking brake, hold the regular Notice: Driving with the parking brake on can brake pedal down with your right foot. Pull up on damage the transmission and brake system parts. the handle with your right hand, until it stops. Verify that the parking brake is fully released and the brake warning light is off before driving.
Page 106: Air Brake
Air Brake Vehicles built for use as tractors or towing vehicles have two air brake controls. They look like this: If your vehicle has air brakes, you will have this parking brake. It is located above the radio in the instrument panel.
Page 107 To charge a trailer’s air brake system do the following: CAUTION: 1. Move your vehicle into the proper position. 2. Apply the parking brake by pulling the yellow parking brake knob out. If you apply any one of the air brake parking 3.
Page 108: Air Suspension
Rear Air Suspension Dump Control If you ever have a complete loss of air so that your air brakes automatically apply, there is a way that the If your vehicle is equipped with the Hendrickson HAS tow operator can release the parking brakes to tow the Series single-axle air suspension, you may have vehicle.
Page 109: 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 110: 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 111: Mirrors
Mirrors Outside Power Mirrors If you have outside power mirrors, they can be adjusted Manual Rearview Mirror from the inside of the vehicle. The control for this If your vehicle has this feature, pull the tab under the feature is located on the mirror toward you to reduce glare from headlamps driver’s door.
Page 112: Outside Convex Mirrors
Outside Convex Mirrors Outside Heated Mirrors Your vehicle has convex mirrors on the lower quarter of If your vehicle has this feature, your outside rearview both the driver’s and passenger’s side rearview mirrors. mirrors can be defrosted. A convex mirror’s surface is curved so you can see The switch for this feature more from the driver’s seat.
Page 113: 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 114 NOTES 2-48...
Page 115 Section 3 Instrument Panel Instrument Panel Overview .......3-4 Warning Lights, Gages, and Indicators ....3-24 Hazard Warning Flashers ........3-6 Instrument Panel Cluster ........3-25 Other Warning Devices ........3-6 Speedometer and Odometer ......3-26 Horn .............3-6 Trip Odometer ..........3-26 Tilt Wheel .............3-7 Tachometer ..........3-26 Turn Signal/Multifunction Lever ......3-7 Engine Speed Limiter ........3-26 Turn and Lane-Change Signals ......3-8...
Page 116 Section 3 Instrument Panel Transmission Temperature Gage .....3-39 Audio System(s) ..........3-44 Exhaust Brake Indicator Light ......3-40 Setting the Time ...........3-45 Differential Lock Indicator Light .......3-40 AM-FM Radio ..........3-45 Reduced Engine Power Light ......3-41 Radio with Cassette ........3-48 Highbeam On Light ........3-41 Radio with CD ..........3-53 Daytime Running Lamps (DRL) Indicator Light ..3-41 Theft-Deterrent Feature (Non-RDS Radios) ..3-57...
Page 117 NOTES...
Page 118 Instrument Panel Overview...
Page 119 A. Air Outlets. See Outlet Adjustment on page 3-23. H. Turn Signal/Multifunction Lever. See Turn Signal/Multifunction Lever on page 3-7. B. Instrument Panel Cluster. See Instrument Panel Cluster on page 3-25. I. Hazard Warning Flashers Button. See Hazard Warning Flashers on page 3-6. C.
Page 120 Hazard Warning Flashers Other Warning Devices Your hazard warning ﬂashers let you warn others. They If you carry reﬂective triangles, you can set them up at also let police know you have a problem. Your front the side of the road about 300 feet (100 m) behind and rear turn signal lamps will ﬂash on and off.
Page 121: 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 122 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 5-89.
Page 123 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 band solid band below the delay settings.
Page 124: Windshield Washer
Windshield Washer Cruise Control (Washer Fluid): There is a paddle marked with the If your vehicle has this feature, it is located at windshield washer symbol at the top of the multifunction the end of the lever. To spray washer ﬂuid on the windshield, press multifunction lever.
Page 125 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 126 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 127 Reducing Speed While Using Cruise Ending Cruise Control Control There are four different ways to turn off the cruise control: Press in the button at the end of the lever until you • reach the lower speed you want, then release it. Step lightly on the brake pedal (manual and automatic transmissions).
Page 128: 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 129: 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 130: Instrument Panel
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 131: Entry Lighting
Entry Lighting The delayed illumination feature will allow you to enter or exit your vehicle with the lights on for about 20 seconds, after the door is closed or the ignition is cycled. Reading Lamps If your vehicle has reading lamps, press the button next to the lamp to turn the lamp on or off.
Page 132: Instrument Panel Overview
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 “Manual High Idle System” under High Idle System ® (Caterpillar Diesel/Gasoline Engine) on page 2-19. (Traction Control Switch): See Traction Control System (TCS) on page 4-10.
Page 133: Accessory Power Outlets
Notice: Leaving electrical equipment on for (Exhaust Brake Switch): See Diesel Engine extended periods will drain the battery. Always turn Exhaust Brake on page 2-25. 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 134: Climate Controls
Ashtrays and Cigarette Lighter Climate Controls Your vehicle may have an ashtray and a cigarette Climate Control System lighter located in the center ﬂoor console. See Instrument Panel Overview on page 3-4. To open the With these systems, you can control the heating, removable ashtray, ﬂip open the top.
Page 135 If your vehicle has air conditioning, the controls will look (Bi-Level): This mode directs half of the air to the like this: instrument panel vents, then directs the remaining air to the ﬂoor vents. Cooler air is directed to the upper vents and warmer air to the ﬂoor vents.
Page 136: Defogging And Defrosting
Defogging and Defrosting The defog setting is useful for cold weather with a large number of passengers or very humid conditions to Fog on the inside of windows is a result of high humidity help keep the windshield clear. Use defrost to remove (moisture) condensing on the cool window glass.
Page 137: Operation Tips
Operation Tips The rear window defogger will turn off several minutes after the button is pressed. The defogger can also • Keep the hood and front air inlets free of ice, snow, be turned off by pressing the button again or by turning or any other obstruction (such as leaves).
Page 138: Warning Lights, Gages, And Indicators
Rear Heating System Warning Lights, Gages, and Indicators If you have a crew cab This part describes the warning lights and gages that and your vehicle has a may be on your vehicle. The pictures will help you rear heater, the locate them.
Page 139: Instrument Panel Cluster
Instrument Panel Cluster Your instrument panel cluster is designed to let you know at a glance how your vehicle is running. You’ll know how fast your going, about how much fuel is left and many other things you’ll need to drive safely and economically. United States Diesel Engine shown, Canada and Gasoline Engine similar 3-25...
Page 140: 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 141 Engine Road Speed Governor Safety Belt Reminder Tone This system controls maximum vehicle speed If your vehicle has this feature, when you turn your key automatically and reduces engine power until vehicle to RUN or START, a tone will sound for several speed gets down to maximum governed speed.
Page 142: Airbag Off Light
Airbag Off Light If the airbag readiness light stays on after you start the vehicle or comes on when you are driving, your airbag system may not work properly. Have your vehicle If your vehicle is equipped with an airbag off switch, serviced right away.
Page 143 CAUTION: CAUTION: If the right front passenger’s airbag is turned If the airbag readiness light ever comes on off for a person who is not in a risk group when you have turned off the airbag, it means identiﬁed by the national government, that that something may be wrong with the airbag person will not have the extra protection of an system.
Page 144 Charging System Light Voltmeter Gage The charging system light When your engine is may be located in the running, the voltmeter instrument panel cluster, or gage shows the charging with the auxiliary warning system voltage. lights in the center of the instrument panel.
Page 145 Service Transmission Warning Light Range Inhibit Warning Indicator If your vehicle has an Allison automatic transmission, If your vehicle has an Allison certain transmission malfunctions will turn this light on. 1000/2000/2200/2400/2500 series automatic transmission, a lighted bar under the current gear This light is located with selected will ﬂash.
Page 146 Hydraulic Brake System If the service brakes soon warning light comes on, it Warning Lights means there may be something wrong in the Vehicles with hydraulic brake systems have two brake brake system. system warning lights on the instrument panel. If the BRAKE system warning light comes on, it means that the ﬂuid...
Page 147 Parking Brake Warning Light When the warning light comes on while you are driving, you should drive only as far as the nearest point of This light will also come on when you set the parking safety and then stop the vehicle. Here’s a very important brake.
Page 148 Anti-Lock Brake System Trailer Anti-Lock Brake System Warning Light Warning Light This light should come on If your vehicle is connected brieﬂy when you start the to a trailer with anti-lock engine, if it does not brakes, this light should have your vehicle ﬁxed come on brieﬂy, as a immediately.
Page 149: Engine Coolant Temperature Gage
Engine Coolant Temperature Gage Low Coolant Warning Light You have a low coolant warning light. If this light comes on, your system is low on coolant and the engine may overheat. The warning light should come on brieﬂy, as a check, when you turn on the ignition.
Page 150: Wait To Start Indicator
Wait to Start Indicator Malfunction Indicator Lamp (Diesel Engine) Service Engine Soon Light ® If your vehicle has the DURAMAX 6600, you will have ® If this light comes on or glow plugs. If your vehicle has the DURAMAX 7800, ﬂashes while you are you will have glow plugs and an inlet heater.
Page 151 Oil Pressure Gage A reading in the low pressure zone may be caused by a dangerously low oil level or other problem. ® If you have a Caterpillar diesel engine, also see your ® Caterpillar Operation & Maintenance Manual. CAUTION: Do not keep driving if the oil pressure is low.
Page 152 Low Oil Level Light Change Engine Oil Light This light should come on The change engine oil light as a check, when you start should come on brieﬂy as your engine. If the light a bulb check when you fails to come on, have it start the engine.
Page 153: Engine Overspeed Warning Light
Engine Overspeed Warning Light Transmission Temperature Gage If your vehicle has this If you have an automatic light, it will come on if your transmission and this engine is operating at gage, it is located too many revolutions per above the switchbank in minute (rpm).
Page 154: Exhaust Brake Indicator Light
Exhaust Brake Indicator Light Differential Lock Indicator Light If your vehicle is equipped If your vehicle has this with an exhaust brake, you feature, this light is located will have this light, in the center of the located above the comfort instrument panel.
Page 155: Reduced Engine Power Light
Reduced Engine Power Light Highbeam On Light If the check engine and This light will come on reduced engine power when the high-beam lights are on, the throttle headlamps are in use. may be disabled, and a noticeable change in the vehicle’s performance may occur.
Page 156: Low Washer Fluid Warning Light
Low Washer Fluid Warning Light When the check gages light comes on, you will also hear a warning tone. The tone and the light will stay activated until the problem is corrected. This light will come on This light may also come on if your vehicle is equipped when your vehicle is low with the optional automatic engine shutdown system on windshield washer ﬂuid.
Page 157: Water In Fuel Warning Light
Air Filter Restriction Indicator If your vehicle has dual fuel tanks, the reading on the gage is the total fuel left in both tanks. Here are four concerns of some operators. None of If your vehicle has this these shows a problem with your fuel gage: feature, the gage is •...
Page 158: Audio System(S)
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 The instrument panel cluster displays the accumulated gage is located above the engine run time hours using the reconﬁgurable switchbank in the center odometer display.
Page 159: Setting The Time
AM-FM Radio Notice: The chime signals related to seat belts, parking brake, and other functions of your vehicle operate through the GM radio/entertainment system. If that equipment is replaced or additional equipment is added to your vehicle, the chimes may not work.
Page 160 Finding a Station Setting Preset Stations Up to 18 stations (six FM1, six FM2, and six AM) can be AM FM: Press this button to switch between FM1, FM2, programmed on the six numbered pushbuttons, by or AM. The display will show the selection. performing the following steps: TUNE: Turn this knob to select radio stations.
Page 161 To adjust both tone controls and both speaker controls To adjust both tone controls and both speaker controls to the middle position, ﬁrst end out of audio mode to the middle position, ﬁrst end out of audio mode by pressing another button, causing the radio to perform by pressing another button, causing the radio to perform that function or by waiting ﬁve seconds for the display that function or by waiting ﬁve seconds for the display...
Page 162: 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 163 Setting Preset Stations Adjusting the Speakers (Balance/Fade) Up to 18 stations (six FM1, six FM2, and six AM) can be AUDIO: To adjust the balance between the right programmed on the six numbered pushbuttons, by and the left speakers, press and release AUDIO until performing the following steps: BAL appears on the display.
Page 164: Playing A Cassette Tape
Radio Messages While the tape is playing, use the VOL, AUDIO, and SEEK controls just as you do for the radio. The radio will display UP if the top side of the tape is playing. CAL (Calibration): The audio system has been DN (Down) will appear if the bottom side is playing.
Page 165 2 NEXT: The tape must have at least three seconds of 6 RPT (Repeat): The tape must have at least silence between each selection for next to work. three seconds of silence between each selection for Press this pushbutton to go to the next selection on the repeat to work.
Page 166: 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 167 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 168 Setting Preset Stations To adjust both tone controls and both speaker controls to the middle position, ﬁrst end out of audio mode Up to 18 stations (six FM1, six FM2, and six AM), can by pressing another button, causing the radio to perform be programmed on the six numbered pushbuttons, that function, or by waiting ﬁve seconds for the display by performing the following steps:...
Page 169: Playing A Cd
Playing a CD To adjust both tone controls and both speaker controls to the middle position, ﬁrst end out of audio mode Insert a CD partway into the slot, label side up. The by pressing another button, causing the radio to perform player will pull it in and the CD should begin playing.
Page 170 Do not add paper labels to CDs, they could get caught 4 FWD (Forward): Press and hold this pushbutton to in the CD player. advance quickly within a track. Release this pushbutton to play the passage. The elapsed time of the track Notice: If you add paper labels to a CD, insert more will appear on the display.
Page 171: Theft-Deterrent Feature (Non-Rds Radios)
Theft-Deterrent Feature CD: Press this button to play a CD when listening to the radio. CD will appear on the display if a CD is loaded. (Non-RDS Radios) (Eject): Press this button to eject a CD. Eject may ® THEFTLOCK is designed to discourage theft of be activated with either the ignition or radio off.
Page 172: Care Of The Cassette Tape Player
Care of the Cassette Tape Player The cut tape detection feature of the cassette tape player may identify the cleaning cassette as a damaged tape. To prevent the cleaning cassette from being A tape player that is not cleaned regularly can cause ejected, use the following steps: reduced sound quality, ruined cassettes or a damaged mechanism.
Page 173: Care Of Your Cds
Care of Your CDs Chime Level Adjustment Handle CDs carefully. Store them in their original cases The radio is the vehicle chime producer. The chime is or other protective cases and away from direct produced from the driver’s side front door speakers. sunlight and dust.
Page 174 NOTES 3-60...
Page 175: Driving Your Vehicle
Section 4 Driving Your Vehicle Your Driving, the Road, and Your Vehicle ..4-2 Driving in Rain and on Wet Roads ....4-18 Defensive Driving ...........4-2 City Driving ..........4-21 Drunken Driving ..........4-2 Freeway Driving ...........4-22 Control of a Vehicle ........4-5 Highway Hypnosis ........4-23 Braking ............4-5 Hill and Mountain Roads ........4-24 Hydraulic Brake Systems .........4-6...
Page 176: Your Driving, The Road, And Your Vehicle
Your Driving, the Road, and proper defensive driving more difficult and can even cause a collision, with resulting injury. Ask a passenger to Your Vehicle help do things like this, or pull off the road in a safe place to do them yourself. These simple defensive driving techniques could save your life.
Page 177 Many adults — by some estimates, nearly half the adult same BAC by drinking three 4 ounce (120 ml) glasses population — choose never to drink alcohol, so they of wine or three mixed drinks if each had 1-1/2 ounces never drive after drinking.
Page 178 There is a gender difference, too. Women generally Statistics show that the chance of being in a collision have a lower relative percentage of body water increases sharply for drivers who have a BAC of than men. Since alcohol is carried in body water, this 0.05 percent or above.
Page 179: Control Of A Vehicle
Braking CAUTION: Braking action involves perception time and reaction time. Drinking and then driving is very dangerous. First, you have to decide to push on the brake pedal. Your reﬂexes, perceptions, attentiveness, and That is perception time. Then you have to bring up your judgment can be affected by even a small foot and do it.
Page 180: Hydraulic Brake Systems
Avoid needless heavy braking. Some people drive You may ﬁnd that the steering wheel seems hard to turn in spurts — heavy acceleration followed by heavy when you are turning and braking at the same time. braking — rather than keeping pace with traffic. This is Also, the primary brake warning light may come on and a mistake.
Page 181 Let us say the road is wet and you are driving safely. As you brake, your computer keeps receiving updates Suddenly, an animal jumps out in front of you. You slam on wheel speed and controls braking pressure on the brakes and continue braking. Here is what accordingly.
Page 182: Braking In Emergencies
Using Anti-Lock You can apply the trailer brakes a little or apply them all the way if you have to. Use this control only when Do not pump the brakes. Just hold the brake pedal you are driving. Do not use it for parking or to hold the down ﬁrmly and let anti-lock work for you.
Page 183: Rear Axle Differential Lock Control
Rear Axle Differential Lock Control If you’re approaching a slippery surface where it looks like one or even both wheels may start to slip, you can press the bottom of this switch. It locks your rear If your vehicle has a differential so that power is transmitted equally to controlled traction or both rear wheels.
Page 184: Traction Control System (Tcs)
Traction Control System (TCS) The traction control system automatically comes on whenever you start your vehicle. To limit wheel spin, especially in slippery road conditions, you should Your vehicle may have a traction control system that always leave the system on. But you can turn the limits wheel spin.
Page 185: Steering
Steering The traction you can get in a curve depends on the condition of your tires and the road surface, the angle at which the curve is banked, and your speed. While Power Steering you are in a curve, speed is the one factor you can control.
Page 186: Steering In Emergencies
Steering in Emergencies There are times when steering can be more effective than braking. For example, you come over a hill and ﬁnd a truck stopped in your lane, or a car suddenly pulls out from nowhere, or a child darts out from between parked cars and stops right in front of you.
Page 187: Off-Road Recovery
Off-Road Recovery Passing You may ﬁnd that your right wheels have dropped The driver of a vehicle about to pass another on a off the edge of a road onto the shoulder while you two-lane highway waits for just the right moment, are driving.
Page 188 • • Watch for traffic signs, pavement markings and If other cars are lined up to pass a slow vehicle, wait lines. If you can see a sign up ahead that might your turn. But take care that someone is not trying to indicate a turn or an intersection, delay your pass.
Page 189: Loss Of Control
Loss of Control If you have the Traction Control System (TCS), remember: It helps avoid only the acceleration skid. See Traction Control System (TCS) on page 4-10. If you Let us review what driving experts say about what do not have this system, or if the system is off, then an happens when the three control systems —...
Page 190: Driving At Night
Driving at Night Here are some tips on night driving. • Drive defensively. • Do not drink and drive. • Since you cannot see as well, you may need to slow down and keep more space between you and other vehicles. •...
Page 191 No one can see as well at night as in the daytime. But Keep your windshield and all the glass on your vehicle as we get older these differences increase. A clean — inside and out. Glare at night is made much 50-year-old driver may require at least twice as much worse by dirt on the glass.
Page 192: Driving In Rain And On Wet Roads
Driving in Rain and on Wet Roads The heavier the rain, the harder it is to see. Even if your windshield wiper blades are in good shape, a heavy rain can make it harder to see road signs and traffic signals, pavement markings, the edge of the road, and even people walking.
Page 193: Driving Through Deep Standing Water
Hydroplaning does not happen often. But it can if your tires do not have much tread or if the pressure in one or CAUTION: more is low. It can happen if a lot of water is standing on the road. If you can see reﬂections from trees, telephone poles, or other vehicles, and raindrops dimple Wet brakes can cause accidents.
Page 194: Driving Through Flowing Water
Driving Through Flowing Water Some Other Rainy Weather Tips • Turn on your low-beam headlamps and your marker and clearance lamps, if your vehicle has CAUTION: them — not just your parking lamps — to help make you more visible to others. Flowing or rushing water creates strong forces.
Page 195: 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 196: 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 197: Highway Hypnosis
Highway Hypnosis Before changing lanes, check your mirrors. Then use your turn signal. Is there actually such a condition as highway hypnosis? Once you are moving on the freeway, make certain you Or is it just plain falling asleep at the wheel? Call it allow a reasonable following distance.
Page 198: Hill And Mountain Roads
Hill and Mountain Roads Here are some tips that can make your drive through steep country safer: • Keep the vehicle in good shape. Check all ﬂuid levels and also the brakes, tires, cooling system, and transmission. These parts can work hard on mountain roads.
Page 199 • Stay in your own lane when driving on two-lane roads in hills or mountains. Do not swing wide CAUTION: or cut across the center of the road. Drive at speeds that let you stay in your own lane. Coasting downhill in NEUTRAL (N) or with the •...
Page 200: Winter Driving
Winter Driving 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 201 If you have the traction control system (TCS), it will improve your ability to accelerate when driving on a slippery road. But you can turn the TCS off if you ever need to. You should turn the system off if your vehicle ever gets stuck in sand, mud, ice, or snow.
Page 202: If You Are Caught In A Blizzard
• Remember, unless you have ABS, if you brake so hard Put on extra clothing or wrap a blanket around you. that your wheels stop rolling, you will just slide. Brake If you do not have blankets or extra clothing, make so your wheels always keep rolling and you can body insulators from newspapers, burlap bags, still steer.
Page 203 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 204: If Your Vehicle Is Stuck In Sand, Mud
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 205: Tow Hooks
Tow Hooks CAUTION: If your vehicle has tow hooks, the hooks are provided at the front and, on some models, the rear of your vehicle. You may need to use them if you are stuck These hooks, when used, are under a lot of off-road and need to be pulled to some place where you force.
Page 206: 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 There is a vehicle speciﬁc GVW Rating label on your and rear axles, called Gross Axle Weight Rating vehicle that shows how much weight it may properly (GAWR).
Page 207 CAUTION: CAUTION: Do not load your vehicle any heavier than the Things you put inside your vehicle can strike Gross Vehicle Weight Rating (GVWR), or either and injure people in a sudden stop or turn, or the maximum front or rear Gross Axle Weight in a crash.
Page 208: 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 equipped with certain front recommend that the vehicle be equipped with the mounted equipment, such as a snow plow, it snow plow prep package (RPO ANQ).
Page 209: 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 210 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 211: Trailer Connections
Trailer Connections The eight-wire harness contains the following trailer circuits: Heavy-Duty Trailer Wiring Package • Yellow: Left Stop/Turn Signal • Dark Green: Right Stop/Turn Signal Your vehicle may be equipped with an eight-wire trailer towing harness. This harness, with a seven-pin •...
Page 212: Power Take-Off (Pto)
Trailer Connections Power Take-Off (PTO) (C7/C8 Models Only) If your vehicle is equipped If your vehicle has these trailer connections, they are for the addition of a PTO, located at the rear of the cab for a tractor and at the rear this factory installed of the chassis when towing a trailer.
Page 213: Service And Appearance Care
Section 5 Service and Appearance Care Service ............5-3 Engine Air Cleaner/Filter ........5-33 Doing Your Own Service Work ......5-4 Automatic Transmission Fluid ......5-34 Two Safety Cautions about Engine Fan Manual Transmission Fluid ......5-35 Breakage ...........5-5 Engine Coolant (Gas and ® DURAMAX Engines) .........5-36 Fuel ..............5-6 ®...
Page 214 Section 5 Service and Appearance Care Other Service Items ........5-66 Washing Your Vehicle ........5-83 Fuel Filter ............5-66 Cleaning Exterior Lamps/Lenses .....5-83 Primary Fuel Filter and Water Separator ..5-67 Finish Care ..........5-83 Secondary Fuel Filter and Water Separator/ Windshield and Wiper Blades ......5-84 ®...
Page 215: 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 216: Doing Your Own Service Work
Doing Your Own Service Work CAUTION: If you want to do some of your own service work, you will want to use the proper service manual. It tells you much more about how to service your vehicle than You can be injured and your vehicle could be this manual can.
Page 217: Two Safety Cautions About Engine Fan
Two Safety Cautions about CAUTION: (Continued) Engine Fan Breakage Winter Fronts, Grille Covers or Obstructions: CAUTION: Winter Fronts, grille covers or other add-on equipment causing obstructions in front or behind the fan should not be used on this Changing the Fan Drive Ratio or Engine vehicle.
Page 218: Fuel
Fuel Gasoline Speciﬁcations It is recommended that gasoline meet speciﬁcations If your vehicle has a diesel engine, see Diesel Engine which were developed by automobile manufacturers Fuel on page 5-7. around the world and contained in the World-Wide Fuel For vehicles with gasoline engines, please read this. Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm.
Page 219: Diesel Engine Fuel
Diesel Engine Fuel Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in ® ® your area to contribute to clean air. General Motors For the Caterpillar diesel, see the Caterpillar recommends that you use these gasolines, particularly if Operation &...
Page 220: What Fuel To Use
What Fuel to Use Biodiesel is produced from vegetable oils or animal fat that have been chemically modiﬁed to reduce the In the United States, for best results use Number 2-D possibility of damage to your fuel system and engine. diesel fuel year-round (above and below freezing Higher concentration (i.e., greater than B5) conditions) as oil companies blend Number 2-D fuel to...
Page 221 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 222: 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 223: Water In Fuel Light Chart
Water In Fuel Light Chart 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 224 Fuel Priming 5. Remove the fuel-resistant container and properly dispose of the contaminated fuel. To ﬁnd out how to ® If your vehicle has a Caterpillar diesel engine, see the properly dispose of contaminated diesel fuel, ® ® Caterpillar Diesel Engine Operation and Maintenance see Engine Oil (Caterpillar Diesel Engine) on Manual provided with your vehicle.
Page 225 ® Priming the 6.6L DURAMAX Diesel 4. Remove any dirt from the fuel ﬁlter head and vent valve by wiping with a cloth. Engine ® 5. Open the fuel ﬁlter vent If your vehicle is equipped with the 6.6L DURAMAX valve by turning the diesel engine, it has a priming pump which is part of the screw counterclockwise...
Page 226 ® 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 of diesel engine, use the following procedure to prime the your hand.
Page 227: Running Out Of Fuel
Running Out of Fuel 6. Use the palm of your hand to repeatedly press and release the plunger (1) at the top of the fuel ﬁlter If the diesel engine stalls and you think that you have priming pump. Continue until the plunger resistance run out of fuel, do this to restart your engine: becomes ﬁrm.
Page 228: Fuel Filter Replacement
Fuel Filter Replacement The fuel ﬁlter is located in the engine compartment on the passenger’s side of the vehicle, or on the driver’s side frame rail in front of the fuel tank. If you want to change the diesel engine fuel ﬁlter yourself, here is how to do it: 1.
Page 229: 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 230: 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 to the left (counterclockwise). CAUTION: If you get fuel on yourself and then something ignites it, you could be badly burned.
Page 231: Filling A Portable Fuel Container
Filling a Portable Fuel Container When you put the cap back on, turn it to the right (clockwise) until it is tight. Notice: If you need a new fuel cap, be sure to get CAUTION: the right type. Your dealer can get one for you. If you get the wrong type, it may not ﬁt properly.
Page 232: 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 233 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. 5-21...
Page 234: 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. 1. If the engine is at normal operating temperature and ®...
Page 235 This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities and Speciﬁcations on page 5-95. 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 236 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 237 • 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 238: Checking Engine Oil
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 239 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 240 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 241: 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 242: How To Reset The Engine Oil Life System
How to Reset the Engine Oil Life What to Do with Used Oil 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 243 Engine Oil Life System If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km), or 150 hours ® (DURAMAX Diesel) 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 244 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 Life Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a System good hand cleaner.
Page 245: 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 the engine compartment. air cleaner/ﬁlter change indicator, inspect the indicator at every oil change and replace the ﬁlter when the indicator tells you to.
Page 246: Automatic Transmission Fluid
How to Inspect the Engine Automatic Transmission Fluid Air 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 247: 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 248: Engine Coolant
Engine Coolant (Gas and What to Use ® 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 249: 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 the proper coolant, you do not have to add extra inhibitors or additives which claim Turning the surge tank pressure cap when the to improve the system.
Page 250: Coolant Surge Tank Pressure Cap
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 engine is cool.
Page 251: 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 3-35 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 252: 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, you will see:...
Page 253 If the coolant inside the coolant surge tank is boiling, do not do anything else until it cools down. The vehicle CAUTION: should be parked on a level surface. The coolant level should Heater and radiator hoses, and other engine be at the FULL COLD parts, can be very hot.
Page 254: 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 255 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 256 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 257: Engine Fan Noise
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 258: Windshield Washer Fluid
Windshield Washer Fluid Notice: • When using concentrated washer ﬂuid, What to Use follow 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 259: 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 260 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 261: Brake Adjustment
Four-Wheel Disc Brakes Brake Adjustment (Hydraulic Only) Every time you make a brake stop, your brakes adjust for wear. Your vehicle has four-wheel disc brakes. Replacing Brake System Parts Some driving conditions or climates may cause a brake squeal when the brakes are ﬁrst applied or lightly The braking system on a vehicle is complex.
Page 262: 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 263 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 264 Single Axle Models Item Number Item Remarks Brake Camshaft** One ﬁtting each (apply sparingly). Steering Column Slip Joint* One ﬁtting. Steering Drag Link Ends One ﬁtting each end. 5-52...
Page 265 Item Number Item Remarks Pivot Points and Hinges Apply chassis lubricant. Pivot Points and Hinges Apply chassis lubricant. Slack Adjuster** One ﬁtting. Brake Cam Roller Pins at interface Apply engine oil. of pin and shoe** One ﬁtting each side, lower bushing. Front Steering Knuckles (Hand-operated grease gun only.) Hand-pack upper bearing.
Page 266 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 Brake Shoe at pin to shoe Roller Pins joint only.
Page 267: 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 268: 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 battery (or batteries) has run down, you may want to use another vehicle and some jumper cables to Trying to start your vehicle by pushing or pulling it start your vehicle.
Page 269 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 270 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 271 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 remote negative (−) terminal if the vehicle has one. of the dead battery.
Page 272: Rear Axle
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 273 You should avoid driving your vehicle through deep puddles or standing water. If you must drive through water that is higher than the front or rear axle, see your dealer immediately afterward to have the condition of the axle lubricant checked. How to Check Lubricant HD2 Axle Your vehicle may be equipped with one of the axles...
Page 274: Rear Axle Shift Motor
Rear Axle Shift Motor How to Check Lubricant When to Check and Change Fluid If you have an optional air-shift two-speed, controlled traction, or locking differential type rear axle, a good time to check the ﬂuid level in the axle shift motor is when the rear axle lubricant is checked.
Page 275: Front Axle
When to Change Lubricant How to Check Lubricant Refer to the Maintenance Schedule to determine how often to change the lubricant. See Scheduled Maintenance on page 6-5. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See Part C: Recommended Fluids and Lubricants on page 6-32.
Page 276: Noise Control System
Noise Control System Among those acts presumed to constitute tampering are the acts listed below. Insulation: Tampering with Noise Control • Removal of the noise shields or any underhood System Prohibited insulation. The following information relates to compliance with Engine: federal noise emission standards for vehicles with a •...
Page 277: Bulb Replacement
Bulb Replacement Here’s how to remove the Shephard’s Hook type: It is recommended that all bulbs be replaced by your dealer. 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 6-28 for more information.
Page 278: Other Service Items
Other Service Items Fuel Filter Fuel Filter (Gasoline Engines) 2. Push the release lever and slide the wiper assembly toward the driver’s side of the vehicle. 3. Install a new blade by reversing Steps 1 and 2. The steel fuel ﬁlter is located near the engine compartment on the driver’s side of the vehicle.
Page 279: Primary Fuel Filter And Water Separator
Fuel Filter (Diesel Engines) It has a clear plastic drain bowl at the bottom. Check the drain bowl occasionally for any water or particles. If you have a diesel engine, your fuel ﬁlter is located in To drain the bowl, do the following: the engine compartment on the driver’s side of the vehicle, or along the driver’s side frame rail.
Page 280: Secondary Fuel Filter And Water Separator/Heater (Caterpillar Diesel)
Secondary Fuel Filter and Water Automatic Ether Injection System ® Separator/Heater (Caterpillar Diesel) ® (Caterpillar Diesel) ® If you have a Caterpillar diesel engine, you may ® If you have a Caterpillar have this feature. The diesel engine, you may ether cylinder is located in also have this spin-on ﬁlter the engine compartment...
Page 281: Front Wheel Bearings With Oil-Filled Hubs
6. Install a new gasket whenever you take out the If your vehicle has oil-ﬁlled cylinder. Use only one gasket and spread a light hubs, occasionally check ﬁlm of clean oil on it before installation. to see if they have enough oil.
Page 282: 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 283: Inﬂation - Tire Pressure
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 284: Dual Tire Operation
Dual Tire Operation When It Is Time for New Tires Replace your tires when the tread depth is down to When the vehicle is new, check the wheel nut tightness 1/8 of an inch (3.2 mm) for the front tires, or 1/16 of an on all wheels with a torque wrench after your ﬁrst inch (1.6 mm) for a rear tire.
Page 285: 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 286 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 287 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) 8-Hole CAUTION: Never use oil or grease on studs or the threads of the wheel nuts.
Page 288 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 289: 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 290: Used Replacement Wheels
Used Replacement Wheels A rear blowout, particularly on a curve, acts much like a skid and may require the same correction you’d use in a skid. In any rear blowout, remove your foot from the accelerator pedal. Get the vehicle under control by CAUTION: steering the way you want the vehicle to go.
Page 291: Appearance Care
Appearance Care For example, you would need a truck jack that can lift several thousand pounds and a torque wrench that can generate several hundred foot-pounds (Y) of Cleaning products can be hazardous. Some are toxic. twisting force. Other cleaning products can burst into ﬂames if a match is struck near them or if they get on a hot part of the vehicle.
Page 292: Cleaning The Inside Of Your Vehicle
They can all be hazardous — some more than When cleaning your vehicle’s interior, only use cleaners others —and they can all damage the vehicle, too. speciﬁcally designed for the surfaces being cleaned. Permanent damage may result from using cleaners on Do not use any of these products unless this manual surfaces for which they were not intended.
Page 293: Fabric/Carpet
Fabric/Carpet Do not clean your vehicle using the following cleaners or techniques: Use a vacuum cleaner with a soft brush attachment • Never use a knife or any other sharp object to frequently to remove dust and loose dirt. A canister remove a soil from any interior surface.
Page 294: Instrument Panel, Vinyl, And Other Plastic Surfaces
If any of the soil remains, a commercial fabric cleaner or Some commercial products may increase gloss on spot lifter may be necessary. When a commercial your instrument panel. The increase in gloss may upholstery cleaner or spot lifter is to be used, test a cause annoying reﬂections in the windshield and even small hidden area for colorfastness ﬁrst.
Page 295: Washing Your Vehicle
Washing Your Vehicle Finish Care Occasional waxing or mild polishing of your vehicle by The paint ﬁnish on the vehicle provides beauty, depth of hand may be necessary to remove residue from the color, gloss retention, and durability. paint ﬁnish. You can get GM-approved cleaning products The best way to preserve the vehicle’s ﬁnish is to from your dealer.
Page 296: Windshield And Wiper Blades
Protecting Exterior Bright Metal Parts Aluminum or Chrome-Plated Wheels Bright metal parts should be cleaned regularly to keep The vehicle may be equipped with either aluminum or their luster. Washing with water is all that is usually chrome-plated wheels. needed. However, you may use chrome polish on Keep the wheels clean using a soft clean cloth with mild chrome or stainless steel trim, if necessary.
Page 297: Tires
Tires Underbody Maintenance To clean the tires, use a stiff brush with tire cleaner. Chemicals used for ice and snow removal and dust control can collect on the underbody. If these are not Notice: Using petroleum-based tire dressing removed, corrosion and rust can develop on the products on your vehicle may damage the paint underbody parts such as fuel lines, frame, ﬂoor pan, ﬁnish and/or tires.
Page 298 Vehicle Care/Appearance Materials Vehicle Care/Appearance Materials (cont’d) Description Usage Description Usage Polishing Cloth Interior and exterior Wax- Treated polishing cloth. Removes light scratches Cleaner Wax and protects ﬁnish. Tar and Road Removes tar, road oil and Oil Remover asphalt. Cleans, shines and Foaming Tire Shine protects in one easy step, Chrome Cleaner...
Page 299: Vehicle Identiﬁcation
Vehicle Identiﬁcation Engine Identiﬁcation The eighth character in your VIN is the engine code. This code will help you identify your engine, Vehicle Identiﬁcation Number (VIN) speciﬁcations and replacement parts. Service Statement One of these statements is on your GVW Rating label. Here is what each one means.
Page 300: Service Parts Identiﬁcation Label
Service Parts Identiﬁcation Label Headlamp Wiring You will ﬁnd this label in a location determined by the The headlamp wiring is protected by a circuit breaker in body manufacturer. It is very helpful if you ever need to the light switch. An electrical overload will cause the order parts.
Page 301: Fusible Links
Fusible Links Fuses and Circuit Breakers A fusible link is a short piece of wire several gauge The wiring circuits in your vehicle are protected from sizes smaller than the circuit it protects. It will melt in an short circuits by a combination of fuses, circuit breakers, overload situation, opening the circuit.
Page 302 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. Circuit Breaker Usage Circuit Breaker Usage Stoplamps Courtesy Lamps Center High-Mounted Stoplamp Warning Lights, Gages and Indicators Parking Lamps Starter...
Page 303 Circuit Breaker Usage Fuse Usage Air Bag System Blank Not Used Exterior/Interior Lamps LT PARK Left-hand Parking Lamps Parking Brake Blank Not Used Accessory Power RT REAR Right Rear Turn Signal/Stoplamp TRN/STOP Ignition 4 LT REAR Sidemarker Lamps Left Rear Turn Signal/Stoplamp TRN/STOP Turn Signal/Backup Lamps RADIO...
Page 304: Underhood Fuse Block
Underhood Fuse Block When a circuit goes out, the problem could be in either the primary or secondary underhood fuse blocks. These blocks use blade-type fuses. Both underhood fuse blocks are located in the engine compartment, on the passenger’s side of the vehicle. To access the fuse blocks, gently squeeze both sides of the cover to unlatch the tabs at the top.
Page 305 Fuse Usage Relay Usage ENG 2 Engine 2 LG4 Powertrain Control Valve, NOTE 1 L18 Fuel Pump, LG5 Heated Fuel HTD FUEL Heated Fuel IGN B Ignition BLANK Empty STARTER Starter BLANK Empty HORN Horn BLANK Empty IGN A Ignition A/C COMP Air Conditioning Compressor Power Take-Off/Engine Control Unit...
Page 306 Fuse Usage IGN 1 Four-Wheel Drive Module IGN 4 Ignition 4 IGN 3 Ignition 3 BATT/HAZ Battery/Hazard Warning Flashers HEADLAMP Headlamps LIGHTING Interior/Exterior Lamps HVAC Comfort Control System C4/C5 Electric Brake, NOTE C6/C7/C8 Brake Lamps Secondary Underhood Fuse Block 5-94...
Page 307: 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 6-32 for more information. Capacities Application English Metric Air Conditioning Refrigerant R134a 2.1 lbs 1.0 kg Cooling System – C4/C5 Models 6.6L AutomaticTransmission 27.3 qt 25.8 L...
Page 308 Capacities Application English Metric Cooling System – C6/C7/C8 Manual Transmission 7.2L 207 - 230 hp Engine 29.3 qt 27.7 L 7.2L 207 - 230 hp Engine with A/C and Increased Cooling 33.0 qt 31.2 L 7.2L 250 - 300 hp Engine 32.8 qt 31.0 L 7.2L 250 - 300 hp Engine with A/C and Increased Cooling...
Page 309 Capacities Application English Metric Fuel Capacity – C4/C5 Models Optional* (Dual Tanks) 40 gal 151.4 L Optional 25 gal 94.6 L Optional 32 gal 121.1 L Standard 40 gal 151.4 L Optional 60 gal 227.1 L Optional 80 gal 302.8 L *One 25-gallon (94.6 L) tank and one 15-gallon (56.8 L) tank Fuel Capacity –...
Page 310 Capacities Application English Metric Front Axle (G38) and (FRX) 7.8 pt 3.7 L Rear Axle – Single Speed 80 (GL4) 10.0 pt 4.7 L 19060D (HPL), 19060S (HPK), 21060D (HPN), 31.0 pt 14.7 L 21060S (HPP) 23090S (HPT) 40.0 pt 19.0 L 23105D (HNB), 23105S (HNA) 56.0 pt...
Page 311 Capacities Application English Metric 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 PTS and EVS, 2500 HS and RDS, and 2400 Series Add 2 pints (1 L) when changing spin-on or remote ﬁlter.
Page 312: Normal Maintenance Replacement Parts
Engine Speciﬁcations Engine Type ® 6.6LV8 DURAMAX 6600 Common Rail Fuel System ® 7.2L L6 Caterpillar HEUI Fuel System ® 7.8L L6 DURAMAX 7800 Common Rail Fuel System 8.1L V8 Vortec 8100 SPFI Fuel System Normal Maintenance Replacement Parts Replacement parts identiﬁed by name, part number, or speciﬁcation can be obtained from your dealer. ®...
Page 313 ® Part GM Part Number ACDelco Part Number Fuel Filter 6.6L 97385488 TP1298A 7.2L — 915 Primary** 7.8L 94392474 — 8.1L — GF626* Power Steering Fluid Filter 88892858 — Pressure Caps 6.6L; 7.8L 15075118 — 7.2L — — 8.1L 15997145 —...
Page 314 NOTES 5-102...
Page 315 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Scheduled Maintenance ........6-5 Introduction ...........6-2 Part B: Owner Checks and Services ....6-27 Maintenance Requirements ......6-2 At Each Fuel Fill ..........6-27 Your Vehicle and the Environment ....6-2 At Least Twice a Year ........6-28 How This Section is Organized ......6-3 At Least Once a Year ........6-31 Part A: Scheduled Maintenance Services ...6-4 Part C: Recommended Fluids and Lubricants ..6-32...
Page 316: Maintenance Schedule
Maintenance Schedule Maintenance Requirements Maintenance intervals, checks, inspections and Introduction recommended ﬂuids and lubricants as prescribed in this manual are necessary to keep your vehicle in good Important: Keep engine oil at the proper level and working condition. Any damage caused by failure change as recommended.
Page 317: 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 318: Part A: Scheduled Maintenance Services
Part A: Scheduled Maintenance This part tells you the maintenance services you should have done and when to schedule them. Services When you go to your dealer for your service needs, you will know that GM-trained and supported service In this part are scheduled maintenance services which people will perform the work using genuine GM parts.
Page 319: Scheduled Maintenance Supplements
® Scheduled Maintenance Gasoline engine vehicles and some DURAMAX diesel engine vehicles have a computer that lets you know Supplements when to change your engine oil. This is not based on mileage, but on engine operation and engine ® If your vehicle has a Caterpillar diesel engine, your temperature.
Page 320 7,500 Miles (12 000 km) 12,000 Miles (20 000 km) ® Gasoline Engine Only: Check engine oil life system. If 7.8L DURAMAX Diesel Without Engine Oil Life engine oil and ﬁlter are changed, reset system. See System Only: Change engine oil and ﬁlter (or “Engine Oil (Gasoline Engine)”...
Page 321 Check ﬂuid levels (or every 3 months, whichever Parking brake service (or every 6 months, whichever occurs ﬁrst). (1) (5) occurs ﬁrst). (21) Gasoline Engine: Inspect engine air cleaner ﬁlter. If Air brake service (or every 6 months, whichever necessary, replace the ﬁlter. If vehicle is driven in occurs ﬁrst).
Page 322 22,500 Miles (36 000 km) Parking brake service (or every 6 months, whichever occurs ﬁrst). (21) Gasoline Engine Only: Check engine oil life system. If Air brake service (or every 6 months, whichever engine oil and ﬁlter are changed, reset system. See occurs ﬁrst).
Page 323 24,000 Miles (40 000 km) Gasoline Engine: Inspect engine air cleaner ﬁlter. If necessary, replace the ﬁlter. If vehicle is driven in ® 7.8L DURAMAX Diesel Without Engine Oil Life dusty/dirty conditions, inspect ﬁlter at every engine oil System Only: Change engine oil and ﬁlter (or change.
Page 324 36,000 Miles (55 000 km) Air brake service (or every 6 months, whichever occurs ﬁrst). (32) ® 7.8L DURAMAX Diesel Without Engine Oil Life Air brake automatic slack adjuster service (or every System Only: Change engine oil and ﬁlter (or 500 hours, whichever occurs ﬁrst).
Page 325 Parking brake service (or every 6 months, whichever Check ﬂuid levels (or every 3 months, whichever occurs ﬁrst). (21) occurs ﬁrst). (1) (5) Air brake service (or every 6 months, whichever Gasoline Engine: Replace engine air cleaner ﬁlter. occurs ﬁrst). (32) See Engine Air Cleaner/Filter on page 5-33 for more information.
Page 326 Front and rear suspension service. (13) Shields and underhood insulation service. (3) (4) (20) Spring-to-axle U-bolts and shackle bolts service. (15) Rear axle air shift motor service. (10) Exhaust system service (or every 6 months, whichever Air intake system service (or every 24 months, occurs ﬁrst).
Page 327 52,500 Miles (84 000 km) 60,000 Miles (96 000 km) Gasoline Engine Only: Check engine oil life system. If Gasoline Engine Only: Check engine oil life system. If engine oil and ﬁlter are changed, reset system. See engine oil and ﬁlter are changed, reset system. See “Engine Oil (Gasoline Engine)”...
Page 328 Gasoline Engine: Inspect engine air cleaner ﬁlter. If Hydraulic brake service (or every 6 months, whichever necessary, replace the ﬁlter. If vehicle is driven in occurs ﬁrst). (6) (36) dusty/dirty conditions, inspect ﬁlter at every engine oil Parking brake service (or every 6 months, whichever change.
Page 329 67,500 Miles (108 000 km) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever Gasoline Engine Only: Check engine oil life system. If occurs ﬁrst). engine oil and ﬁlter are changed, reset system. See Clean air brake application valve (or every 3 months, “Engine Oil (Gasoline Engine)”...
Page 330 ® 75,000 Miles (120 000 km) DURAMAX Diesel Only: Replace fuel ﬁlter (or every 750 hours of engine operation, whichever occurs ﬁrst). Gasoline Engine Only: Check engine oil life system. If Steering system service. (12) engine oil and ﬁlter are changed, reset system. See Front and rear suspension service.
Page 331 EGR system inspection (if equipped) (or every Air brake automatic slack adjuster service (or every 72 months, whichever occurs ﬁrst). (2) (27) 500 hours, whichever occurs ﬁrst). (33) Thermostatically controlled engine cooling fan Check air brake relay valve operation and check for service.
Page 332 90,000 Miles (144 000 km) Cooling system service. Clean the cooling system ﬁller cap with clean water, clean the core, pressure test the Gasoline Engine Only: Check engine oil life system. If cap and the system for proper pressure capability, and engine oil and ﬁlter are changed, reset system.
Page 333 96,000 Miles (152 000 km) Air brake automatic slack adjuster service (or every 500 hours, whichever occurs ﬁrst). (33) ® 7.8L DURAMAX Diesel Without Engine Oil Life Check air brake relay valve operation and check for System Only: Change engine oil and ﬁlter (or leaks (or every month, or every 300 hours, whichever every 12 months, or every 600 hours of engine occurs ﬁrst).
Page 334 Air brake automatic slack adjuster service (or every Exhaust brake service, if equipped. Check for 500 hours, whichever occurs ﬁrst). (33) excessive spindle free play and smooth operation. Lubricate ball joint cap. Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, whichever Inspect air compressor discharge port (or every occurs ﬁrst).
Page 335 200,000 Miles (320 000 km) Footnotes Remove, disassemble, clean, and inspect the air † = The U.S. Environmental Protection Agency or the brake trailer supply valve (or every 2 years, or California Air Resources Board has determined that the every 7,200 hours, whichever occurs ﬁrst). failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to Diesel Engine Only: Inspect engine drive belt;...
Page 336 (6) = Inspect brake lines and hoses for proper hook-up, Under severe conditions, the indicator may come on binding, leaks, cracks, chaﬁng, etc. Inspect disc before 3,000 miles (5 000 km). Never drive your gasoline brake pads for wear and rotors for surface condition. engine vehicle more than 7,500 miles (12 000 km) or Inspect caliper assemblies.
Page 337 (10) = Inspect rear axle air shift motor for ﬂuid leaks. (12) = Check steering system: Remove plug to check ﬂuid level. Inspect air lines and • Look for damaged, loose, or missing parts. Inspect hoses for proper hook-up, binding, leaks, etc. Inspect at the steering linkage relay rod and tie rod ends for 1,000 miles (1 600 km) and 22,500 miles (36 000 km) looseness or lack of lubricant.
Page 338 (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 5-70 for further details. Check controlled engine cooling fan can be rotated by hand on tires for excessive or abnormal wear or damage.
Page 339 (24) = Evaporative Control System Service, if equipped: neck. Pressure test cooling system and pressure cap. For ® Check all fuel and vapor lines and hoses for proper Caterpillar diesel engines, always refer to the ® connections and correct routing (or every 24 months, Caterpillar Diesel Engine Operation &...
Page 340 • (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 341: Part B: Owner Checks And Services
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 342: Weatherstrip Lubrication
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 4-32 and Tires on silicone grease with a clean cloth.
Page 343: Starter Switch Check
Starter Switch Check Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen. CAUTION: Steering Check When you are doing this inspection, the Be alert for any changes in steering action, abnormal vehicle could move suddenly. If the vehicle front tire wear or steering wheel position.
Page 344: Exhaust System Check
Engine Cooling System Service Mirrors and Sun Visors Check Inspect the hoses and have them replaced if they are Check that friction joints hold mirrors and sun visors cracked, swollen, or deteriorated. Inspect all pipes, in place. ﬁttings, and clamps; replace as needed. Clean Seat Adjuster Check the outside of the radiator and air conditioning condenser.
Page 345: At Least Once A Year
Door Latches Check Engine Cover Check Check that doors close, latch, and lock tightly. Check for Check that the cab’s engine cover and seal (if equipped) broken, damaged, or missing parts that might prevent are not torn or damaged. Be sure that the cover is tight latching.
Page 346: Part C: Recommended Fluids And Lubricants
Part C: Recommended Fluids and Usage Fluid/Lubricant ® Lubricants Engine Coolant See the Caterpillar Operation & ® (Caterpillar Maintenance Manual for engine Diesel Engine) coolant recommendations. Fluids and lubricants identiﬁed below by name, part Engine Coolant number, or speciﬁcation may be obtained from 50/50 mixture of clean, drinkable (Gasoline your dealer.
Page 347 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 348: 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 349 Miles/km Or Date Serviced By Maintenance Record Hours 6-35...
Page 350 Miles/km Or Date Serviced By Maintenance Record Hours 6-36...
Page 351 Section 7 Customer Assistance and Information Customer Assistance and Information ....7-2 Reporting Safety Defects ........7-7 Customer Satisfaction Procedure ......7-2 Reporting Safety Defects to the United States Online Owner Center ........7-3 Government ..........7-7 Customer Assistance for Text Reporting Safety Defects to the Canadian Telephone (TTY) Users ........7-4 Government ..........7-7 Customer Assistance Offices ......7-4...
Page 352: Customer Assistance And Information
Your satisfaction and goodwill are important to the windshield. your dealer and to Chevrolet. Normally, any concerns with the sales transaction or the operation of your • Dealership name and location.
Page 353: Online Owner Center
Online Owner Center The BBB Auto Line Program is an out of court program administered by the Council of Better Business Bureaus to settle automotive disputes regarding vehicle The Owner Center is a resource for your GM ownership repairs or the interpretation of the New Vehicle needs.
Page 354: Customer Assistance For Text Telephone (Tty) Users
Roadside Assistance: 1-800-268-6800 number for assistance. If a U.S. customer wishes to write Overseas — Customer Assistance to Chevrolet, the letter should be addressed to the GM Medium Duty Truck Customer Assistance Center. Please contact the local General Motors Business Unit.
Page 355: 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 356: Canadian Roadside Assistance
Canadian Roadside Assistance In a crash event, computer systems, such as the Airbag Sensing and Diagnostic Module (SDM) in your vehicle In Canada, Medium Duty trucks are not eligible for may record information about the condition of the vehicle Roadside Assistance services. However, and how it was operated, such as data related to owners/operators who contact Roadside Assistance by engine speed, brake application, throttle position, vehicle...
Page 357: Reporting Safety Defects
In addition, once GM collects or receives data, GM may: If NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in • use the data for GM research needs, a group of vehicles, it may order a recall and remedy •...
Page 358: Reporting Safety Defects To General Motors
Reporting Safety Defects to General Service Publications Ordering Motors Information In addition to notifying NHTSA (or Transport Canada) in Service Manuals a situation like this, we certainly hope you’ll notify us. Please call us at 1-800-862-4389, or write: Service Manuals have the diagnosis and repair information on engines, transmission, axle suspension, GM Medium Duty Truck brakes, electrical, steering, body, etc.
Page 359: Service Bulletins
Service Bulletins Current and Past Model Order Forms Service Bulletins give technical service information Service Publications are available for current and needed to knowledgeably service General Motors cars past model GM vehicles. To request an order form, and trucks. Each bulletin contains instructions to please specify year and model name of the vehicle.
Page 360 NOTES 7-10...
Page 361 Airbag System (cont.) When Should an Airbag Inﬂate? ....1-53 Accessory Power Outlets ......... 3-19 Where Are the Airbags? ....... 1-52 Adding a Snow Plow or Similar Equipment ..4-34 AM-FM Radio ..........3-45 Adding Equipment to Your Airbag-Equipped Antenna, Fixed Mast ........3-59 Vehicle ............
Page 362 Audio System(s) ..........3-44 AM-FM Radio ..........3-45 Battery ............5-55 Care of Your Cassette Tape Player ....3-58 Bench Seat, Split ..........1-6 Care of Your CD Player ....... 3-59 Brake Care of Your CDs ........3-59 Anti-Lock Brake System (ABS) ......4-6 Chime Level Adjustment .......
Page 363 Child Restraints (cont.) Securing a Child Restraint in the Center Canadian Owners ..........ii Rear Seat Position (Crew Cab) or Capacities and Speciﬁcations ......5-95 Center Front Position ........ 1-42 Carbon Monoxide ........2-43, 4-26 Securing a Child Restraint in the Right Care of Front Seat Position ........
Page 364 Climate Control System ........3-20 Outlet Adjustment ........3-23 Daytime Running Lamps ........3-15 Rear Heating System ........3-24 Daytime Running Lamps Indicator Light ..... 3-41 Control of a Vehicle .......... 4-5 Defensive Driving ..........4-2 Coolant Diesel Engine Engine Temperature Gage ......3-35 Engine Alarm and Automatic Shutdown ...
Page 365 Driving (cont.) Engine (cont.) Drunken ............4-2 Checks Before Operating ......2-22 Freeway ............. 4-22 Coolant ..........5-36, 5-38 Hill and Mountain Roads ......4-24 Coolant Heater ..........2-24 In Rain and on Wet Roads ......4-18 Coolant Temperature Gage ......3-35 Rocking Your Vehicle to Get it Out ....
Page 366 Fuel (cont.) Fuels in Foreign Countries ......5-17 Filter Gage ............3-42 Engine Air Cleaner ........5-33 Gasoline Octane ........... 5-6 Filter Minder Gage .......... 3-43 Gasoline Speciﬁcations ........5-6 Finish Damage ..........5-85 Primary Filter and Water Separator ....5-67 Fixed Mast Antenna ........
Page 367 Heater ............3-20 High Idle System ..........2-19 Gage Highbeam On Light ......... 3-41 Air Pressure ..........3-44 Highway Hypnosis ........... 4-23 Check Gages Warning Light ......3-42 Hill and Mountain Roads ........4-24 Engine Coolant Temperature ......3-35 Hood Filter Minder ..........
Page 368 Light (cont.) Engine Overspeed Warning ......3-39 Jump Starting ..........5-56 Engine Shutdown Warning ......3-39 Exhaust Brake Indicator ........ 3-40 Highbeam On ..........3-41 Low Coolant Warning ........3-35 Low Oil Level ..........3-38 Keyless Entry System ........2-3 Low Washer Fluid Warning ......
Page 369 Mirrors (cont.) Outside Manual Mirrors ........ 2-45 Maintenance, Normal Replacement Parts ..5-100 Outside Power Mirrors ........2-45 Maintenance Schedule MyGMLink.com ..........7-3 At Each Fuel Fill ......... 6-27 At Least Once a Year ........6-31 At Least Twice a Year ........6-28 How This Section is Organized .......
Page 370 Other Service Items (cont.) Power Primary Fuel Filter and Water Separator ..5-67 Accessory Outlets ........3-19 Secondary Fuel Filter and Water Separator/ Door Locks ..........2-7 Heater ............ 5-68 Electrical System ......... 5-89 Other Warning Devices ........3-6 Reduced Engine Light ........3-41 Outlet Adjustment ..........
Page 371 Reading Lamps ..........3-17 Rear Axle ............5-60 Safety Belt Differential Lock Control ......... 4-9 Reminder Light ..........3-27 Shift Motor ..........5-62 Reminder Tone ..........3-27 Two-Speed Electric Shift Control ....2-26 Safety Belts Rear Heating System ........3-24 Care of ............
Page 372 Securing a Child Restraint Storage Areas ..........2-47 Center Rear Seat Position (Crew Cab) or Center Console Storage Area ......2-47 Center Front Position ........ 1-42 Stuck in Sand, Mud, Ice or Snow ...... 4-30 Rear Outside Seat Position ......1-40 Sun Visors .............
Page 373 Towing Power Take-Off (PTO) ........4-38 Understanding Radio Reception ......3-57 Your Vehicle ..........4-35 Traction Control System (TCS) ........4-10 Trailer Connections ..........4-37 Vehicle Trailer Brake Hand Control Valve ......4-8 Control ............4-5 Transmission Damage Warnings ........... iv Fluid, Automatic ...........
Page 374 Where to Put the Restraint ....... 1-36, 1-38 Windows ............2-8 Wait to Start Indicator ........3-36 Manual ............2-8 Warning Lights, Gages and Indicators ....3-24 Power ............2-9 Warnings Sliding Rear ..........2-10 Hazard Warning Flashers ....... 3-6 Windshield Other Warning Devices ........

Chevrolet KODIAK 2005 Owner's Manual

Table of Contents

Seats and Restraint Systems

Features and Controls

Section 3 Instrument Panel

Section 4 Driving Your Vehicle

Driving Your Vehicle

Your Driving, the Road, and Your Vehicle

Towing

Section 5 Service and Appearance Care

Service

Fuel

Checking Things under the Hood

Rear Axle

Four-Wheel Drive

Front Axle

Noise Control System

Bulb Replacement

Windshield Wiper Blade Replacement

Other Service Items

Tires

Appearance Care

Vehicle Identiﬁcation

Electrical System

Capacities and Speciﬁcations

Normal Maintenance Replacement Parts

Section 6 Maintenance Schedule

Quick Links

Chapters

Related Manuals for Chevrolet KODIAK 2005

Summary of Contents for Chevrolet KODIAK 2005