Chevrolet 2000 C-Series Owner's Manual
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Chevrolet 2000 C-Series Owner's Manual

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Summary of Contents for Chevrolet 2000 C-Series

  • Page 2 This section tells you when to perform vehicle maintenance and what fluids and lubricants to use. Customer Assistance Information This section tells you how to contact Chevrolet for assistance and how to get service and owner publications. It also gives you information on “Reporting Safety Defects” on page 8...
  • Page 3 We support voluntary technician certification. GENERAL MOTORS, GM, the GM Emblem, CHEVROLET and the CHEVROLET Emblem are registered trademarks of General Motors Corporation. This manual includes the latest information at the time it was printed. We reserve the right to make changes in the product after that time without further notice.

  • Page 4: How To Use This Manual

    How to Use this Manual CAUTION: Many people read their owner’s manual from beginning to end when they first receive their new vehicle. If you do this, it will help you learn about the features These mean there is something that could hurt and controls for your vehicle.

  • Page 5: Vehicle Damage Warnings

    Vehicle Damage Warnings In the notice area, we tell you about something that can damage your vehicle. Many times, this damage would Also, in this book you will find these notices: not be covered by your warranty, and it could be costly. But the notice will tell you what to do to help avoid the damage.
  • Page 6 Vehicle Symbols These are some of the symbols you may find on your vehicle. For example, These symbols These symbols These symbols These symbols Here are some these symbols are important have to do with are on some of are used on other symbols are used on an for you and...

  • Page 7: Model Reference

    Model Reference This manual contains information which covers conventional cab models as shown. Most models are unfinished from the factory. Since C-Series models delivered from the factory are finished in a variety of ways by a number of companies, you’ll probably find other manuals in your finished vehicle.

  • Page 8: Section 1 Seats And Restraint Systems

    Section 1 Seats and Restraint Systems Here you’ll find information about the seats in your vehicle and how to use your safety belts properly. You can also learn about some things you should not do with safety belts. Seats and Seat Controls Center Passenger Position Safety Belts: They’re for Everyone Children...
  • Page 9 Seats and Seat Controls Bucket and Bench Seats This section tells you about the seats in your vehicle and how to adjust them. 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 you don’t want to.

  • Page 10: Head Restraints

    Head Restraints To fold the seatback forward, push the seatback Some seats have adjustable head restraints. Slide an toward the rear of the adjustable head restraint up or down so that the top of vehicle as you lift this latch. the restraint is closest to the top of your ears.
  • Page 11 National Seats (If Equipped) Height Adjustment To adjust the height of a self contained seat (hand pumped air seat), push the seat height adjustment pump lever, located on the lower outboard side, down and continue pumping to raise the seat. Press the lever and hold it to lower the seat.
  • Page 12 To adjust the height of the Seatback Adjustment cushion, lift the cushion To tilt the seatback, turn the height adjustment handle backrest tilt knob. The knob up and forward. You can is located on the lower choose between two cushion, on the outboard settings.
  • Page 13 Chugger Snubber Lock Out Feature (If Equipped) CAUTION: This handle is located on the lower outboard side of the driver’s seat and the If a head restraint is not installed on the seatback inboard side of the or stored in the vehicle properly, it could be passenger’s seat.
  • Page 14 Safety Belts: They’re for Everyone CAUTION: This part of the manual tells you how to use safety belts properly. It also tells you some things you should not do with safety belts. It is extremely dangerous to ride in a cargo area, inside or outside of a vehicle.
  • Page 15 In most states and Canadian provinces, the law says to Why Safety Belts Work wear safety belts. Here’s why: They work. Aren’t safety belts for kids? You never know if you’ll be in a crash. If you do have a crash, you don’t know if it will be a bad one. Yes.
  • Page 16 If the vehicle hits something, it stops right then. Then something will stop them. It could be the windshield. But nothing stops the people. They keep moving.
  • Page 17 Or it could be the instrument panel. With belts, you slow down as the vehicle does. You get more time to stop. Now, what if you and your passengers were to give that big vehicle a chance to deal with the force of the impact, You stop over more distance, and your strongest bones instead of you? take the forces.
  • Page 18 Here Are Questions Many People Ask If I’m a good driver, and I never drive far from home, why should I wear safety belts? About Safety Belts and the Answers You may be an excellent driver, but if you’re in an Won’t I be trapped in the vehicle after an accident even one that isn’t your fault...

  • Page 19: How To Wear Safety Belts Properly

    How to Wear Safety Belts Properly Lap-Shoulder Belt The driver has a lap shoulder belt. Here’s how to wear Adults it properly. This part is only for people of adult size. 1. Close and lock the door. Be aware that there are special things to know about 2.
  • Page 20 3. Pick up the latch plate and pull the belt across you. Don’t let it get twisted. 4. Push the latch plate into the buckle until it clicks. For suspension type seats (B), if the belt stops before it reaches the buckle, tilt the latch plate and keep pulling until you can buckle the belt.
  • Page 21 If the shoulder belt is too tight: Suspension (B) 5. To make the lap part tight on suspension type Pull out the belt at least 5 inches (130 mm). seats (B), pull down on the buckle end of the belt as you pull up on the shoulder belt.
  • Page 22 Let it go back all the way. You can add a small amount of slack. The system works like a window shade. To add a little slack, pull down on the shoulder belt just a little no more than 1 inch (25 mm). If it’s now too loose, pull it out like you did before and start again.
  • Page 23 The lap part of the belt should be worn low and snug on the hips, just touching the thighs. In a crash, this applies force to the strong pelvic bones. And you’d be less likely to slide under the lap belt. If you slid under it, the belt would apply force at your abdomen.
  • Page 24 What’s wrong with this? CAUTION: You can be seriously hurt if your shoulder belt is too loose. In a crash, you would move forward too much, which could increase injury. The shoulder belt should fit against your body. Don’t allow more than 1 inch (25 mm) of slack.
  • Page 25 What’s wrong with this? CAUTION: You can be seriously injured if your belt is buckled in the wrong place like this. In a crash, the belt would go up over your abdomen. The belt forces would be there, not at the pelvic bones. This could cause serious internal injuries.
  • Page 26 What’s wrong with this? CAUTION: You can be seriously injured if you wear the shoulder belt under your arm. In a crash, your body would move too far forward, which would increase the chance of head and neck injury. Also, the belt would apply too much force to the ribs, which aren’t as strong as shoulder bones.
  • Page 27 What’s wrong with this? CAUTION: You can be seriously injured by a twisted belt. In a crash, you wouldn’t have the full width of the belt to spread impact forces. If a belt is twisted, make it straight so it can work properly, or ask your dealer to fix it.
  • Page 28 Bench (A) Suspension (B) To unlatch the belt, just push the button on the buckle. The belt should go back out of the way. For a suspension type seat, if the belt is pulled out all the way so that it locks, press down on the button on the retractor cover to make it retract.

  • Page 29: Safety Belt Use During Pregnancy

    Safety Belt Use During Pregnancy A pregnant woman should wear a lap shoulder belt, and the lap portion should be worn as low as possible, below Safety belts work for everyone, including pregnant the rounding, throughout the pregnancy. women. Like all occupants, they are more likely to be The best way to protect the fetus is to protect the seriously injured if they don’t wear safety belts.

  • Page 30: Center Passenger Position

    Center Passenger Position Lap Belt If your vehicle has a full bench seat or a two passenger bench seat, someone can sit in the center position. When you sit in a center seating position, you have a lap safety belt, which has no retractor. To make the belt longer, tilt the latch plate and pull it along the belt.
  • Page 31 Buckle, position and release it the same way as the lap part of a lap shoulder belt. If the belt isn’t long enough, see “Safety Belt Extender” at the end of this section. 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 Smaller Children and Babies Infants need complete support, including support for the head and neck. This is necessary because an infant’s neck is weak and its head weighs so much compared with the rest of its body. In a frontal crash, an infant CAUTION: in a rear facing restraint settles into the restraint, so the...
  • Page 33 CAUTION: (Continued) at only 25 mph (40 km/h), a 12 lb. (5.5 kg) baby will suddenly become a 240 lb. (110 kg) force on your arms. The baby would be almost impossible to hold. Secure the baby in an infant restraint. CAUTION: Never hold a baby in your arms while riding in a vehicle.

  • Page 34: Child Restraints

    Child Restraints Every time infants and young children ride in vehicles, they should have protection provided by appropriate restraints. What are the different types of add child restraints? on child restraints are available in four basic types. When selecting a child restraint, take into consideration not only the child’s weight and size, but also whether or not the restraint will be compatible with the motor vehicle in which it...
  • Page 35 A rear facing infant restraint (B) positions an infant to face the rear of the vehicle. Rear facing infant restraints are designed for infants of up to about 20 lbs. (9 kg) and about one year of age. This type of restraint faces the rear so that the infant’s head, neck and body can have the support they need in a frontal crash.
  • Page 36 A forward facing child restraint (C E) positions a child upright to face forward in the vehicle. These forward facing restraints are designed to help protect children who are from 20 to 40 lbs. (9 to 18 kg) and about 26 to 40 inches (66 to 102 cm) in height, or up to around four years of age.
  • Page 37 When choosing a child restraint, be sure the child restraint is designed to be used in a vehicle. If it is, it will have a label saying that it meets federal motor vehicle safety standards. Then follow the instructions for the restraint. You may find these instructions on the restraint itself or in a booklet, or both.

  • Page 38: Top Strap

    Top Strap In Canada, the law requires that forward facing child restraints have a top strap, and that the strap be anchored. In the United States, some child restraints also have a top strap. If your child restraint has a top strap, it should be anchored.
  • Page 39 Securing a Child Restraint in the Center Seat Position (Full Bench Seat and Two-Passenger Bench Seat) You’ll be using the lap belt. Be sure to follow the instructions that came with the child restraint. Secure the child in the child restraint when and as the instructions 1.
  • Page 40 5. To tighten the belt, pull its free end while you push down on the child restraint. If you’re using a forward facing child restraint, you may find it helpful to use your knee to push down on the child restraint as you tighten the belt. 6.
  • Page 41 Larger Children Children who have outgrown child restraints should wear the vehicle’s safety belts. If you have the choice, a child should sit next to a window so the child can wear a lap shoulder belt and get the additional restraint a shoulder belt can provide. Children who aren’t buckled up can be thrown out in a crash.
  • Page 42 CAUTION: Never do this. Here two children are wearing the same belt. The belt can’t properly spread the impact forces. In a crash, the two children can be crushed together and seriously injured. A belt must be used by only one person at a time. What if a child is wearing a lap shoulder belt, but the child is so small that the shoulder belt is...
  • Page 43 CAUTION: Never do this. Here a child is sitting in a seat that has a 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. The belt’s force would then be applied right on the child’s abdomen.

  • Page 44: Safety Belt Extender

    Safety Belt Extender Replacing Restraint System Parts After a Crash If the vehicle’s safety belt will fasten around you, you should use it. If you’ve had a crash, do you need new belts? But if a safety belt isn’t long enough to fasten, your After a very minor collision, nothing may be necessary.

  • Page 45: Section 2 Features And Controls

    Section 2 Features and Controls Here you can learn about the many standard and optional features on your vehicle, and information on starting, shifting and braking. Also explained are the instrument panel and the warning systems that tell you if everything is working properly and what to do if you have a problem.
  • Page 46 Keys CAUTION: Leaving children in a vehicle with the ignition key is dangerous for many reasons. A child or others could be badly injured or even killed. They could operate the controls or even make the vehicle move. Don’t leave the keys in a vehicle with children.
  • Page 47 The oval head key is for The square head key the doors. is for the ignition switch only. If you have the optional one key system, the oval key will operate all locks, including the ignition switch. When a new vehicle is delivered, the dealer removes the plugs from the keys and gives them to the first owner.

  • Page 48: Door Locks

    Door Locks NOTICE: CAUTION: Your vehicle has a number of new features that can help prevent theft. But you can have a lot of trouble getting into your vehicle if you ever lock Unlocked doors can be dangerous. your keys inside. You may even have to damage Passengers especially children can easily...

  • Page 49: Power Door Locks - If Equipped

    To lock your door from the Leaving Your Vehicle inside, slide the manual lock If you are leaving the vehicle, take your keys, open your control down. door and set the locks from inside. Then get out and close the door. Theft Vehicle theft is big business, especially in some cities, and even commercial vehicles are no exception.
  • Page 50 New Vehicle “Break In” NOTICE: (Continued) Avoid making hard stops for the first NOTICE: 200 miles (322 km) or so. During this time your new brake linings aren’t yet broken Your vehicle doesn’t need an elaborate in. Hard stops with new linings can mean “break in.”...

  • Page 51: Ignition Positions

    Ignition Positions Engine Starter Over Crank Protection (If Equipped) Use your ignition key to start your vehicle. You can Some vehicles have an engine starter over crank turn the ignition switch to protection system. This system includes a built five different positions. temperature limiting switch to prevent internal damage to the starter.

  • Page 52: Manual Transmission

    Manual Transmission Starting Your Engine Set the parking brake, shift your gear selector to 1. Without pushing the accelerator pedal, turn your NEUTRAL and hold the clutch pedal to the floor while ignition key to START. When the engine starts, let starting the engine.
  • Page 53 Restarting the Gasoline Engine While NOTICE: Moving (Automatic Transmission) If you have to restart the engine while the vehicle is Your engine is designed to work with the moving, you’ll first have to shift the automatic electronics in your vehicle. If you add electrical transmission to NEUTRAL (N).

  • Page 54: Starting Your Diesel Engine

    While your engine is idling before you turn it off, you NOTICE: can make a list of any operational or handling concerns to give to responsible maintenance personnel so they can handle them right away. Your diesel engine has an electric air intake Moisture will condense in a fuel tank that is almost heater system which reduces white smoke and empty if the vehicle is not run for a while, even just...

  • Page 55: Stopping The Diesel Engine

    Restarting the Diesel Engine While Moving Cold Weather Starting (Automatic Transmission) (Caterpillar Diesel) If you have to restart the engine while the vehicle is Because the diesel engine uses compression ignition, it moving, you’ll first have to shift the automatic is harder to start in cold weather than a gasoline engine.
  • Page 56 Engine Alarm and Automatic Shutdown Fast Idle System (Electronically Controlled (If Equipped) Caterpillar Diesel and Gasoline Engines) Your CHECK GAGES light will come on if the system If your vehicle is equipped with an electronically senses high engine temperature or low engine oil controlled diesel engine, it has both automatic and pressure.
  • Page 57 Manual Fast Idle System The manual fast idle feature is activated by pressing the (Caterpillar Diesel and Gasoline Engines) switch on the instrument panel. When the switch is pressed again, or any of the previous conditions are not The manual fast idle switch met, manual fast idle will be deactivated.

  • Page 58: Engine Checks Before Operating

    Radiator Shutters -- Caterpillar If you have air brakes, the dual needle air pressure gage should read at least 105 psi (720 kPa) for both (If Equipped) service systems before you try to move the vehicle. Radiator shutters aid engine warm up by blocking the When air pressure is below 60 psi (420 kPa), the airflow through the radiator and charge the air cooler to...
  • Page 59 Engine Coolant Heater (If Equipped) NOTICE: If your vehicle is equipped with this feature, the plug Don’t allow the engine to operate at low idle for receptacle is located behind more than five minutes. This can cause low the front bumper as shown, engine operating temperatures which can affect or in the component box engine operation and reduce engine life.

  • Page 60: To Use The Engine Coolant Heater

    To Use the Engine Coolant Heater How long should you keep the coolant heater plugged in? The answer depends on the outside temperature. 1. Turn off the engine. Above 32 _ F (0 _ C), the coolant heater is not required. From 32 _ F to 10 _ F (0 _ C to 23 _ C), keep the coolant...
  • Page 61 Diesel Engine Exhaust Brake The exhaust brake is used to help slow the vehicle and may assist the vehicle’s foundation brakes. The use of The exhaust brake is available on vehicles equipped the exhaust brake will assist the braking of the vehicle with a diesel engine and air brakes (or an air and prolong the life of the foundation brake compressor).

  • Page 62: Automatic Transmission

    Speed Rear Axle Electric Shift CAUTION: Control (If Equipped) If your vehicle is equipped with this feature, you’ll find Be careful when using the exhaust brake or you a label on the ceiling above the windshield or in another could lock the wheels and lose control of the place near the driver that show how to use it.
  • Page 63 The two speed axle should be in low range when you Manual Transmission park the vehicle. Apply the parking brake, shift to The switch for the rear axle PARK (P) or NEUTRAL (N) and shut off the engine. shift control is on the shift To operate off road or under a heavy load, shift into low lever.

  • Page 64: Air Suspension (If Equipped)

    Air Shift Control Also, always start the vehicle in motion with the speed axle in the LOW position. When you upshift (Manual Transmissions Only) the rear axle from LOW to HI, move the lever to the HI position, disengage the clutch, pause, engage the clutch The lever for the rear axle and then press down on the accelerator.
  • Page 65 Air Suspension Dump Control (If Equipped) Automatic Transmission Operation If your vehicle is equipped with the Hendrickson HAS We build vehicles with four, five and six speed Series single axle air suspension, you may have this automatic transmissions. This part of the manual covers control.
  • Page 66 CAUTION: CAUTION: It is dangerous to get out of your vehicle if the Shifting out of PARK (P) or NEUTRAL (N) while shift lever is not fully in PARK (P) with the your engine is “racing” (running at high speed) is parking brake firmly set.

  • Page 67: Manual Transmission Operation

    Manual Transmission Operation Eaton Fuller 5 and 6-Speed Transmissions and Dana Spicer 7-Speed Transmissions This part of the manual covers the basics of the manual transmission. With some of the transmissions, you will These transmissions have gears that automatically find another manual in your vehicle that goes into synchronize when you shift up or down (except more detail.
  • Page 68 Eaton Fuller Transmission with Clutch CAUTION: Brake (Option) Some vehicles have an optional clutch brake. It engages when you push your clutch pedal all the way to the If you skip a gear when you downshift, you could floor. Use it when you shift into first or reverse gear. lose control of your vehicle.

  • Page 69: Two-Speed Rear Axle

    Two-Speed Rear Axle Propshaft Brake Burnish Procedure 1. With the engine running, shift the two speed rear It is recommended that the propshaft mounted parking axle into low. To be sure it’s in low, you’ll need to brake be burnished as part of the new vehicle break move the vehicle in gear just a little.
  • Page 70 You can easily adjust the parking brake by turning the NOTICE: knob on the lever. Turning it clockwise makes the brake grip more tightly. It will also make the lever seem harder to pull up. Turning the knob counterclockwise makes the Driving with the parking brake on can overheat parking brake apply less firmly.
  • Page 71 If your vehicle has this The PARK BRAKE light may flash while the parking system, you will have a brake is being applied or released. This is normal for knob located to the right of this system. the steering column. If your vehicle needs towing or the parking brake will not release, the towing operator will need to disconnect the propshaft before towing your vehicle.
  • Page 72 If your vehicle has air To charge a trailer’s air brake system: brakes, you will have this 1. Move your tractor into the proper position. Apply the control. Pulling it out parking brake by pulling the yellow SYSTEM PARK applies the parking brake. knob out.
  • Page 73 For driving with a trailer, the yellow, red and blue If the air pressure drops below 60 to 70 psi (if equipped) knobs all must be pushed in. It’s the same (413 to 482 kPa), the PRIMARY BRAKE light will when you’re not pulling a trailer except that the red come on.

  • Page 74: Parking Over Things That Burn

    Parking Over Things That Burn Engine Exhaust CAUTION: Engine exhaust can kill. It contains the gas carbon monoxide (CO), which you can’t see or smell. It can cause unconsciousness and death. You might have exhaust coming in if: Your exhaust system sounds strange or different.
  • Page 75 Running Your Engine While You’re CAUTION: Parked (Automatic Transmission) It’s better not to park with the engine running. But if It can be dangerous to get out of your vehicle if ever you have to, here are some things to know. the shift lever is not fully in PARK (P) with the parking brake firmly set.

  • Page 76: Power Windows - If Equipped

    Power Windows (If Equipped) CAUTION: If you have power windows, the controls are on each door. The driver’s door has a switch for the passenger’s window as well. Your power windows will not move It can be dangerous to get out of your vehicle unless the ignition switch is turned to ON.
  • Page 77 Horn Sound the horn by pushing the center of the steering wheel. If you have the optional air horn, it is controlled by a cord that you’ll find up above and to the left of the driver. The harder you pull on the cord, the louder the air horn will sound.

  • Page 78: Turn Signal/Multifunction Lever

    Turn Signal/Multifunction Lever Turn and Lane Change Signals The turn signal has two upward (for right) and two downward (for left) positions. These positions allow you to signal a turn or a lane change. To signal a turn, move the lever all the way up or down.
  • Page 79 If a bulb is burned out, replace it to help avoid an accident. To signal a turn, move the lever all the way up or down. If the arrows don’t go on at all when you signal a turn, When the turn is completed, move the lever back to the check the circuit breaker and for burned out bulbs.

  • Page 80: Windshield Wipers

    Windshield Wipers Low Speed Delay Wipers (If Equipped) You can set the wiper speed for a long or short delay between wipes. This can be very useful in light rain or snow. Turn the band to choose the delay time. The closer to LO, the shorter the delay.

  • Page 81: Windshield Washer

    Windshield Washer Cruise Control (If Equipped) At the top of the multifunction lever, there’s a paddle If your vehicle has with the word PUSH on it. To spray washer fluid on the this feature, it is located windshield, push the paddle. at the end of the turn signal/multifunction lever.
  • Page 82 If you have a manual transmission and you apply your Setting Cruise Control brakes or push the clutch pedal, the cruise control will shut off. CAUTION: CAUTION: If you leave your cruise control switch on when you’re not using cruise, you might hit a button Cruise control can be dangerous where you and go into cruise when you don’t want to.
  • Page 83 Resuming a Set Speed Increasing Speed While Using Cruise Control Once you’re going about 30 mph (48 km/h) or more, There are two ways to go to a higher speed: you can move the cruise control switch from ON to Use the accelerator pedal to get to the higher speed.
  • Page 84 Reducing Speed While Using Cruise Control Using Cruise Control on Hills Press in the button at the end of the lever until you How well your cruise control will work on hills depends reach the lower speed you want, then release it. upon your speed, load and the steepness of the hills.
  • Page 85 Trailer Brake Hand Control This feature lets you apply the trailer brakes without applying the tractor brakes. You can apply the trailer Valve (Option) brakes a little or apply them all the way if you have to. Use this control only when you’re driving. Don’t use it If your vehicle is equipped with this feature, it is for parking or to hold the rig on a hill.
  • Page 86 Inter Axle Differential Lock Control NOTICE: (If Equipped) Activating the inter axle differential lock when If your vehicle has this feature, the control is the rear wheels are actually spinning freely, as located at the lower they might on ice or snow, can cause you to lose right corner of the control of the vehicle.
  • Page 87 If you’re approaching a slippery surface where it looks Engine Air Control (If Equipped) like one or even both wheels may start to slip, you can use this control. It locks your rear differential so that power is transmitted equally to both rear wheels. Let up on the accelerator before you turn on your rear axle differential lock.

  • Page 88: Exterior Lamps

    When the handle is pulled out, the engine air intake supply is closed off from the front scoop and an under hood air supply is opened. This control is intended only for use in cold weather (32 _ F (0 _ C) or below) where snow and ice might plug the external intake.
  • Page 89 Push the bottom left switch to turn on the headlamps, as Daytime Running Lamps (If Equipped) well as all of the lamps just listed. Push the switch Daytime Running Lamps (DRL) can make it easier for marked with the “O” symbol to turn off your lamps. others to see the front of your vehicle during the day.
  • Page 90 To idle your vehicle with the DRL off, set the parking If your vehicle has no radio, the switch is located just brake. The DRL will stay off until you release the above the storage area. Use the switch to operate your parking brake.

  • Page 91: Interior Lamps

    Interior Lamps Outside Mirrors Adjust the outside mirror or Dome Lamp mirrors by hand so you can The dome lamps will come on when you open the just see a little of the side of driver’s door. You can also turn the dome lamps on by your vehicle when you’re turning the interior lamp dimmer dial all the way up sitting in the driver’s seat.
  • Page 92 Convex Outside Mirrors (Option) Heated Outside Mirrors (If Equipped) Your vehicle may have optional convex mirrors. A If your vehicle has heated convex mirror’s surface is curved so you can see more mirrors, you’ll find this from the driver’s seat. switch on the upper right side of your instrument panel area, just above the...

  • Page 93: Sun Visors

    Ashtray and Cigarette Lighter To remove the ashtray for cleaning, pull up on the front of it. (If Equipped) The ashtray is located below the gages on the right side NOTICE: of your instrument panel. If you have a cigarette lighter, it is inside the ashtray.
  • Page 94 Auxiliary Power Jacks (If Equipped) These jacks provide 12 volt power so you can operate things such as a citizen’s band (CB) radio or a cellular phone. You’ll see positive (red) and negative (black) If your vehicle has these outlets. They have a 20 amp fuse that is common with power jacks, you’ll find the cigarette lighter.

  • Page 95: Air Connections

    Trailer Connections (If Equipped) Electrical Connections (If Equipped) If your vehicle has this system, it has a seven wire cable These connections are located at the rear of the cab. that will go to the trailer to supply electrical power to There is an air connection and a trailer the trailer’s lighting system.
  • Page 96 The Instrument Panel Your Information System 2-52...
  • Page 97 A. Left Side Window Defogger J. Glove Box B. Main Lamps Switch K. Hourmeter (Option) C. Vent L. Convenience Center Fuse Panel D. Instrument Panel Cluster M. Air Vent Controls E. Warning Lights N. Ashtray F. Heated Mirror Switch (If Equipped) O.

  • Page 98: 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 you’re going, about how much fuel is left and many other things you’ll need to drive safely and economically. 2-54...

  • Page 99: Speedometer And Odometer

    Speedometer and Odometer Your odometer is tamper resistant. The odometer will show silver lines between the numbers if someone tries to turn it back. You may wonder what happens if your vehicle needs a new odometer installed. If the new one can be set to the mileage total of the old odometer, then it must be.

  • Page 100: Tachometer (If Equipped)

    Tachometer (If Equipped) Warning Lights, Gages and Indicators This part describes the warning lights and gages that may be on your vehicle. The pictures will help you locate them. Warning lights and gages can signal that something is wrong before it becomes serious enough to cause an expensive repair or replacement.
  • Page 101 When one of the warning lights comes on and stays on Charging System Indicator Light when you are driving, or when one of the gages shows there may be a problem, check the section that tells you what to do about it. Please follow this manual’s advice. CAUTION: Waiting to do repairs can be costly and even...
  • Page 102 If it stays on, or comes on while you are driving, have it Readings in either warning zone indicate a possible checked right away. You could have a loose generator problem in the electrical system. drive belt or some other problem. Readings in the low warning zone may occur when a large Driving while this light is on could drain your battery.

  • Page 103: Brake System Warning Light

    Do Not Shift Warning Light NOTICE: If your vehicle has the Allison MD automatic If the DO NOT SHIFT warning light comes on transmission, certain while you are driving, it is a warning that making transmission malfunctions a transmission “range” change could leave you will turn this light on.
  • Page 104 If the PRIMARY BRAKE Both of these lights should come on briefly every time warning light comes on, it you start the engine. If they don’t come on then, have means that the fluid level them fixed so they will be ready to warn you if there’s a in the master cylinder problem.
  • Page 105 Air Brake System Warning Light When this warning light comes on, you will also hear a warning tone. If the warning light and tone come on Vehicles with air brake systems have one brake system while you are driving, you should drive only as far as warning light on the instrument panel cluster.

  • Page 106: Parking Brake Warning Light

    Apply Park Brake Warning Light (Option) When the SERVICE PARK BRAKE light comes on, you will also hear a warning tone. If this light comes on, This light warns the driver have the system repaired immediately. that the ignition has been turned off without applying the parking brake.

  • Page 107: Anti-Lock Brake System Warning Light

    Parking Brake Indicator Light Anti-Lock Brake System Warning Light Vehicles with hydraulic or With the anti lock brake air brakes have a parking system, this light will come brake indicator light. When on when you start your the ignition is on, this light engine and it may stay on will come on when you set for several seconds.

  • Page 108: 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 109 Manual Fast Idle Indicator Light Intake Heater Indicator Light (If Equipped) (Diesel Engines) If your vehicle is equipped This light on the instrument with an electronically panel cluster will come on controlled diesel engine or when the intake heater gasoline engine, you may is on and the ignition key have this indicator light.

  • Page 110: Malfunction Indicator Lamp (Check Engine Light)

    Service Trans Filter Indicator Light If this light comes on or flashes while you are (If Equipped) driving, two things may happen. If your vehicle has this light, you’ll find it located below the the instrument panel cluster. First, you won’t notice any difference in engine performance, but your tail pipe emissions may increase.
  • Page 111 Engine 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: Don’t keep driving if the oil pressure is low. If you do, your engine can become so hot that it catches fire.
  • Page 112 Change Oil Light (If Equipped) Reduced Engine Power Warning Light The CHANGE OIL light If the SERVICE ENGINE should come on briefly as a SOON and REDUCED bulb check when you start ENGINE POWER lights are the engine. If the light on, a noticeable reduction in doesn’t come on, have the vehicle’s performance...

  • Page 113: Daytime Running Lamps (Drl) Indicator Light

    Diff Lock Indicator Light (If Equipped) When your ignition is on, the gage shows the temperature of the transmission oil. A reading in the warning zone This light located on the means you must stop driving and check into the cause. instrument panel cluster is One possible cause is a low oil level in the transmission.
  • Page 114 Check Gages Indicator Light (If Equipped) Fuel Gage This light will come on as you’re starting the engine, just as a check. If it ever comes on and stays on while you are driving, however, it means that either your engine coolant temperature gage or your engine oil pressure gage may Gasoline Engine Diesel Engine...
  • Page 115 If your vehicle has dual fuel tanks, the reading on the Air Pressure Gage (If Equipped) gage is the average of the two tanks. If your vehicle has air Here are four concerns of some operators. None of these brakes, this gage at the shows a problem with your fuel gage: center of your instrument The gage moves a little when you turn a corner or...
  • Page 116 Filterminder Gage (Diesel Engine) (Option) Hourmeter Gage (If Equipped) This optional gage is If your vehicle has this in the lower center of the gage, it will be to the lower instrument panel cluster. left of the steering column, It monitors the engine mounted on a bracket either air filter.

  • Page 117: Section 3 Comfort Controls And Audio Systems

    Section 3 Comfort Controls and Audio Systems In this section, you’ll find out how to operate the comfort control and audio systems offered with your vehicle. Be sure to read about the particular systems supplied with your vehicle. Comfort Controls AM/FM Stereo Air Conditioning Remote Cassette Tape Player (If Equipped)

  • Page 118: Comfort Controls

    Comfort Controls HEATER: Heated air comes out near the floor. This is the best setting for cold weather. Standard Comfort Controls DEFOG: This setting operates the defogger. If your vehicle does not have air conditioning, this is Heated air comes out near the windshield. Use this what your comfort controls will look like.
  • Page 119 Optional Comfort Controls (If Equipped) If your vehicle has air conditioning, your comfort controls will look like this. Temperature Selector Bar The bar under your system display lets you select the temperature of the air coming into the passenger area of your vehicle.
  • Page 120 Left Blend Button HEATER: Press the bottom of this button and The airflow can be blended between the two positions. heated air comes out near the floor. To blend between the positions, press the side of the button showing the area where you would like more A/C Button airflow.

  • Page 121: Air Conditioning

    If your air conditioner develops high system pressure, it will automatically go into the MAX mode and REC Press this button to turn the air conditioning/heating will light on your display. The A/C system will remain system off. Pressing OFF will erase the present mode in the MAX mode, even if you press the MAX button, of operation from the system’s memory.

  • Page 122: Ventilation System

    Defogging Ventilation Tips Keep the hood and front air inlet free of ice, snow or Use DEFOG, along with the HEATER setting, when any other obstruction (such as leaves). The heater there is fog or ice on the windshield. This will direct and defogger will work far better, reducing the airflow toward the windshield and front side windows.

  • Page 123: Audio Systems

    Audio Systems AM-FM Stereo Your audio system has been designed to operate easily and give years of listening pleasure. You will get the most enjoyment out of it if you acquaint yourself with it first. Find out what your audio system can do and how to operate all its controls, to be sure you’re getting the most out of the advanced engineering that went into it.
  • Page 124 Finding a Station 4. Press SET. (SET will appear on the display and will blink for about eight seconds.) AM/FM: Press this button to switch between AM and FM. The display shows your selection. 5. Press one of the six pushbuttons within eight seconds.
  • Page 125 Setting the Tone Remote Cassette Tape Player (If Equipped) BAS: Slide this lever left or right to decrease or increase the bass. TRE: Slide this lever left or right to decrease or increase the treble. If a station is weak or noisy, you may want to decrease the treble.

  • Page 126: Understanding Radio Reception

    REW: Press the left arrow to rapidly reverse the tape. Tips About Your Audio System Press FF to stop reversing the tape. Hearing damage from loud noise is almost undetectable FF: Press the right arrow to rapidly advance the tape. until it is too late.

  • Page 127: Care Of Your Cassette Tape Player

    Care of Your Cassette Tape Player You may also choose a non scrubbing action, wet type cleaner which uses a cassette with a fabric belt to clean A tape player that is not cleaned regularly can cause the tape head. This type of cleaning cassette will not reduced sound quality, ruined cassettes or a damaged eject on its own.

  • Page 128: Section 4 Your Driving And The Road

    Section 4 Your Driving and the Road Here you’ll find information about driving on different kinds of roads and in varying weather conditions. We’ve also included many other useful tips on driving. Defensive Driving Driving in Rain and on Wet Roads Drunken Driving City Driving Control of a Vehicle...

  • Page 129: Defensive Driving

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

  • Page 130: Drunken Driving

    Drunken Driving The obvious way to solve the leading highway safety problem is for people never to drink alcohol and then Death and injury associated with drinking and driving drive. But what if people do? How much is “too much” is a national tragedy.
  • Page 131 Since alcohol is carried in body water, this means that a woman generally will reach a higher BAC level than a man of her same body weight when each has the same number of drinks. The law in many U.S. states sets the legal limit at a BAC of 0.10 percent.
  • Page 132 The body takes about an hour to rid itself of the alcohol in one drink. No amount of coffee or number of cold CAUTION: showers will speed that up. “I’ll be careful” isn’t the right answer. What if there’s an emergency, a need to Drinking and then driving is very dangerous.

  • Page 133: Control Of A Vehicle

    Control of a Vehicle Braking You have three systems that make your vehicle go where Braking action involves perception time and you want it to go. They are the brakes, the steering and reaction time. the accelerator. All three systems have to do their work First, you have to decide to push on the brake pedal.

  • Page 134: Hydraulic Brake Systems

    Avoid needless heavy braking. Some people drive Hydraulic Brake Systems in spurts heavy acceleration followed by heavy If your engine stops running, or if your primary brake braking rather than keeping pace with traffic. system stops working, your vehicle has a reserve power This is a mistake.
  • Page 135 Anti-Lock Brakes (ABS) Your vehicle has anti lock brakes (ABS). ABS is an advanced electronic braking system that will help prevent a braking skid. When you start your engine and begin to drive away, your anti lock brake system will check itself. You may hear a momentary motor or clicking noise while this test is going on.
  • Page 136 The anti lock system can change the brake pressure faster As you brake, your computer keeps receiving updates on than any driver could. The computer is programmed to wheel speed and controls braking pressure accordingly. make the most of available tire and road conditions. Remember: Anti lock doesn’t change the time you need to get your foot up to the brake pedal or always decrease...

  • Page 137: Power Steering

    Steering The traction you can get in a curve depends on the condition of your tires and the road surface, the angle at Power Steering which the curve is banked, and your speed. While you’re in a curve, speed is the one factor you can control. If you lose power steering assist because the engine stops or the system is not functioning, you can steer What should you do if this ever happens? Ease up on...

  • Page 138: 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 139: Off-Road Recovery

    Road Recovery Passing You may find that your right wheels have dropped off the The driver of a vehicle about to pass another on a edge of a road onto the shoulder while you’re driving. lane highway waits for just the right moment, accelerates, moves around the vehicle ahead, then goes back into the right lane again.
  • Page 140 Watch for traffic signs, pavement markings and lines. If other cars are lined up to pass a slow vehicle, wait If you can see a sign up ahead that might indicate a your turn. But take care that someone isn’t trying to turn or an intersection, delay your pass.

  • Page 141: Loss Of Control

    Loss of Control A cornering skid and an acceleration skid are usually best handled by easing your foot off the Let’s review what driving experts say about what happens accelerator pedal. when the three control systems (brakes, steering and Of course, traction is reduced when water, snow, ice, acceleration) don’t have enough friction where the tires gravel or other material is on the road.

  • Page 142: Driving At Night

    Driving at Night Here are some tips on night driving. Drive defensively. Don’t drink and drive. Since you can’t see as well, you may need to slow down and keep more space between you and other vehicles. Slow down, especially on higher speed roads. Your headlamps can light up only so much road ahead.

  • Page 143: Driving In Rain And On Wet Roads

    You can be temporarily blinded by approaching Driving in Rain and on Wet Roads headlamps. It can take a second or two, or even several seconds, for your eyes to readjust to the dark. When you are faced with severe glare (as from a driver who doesn’t lower the high beams, or a vehicle with misaimed headlamps), slow down a little.
  • Page 144 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 145: Driving Through Deep Standing Water

    Hydroplaning doesn’t 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 Wet brakes can cause accidents.

  • Page 146: 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 them CAUTION: just your parking lamps to help make you more visible to others. Flowing or rushing water creates strong forces. Besides slowing down, allow some extra following If you try to drive through flowing water, as you distance.

  • Page 147: 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 148: 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 slow driving breaks a smooth traffic flow. Treat the left lane on a freeway as a passing lane.

  • Page 149: Highway Hypnosis

    Once you are moving on the freeway, make certain you When you drive the vehicle for a long distance, there is allow a reasonable following distance. Expect to move something about an easy stretch of road with the same slightly slower at night. scenery, along with the hum of the tires on the road, the drone of the engine, and the rush of the wind against the When you want to leave the freeway, move to the proper...

  • Page 150: 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 151 Know how to go uphill. Use lower gears. They help cool your engine and transmission, and you can CAUTION: climb the hill better. Stay in your own lane when driving on two lane Coasting downhill in NEUTRAL (N) or with the roads in hills or mountains.

  • Page 152: 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 153 Whatever the condition smooth ice, packed, blowing or loose snow drive with caution. Accelerate gently. Try not to break the fragile traction. If you accelerate too fast, the drive wheels will spin and polish the surface under the tires even more. Allow distance on any slippery road.

  • Page 154: If You're Caught In A Blizzard

    If You’re Caught in a Blizzard Tie a red cloth to your mirror arm to alert police that you’ve been stopped by the snow. Put on extra clothing or wrap a blanket around you. If you have no blankets or extra clothing, make body insulators from newspapers, burlap bags, rags, floor mats anything you can wrap around yourself or...
  • Page 155 Run your engine only as long as you must. This saves fuel. When you run the engine, make it go a little faster CAUTION: than just idle. That is, push the accelerator slightly. This uses less fuel for the heat that you get and it Snow can trap exhaust gases under your vehicle.

  • Page 156: Loading Your Vehicle

    Loading Your Vehicle This is called the Gross Vehicle Weight Rating (GVWR). The GVWR includes the weight of the The GVW/Tire Information label is found on the rear vehicle, all occupants, fuel and cargo. edge of the driver’s door. The label shows the size of The Certification/Tire label is provided by the final your original tires and the inflation pressures needed to manufacturer and should be on the door or door jamb.
  • Page 157 If you put things inside your vehicle like suitcases, tools, packages or anything else they will go as fast as CAUTION: the vehicle goes. If you have to stop or turn quickly, or if there is a crash, they’ll keep going. Do not load your vehicle any heavier than the GVWR, or either the maximum front or rear CAUTION:...
  • Page 158 Power Take Off (PTO) (If Equipped) 4. The PTO Enable and cruise control Before using a PTO, refer to the manufacturer’s or (if equipped) installer’s instructions. switch must be To engage a PTO with Stationary Preset: in ON prior to enabling the PTO 1.
  • Page 159 To engage a PTO with Stationary Variable: To engage a PTO with Mobile Variable: 1. Make sure the vehicle is stopped. 1. The PTO Enable and cruise control (if equipped) switch must be in ON. 2. Shift the transmission into NEUTRAL (N) or PARK (P), if equipped.

  • Page 160: Section 5 Problems On The Road

    Section 5 Problems on the Road Here you’ll find what to do about some problems that can occur on the road. Hazard Warning Flashers Cooling System (Diesel Engine) Other Warning Devices Engine Fan Noise Jump Starting If a Tire Goes Flat Towing Your Vehicle Changing a Flat Tire Engine Overheating...

  • Page 161: Hazard Warning Flashers

    Hazard Warning Flashers Press the button in to make your front and rear turn signal lamps flash on and off. Your hazard warning flashers work no matter what position your key is in, and even if the key isn’t in. Your hazard warning flashers let you warn others.
  • Page 162 Hazard Warning Flasher Switch Pull the switch out to make your front and rear turn signal lamps flash on and off. A light next to the switch (If Equipped) will also flash. Push it back in to turn off the flashers. The turn signal lamps won’t flash if you’re braking.

  • Page 163: Other Warning Devices

    To turn off the flasher, move the turn signal lever either up or down. Then move the signal lever back to the center position. When the hazard warning flashers are on, your turn signals won’t work. To make it work, pull out on the hazard lever until it Other Warning Devices locks into place.

  • Page 164: Jump Starting

    Jump Starting NOTICE: If your battery (or batteries) has run down, you may want to use another vehicle and some jumper cables to Ignoring these steps could result in costly damage start your vehicle. But please follow the steps below to to your vehicle that wouldn’t be covered by do it safely.
  • Page 165 1. Check the other vehicle. It must have a 12 volt battery with a negative ground system. CAUTION: NOTICE: If your vehicle has air conditioning, the auxiliary electric fan under the hood can start up even when the engine is not running and can injure If the other system isn’t a 12 volt system with a you.
  • Page 166 4. Locate the batteries on each vehicle. Find the 5. Check that the jumper cables don’t have loose or positive (+) and negative ( ) terminals on missing insulation. If they do, you could get a shock. each battery. The vehicles could be damaged, too. Before you connect the cables, here are some basic things you should know.
  • Page 167 6. Connect the red 8. Now connect the positive (+) cable to the black negative ( ) cable positive (+) terminal of to the good battery’s the vehicle with the negative ( ) terminal. dead battery. Don’t let the other end touch anything until the next 7.
  • Page 168 9. Attach the cable at least 18 inches (45 cm) away from the dead battery, but not near engine parts that move. The electrical connection is just as good there, but the chance of sparks getting back to the battery is much less. 10.

  • Page 169: Towing Your Vehicle

    Towing Your Vehicle CAUTION: CAUTION: Working on air brakes without first using the release studs to compress the springs To help avoid serious personal injury to you can lead to injury. Never work on the air or others: brake chambers without first using the release studs to compress the brake springs.
  • Page 170 Try to have a GM dealer or a professional towing Towing Your Vehicle From the Front service tow your vehicle. They can provide the right (Front Wheels Off the Ground) equipment and know how to tow it without damage. Before Towing Before you do anything, turn on the hazard warning flashers (if they have not been damaged).
  • Page 171 Towing the Vehicle with the Front Bumper Removed 3. Place a 6 x 6 x 5 hardwood beam underneath and slightly behind the front spring shackle brackets. 1. Remove the front bumper. 4. Connect lift chains to the tow bar and raise the tow 2.
  • Page 172 Towing the Vehicle with the Front Bumper Installed 1. Connect and lock the lift chains to the front axle, outside of the spring anchor plates as previously shown. 2. Place a 6 x 6 x 5 hardwood beam underneath and slightly behind the front spring shackle brackets as previously shown.
  • Page 173 4. Remove the remaining slack in the lift chains. Single Drive Rear Axle The tow bar swing arm should rest against the Disconnect the propshaft at the rear axle. Secure the 2 x 12 x 40 hardwood board as shown. propshaft to the frame or crossmember.
  • Page 174 Towing Your Vehicle From the Front If there is damage or suspected damage to the axle(s), remove the axle shafts. Cover the hub openings to (All Wheels On the Ground) prevent the loss of lubricant or entry of dirt or Your vehicle may be towed on all wheels provided the foreign objects.
  • Page 175 Releasing Air-Operated Parking Brakes 1. Block the wheels of the vehicle. If your vehicle has air brakes, you could have a special towing problem. If your vehicle has to be towed because you had a complete loss of air pressure from both systems, the parking brakes may have applied.
  • Page 176 3. Remove the rubber 6. Using a wrench, turn the cap from the rear of stud nut clockwise the chamber. several turns to release the brakes. Follow the same procedure to release the other brake. 4. Put the release stud, nut and flat washer into 7.

  • Page 177: Engine Overheating

    Engine Overheating CAUTION: You will find a coolant temperature warning gage on your vehicle’s instrument panel, as well as a LOW COOLANT warning light. Your vehicle also has a Steam from an overheated engine can burn you CHECK GAGES warning light on the instrument panel. badly, even if you just open the hood.

  • Page 178: If No Steam Is Coming From Your Engine

    If No Steam Is Coming From Your Engine If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about If you get an engine overheat warning but see or hear no 10 minutes. If the warning doesn’t come back on, steam, the problem may not be too serious.
  • Page 179 Cooling System (Gasoline Engines) When you decide it’s safe to lift the hood, here’s what you’ll see: Sloped Hood A. Engine Fan B. Coolant Recovery Tank Specialty Hood C. Radiator Pressure Cap A. Coolant Recovery Tank B. Radiator Pressure Cap C.
  • Page 180 When the engine is CAUTION: cold, the coolant level should be above the HOT LEVEL mark on If your vehicle has air conditioning, the auxiliary the vehicle with the electric engine cooling fan under the hood can specialty hood, or start up even when the engine is not running and at or above the can injure you.
  • Page 181 NOTICE: CAUTION: When adding coolant, it is important that you Heater and radiator hoses, and other engine parts, use only DEX COOL (silicate free) coolant. can be very hot. Don’t touch them. If you do, you If coolant other than DEX COOL is added to can be burned.
  • Page 182 How to Add Coolant to the Coolant NOTICE: Recovery Tank If you haven’t found a problem yet, but the coolant level In cold weather, water can freeze and crack the isn’t at or above the HOT LEVEL mark on the vehicle with engine, radiator, heater core and other parts.
  • Page 183 CAUTION: CAUTION: You can be burned if you spill coolant on hot Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They engine parts. Coolant contains ethylene glycol are under pressure, and if you turn the radiator and it will burn if the engine parts are hot pressure cap even a little...
  • Page 184 How to Add Coolant to the Radiator 2. Then keep turning the pressure cap, but now 1. You can remove the push down as you radiator pressure cap turn it. Remove the when the cooling pressure cap. system, including the radiator pressure cap and upper radiator hose, is no longer hot.
  • Page 185 4. Then fill the coolant recovery tank to the HOT 7. By this time, the coolant level inside the radiator LEVEL mark on the vehicle with the specialty hood, filler neck may be lower. If the level is lower, add or approximately one half full on the vehicle with more of the proper DEX...
  • Page 186 Cooling System (Diesel Engine) CAUTION: When you decide it’s safe to lift the hood, here’s what you’ll see: If your vehicle has air conditioning, the auxiliary electric engine cooling fan under the hood can start up even when the engine is not running and can injure you.
  • Page 187 How to Add Coolant to the Coolant CAUTION: Surge Tank If you haven’t found a problem yet, but the coolant level Heater and radiator hoses, and other engine parts, isn’t at the COLD ADD mark or higher, add a 50/50 mixture of clean, drinkable water and coolant at the can be very hot.
  • Page 188 CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid like alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you wouldn’t get the overheat warning.
  • Page 189 NOTICE: In cold weather, water can freeze and crack the engine, radiator, heater core and other parts. So use the recommended coolant. CAUTION: You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot 1.
  • Page 190 2. Then keep turning the cap, but now push down as 3. Then fill the coolant surge tank with the proper you turn it. Remove the pressure cap. coolant mixture, up to the COLD FULL mark. 5-31...
  • Page 191 4. With the coolant surge tank pressure cap off, start the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine fan. By this time, the coolant level inside the coolant surge tank may be lower.

  • Page 192: Engine Fan Noise

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

  • Page 193: Changing A Flat Tire

    Changing a Flat Tire CAUTION: A flat or damaged tire can be a major roadside problem. You’re very likely to have to go for help. Few drivers of these vehicles have the necessary equipment aboard to Tire rim assemblies can explode. If you work on be able to change a flat tire safely.
  • Page 194 If the lock ring and side rings seem to be seated properly (or if the wheel doesn’t have these), let the CAUTION: air out of the tire. You can do this by taking out the valve core. If you work on a pressurized tire mounted on a If the flat or damaged tire is one of a dual set, let the damaged wheel, the assembly can expand with air out of both tires of the dual before you take off...
  • Page 195 CAUTION: CAUTION: There are many ways to be hurt badly, Incorrect wheel nuts or improperly tightened or be killed, while you are trying to change wheel nuts can cause the wheel to become loose a truck tire and rim. Follow all of the and even come off.

  • Page 196: Rocking Your Vehicle To Get It Out

    If You’re Stuck: In Sand, Mud, NOTICE: Ice or Snow In order to free your vehicle when it is stuck, you will Spinning your wheels can destroy parts of your need to spin the wheels, but you don’t want to spin your vehicle as well as the tires.

  • Page 197: Section 6 Service And Appearance Care

    Section 6 Service and Appearance Care Here you will find information about the care of your vehicle. This section begins with service and fuel information, and then it shows how to check important fluid and lubricant levels. There is also technical information about your vehicle, and a part devoted to its appearance care.

  • Page 198: Doing Your Own Service Work

    Service Doing Your Own Service Work If you want to do some of your own service work, you’ll Your dealer knows your vehicle best and wants you to want to use the proper service manual. It tells you much be happy with it. We hope you’ll go to your dealer for more about how to service your vehicle than this manual all your service needs.

  • Page 199: Two Safety Cautions About Engine Fan Breakage

    Two Safety Cautions about Engine CAUTION: (Continued) Fan Breakage Winter Fronts, Grille Covers or Obstructions Winter fronts, grille covers or other add CAUTION: equipment causing obstructions in front or behind the fan should not be used on this vehicle. Changing the Fan Drive Ratio or Engine They may increase the stress on the fan as the Governed Speed blades pass over the covered areas.
  • Page 200 Fuel (Gasoline Engine) If you’re using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs service. But If your vehicle has a diesel engine, see “Diesel Engine don’t worry if you hear a little pinging noise when Fuel”...

  • Page 201: Diesel Fuel Requirements And Fuel System

    To provide cleaner air, all gasolines in the United States Diesel Fuel Requirements and are now required to contain additives that will help Fuel System prevent deposits from forming in your engine and fuel system, allowing your emission control system to Diesel Engine Fuel function properly.
  • Page 202 Fuels in Foreign Countries NOTICE: (Gasoline Engines) If you plan on driving in another country outside the If there is water in your diesel fuel and the United States or Canada, the proper fuel may be hard to weather is warm or humid, fungus and bacteria find.

  • Page 203: Filling Your Tank

    Filling Your Tank CAUTION: Fuel vapor is highly flammable. It burns violently, and that can cause very bad injuries. Don’t smoke if you’re near gasoline or diesel fuel, or if you’re refueling your vehicle. Keep sparks, flames and smoking materials away from gasoline or diesel fuel.

  • Page 204: Filling A Portable Fuel Container

    If you have dual tanks, fill the driver’s side first. The fuel gage will give better readings this way. Your gage CAUTION: will show the average level of both tanks combined. Filling a Portable Fuel Container Gasoline Engine Vehicles: If you get gasoline on you and then something ignites it, you could be badly burned.

  • Page 205: Checking Things Under The Hood

    Checking Things Under the Hood Then take the hand holds and pull the hood forward. To tilt the hood forward, pull out on each of the hood latches. If the hood is equipped with hood access panels, make sure the panel latches are locked down before lifting the hood open.
  • Page 206 When you tilt the hood far enough, the cables will If your vehicle has the optional hood access panels, you support it. can easily get to one side of the engine or the other as you need to. Pull out on the top of each hood latch. Then push the latch down and swing the bottom out.

  • Page 207: Noise Control System

    Then place the prop rod, located on the panel, where CAUTION: the arrow is pointing. 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.

  • Page 208: Tampering With Noise Control System Prohibited

    Tampering With Noise Control Engine: System Prohibited Removal or rendering engine speed governor (if equipped) inoperative so as to allow engine speed Federal law prohibits the following acts or the to exceed manufacturer specifications. causing thereof: Fan and Drive: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or Removal of fan clutch (if equipped) or rendering replacement, of any device or element of design...

  • Page 209: Checking Engine Oil

    Engine Oil (Gasoline Engine) Turn off the engine and give the oil several minutes to drain back into the oil pan. If you don’t, the oil dipstick Checking Engine Oil might not show the actual level. Pull out the dipstick and clean it with a paper towel or It’s a good idea to check your engine oil every time you cloth, then push it back in all the way.
  • Page 210 When to Add Engine Oil What Kind of Engine Oil to Use If the oil is at or below the cross hatched area, then Oils recommended for your vehicle can be identified by you’ll need to add at least one quart of oil. But you must looking for the starburst symbol.
  • Page 211 As shown in the chart, SAE 5W 30 is best for your vehicle. However, you can use SAE 10W 30 if it’s going to be 0 C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils, such as SAE 20W NOTICE: Use only engine oil with the American Petroleum...

  • Page 212: Engine Oil Additives

    Engine Oil Additives How to Reset the Change Oil Light To reset the CHANGE OIL light, turn the ignition key to Don’t add anything to your oil. The recommended oils RUN with the engine off. Fully press and release the with the starburst symbol are all you will need for good accelerator pedal three times within 10 seconds.

  • Page 213: Engine Oil

    Engine Oil After the air filter is properly serviced, the indicator can be reset by pushing the button on top of the indicator to (Caterpillar Diesel Engines) reset it. See your Caterpillar Operation & Maintenance Manual Engine Air Filter Restriction for information on oil quality and viscosities as well as Indicator (Diesel Engines) the temperature range chart.

  • Page 214: Engine Air Cleaner/Filter

    Engine Air Cleaner/Filter CAUTION: Your GM Maintenance Schedule says when to replace the air filter. Gasoline Engines Only: Operating the engine with the air cleaner/filter off can cause you or others to be burned. The air cleaner not only cleans the air, it stops flame if the engine backfires.

  • Page 215: Automatic Transmission Fluid

    Automatic Transmission Fluid Automatic Transmission External Filter Your automatic transmission spin on type filter requires When to Check periodic replacement. It is mounted just behind the A good time to have it checked is when the engine oil is radiator on the outside of the passenger’s side frame rail. checked.

  • Page 216: Rear Axle

    How to Check and What to Use How to Check Lubricant The Eaton Fuller Transmission Operator’s Manual that came with the vehicle shows how to check the manual transmission fluid and what fluid to use. NOTICE: Too much or too little fluid can damage your transmission.
  • Page 217 Rear Axle Shift Motor (Option) Engine Coolant (Gasoline Engine) The cooling system in your vehicle is filled with When to Check and Change Fluid COOL engine coolant. This coolant is designed If you have an optional air shift two speed, controlled to remain in your vehicle for 5 years or 150,000 miles traction, or locking differential type rear axle, a good (240 000 km), whichever occurs first, if you add only...

  • Page 218: What To Use

    What to Use NOTICE: Use a mixture of one half clean, drinkable water and half DEX COOL coolant which won’t damage When adding coolant, it is important that you aluminum parts. If you use this coolant mixture, you use only DEX COOL (silicate free) coolant.

  • Page 219: Checking Coolant

    Checking Coolant NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost wouldn’t be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts.
  • Page 220 Coolant Recovery Tank Surge Tank (Caterpillar Diesel Engines) (Gasoline Engines Sloped Hood) When your engine is cold, the coolant level should be at the COLD level, or a little higher, on the coolant recovery tank with the gasoline engine, or at the COLD FULL mark, visible through the surge tank, with the diesel engine.
  • Page 221 If this light comes on and stays on, it means you’re CAUTION: low on engine coolant. Turning the radiator pressure cap (on a gasoline engine) or the surge tank cap (on a diesel engine) when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn See “Lights, Low Coolant Warning Light”...
  • Page 222 Radiator Pressure Cap CAUTION: (Gasoline Engines) The radiator pressure cap You can be burned if you spill coolant on hot must be tightly installed engine parts. Coolant contains ethylene glycol, with the arrows on the cap and it will burn if the engine parts are hot lined up with the top of the enough.

  • Page 223: How To Check Power Steering Fluid

    Surge Tank Pressure Cap Power Steering Fluid (Diesel Engines) See your Maintenance Schedule for when to check your power steering fluid. The surge tank pressure cap How To Check Power Steering Fluid must be tightly installed with the arrows on the cap Check your power steering fluid only when the engine is lined up with the top tube of warm.
  • Page 224 What to Use To determine what kind of fluid to use, see “Recommended Fluids and Lubricants” in the Index. NOTICE: When adding power steering fluid or making a complete fluid change, always use the proper fluid. Failure to use the proper fluid can cause leaks and damage hoses and seals.

  • Page 225: Windshield Washer Fluid

    Windshield Washer Fluid NOTICE: What to Use When using concentrated washer fluid, When you need windshield washer fluid, be sure to read follow the manufacturer’s instructions for the manufacturer’s instructions before use. If you will be operating your vehicle in an area where the temperature adding water.

  • Page 226: Brake Fluid

    Brakes Checking Brake Fluid Apply the brake pedal several times with the ignition Brake Fluid off. Then clean one of the reservoir caps and the area around the cap, and remove it. The fluid level should be If your vehicle has even with the bottom ring of the filler opening.

  • Page 227: Brake Pedal Travel

    Four-Wheel Disc Brakes (Hydraulic Only) CAUTION: Your vehicle has four wheel disc brakes. Some driving conditions or climates may cause a brake With the wrong kind of fluid in your brake squeal when the brakes are first applied or lightly system, your brakes may not work well, or they applied.

  • Page 228: Brake Adjustment

    Brake Adjustment Moisture Ejector (Option) Every time you make a brake stop, your brakes adjust If you have air brakes with a moisture ejector, the valve for wear. automatically ejects moisture from the reserve tank when the air compressor cycles. Air Brake Systems (If Equipped) Air Dryer (Option) If you have air brakes, it is important to get rid of...
  • Page 229 Alcohol Injector (Option) To turn it on in cold weather, turn the valve If your vehicle has air brakes, it may have an alcohol so that the word ON is injector. It is located on the frame or crossmember at the on top.

  • Page 230: Replacing Brake System Parts

    Replacing Brake System Parts Electric/Hydraulic Parking Brake Fluid The braking system on a vehicle is complex. Its many parts have to be of top quality and work well together if If you have an electric/hydraulic parking brake, a good the vehicle is to have really good braking. Your vehicle time to check the fluid level is when you check the fluid was designed and tested with top quality GM brake...

  • Page 231: Clutch Pedal Free Travel

    How to Check and Add Fluid Clutch Pedal Free Travel First, apply the parking brake. To check the fluid level, If you have a manual transmission, your clutch will need look at the MAX and MIN lines on the side of the adjustment when pedal free travel gets down to about reservoir.
  • Page 232 Single Axle Models 6-36...
  • Page 233 ITEM NO. ITEM REMARKS Brake Camshaft , Brake One fitting each (apply sparingly). For caliper rails, Caliper Rails (If Equipped)$ apply Aero Shell #5 Lubricant. Steering Column Slip Joint* One fitting. Steering Drag Link Ends One fitting at each end. One fitting each joint.
  • Page 234 ITEM NO. ITEM REMARKS Parking Brake Bell Crank*$ One fitting. Transmission Fill to level of filler plug. Check fluid level. Transmission Auto* Propshaft Slip Joint One fitting each joint; lubricate with GM Part No. 1051344 Wheel Bearing Lubricant. One fitting each joint (1480 and 1550 Series); lubricate Propshaft U Joints with GM Part No.
  • Page 235 Tandem Axle Models ITEM ITEM REMARKS Brake Camshafts One fitting each. Joint One fitting each joint Propshaft U (1480 and 1550 Series). Lubricate with GM Part No. 1051344, Wheel Bearing Lubricant. Brake Shoe Apply engine oil at pin Roller Pins to shoe joint only.

  • Page 236: Vehicle Storage

    Battery CAUTION: Your new vehicle comes with one or more maintenance free ACDelco batteries. When it’s time for a new battery, be sure it has the replacement number shown Batteries have acid that can burn you and gas on the original battery’s label. We recommend an that can explode.

  • Page 237: Windshield Wiper Blade Replacement

    Windshield Wiper Blade Replacement Replacement blades come in different types and are removed in different ways. Windshield wiper blades should be inspected at Here’s how to remove the Sheppard’s Hook type: least twice a year for wear or cracking. See “Wiper 1.
  • Page 238 Other Service Items You can then remove the front cover if you need to, by removing the two 8 mm bolts and pulling it off. Component Box When you’re through, be sure to put the front cover on, Your vehicle has a component box located along the left before you put on the top cover.
  • Page 239 Fuel Filter (Diesel Engines) Secondary Fuel Filter and Water Separator/Heater (Option) The ACDelco fuel filter is located in the component box. See your Maintenance Schedule for recommended If you have a Caterpillar service intervals. diesel engine, you may have this spin on filter and fuel Primary Fuel Filter and Water separator/heater.
  • Page 240 Automatic Ether Injection System (Option) 3. Clean any dirt from the neck of the cylinder and the top of the valve before you take out the cylinder. If your diesel engine vehicle 4. Check the inside of the valve for any foreign matter. has this feature, the ether Clean the valve as necessary.

  • Page 241: Front Wheel Bearings With Oil-Filled Hubs

    Front Wheel Bearings with Oil-Filled Hubs Air Conditioning System Every now and then, have your dealership check your If your vehicle has oil filled air conditioning system to be sure it has not lost any hubs, occasionally check to cooling ability. If you think the system is not working see if they have enough oil.

  • Page 242: Inflation -- Tire Pressure

    Inflation -- Tire Pressure CAUTION: The Certification/Tire label, which is on the driver’s door, shows the correct inflation pressures for your tires when they’re cold. “Cold” means your vehicle has been Poorly maintained and improperly used tires sitting for at least three hours or driven no more than are dangerous.

  • Page 243: Dual Tire Operation

    Rims and Wheels NOTICE: (Continued) Rims and wheels are stamped with a maximum load and cold inflation rating. Be sure you don’t exceed If your tires have too much air (overinflation), these limits. you can get the following: Unusual wear Dual Tire Operation Bad handling When the vehicle is new, or whenever a wheel, wheel...

  • Page 244: Wheel Alignment And Tire Balance

    CAUTION: CAUTION: If you operate your vehicle with a tire that is Mixing tires could cause you to lose control while badly underinflated, the tire can overheat. An driving. If you mix tires of different types like overheated tire can lose air suddenly or catch radial and bias belted tires the vehicle may not...

  • Page 245: Tightening The Wheel Nuts

    Tightening the Wheel Nuts CAUTION: Wheel nuts that are not tight can work loose. If all the nuts on a wheel come off, the wheel can come off the vehicle, causing a serious crash. All wheel nuts must be properly tightened. Follow the rules in this section to be sure they are.
  • Page 246 Piloted Wheels, 8 Hole or 10 Hole 6. Tighten the nuts to 400 lb ft (542 N·m) The studs and nuts used with these wheels have if an eight hole right hand threads. stud or 480 lb 1. With intermittent pilot pads, position a pad at (650 N·m) if a 12 o’clock to center the wheel and reduce run out.
  • Page 247 CAUTION: CAUTION: If wheel studs are damaged, they can break. If all Rust or dirt on a wheel, or on the parts to which the studs on a wheel broke, the wheel could come it is fastened, can make the wheel nuts become off and cause a serious crash.

  • Page 248: Wheel Replacement

    Wheel Replacement CAUTION: Replace any wheel that is bent, cracked or badly rusted. 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 249: Appearance Care

    Appearance Care NOTICE: Remember, cleaning products can be hazardous. Some are toxic. Others can burst into flame if you strike a The wrong wheel can cause trouble in bearing match or get them on a hot part of the vehicle. Some are life, brake cooling, speedometer/odometer dangerous if you breathe their fumes in a closed space.

  • Page 250: Cleaning The Inside Of Your Vehicle

    Don’t use any of these unless this manual says you can. Here are some cleaning tips: In many uses, these will damage your vehicle: Always read the instructions on the cleaner label. Alcohol Clean up stains as soon as you can before they set.

  • Page 251: Special Fabric Cleaning Problems

    5. As soon as you’ve cleaned the section, use a sponge Stains caused by candy, ice cream, mayonnaise, chili to remove the suds. sauce and unknown stains can be removed as follows: 6. Wipe cleaned area with a clean, damp towel or cloth. 1.

  • Page 252: Care Of Safety Belts

    Cleaning the Top of the Instrument Panel Care of Safety Belts Use only mild soap and water to clean the top surfaces Keep belts clean and dry. of the instrument panel. Sprays containing silicones or waxes may cause annoying reflections in the windshield and even make it difficult to see through the windshield CAUTION: under certain conditions.

  • Page 253: Cleaning The Outside Of Your Vehicle

    Cleaning the Outside of the Cleaning the Outside of Your Vehicle Windshield and Wiper Blades The paint finish on your vehicle provides beauty, depth of color, gloss retention and durability. If the windshield is not clear after using the windshield washer, or if the wiper blade chatters when running, Washing Your Vehicle wax, sap or other material may be on the blade...

  • Page 254: Cleaning Exterior Lamps/Lenses

    Cleaning Exterior Lamps/Lenses Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird Use lukewarm or cold water, a soft cloth and a car droppings, chemicals from industrial chimneys, etc., can washing soap to clean exterior lamps and lenses.

  • Page 255: Cleaning Tires

    Cleaning Aluminum or Cleaning Tires Chrome Plated Wheels (If Equipped) To clean your tires, use a stiff brush with a tire cleaner. Keep your wheels clean using a soft clean cloth with mild soap and water. Rinse with clean water. After NOTICE: rinsing thoroughly, dry with a soft clean towel.

  • Page 256: Finish Damage

    Finish Damage Chemical Paint Spotting Any stone chips, fractures or deep scratches in the finish Some weather and atmospheric conditions can create a should be repaired right away. Bare metal will corrode chemical fallout. Airborne pollutants can fall upon and quickly and may develop into a major repair expense.
  • Page 257 GM Vehicle Care/Appearance Materials PART NUMBER SIZE DESCRIPTION USAGE 994954 23 in. x 25 in. Polishing Cloth – Wax Treated Exterior polishing cloth 1050172 16 oz. (0.473 L) Tar and Road Oil Remover Removes tar, road oil and asphalt 1050173 16 oz.

  • Page 258: Vehicle Identification Number (Vin)

    Vehicle Identification Number (VIN) Service Statement One of these statements is on your Certification/Tire label. Here is what each one means. TRUCK SERVICE A vehicle made to carry property or special equipment. It is made for uniform frame loading. That includes using the vehicle to pull a full trailer. TRUCK TRACTOR A vehicle made to draw other...

  • Page 259: Service Parts Identification Label

    Service Parts Identification Label Electrical System You’ll find this label in a location determined by the Add-On Electrical Equipment body manufacturer. It’s very helpful if you ever need to order parts. On this label is: NOTICE: your VIN, the model designation, Don’t add anything electrical to your vehicle paint information and unless you check with your dealer first.

  • Page 260: Power Windows And Other Power Options

    Headlamp Wiring The hydraulic brake booster motor feed circuit and starter relay circuit are protected by a fusible link. The headlamp wiring is protected by a circuit breaker in Vehicles with a diesel engine have a fusible link for the the light switch.
  • Page 261 Instrument Panel Circuit Breaker Block To reinstall the door, place the lower door into the bottom retainer and push the top of the door in until it This fuse block is in the lower portion of the instrument snaps into place. panel, to the left of the steering column.
  • Page 262 Name Circuits Protected B/U IGN3 Fuel Filter Relay, Blower Motor Relays, Air ABS Power Relay, Back Up Lamps, Auxiliary Wiring Relay, IGN 3 Relay, Power Window Relay, Transmission Temperature Gage STOP Stoplamps, Stoplamp Relay WASH/WIPE Windshield Wipers/Washer, Accessory Relay DOME/PNL Dome Lamp, Radio Lighting Relay, Instrument Panel Lights, A/C Controller, Headlamp/Seatbelt...
  • Page 263 Name Circuits Protected Name Circuits Protected ENG2 Ignition Coils, Fuel Injectors Even Vehicle Interface Module (Diesel Bank (Gasoline Engines) RLY/VIM Engines), Mass Air Flow, Engine Control Module, Electronic PARK LP Auxiliary Wiring, Parking Lamps, Throttle Control Taillamps, Marker Lamps, Trailer (Gasoline Engines) Running Lamps, Lighted Mirrors Power Windows...
  • Page 264 Maxi Fuse Block To access the maxi fuse block, gently squeeze both sides of the cover to unlatch the tabs at the top. Then, When a circuit goes out, first check the instrument panel unsnap both attachments at the bottom and remove circuit breaker block.
  • Page 265 Name Circuits/Circuit Breakers Protected INT/EXT Parking Lamps, LIGHTS Dome/Panel Lights HEAD LAMP Headlamps, Daytime Running Lamps AUX WRG Auxiliary, Park Brake IGN SW1 Ignition Switch, Wash/Wipe, Crank, Radio HYD PUMP Hydraulic Brake, Brake Pump Motor HYD ABS Hydraulic ABS Window, Door Locks WDO/LCKS PARK BRK Parking Brake Motor...

  • Page 266: Replacement Bulbs

    Replacement Bulbs Wheel Nut Torque Refer to “Tightening the Wheel Nuts” in this section for It is recommended that you use an AC type bulb wheel nut torque information. whenever you need to replace one. Before you replace any bulbs, be sure that all lamps are Cooling System Capacity off and the engine isn’t running.

  • Page 267: Fuel Tank Capacity

    Crankcase Capacity Fuel Tank Capacity Model ......Gallons (Liters) Capacities (volumes) shown are for normal refill. Add oil as indicated when the oil filter element is changed.
  • Page 268 Rear Axle Lubricant Capacity Manual Transmission Pints (Liters) RT6609 ......12.0 (5.7) Single Speed Axle Lubricant, Pints (Liters) RT6610...

  • Page 269: Normal Maintenance Replacement Parts

    Normal Maintenance Tandem Axles Lubricant, Pints (Liters) DS344 (front) ..... . . 29.0 (15.1) Replacement Parts RS344 (rear) ......28.0 (13.2) Allison Transmission External Filters DS454 (front)
  • Page 270 Service Replacement Part and Filter Recommendations Engine 7.2L 7.4L LP4/L21 Spark Plug — AC Type R41 —Gap — 0.060 inch (1.52 mm) —Torque — 22.0 lb. ft. (30.0 Nm) Oil Filter 2P4004 AC Type PF PCV Valve — AC Type CV 774C Air Cleaner Donaldson P522606...

  • Page 271: Section 7 Scheduled Maintenance Services

    Section 7 Scheduled Maintenance Services This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety, dependability and emission control performance. Introduction Part B: Owner Checks and Services Part A: Scheduled Maintenance Services Part C: Recommended Fluids and Lubricants Scheduled Maintenance Part D: Maintenance Record...

  • Page 272: Your Vehicle And The Environment

    Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance can even affect the quality of the air we breathe. Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle.

  • Page 273: 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 This maintenance schedule is divided into four parts: what you can easily do to help keep your vehicle in good condition.

  • Page 274: Using Your Maintenance Schedule

    Part A: Scheduled The proper fluids and lubricants to use are listed in Part C. Make sure whoever services your vehicle uses Maintenance Services these. All parts should be replaced and all necessary repairs done before you or anyone else drives the vehicle. Using Your Maintenance Schedule This schedule is for vehicles that: We at General Motors want to help you keep your...

  • Page 275: Scheduled Maintenance

    Scheduled Maintenance 100 Miles (160 km) Wheel stud nut service. (45) The services shown in this schedule up to 100,000 miles (166 000 km) should be performed after 100,000 miles 500 Miles (800 km) (166 000 km) at the same intervals. The services shown Wheel stud nut service.
  • Page 276 6,000 Miles (10 000 km) 12,000 Miles (20 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 277 15,000 Miles (25 000 km) Chassis lubrication service (or every 6 months, whichever occurs first). (12) Check Oil Life Monitor. If engine oil and filter Inspect door hinge pins and bushings and replace are changed, reset monitor. See “Engine Oil” as necessary.
  • Page 278 24,000 Miles (40 000 km) Thermostatically controlled engine cooling fan service. (4)(20) Check Oil Life Monitor. If engine oil and filter Shields and underhood insulation service. (4)(5)(21) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Air intake system service (or every 24 months, whichever occurs first).
  • Page 279 30,000 Miles (50 000 km) Hydraulic brake service (or every 6 months, whichever occurs first). (7) Check Oil Life Monitor. If engine oil and filter Hydraulic parking brake service (or every 6 months, are changed, reset monitor. See “Engine Oil” whichever occurs first).
  • Page 280 36,000 Miles (60 000 km) (Continued) 39,000 Miles (65 000 km) Inspect door hinge pins and bushings and replace Check Oil Life Monitor. If engine oil and filter as necessary. Lubricate door hinge pins and rollers are changed, reset monitor. See “Engine Oil” with engine oil.
  • Page 281 45,000 Miles (75 000 km) Lubricate door hinge pins and rollers with engine oil. Check Oil Life Monitor. If engine oil and filter Wheel bearing (grease type) service (or every are changed, reset monitor. See “Engine Oil” 24 months, whichever occurs first, and whenever in the Index.
  • Page 282 48,000 Miles (80 000 km) (Continued) Chassis lubrication service (or every 6 months, whichever occurs first). (12) Rear axle air shift motor service. (11) Inspect door hinge pins and bushings and replace Check air brake relay valve operation and check if necessary.
  • Page 283 60,000 Miles (100 000 km) Hydraulic parking brake service (or every 6 months, whichever occurs first). (8) Check Oil Life Monitor. If engine oil and filter Engine drive belts service (or every 12 months, are changed, reset monitor. See “Engine Oil” whichever occurs first).
  • Page 284 66,000 Miles (110 000 km) 72,000 Miles (120 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 285 Clutch pedal free travel service. (10) Clean air brake application valve (or every 3 months, or every 300 hours, whichever occurs first); Throttle linkage service. (19) lubricate linkage. Thermostatically controlled engine cooling Air brake chamber service (or every 2 months, fan service.
  • Page 286 78,000 Miles (130 000 km) 84,000 Miles (140 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” are changed, reset monitor. See “Engine Oil” in the Index.
  • Page 287 87,000 Miles (145 000 km) Air brake service (or every 6 months, whichever occurs first). (39) Check Oil Life Monitor. If engine oil and filter Inspect door hinge pins and bushings and replace are changed, reset monitor. See “Engine Oil” as necessary.
  • Page 288 96,000 Miles (160 000 km) Thermostatically controlled engine cooling fan service. (4)(20) Check Oil Life Monitor. If engine oil and filter Shields and underhood insulation service. (4)(5)(21) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Air intake system service (or every 24 months, whichever occurs first).
  • Page 289 100,000 Miles (166 000 km) 200,000 Miles (320 000 km) Change power steering fluid (or every 36 months, Remove, disassemble, clean and inspect the air brake whichever occurs first). (13) trailer supply valve (or every 2 years, or 7,200 hours, whichever occurs first).
  • Page 290 Footnotes (7) = Inspect brake lines and hoses for proper hook binding, leaks, cracks, chafing, etc. Inspect disc brake = The U.S. Environmental Protection Agency or pads for wear and rotors for surface condition. Check the California Air Resources Board has determined that brake pedal for excessive free play or travel (or every the failure to perform this maintenance item will not 6 months, whichever occurs first) and have serviced if...
  • Page 291 (10) = Check clutch pedal for free travel. Press pedal (13) = Check steering system: by hand until resistance is felt. Free travel should be Look for damaged, loose or missing parts. maintained at 1.5 to 2 inches (38 to 51 mm) measured Also look for parts showing signs of wear or lack at the clutch pedal pad.
  • Page 292 (16) = Check spring axle U bolts and shackle (20) = With the engine off and below normal operating bolts for proper torque. See the service manual for temperature, check to see that the thermostatically torque sequence and specifications. When parts are controlled engine cooling fan can be rotated by hand replaced, the torque must be checked and adjusted on viscous...
  • Page 293 (24) = Check the air intake system installation (31) = Check EGR system as described in the service to see that gaskets are seated properly and all hose manual. See “Service and Owner Publications” in connections, fasteners and other components are tight. the Index.
  • Page 294 (38) = Front axle service: Re pack upper kingpin Replace the air compressor filter element, mounted roller bearing. on the air compressor. For remote air compressor intake service, refer to air cleaner filter replacement. (39) = Air brake service: (40) = Clean and lubricate air brake automatic slack Inspect brake lines and hoses for proper hook adjuster.
  • Page 295 (45) = For Stud Piloted Wheels Only: Tighten the (47) = Service is required now if you operate under wheel stud nuts to the specified torque values at any of these Short Trip/City conditions: 100 miles (160 km), 500 miles (800 km) and Most trips are less than 5 to 10 miles (8 to 16 km).

  • Page 296: At Each Fuel Fill

    Part B: Owner Checks and Services Engine Coolant Level Check Check the engine coolant level and add DEX COOL Listed in this part are owner checks and services which coolant mixture if necessary. See “Engine Coolant” in should be performed at the intervals specified to help the Index for further details.
  • Page 297 Wiper Blade Check Starter Switch Check Inspect wiper blades for wear or cracking. Replace blade inserts that appear worn or damaged or that streak or CAUTION: miss areas of the windshield. Also see “Wiper Blades, Cleaning” in the Index. When you are doing this check, the vehicle could Weatherstrip Lubrication move suddenly.
  • Page 298 Automatic Transmission Shift Indicator Check Engine Cooling System Service Check that the indicator points to the gear chosen. Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, Steering Check fittings and clamps; replace as needed. Clean the outside of the radiator and air conditioning condenser.
  • Page 299 Defroster Check Glass, Mirrors, Lamps and/or Reflectors Condition Check Move the control to the defrost symbol and the fan to HI or the high symbol. Then check the airflow from the Look for broken, scratched, dirty or damaged glass, ducts at the inside base of the windshield. mirrors, lamps or reflectors that could reduce the view or visibility or cause injury.
  • Page 300 Underbody Inspection At Least Once a Year Corrosive materials used for ice, snow removal and dust Key Lock Cylinders Service control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can occur Lubricate the key lock cylinders with the lubricant specified in Part C.
  • Page 301 Part C: Recommended Fluids USAGE FLUID/LUBRICANT and Lubricants Engine Coolant 50/50 mixture of clean, (GM Gasoline drinkable water and use only GM NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from Engine) Goodwrench COOL your dealer.
  • Page 302 USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Exhaust Brake High Temperature Grease (GM Power GM Power Steering Fluid Ball Joint Cap Part No. 1051344 or equivalent) Steering System (GM Part No. 1052884 1 pint, Lubricant or NLGI #3 consistency. 1050017 1 quart, or equivalent). Spring Parking DEXRON III Automatic...
  • Page 303 USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Wheel Bearing Wheel Bearing Lubricant meeting Propshafts Wheel Bearing Lubricant Grease requirements of NLGI # 2, and Splines meeting requirements of NLGI # 2, Category GC or GC LB (GM Category GC or GC LB (GM Part No.

  • Page 304: Maintenance Record

    Part D: Maintenance Record After the scheduled services are performed, enter the added on the following record pages. Also, you should date, odometer reading and services performed on the retain all maintenance receipts. Your owner information maintenance record charts provided here. Any additional portfolio is a convenient place to store them.
  • Page 305 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-35...
  • Page 306 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-36...

  • Page 307: Section 8 Customer Assistance Information

    Section 8 Customer Assistance Information Here you will find out how to contact Chevrolet if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects. Customer Satisfaction Procedure Reporting Safety Defects to the...

  • Page 308: Customer Satisfaction Procedure

    Customer Satisfaction Procedure Your satisfaction and goodwill are important to your dealer and to Chevrolet. Normally, any concerns with the sales transaction or the operation of your vehicle will be resolved by your dealer’s sales or service departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur.

  • Page 309: Customer Assistance For Text Telephone (Tty) Users

    That number for assistance. If a U.S. customer wishes to write is why we suggest you follow Step One first if you have to Chevrolet, the letter should be addressed to Chevrolet a concern. Medium Duty Truck’s Customer Assistance Center.

  • Page 310: All Overseas Locations

    Canada Caribbean Numbers General Motors of Canada Limited 1-800-496-9992 (English) Puerto Rico Customer Communication Centre, 163-005 1-800-496-9993 (Spanish) Puerto Rico 1908 Colonel Sam Drive 1-800-751-4135 (English) Dominican Republic Oshawa, Ontario L1H 8P7 1-800-751-4136 (Spanish) Dominican Republic 1-800-496-9994 U.S. Virgin Islands 1-800-263-3777 (English) 1-800-389-0009 Bahamas 1-800-263-7854 (French)

  • Page 311: Roadside Assistance

    Roadside Assistance This service combines the efforts of trained telephone representatives with a network of GM Medium Duty Truck’s dealer services. Just dial Medium Duty Truck Roadside Assistance at CHEVY (1 4389) to reach a qualified representative who can assist you in a repair or arrange a tow.

  • Page 312: Reporting Safety Defects To The United States Government

    REPORTING SAFETY DEFECTS REPORTING SAFETY DEFECTS TO TO THE UNITED STATES THE CANADIAN GOVERNMENT GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify If you believe that your vehicle has a defect which could Transport Canada, in addition to notifying General cause a crash or could cause injury or death, you should Motors of Canada Limited.

  • Page 313: Reporting Safety Defects To General Motors

    Please call us at 1 8782, or write: The toll-free telephone number for ordering information Chevrolet Motor Division in Canada is 1-800-668-5539. Chevrolet Customer Assistance Center P.O. Box 436008 Pontiac, MI 48343-6008 In Canada, please call us at 1 3777 (English) or 1 7854 (French).
  • Page 314 2000 CHEVROLET SERVICE PUBLICATIONS ORDERING INFORMATION The following publications covering the operation and servicing of your vehicle can be purchased by filling out the Service Publication Order Form in this book and mailing it in with your check, money order, or credit card information to Helm, Incorporated (address below.)
  • Page 315 Orders will be mailed within 10 days of receipt. Please allow adequate time for postal ORDER TOLL FREE service. If further information is needed, write to the address shown below or call (NOTE: For Credit Card Holders Only) 1-800-551-4123. Material cannot be returned for credit without packing slip with return 1-800-551-4123 information within 30 days of delivery.

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