Chevrolet 4500HD Series 2019 Manual
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Chevrolet 4500HD Series 2019 Manual

Chevrolet 4500HD Series 2019 Manual

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2019
Low Cab Forward 5.2L Diesel Engine
4500HD/4500XD/5500HD Series
chevrolet.com

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Summary of Contents for Chevrolet 4500HD Series 2019

  • Page 1 2019 Low Cab Forward 5.2L Diesel Engine 4500HD/4500XD/5500HD Series chevrolet.com...

  • Page 2: Table Of Contents

    Contents Introduction ..... . 2 In Brief ......9 Keys, Doors, and Windows .

  • Page 3: Introduction

    Crew Cab: this manual including, but not limited satisfaction, follow the steps in the to, GM, the GM logo, CHEVROLET, separate Warranty and Owner and the CHEVROLET Emblem are Assistance Information booklet. We...
  • Page 4 Introduction Using this Manual If any of these labels are peeling or Caution illegible due to wear or scratches, To quickly locate information about please contact your dealer for a Caution indicates a hazard that the vehicle, use the Index in the replacement.
  • Page 5 Introduction Crew cab model Description Automatic transmission fluid level VIN, weight rating, and Greenhouse Gas (GHG) emissions NO STEP instruction Certified clean idle label Towing Vehicle noise emission control information ID plate Engine cooling Fan blade Description Cab tilt instruction...
  • Page 6 Introduction All models Description Vehicle noise emission control information VIN, weight rating, and Greenhouse Gas (GHG) emissions NO STEP instruction Engine oil level Engine oil level notice Certified clean idle label Towing Engine cooling Fan blade Automatic transmission fluid level ID plate Power steering fluid Power steering fluid...
  • Page 7 Introduction Description Engine cover notice (Crew cab) Safety lock pin (Single cab) Starting aids (Single cab) Description Safety...
  • Page 8 Introduction Description V Diesel fuel Radiator cap Diesel exhaust fluid (DEF) Body...
  • Page 9 Introduction NOTES...

  • Page 10: In Brief

    In Brief In Brief Cruise Control ....22 Driver Information Center (DIC) ....23 Power Outlets .

  • Page 11: Instrument Panel

    In Brief Instrument Panel...
  • Page 12 In Brief 1. Air Flow Direction Control 9. Relay Box. See Electrical Lever. See Air Vents 0 134. System Overload 0 287. 2. Combination Light Control 10. Cupholders 0 56. Switch. See Exterior Lamp 11. Hook. See Shopping Bag Controls 0 92. Hooks 0 57.

  • Page 13: (Driver Side)

    In Brief 7. Rear Power Window Lock Instrument Panel (Driver Side) Switch. See Power Windows 0 35. 8. Outside Rearview Mirror Heater Switch. See Heated Mirrors 0 34. 9. Cruise Control Main Switch. See Cruise Control 0 223. 10. Hazard Warning Flasher Switch.

  • Page 14: Interior)

    In Brief 9. Selector Lever 0 214. Instrument Panel (Vehicle Interior) 10. Fully Adjustable Steering. See Steering Wheel Adjustment 0 65. 1. Overhead Tray. See Storage 5. Seat Back Pocket (Driver s Compartments 0 54. Side). See Storage Compartments 0 54. 2.

  • Page 15: Initial Drive Information

    In Brief Initial Drive Remote Keyless Entry Locking (RKE) System Press the lock button (1) of the Information remote control unit for 1 second or Unlocking and Locking the longer. The vehicle's keyless entry This section provides a brief Doors system causes the right and left turn overview about some of the signal lights to simultaneously flash...

  • Page 16: Door Locks

    In Brief Door Locks Locking the Door from Outside Locking and Unlocking the Door without Using the Key from Inside Locking and Unlocking the Door from Outside Using the Key First, push the lock button (1) on the Push the lock button (1) forward to inside door handle forward and then lock the door;...

  • Page 17: Windows

    In Brief Windows need to press the switch Window Switches on continuously (automatic mode Passenger s Door Window Switches on operation). If you want to stop the The power window switch on the Driver s Door automatic movement of the window passenger's door can raise and before it lowers completely, raise the lower the passenger's side window...

  • Page 18: Seat Adjustment

    In Brief Seat Adjustment Reclining Adjustment Passenger s Seat/Center Seat Driver s Seat Forward/backward Adjustment Passenger s Seat To recline the seatback, raise the seatback tilt lever and gently lean back to the desired position. To move the seatback forward, lean While raising the unlock lever, move forward with your back slightly clear the seat forward or backward.

  • Page 19: Seat Belts

    In Brief Seat Belts sides of the vehicle are provided. Make adjustments and clean mirrors if necessary. Outside Rearview Mirrors After properly adjusting your seat for proper driving position, adjust the mirrors so that they provide adequate views for checking the rear and the sides of the vehicle.

  • Page 20: Interior Lighting

    In Brief 3. Firmly lock the steering wheel Warning (Continued) at the selected position by moving the lock lever to the To reduce the risk of lock position. personal injury, apply force to the steering wheel to Interior Lighting make certain the steering column is firmly locked Front Light before driving.

  • Page 21: Exterior Lighting

    In Brief Between ON and OFF, the light Exterior Lighting : Turns on the parking lights comes on when the driver's door is including all exterior lights, except opened. the headlights. Rear Light (Crew Cab Model Only) : Turns on the headlights together with the parking lights, sidemarker lights, roofmarker lights, taillights, license plate light, and...

  • Page 22: Climate Controls

    In Brief The windshield wiper switch has the Windshield washer fluid is sprayed 1. Outlet Selector Knob following positions, which over the windshield when this switch 2. Air Selector Lever correspond to the states of the is pressed. At the same time, the 3.

  • Page 23: Vehicle Features

    In Brief Vehicle Features Cruise Control 2. Press Tune/Track less than one second again to select the station of your Radio(s) choice. Turning the Power On or Off Settings Press MODE/ /ENTER to turn the Adjustment of bass, treble, fader, power on.

  • Page 24: Driver Information

    In Brief Power Outlets At the same time the cruise set indicator light comes on. See Cruise Control 0 223. Driver Information Center (DIC) 2. Use the accelerator pedal to adjust the vehicle to the The DIC display is in the instrument desired speed.

  • Page 25: Performance And Maintenance

    In Brief Performance and Frequent short trips, excessive produced. The DEF system must be idling and use of the air conditioner maintained for the vehicle to run Maintenance in cool weather when "Vent" would properly. provide adequate comfort, can all DEF is not a fuel additive.

  • Page 26: Keys, Doors, And Windows

    Keys, Doors, and Windows Keys, Doors, and Keys and Locks Both sides of the key are identical, so you can insert the key in the Windows engine control switch without Keys worrying about which way you insert it. Keys and Locks The key code is indicated on a Keys .

  • Page 27: Remote Keyless Entry (Rke)

    Keys, Doors, and Windows If you resell the vehicle, be sure to Remote Keyless Entry Unlocking and Locking the hand over the plate with key code to Doors (RKE) System Operation the new owner together with the vehicle. The keyless entry system allows you to lock/unlock the doors by Remote Keyless Entry simply pressing the remote control...
  • Page 28 Keys, Doors, and Windows system causes the right and left turn The lock or unlock buttons on the Replacing the Battery in the signal lights to simultaneously flash remote control unit must be fully Remote Control Unit once upon receiving the signals pressed for more than 1 second When the battery runs down, from the remote control unit.
  • Page 29 Keys, Doors, and Windows 2. Remote Control Cover 3. Insert a flat head screwdriver Notch or similar tool into the recess of the remote control unit (4) to 3. Remote Control Unit Cover remove the old battery. 4. Remote Control Unit 5.

  • Page 30: Getting In And Out Of The Vehicle

    Keys, Doors, and Windows Getting In and Out of the Warning Warning (Continued) Vehicle When changing the battery, use at 3 points. It is very dangerous to only a battery of the same type as stand on the tire or wheel when the original battery, or an getting in or out of the vehicle.

  • Page 31: Door Locks

    Keys, Doors, and Windows Warning (Continued) Warning (Continued) Warning (Continued) Exercise caution when opening or When you close the door after belts properly, locking the doors closing doors, as strong winds or sitting behind the wheel, check helps prevent people from being steep slopes may cause doors to that the door is fully closed.
  • Page 32 Keys, Doors, and Windows Front Doors Locking the Door from Outside Warning (Continued) without Using the Key Locking and Unlocking the Door sure to control the power windows from Outside Using the Key using the power window switches beside the driver's seat. You and others could be seriously injured.
  • Page 33 Keys, Doors, and Windows Locking and Unlocking the Door panel. To open the door from Locking and Unlocking Doors from Inside outside the vehicle, pull up on the from the Inside handle. Locking the Door from the Outside Push the door lock button forward and then close the door;...

  • Page 34: Power Door Locks

    Keys, Doors, and Windows Power Door Locks Vehicle Security Exterior Mirrors Power Door Lock (Central Guard Against Theft Mirrors Door Lock) Your new vehicle has many features Sit in the correct driving position How the Power Door Lock System to help prevent theft of the vehicle, with the seat adjusted properly.

  • Page 35: Heated Mirrors

    Keys, Doors, and Windows If the outside rearview mirrors fog Warning Warning (Continued) up, press the outside rearview mirror heater switch to defog them. Before driving, be sure to adjust Keep the mirrors in mind when When the switch is pressed the the seat and mirrors to positions passing another vehicle on a indicating light will illuminate.

  • Page 36: Windows

    Keys, Doors, and Windows Windows Window Switches on Warning Driver s Door Power Windows Regardless of whether the vehicle is moving or stationary, you must never allow a child to put his/her Warning head, hands, or other body part If you are traveling with a child, out of the window.
  • Page 37 Keys, Doors, and Windows operation). If you want to stop the only, while, if equipped, the rear Window Switches on Center of automatic movement of the window power window switches can raise Dashboard (Crew Cab Model) before it lowers completely, raise the and lower the rear door windows.

  • Page 38: Sun Visors

    Keys, Doors, and Windows To Lock Rear Power Windows Sun Visors Passenger s Side Rear Power Window Lock Switch The sun visor (1) protects your eyes Driver s Side in strong sunlight. Use it when If you push the rear power window sunlight is too bright.

  • Page 39: Seats And Restraints

    Seats and Restraints Seats and Front Seats Warning Restraints Seat Position Adjust the seat only before you start driving. Adjusting the seat while the vehicle is in motion Warning Front Seats must be avoided not only Seat Position ....38 Use caution when adjusting the because the unlocked seat will Rear Seats...
  • Page 40 Seats and Restraints Warning (Continued) Warning Warning the vehicle to your dealer for Do not place a cushion or similar Before making adjustments, service if you find that your seat object between your back and the check that the seat rails are free adjusters do not latch.
  • Page 41 Seats and Restraints Adjusting the seat for a correct Reclining Adjustment Warning driving posture is a fundamental part of safe driving. Warning Make sure not to hit passengers Forward/backward Adjustment or luggage when adjusting your To reduce the risk of sliding under seat.
  • Page 42 Seats and Restraints To move the seatback forward, lean the scale and counterclockwise to Warning forward with your back slightly clear move it up the scale. The pointer of the seatback and raise the lever. should be alongside your weight on Do not adjust the reclining After making adjustments, check the scale.

  • Page 43: Cab Only)

    Seats and Restraints Rear Seats Rear Seats (Crew Cab Only) Do not remove the seat cushion except when taking out or stowing onboard tools. Warning Do not drive with the seat cushion Passenger s Seat Center Seat removed. The seat would not be stable, which could lead to an You can tip the seatback forward if accident.

  • Page 44: Seat Belts

    Seats and Restraints Seat Belts Familiarizing yourself with the correct use of seat belts is essential for your safety. Warning To help reduce the risk of personal injury in collisions or sudden maneuvers, use the seat belts following these instructions on their proper use, maintenance, and use with child restraint systems.
  • Page 45 Seats and Restraints Warning (Continued) Warning (Continued) Warning (Continued) and be seriously injured. Seat do not use a seat belt if it does disperse shocks efficiently in the belts work best only when the not fit snugly over the child's hips event of a collision or occupant is sitting well back and because restraining the child...

  • Page 46: Three-Point Seat Belt

    Seats and Restraints Warning (Continued) Warning (Continued) Warning (Continued) Do not use one seat belt for more Be careful to keep the buckles Wearing seat belts is a legal than one person. If worn by more and retractors free of dust and requirement.
  • Page 47 Seats and Restraints To Fasten: Warning (Continued) 1. Sit on the seat in the correct driving position. collision or sudden stop if it is in contact with your neck and/ or face. 3. To reduce the risk of sliding under the belt during a collision, position the belt across your lap as low on your hips as possible and adjust it to...

  • Page 48: Seat Belt Use During

    Seats and Restraints To Unfasten: When the passenger's seat belt is Seat Belt Use During fully taken up (or not pulled out), Pregnancy check that the stopper is holding the belt in a fully taut state. Warning Emergency Locking Retractor (ELR) Function Unless the seat belt is correctly worn, it may dig into the abdomen...

  • Page 49: Lap Belt

    Seats and Restraints An expectant mother or a person who is ill riding in the vehicle must also wear a seat belt. In light of the risk that the seat belt will apply pressure to the abdomen, chest and shoulders in the event of a collision, however, an expectant mother or person who is ill should get advice from a physician beforehand.

  • Page 50: Seat Belt Extender

    Seats and Restraints 4. Position the seat belt across Seat Belt Extender replaced and anchorages properly the lap as low as possible on repaired if they were in areas If the vehicle's seat belt will fasten the hips. Pull the fold-back end damaged by a collision, whether the around you, you should use it.
  • Page 51 Seats and Restraints 1. Seat belt fold-back fitting Avoid using anything like a tool to Warning (Continued) portion pass the cloth through the fold-back fitting portion or try to remove 2. Seat belt that may have entered the buckle. stubborn dirt. Using such an object 3.

  • Page 52: Child Restraints

    Seats and Restraints 2. Mix one part neutral detergent If the above-described upkeep Child Restraints into approximately twenty parts operations do not improve the warm water. operation of the seat belt through Child Restraint Systems the retractor, there is a possibility 3.
  • Page 53 Seats and Restraints the child restraint is not properly Installation on Outboard Seat Warning (Continued) secured, the child risks personal injury in the event of a collision. Any unrestrained child could be Using a Lap Belt That Has No injured by striking the vehicle's interior or by ejection from the Retractor vehicle during an accident or...
  • Page 54 Seats and Restraints Secure the child restraint with the When your child restraint is not Warning lap belt portion (1) of the seat belt in installed, remove the locking clip to accordance with the restraint permit normal use of the To help avoid personal injury or manufacturer's instructions.

  • Page 55: Storage

    Storage Storage Storage Seat Back Pocket Compartments Storage Compartments Overhead Compartment Storage Compartments ..54 Instrument Panel Storage ..55 Warning Glove Box ..... 55 Cupholders .

  • Page 56: Instrument Panel Storage

    Storage Instrument Panel Storage Card Holder Glove Box Small Article Storage Pockets Use this to hold your cards. Use the storage pockets for storing small articles. Press on the central mark to lock and unlock the lid.

  • Page 57: Cupholders

    Storage Cupholders Warning Caution For safety, close the glove box When closing the glove box lid, during driving. There is a risk of do not allow stored items to pass injury from the open lid or items the line shown in the illustration. stored in the glove box.

  • Page 58: Rear Storage

    Storage 0.75 kg (1.65 lbs). Doing so may Single Cab Model Only Additional Storage also result in damage to the radio or Features other electronic components. Warning Use the cupholders for storing small Shopping Bag Hooks Do not use the back panel tray to articles or cups.

  • Page 59: Information On Loading The Vehicle

    Storage Information on cab) or on the left center pillar panel Your dealer can advise you of the beside the shoulder seat belt anchor proper loading conditions for your Loading the Vehicle (crew cab). vehicle. Using selected heavier suspension components for added Gross vehicle weight (GVW) is the Overloading durability may not increase any of...
  • Page 60 Storage help. The cargo load should be Model Maximum Front GAWR Rear GAWR distributed on both sides of the GVWR Capacity Capacity center line as equally as possible. kg (lb.) kg (lb.) kg (lb.) Tires 4500HD 6 577 (14,500) 2 431 (5,360) 4 482 (9,880) The tires on your truck must be of 4500XD...
  • Page 61 Storage Load Cargo Correctly Warning (Continued) distributed over the front and rear axles so as not to exceed the axle capacities. It is extremely dangerous to overload the vehicle or to load the vehicle with the cargo positioned on one side. Load the vehicle correctly, observing the maximum loading capacity.
  • Page 62 Storage Cargo loading caution Incorrect Correct Do not place cargo only at the front or only at the rear. Distribute it evenly. When using supports under cargo, position them uniformly along the cargo. To the greatest extent possible, do not allow long cargo to protrude beyond the rear edge of the cargo bed.
  • Page 63 Storage Cargo loading caution Incorrect Correct Use ropes and tarpaulins to secure the cargo so it does not fall off the cargo bed. Use rubber bands or bungee cords to prevent the tarpaulins from flapping in the wind. Avoid loading cargo too high. It can cause the vehicle to tip sideways when it catches side winds and when turning the vehicle.
  • Page 64 Storage Loading Equipment Make Sure There is No Flammable Material between the Cab and Cargo Bed Caution Be careful not to allow a sheet, canvas top, or the ends of ropes or rubber straps to touch or come close to the engine or exhaust pipe.

  • Page 65: Instruments And Controls

    Instruments and Controls Instruments and Brake System Warning Light Vehicle Messages (Parking Brake Light) ..74 Vehicle Messages ... . . 86 Controls Antilock Brake System (ABS) Warning Buzzers .

  • Page 66: Controls

    Instruments and Controls Controls 3. Firmly lock the steering wheel at the selected position by moving the lock lever to the Steering Wheel lock position. Adjustment Horn Warning Adjust the position of the steering wheel before you start driving. To reduce the risk of personal injury, apply force The steering wheel is adjustable up to the steering wheel to...

  • Page 67: Windshield Wiper/Washer

    Instruments and Controls Windshield Wiper/Washer If the wiper frequently stops during operation, contact your nearest Dealer. Clear snow and ice from the wiper blades and windshield before using them. If frozen to the windshield, carefully loosen or thaw them. Damaged blades should be replaced.

  • Page 68: Power Outlets

    Instruments and Controls If windshield washer fluid does not Power Outlets When using accessory power come out, release the windshield outlets, total maximum electrical washer switch immediately. load must not exceed 120W. Always Otherwise the motor may seize up. turn off any electrical equipment when not in use.

  • Page 69: Warning Lights, Gauges, And Indicators

    Instruments and Controls Warning Lights, Some warning lights come on briefly when the engine is started to Gauges, and indicate they are working. When one of the warning lights comes on Indicators and stays on while driving, or when Warning lights and gauges can one of the gauges shows there may be a problem, check the section that signal that something is wrong...

  • Page 70: Instrument Cluster

    Instruments and Controls Instrument Cluster...

  • Page 71: Speedometer

    Instruments and Controls Speedometer Odometer Check Switch To reset the trip odometer to zero, press and hold the trip odometer Press the Odometer Check switch The speedometer shows the reset stem while TRIP A or TRIP B to display the odometer and trip vehicle's speed in either kilometers is displayed.

  • Page 72: Tachometer

    Instruments and Controls LOCK or ACC position. Follow the To check the fuel level with the Caution same procedure to cancel the engine control switch in the LOCK setting. position, press the Odometer Check Exercise extreme care when switch. shifting down on a steep Tachometer Fill the tank well before it downslope.

  • Page 73: Engine Coolant Temperature

    Instruments and Controls Engine Coolant Warning Caution (Continued) Temperature Gauge If the engine coolant temperature does not cross into it, this is not a gauge shows an overheat problem, but check the engine condition or you have any other coolant level in the reservoir. Add reason to suspect the engine may engine coolant as necessary.

  • Page 74: Battery Warning Light

    Instruments and Controls This light comes on briefly when the Malfunction Indicator ignition is turned on, but the engine Lamp (Check Engine is not running, as a check to show Light) the light is working. It should go out when the engine is started. If the light stays on, or comes on This warning light comes on and a while driving, there may be a...

  • Page 75: Service Vehicle Soon Light

    Instruments and Controls If this light comes on intermittently If the light stays on, or comes on The brake system warning light or continuously while driving, while driving, the vehicle control comes on while the engine is service is required. Even if the system may be malfunctioning.
  • Page 76 Instruments and Controls warning light does not go away, or have the vehicle towed to Parking Brake Light brake inspection and maintenance the nearest dealer for repair. should be performed. Continued driving without the necessary repairs could be Check and Corrective Action dangerous.

  • Page 77: Antilock Brake System (Abs)

    Instruments and Controls Brake Low Vacuum Warning whenever the hydraulic brake You may have to push much booster (HBB) becomes faulty. The harder on the brake pedal. Light warning buzzer will stop sounding Have the vehicle repaired before when the parking brake is engaged. you continue driving.

  • Page 78: Exhaust Brake Light

    Instruments and Controls out after approximately Exhaust Brake Light Warning (Continued) three seconds. If the light does not come on, have it fixed so it will be 3. Move the vehicle slowly ready to warn if there is a problem. forward.

  • Page 79: Automatic Transmission Fluid Temperature Warning Light

    Instruments and Controls If this light comes on while driving, it be accompanied by leakage of fluid Overdrive Off Light indicates that there is a malfunction from the transmission in the automatic transmission s breather hose. electronic control system. If the If the light stays on, or comes on warning light is on, see your dealer while driving, slow down and pull off...

  • Page 80: Wait-To-Start Light

    Instruments and Controls Wait-to-Start Light This light comes on when the warning light in combination with the engine oil pressure has fallen below green engine oil level indicator light the normal level while the engine is can indicate if the engine oil level is running or the oil pressure across OK or low.

  • Page 81: Diesel Exhaust Fluid (Def)

    Instruments and Controls Diesel Exhaust Fluid Engine Shutdown Idle Shutdown Light (DEF) Warning Light Warning Light This light comes on briefly when the engine control switch is in the ON This light should come on briefly The Engine Shutdown Warning light position and then should go out when the engine control switch is comes on briefly when the engine...

  • Page 82: Reduced Engine Power

    Instruments and Controls Reduced Engine Power If this light comes on with the Refill Daytime Running Lamps Diesel Exhaust Fluid (DEF) warning Light (DRL) Indicator Light light and the DEF warning light, refill DEF as soon as possible. See Refill Diesel Exhaust Fluid (DEF) Warning Light under Driver Information Center (DIC) 0 82.

  • Page 83: Cruise Control Light

    Instruments and Controls Cruise Control Light Information Displays Driver Information Center (DIC) This light should come on briefly when the engine control switch is turned to the ON position, and then This light should come on briefly should go out after the engine is when the engine control switch is started.
  • Page 84 Instruments and Controls 2. Automatic transmission shift DIC Menu Items economy. Turn the selector indicator clockwise or counterclockwise to toggle through the items: average 3. Diesel Exhaust Fluid (DEF) fuel economy, per trip fuel economy, gauge and instantaneous fuel economy. Average Fuel Economy: Warning Indicates the average fuel...
  • Page 85 Instruments and Controls Red means the battery voltage is decrease the year. While in the year Warning Lights and Messages too low or too high. If the voltmeter setting screen, press the DIC Engine Overheat Warning Light sign appears in red, have the selector once to switch to the month Low Coolant Warning Light vehicle checked and serviced at...
  • Page 86 Instruments and Controls display. Complete the resetting by Tire Rotation Only). Turn clockwise If you want to cancel the setting pressing and holding the DIC to increase distance and procedure, press the DIC selector selector for more than two seconds. counterclockwise to decrease once.

  • Page 87: Vehicle Messages

    Instruments and Controls Vehicle speed will be severely Vehicle Messages This light will also activate the limited when the DEF tank is empty. engine alarm and automatic The Driver Information Center (DIC) Be sure to add DEF in advance of shutdown system, if equipped.
  • Page 88 Instruments and Controls Low Coolant Warning Light section and make sure the warning See Fuel for Diesel Engines 0 227, light goes out. See Water in Fuel Fuel Gauge 0 71, and Running Out LOW COOLANT 0 231. of Fuel 0 233. If this message and light come on, If you continue driving with the Regeneration Required...
  • Page 89 Instruments and Controls If your vehicle is equipped with a regeneration, the color of this light Keep people and flammable objects power take-off (PTO), monitor the changes to red from amber. When away from the exhaust pipe, DIC for DPF related indicators. PTO this light comes on in red, perform because the exhaust temperature and other slow speed applications...
  • Page 90 Instruments and Controls Exhaust System Warning Light result in a severe vehicle speed excess of that. For the items listed limitation. See Diesel Exhaust Fluid below, the displayed color will EXH. SYSTEM 0 189. change from green to amber when remaining distance is below This light comes on when the SCR When DIC ERROR is Displayed...
  • Page 91 Instruments and Controls MAINTENANCE ON or change. When this message next tire rotation displayed. When MAINTENANCE OFF displays amber, the next change of this message displays amber the next tire rotation is near or has transmission oil and differential oil is This indicator displays and hides near or has been reached.

  • Page 92: Warning Buzzers

    Instruments and Controls Hour Meter Low engine coolant beep Engine alarm and automatic HOUR METER shutdown beep This message and light indicate how Diesel particulate filter (DPF) many hours the engine has been switch regeneration three run. The figure(s) on the left side of short beeps or three long beeps the decimal point indicate hours while the figure on the right side...

  • Page 93: Lighting

    Lighting Lighting Exterior Lighting : Turns off all exterior lights. : Turns on the parking lights Exterior Lamp Controls including all exterior lights, except Exterior Lighting the headlights. Exterior Lamp Controls ..92 : Turns on the headlights Headlamp High/Low-Beam together with the parking lights,...

  • Page 94: Headlamp High/Low-Beam

    Lighting Headlamp High/ Flash-to-Pass Low-Beam Changer This indicator light comes on when high beam is selected or the headlights are cycled between high and low beams. Use low beam whenever there are vehicles ahead in the same lane or oncoming vehicles in the opposite lane.

  • Page 95: Hazard Warning Flashers

    Lighting Hazard Warning Flashers engine off. Otherwise, the battery Turn and Lane-Change may go dead, making it impossible Signals to restart the engine. Both indicator lights flash when the hazard warning flasher switch is operated irrespective of the position of the engine control switch. The individual turn signals do not Use the hazard warning light flasher work when the hazard flasher is...

  • Page 96: Cornering Lamps

    Lighting lever is held up or down. The lever Cornering Lamps Interior Lighting moves back to neutral as soon as it The cornering light illuminates the is released. Instrument Panel area to which the vehicle is turning. A green light on the instrument With the headlights or marker lights Illumination Control panel is designed to flash to tell you...

  • Page 97: Cargo Lamp

    Lighting Cargo Lamp Dome Lamps Rear Light (Crew Cab Model Only) Front Light The dome light operates regardless When this switch is pressed, the of the engine control switch position. rear body interior light comes on The dome light operates regardless The switch has three positions.

  • Page 98: Infotainment System

    Infotainment System Infotainment Radio System AM-FM Radio The radio or CD/USB player can be used when the ignition is on or in Control Panel ACC/ACCESSORY. Continued use Radio while engine is stopped may cause AM-FM Radio ....97 the battery to discharge.
  • Page 99 Infotainment System MODE/ /ENTER is pressed again, the audio system resumes the last mode just before it was turned off. Switching the Audio Modes 1. Press MODE/ /ENTER. 2. Turn MODE/ /ENTER to select the audio mode and press ENTER. The audio mode changes in the following order: DISC*1 USB/IPOD(iPod)*3...
  • Page 100 Infotainment System *4 This mode is skipped when Adjusting Bass Adjusting Fader an auxiliary player is not 1. Press FUNC. 1. Press FUNC. connected. 2. Turn MODE/ /ENTER to 2. Turn MODE/ /ENTER to Adjusting the Volume select SOUND, and then press select SOUND, and then press ENTER.
  • Page 101 Infotainment System 4. Turn MODE/ /ENTER 3. Turn MODE/ /ENTER 2. Turn MODE/ /ENTER to clockwise or counterclockwise clockwise or counterclockwise select "FM1", "FM2", "FM3", to adjust the right or left to select SET, and then press "AM1" or "AM2", and then speakers, and then press ENTER.

  • Page 102: Radio Reception

    Infotainment System 2. Tune in the station of your Here are some common reception 2. Press and hold Tune/Track choice. problems that probably do not for more than indicate a problem with your radio. 3. Press and hold down the two seconds.

  • Page 103: Fixed Mast Antenna

    Infotainment System band, your radio may tune in the Certification Audio Players second station until the original For Federal Communications signal can be picked up again. CD Player Commission (FCC) compliance AM Transmissions information for this device, see CD Operations Radio Frequency Statement 0 370.
  • Page 104 Infotainment System If a disc could not be ejected, Random Playback Press for fast forward. contact nearest dealer for service. For CD: Press for fast reverse. To Track (File) Selection stop fast forward or fast reverse, Press 2. is displayed. release.
  • Page 105 Infotainment System To cancel the category Go Back to the First Position TRACK (Track title) selection mode, press LIST (Home Jump) ARTIST (Artist name) again or press BACK. NO/TIME... You can go back to the first file of the first folder on the MP3/WMA For CD (MP3/WMA): 2.
  • Page 106 Infotainment System If Error Appears in the Display NO SUPPORT: This message is The audio may skip due to violent displayed when the disc is in vibrations when the car is traveling The following messages are one of the following conditions: across harsh roads.
  • Page 107 Infotainment System to long exposure to the Mode CD mixed with DTS can Do not stick any paper tape to the environment of the vehicle also not be played accurately. recording side or the label side as it compartment. CD-R, CD-RW This device accepts 8 cm (3 in) may lead the disc to malfunction.
  • Page 108 Infotainment System Discs with copy protection. to improve sound quality or protect This deck has limitations on MP3/ the discs, and CD labels, etc. They WMA file standards and recorded New Disc may change the thickness of the media and formats that can Some new discs may have burrs disc and external specifications and be used.
  • Page 109 Infotainment System Supported channel modes: Variable bit rate (VBR) is time. It is also recommended that supported. CD-R and CD-RW discs be kept in Stereo a light-resistant case because the Lossless compression is not Joint Stereo discs are vulnerable to ultra-violet supported.

  • Page 110: Usb Port

    Infotainment System with the mp3 file extension. Be sure be recorded without files other than When a disc is inserted, the CD to use the .wma file extension when MP3/WMA files and without player screen will be displayed for saving WMA files. The MP letters of unnecessary folders in order to about a few seconds while the unit the file extension will be recognized...
  • Page 111 Infotainment System The music file starts playing. When the USB mode is switched to Press to fast forward. other modes and then switched Playing Music Files in the USB Press to fast reverse. back again, the main unit returns to Memory (When the USB Memory the music file played last.
  • Page 112 Infotainment System Press 2 twice to play the files Display the Text Information 3. Turn MODE/ /ENTER to from the folder being played in select the folder or file of your 1. Press and hold down LIST for the USB Memory in random choice from the list, and then more than one second.
  • Page 113 Infotainment System If there is no text information stored NO MUSIC: This message is Playing Music Files in the iPod in a music file, NO TITLE is displayed when a blank USB device (When the iPod is not Connected) displayed. or the USB device that does not 1.
  • Page 114 Infotainment System Playing Music Files in the iPod Pausing the Music To cancel, press twice. (When the iPod is Connected) disappears. Press 3 to pause the music. To resume, press 4. 1. Press MODE/ /ENTER. When the iPod is removed from the main unit under the Repeat setting, File Selection 2.
  • Page 115 Infotainment System Selecting the Music File from the The following information is 3. Turn MODE/ /ENTER to Category List displayed according to the display the selection mode of category selected: your choice, and then press You can search for a music file you ENTER.
  • Page 116 Infotainment System The display item changes in Order for the display of the the following order. Category SONGS selection mode TR NO/TIME (File number/ PLAYING SONGS Playback time) ALBUM PLAYLISTS PLAYLISTS SONGS (Album title) TRACK (Track title) ARTIST (Artist name) ARTISTS ARTISTS ALBUMS...
  • Page 117 Infotainment System Playable MP3 File Standards Message Description Supported standards: This message is displayed when READING MPEG-1 Audio Layer III reading the file format of the iPod. MPEG-2 Audio Layer III This message is displayed if a problem is detected in the iPod. Supported sampling frequencies: READ ERROR Disconnect the iPod, and check the...

  • Page 118: Auxiliary Devices

    Infotainment System Playable WMA File Standards Display Order of MP3/WMA File/ 1. Use the mini plug cable, and Folder Names connect the portable audio Supported standards: device to the Mini jack. Names of MP3/WMA folders and Supported sampling frequencies: files within the same level are 2.

  • Page 119: Bluetooth Audio

    Infotainment System Reduce the AUX volume to prevent Do not leave the portable device Warning speaker damage. inside the vehicle. (The interior of the vehicle may become too hot Either place the portable Bluetooth Audio under extreme hot weather.) audio device and mini plug Do not set the portable device too cable somewhere where Bluetooth Audio Operation...
  • Page 120 Infotainment System Bluetooth audio operation is subject Repeat Playback : Return to the beginning of the to portable device compatibility. track being played. To return to the Press 1 to repeat the same track Operation of the portable device via previous track, press the again.
  • Page 121 Infotainment System To cancel, press 2 again. If there is no text information stored DISCONNECT: Disconnect the in a music file, NO TITLE is registered portable device. Display the Text Information displayed. DISCONNECT? is displayed, 1. Press and hold LIST for more press ENTER.

  • Page 122: Bluetooth

    Infotainment System Phone DEVICE? is displayed, you must 2. Turn MODE/ /ENTER to delete the registered Bluetooth select BLUETOOTH, and then device. press ENTER. Bluetooth Connect to the Bluetooth Device 3. When PAIRING is displayed, This unit supports Bluetooth. Automatically press ENTER.
  • Page 123 Infotainment System Do not clear the settings while History of outgoing/incoming/ driving. Park your vehicle in a missed calls secure location and then Speed dial data initialize them. Handsfree setting 1. Press FUNC. Bluetooth phone data 2. Turn MODE/ /ENTER to Portable device data select BLUETOOTH, and then Portable device connection...
  • Page 124 Infotainment System In the following conditions, the Operating the Handsfree System system may not function: The mobile phone is turned off. The current position is outside the communication area. The mobile phone is not connected. The mobile phone has a low battery.
  • Page 125 Infotainment System Making a Phone Call Using Making a Phone Call Using Missed 2. Turn MODE/ /ENTER to Phonebook Call History select ENTER NUMBER, and then press ENTER. 1. Press Off Hook on the 1. Press Off Hook on the infotainment controls.
  • Page 126 Infotainment System The person (phone number or If there is a private call, 2. Turn MODE/ /ENTER to name) you called is displayed. UNAVAILABLE is displayed. select INCOMING, and then press ENTER. You can refuse a call by 3. Turn MODE/ /ENTER to pressing On Hook when a call is The person (phone number or...
  • Page 127 Infotainment System Registering a Speed Dial Number Making a Call Using Speed Dial 2. Turn MODE/ /ENTER to from a History select ENTER NUMBER, and 1. Press Off Hook on the then press ENTER. You can select a phone number infotainment controls.
  • Page 128 Infotainment System Alphanumeric characters and Turn counterclockwise: MIC LEVEL is displayed. MIC the following symbols are Decrease the volume. The LEVEL disappears in two seconds available. '< > * + - . / \ = _ adjusted volume value is saved. after the operation is completed, (space) and the display returns to its original...
  • Page 129 Infotainment System This function is available only when DISCONNECT: Disconnect the 3. Press . The selected tone your phone is compatible with the registered mobile phone. When numbers are transmitted. You Call Waiting feature. DISCONNECT? is displayed, will move on to the next step press ENTER.

  • Page 130: Trademarks And License Agreements

    Infotainment System 5. Turn the Volume Adjust. Trademarks and 4. Turn MODE/ /ENTER to switch ON/OFF, and then press Turn clockwise: Increase the License Agreements ENTER. volume. FCC Information TRANSFER ON: Turn on the Turn counterclockwise: phonebook transfer. Decrease the volume. The See Radio Frequency Statement adjusted volume value is 0 370.
  • Page 131 Infotainment System operation of this device or its Bluetooth Handsfree performance compliance with safety and can be influenced by mobile phone regulatory standards. network, handset and driving condition. iPhone, iPod, iPod classic, iPod nano, and iPod touch are The functions of the system may be trademarks of Apple Inc., registered partially limited depending on the in the U.S.

  • Page 132: Climate Controls

    Climate Controls Climate Controls Climate Control Outlet Selector Knob : The Air Selector Knob regulates air flow Systems from the upper, floor and defroster outlets. Climate Control Systems The heating, cooling, and ventilation : Air flows through the upper for the vehicle can be controlled Climate Control Systems .
  • Page 133 Climate Controls heater is being used. To turn off the Set the temperature control knob to : Use this position to prevent air conditioning, push this switch in the desired position. Adjust the fan dusty or otherwise contaminated again. speed control knob to the preferred outside air from entering the cab, speed.
  • Page 134 Climate Controls position, and turn the temperature Defogging and Defrosting the After defrosting, be certain to return control knob fully towards the high Windshield the air selector lever to the temperature direction. position. Failure to do so will cause Defogging : Set the outlet selector the windshield to fog up, impeding Set the fan speed control knob to knob to the...
  • Page 135 Climate Controls Turn the temperature control knob Air Vents fully towards the low-temperature direction. Set the fan speed control knob to the maximum speed position. After prolonged parking in direct sunlight, open the windows or doors to ventilate the interior of the cab and release the heat.
  • Page 136 Climate Controls Air Flow Direction Control Lever Maintenance Passenger Compartment Air Filter Removing the Inside Air Filter 3. Remove and clean the filter. Use a vacuum cleaner or the like to clean dust and dirt from Use the tab to adjust the airflow its surface.
  • Page 137 Climate Controls Installing the Inside Air Filter Removing the Outside Air Filter Installing the Outside Air Filter Install the filter in the reverse order Install the filter in the reverse order to removal. to removal. Ensure that the filter is returned Ensure that the filter is returned securely to its original position.
  • Page 138 Climate Controls Operation Tips Operating the air conditioning while the refrigerant level is too low leads not only to poor cooling performance but also to air conditioning system damage. This vehicle uses the new refrigerant HFC134a (R134a) in the air conditioning system. No other type of refrigerant can be used.

  • Page 139: Driving And Operating

    Driving and Operating Driving and Engine Alarm and Automatic Cruise Control Shutdown ....173 Cruise Control ....223 Operating Idle Shutdown .

  • Page 140: Driving Information

    Driving and Operating Driving Information Warning (Continued) Warning (Continued) Driver Behavior could get into the cab (for driving and you wish to use a example, a place that is mobile telephone, first stop the Napping in the Vehicle poorly ventilated), you could vehicle in a safe place.
  • Page 141 Driving and Operating Pulling Away After Stopping directions, making it hard for you to Warning (Continued) see ahead. Use glass cleaner to and Parking clean the glass and the wiper If a warning light comes on or a Before pulling away, check that blades.
  • Page 142 Driving and Operating Never Stop the Engine While on valves, pistons, and rings. It also Warning (Continued) causes rapid accumulation of Driving sludge within the engine. indicator lights and other Warning Driving at Night electrical circuitry would completely stop working. Nighttime driving is more dangerous Do not move the engine control than daytime driving because the...
  • Page 143 Driving and Operating When the Silencer and Refer to Engine Coolant 0 253. directional correction. The vehicle may catch strong sidewinds in the Exhaust Pipe are Hot Do not put well water, river water following situations: or other hard water in the engine Warning cooling system.

  • Page 144: Braking

    Driving and Operating fluid leakage, fuel leakage and acceleration lane. Pay attention ahead of time. Paying attention component damage. If any part of to vehicles behind you and to to vehicles behind you, turn off the vehicle is damaged or broken, conditions in the lane you are the highway smoothly so as not promptly have the vehicle inspected...
  • Page 145 Driving and Operating amount of brake force applied. time, the amount of force applied to Braking Techniques Please allow for realistic stopping the brake pedal and the speed of For the most effective braking and distances to avoid unnecessary the vehicle. for maximum life from brake system heavy braking.
  • Page 146 Driving and Operating Brake System Warning Light The exhaust brake should be turned Warning (Continued) on as soon as service brake malfunction is detected. This will Caution brake linings faster. This may also slow the engine speed. With the damage the brakes and will waste engine speed under control and If brake low vacuum warning light fuel.
  • Page 147 Driving and Operating safety. Also, leave the vehicle in Do Not Forget to Release the Warning (Continued) gear to further ensure that it will not Parking Brake move. Leave the steering wheel Pulling away with the parking brake should overheat, as indicated by turned such that the vehicle will be still applied can damage the brake the engine coolant temperature...
  • Page 148 Driving and Operating Parking, or Leaving 2. To move the selector lever to brake applied. The risk of knocking "P" (Park), hold in the button against the selector lever and Driver s Seat on the lever and push the lever causing a crash is particularly great all the way toward the front of when you move in or out of...
  • Page 149 Driving and Operating Vapor Lock : If the brakes overheat Brake Effectiveness When the Warning due to frequent use, the heat can Vehicle Has Been Driven on a cause the brake fluid to boil so that Flooded Road or Washed To reduce the risk of personal air bubbles are created in the brake injury, before going down a steep...

  • Page 150: Steering

    Driving and Operating If the vehicle must be driven on a Steering Steering Wheel flooded road or is parked in an area If the steering parts have excess Do Not Leave the Steering that becomes flooded, promptly play or looseness or if any abnormal Wheel Fully Turned for a perform a check for the following condition is noted, have the steering...

  • Page 151: Hill And Mountain Roads

    Driving and Operating road to make a "mirrored surface" Hill and Mountain Roads and slow down when there is any Narrow or Congested Roads doubt. When passing or overtaking a There is a risk of hydroplaning, particularly where water tends to vehicle on a narrow mountain road or on a narrow or congested urban collect on the road surface.

  • Page 152: Winter Driving

    Driving and Operating When going down on a steep Overrunning : An engine overrun is When Ice Prevents You from slope, avoid driving the vehicle an engine-speed increase that Putting Your Key in the Door backward as much as possible. causes the tachometer needle to or Opening the Door Drive it forward slowly on the...
  • Page 153 Driving and Operating Before Sitting in the Driver s Seat scraper, you can remove the snow Use engine brakes together with the and frost without scratching the foot brakes to decelerate. Using the Remove snow and ice from your glass. At this time, check whether exhaust brake on a slippery road shoes when getting into the vehicle.

  • Page 154: If The Vehicle Is Stuck

    Driving and Operating has been parked. If the brakes do Do not use a sharp implement to Warning not work well, drive slowly and remove snow. Sharp edges gently press the brake pedal several could damage rubber parts. If you park in a place where there times until the brakes dry out and Refer to Antilock Brake System is a lot of snowfall, snow...

  • Page 155: (Troubleshooting)

    Driving and Operating wheel. Such actions could get the vehicle (even a small fault) to Caution (Continued) vehicle stuck and make it difficult to prevent it from becoming more get out. serious. If a symptom shown in the conditions. Damage may result following table occurs, perform After driving through deep mud: any from excessive wheel spinning,...
  • Page 156 Driving and Operating Symptom Cause Corrective Action Reference See Battery - North Discharged batteries Recharge or replace America 0 269 Battery terminals After repairing corroded detached, loose, section, connect the or corroded terminals firmly Engine does not Starter does not Starter ground wire After repairing corroded start...
  • Page 157 Driving and Operating Symptom Cause Corrective Action Reference Make sure there are no No fuel fuel leaks, and then add fuel See Running Out Air in the fuel system Bleed fuel system of Fuel 0 233 Fuel filter clogged Engine does not Starter turns over Warm fuel pipe with hot start...
  • Page 158 Driving and Operating Symptom Cause Corrective Action Reference See Running Out There is water or air in Drain water from fuel of Fuel 0 233 or the fuel system filter or bleed the system Water in Fuel Unsteady engine speed 0 231 Fuel system is faulty Engine not sufficiently...
  • Page 159 Driving and Operating Symptom Cause Corrective Action Reference Engine Control system faulty The air cleaner clogged Fuel system faulty Black exhaust smoke Exhaust system clogged Exhaust injector Diesel particulate filter (DPF) faulty...
  • Page 160 Driving and Operating Symptom Cause Corrective Action Reference See Engine No engine coolant Add engine coolant Coolant 0 253 Front of radiator is Wash clean with tap See Exterior Care clogged with dirt water 0 317 Make sure it is firmly Radiator cap not tightened or replace the sufficiently tightened...
  • Page 161 Driving and Operating Symptom Cause Corrective Action Reference Parking brake not fully Make sure it is fully released released Brake dragging Air cleaner clogged Fuel filter clogged Not enough engine power Engine control system faulty Common rail system faulty Engine faulty DPF clogged Drum-to-lining gap too large...
  • Page 162 Driving and Operating Symptom Cause Corrective Action Reference Unbalanced air pressure Adjust to proper air See Wheels and in tires pressure Tires 0 295 See Wheels and Tire unevenly worn Replace tire Tires 0 295 Uneven braking Drum brake out of adjustment Poor wheel alignment The electrical system is...
  • Page 163 Driving and Operating Symptom Cause Corrective Action Reference Wheel studs and nuts Tighten to the specified See Wheels and loose torque Tires 0 295 Unbalanced inflation Adjust to proper inflation See Wheels and pressure in the tires pressure Tires 0 295 Excessive play in the steering wheel Unbalanced tires Excessive steering...
  • Page 164 Driving and Operating Symptom Cause Corrective Action Reference See Automatic Insufficient Add oil Transmission Fluid transmission oil From the 0 251 transmission Transmission inner components faulty See Rear Axle (Gear Oil Viscosity Insufficient differential Add oil Chart) 0 271 or gear oil Loud or abnormal Rear Axle (Oil...

  • Page 165: Vehicle)

    Driving and Operating Emergencies (Disabled When the Vehicle Breaks Down Warning During Driving Vehicle) 1. Use the hazard warning flasher Vehicle operations will change, so When the Vehicle any time to warn other drivers, stop the vehicle in a safe place Breaks Down day or night, and pull the with the following in mind.

  • Page 166: Starting And Operating

    Driving and Operating If There is a Fuel Leak Starting and Use the correct gear to maintain the desired road speed without Operating lugging the engine. Danger Avoid racing the engine, New Vehicle Break-In Leaking fuel from the vehicle is full-throttle starts and aggressive dangerous due to possible application of brakes when...

  • Page 167: Pedals

    Driving and Operating Mechanical Driveshaft Brake Pedals Warning Burnish Procedure It is recommended that the A can or bottle rolling on the floor driveshaft mounted parking brake may prevent brake pedal be burnished as part of the new operation if it is caught under the vehicle break-in procedure.
  • Page 168 Driving and Operating control switch in the LOCK position, Caution press and hold the key in the ACC position and then turn it to the After starting the engine, do not LOCK position. If you will leave the turn the engine control switch to vehicle, remove the key and turn the the START position.

  • Page 169: Starting And Stopping The Vehicle

    Driving and Operating 4 START : On all engines, start is in around the vehicle. Take off the Warning (Continued) the position furthest clockwise. The chocks after confirming that the engine is started in this position. parking brake is securely applied. also essential to lay floor mats Turn the key against spring Sit behind the wheel, adjust the seat...
  • Page 170 Driving and Operating Starting the Engine It is normal for the vacuum warning buzzer to sound for a few seconds Do not keep the engine control after the engine has started. switch in the START position for more than about 10 seconds. After the engine has started, check Operating the starter for too long to be sure the selector lever is still...
  • Page 171 Driving and Operating usually requires 30 seconds to Cold Weather Starting Maintenance Items to Aid Cold 2 minutes depending on ambient Weather Starting If you plan ahead for cold weather, conditions. This will help reduce starting and driving your vehicle Since the basic principle of diesel white start-up smoke.

  • Page 172: Operating Temperature

    Driving and Operating 3. Always refuel at the end of a Do not shut down the engine the required levels. If there is day's operation. Moisture will immediately after driving the vehicle. insufficient oil, it will not adequately condense in an empty tank; Otherwise, a seizure or other reach and lubricate components, therefore, the tank should be...

  • Page 173: Winter Cover

    Driving and Operating Do not race the engine or quickly when the pedal is released. Warning (Continued) accelerate before the engine has Warm-up is automatically cancelled sufficiently warmed up. Oil would entirely after the engine coolant loading of the blades as they not have adequately reached and temperature rises above 65 °C pass by the masked area...

  • Page 174: Engine Alarm And Automatic

    Driving and Operating The engine block and oil pan If the cord is too short, use a heavy If the system senses any of the heaters are designed to warm the duty, three-prong extension cord. Do following conditions: high engine block and oil pan areas that will let not use an extension cord such as temperature, low engine oil pressure...

  • Page 175: Idle Shutdown

    Driving and Operating Idle Shutdown High Idle System Idle Stop is a dealer programmable Use high idle mode to increase function which will automatically turn engine idle speed to 1,200 r/min off the engine, at idle, when specific when the vehicle is stationary. programmed conditions are met.

  • Page 176: Engine Checks Before

    Driving and Operating 4. Press the cruise control main The cruise set indicator light will does not go out or comes on switch to set it to ON. At this stop flashing and the engine speed during normal operation, have time, the operation indicating will return to normal.

  • Page 177: Parking Over Things

    Driving and Operating engine operating temperature Keep Flammable Material Away Warning causes several conditions that are from the Vehicle harmful to engine operation and life. The exhaust pipe is extremely hot To reduce the chance of personal Incomplete combustion of fuel in an immediately after vehicle operation.

  • Page 178: Engine Exhaust

    Driving and Operating Engine Exhaust Warning (Continued) Warning (Continued) Engine Exhaust Emissions grass vegetation or stubble exhaust system has not been Caution (Carbon Monoxide) high enough to touch, catch properly maintained. Combustible or collect on its hot exhaust materials could catch fire from hot Warning system.
  • Page 179 Driving and Operating Warning (Continued) Warning (Continued) Warning (Continued) joint, or a hole or crack caused by We recommend that the exhaust for longer periods of time is not corrosion), have checks and system and cab be inspected by recommended. Entry of carbon maintenance performed by the a competent technician: monoxide into the cab is possible...

  • Page 180: Running The Vehicle While

    Driving and Operating Running the Vehicle Avoid Unnecessary Idling of the Warning (Continued) Diesel Engine While Parked If the engine idles too long, the Set the air selector lever to engine coolant temperature will fall the fresh air position. Caution below the operating range.

  • Page 181: Diesel Particulate Filter

    Driving and Operating Diesel Particulate This is to prevent the DPF from Warning being damaged. When operating Filter PTO during parking, check to Exhaust parts and gases become ensure that the regeneration Diesel Particulate Filter (DPF) very hot when the DPF is being required warning light or selectable regenerated.
  • Page 182 Driving and Operating The selectable (switch) regeneration Automatic regeneration is performed exhaust brake or exhaust throttle is required warning light (amber) will under normal driving conditions activated or deactivated. The turn on when regeneration cannot (DPF soot accumulation status level sounds do not indicate a fault.
  • Page 183 Driving and Operating White smoke may be produced DPF Regeneration Status The DPF will regenerate itself as during DPF regeneration when a part of normal operation. new vehicle has been driven a The engine control module (ECM) certain distance, but this is not a controls this function based on malfunction.
  • Page 184 Driving and Operating The DPF performs regeneration DPF Switch The DPF switch is used to burn PM automatically when a certain (regenerate the filter). You can quantity of PM accumulates in the initiate regeneration when the filter. regeneration required warning light or selectable (switch) regeneration Depending upon running conditions, required warning light turns on with...
  • Page 185 Driving and Operating regeneration or Switch regeneration or selectable (switch) regeneration 2. Increase the vehicle speed in order to complete the DPF required warning light is displayed above 48 km/h (30 MPH) and regeneration. on the DIC. keep a constant speed. If the selectable (switch) Continuing to drive without 3.
  • Page 186 Driving and Operating Switch Regeneration Procedure 5. The regeneration required Warning (Continued) warning light (amber or red) or selectable (switch) exhaust pipe. Remember that the regeneration required warning temperature of exhaust gases is light (amber or red) on the DIC high enough to burn you.
  • Page 187 Driving and Operating displayed on the DIC, the message Once the Switch regeneration is During regeneration, white smoke will change to red. The selectable started, it cannot be switched to the may be temporarily produced from (switch) regeneration required Running regeneration if interrupted. the exhaust pipe.
  • Page 188 Driving and Operating Switch regeneration will be Selectable regeneration may only 1. Stop the vehicle at a safe place interrupted in the following be performed when no other DPF free of flammable material such circumstances: message is present on the DIC. Be as dead grass, leaves or waste sure to follow any DPF messages paper.
  • Page 189 Driving and Operating operating temperature. Regeneration may take longer if the engine is cold. 9. When the regeneration in progress indicator light goes out, the Selectable regeneration is complete. If the Selectable regeneration is interrupted, a selectable (switch) regeneration required warning light (amber) will appear on the DIC.

  • Page 190: Diesel Exhaust Fluid

    Driving and Operating the selectable (switch) regeneration The engine coolant temperature Diesel Exhaust Fluid required warning light (red) is may rise during regeneration. Diesel exhaust fluid (DEF) is used displayed on the DIC. DPF Regeneration during exclusively for the selective catalytic Continued driving without Prolonged Idling reduction (SCR) system.
  • Page 191 Driving and Operating Handling of DEF Adding DEF Before Driving the Warning (Continued) Vehicle Use only API certified DEF (or ISO: AUS 32). DEF is a colorless, Add DEF regularly to maintain an Although it is rare, a person with transparent solution.
  • Page 192 Driving and Operating Any substance other than the After stopping the engine, a flow 2. Wipe off dust or dirt from DEF may cause a breakdown to sound may be heard from the around the filler port of the the SCR system. DEF tank or DEF supply pump.
  • Page 193 Driving and Operating When DEF dries it will leave a DEF is added. Take the following Warning (Continued) crystalline residue, this condition is actions to avoid this condition in normal. Wash with water or wipe cold weather: Do not dilute DEF with water. away the residue to prevent it from 1.
  • Page 194 Driving and Operating Make sure to stop the engine before To store or carry DEF, use the Warning adding the DEF. See Warning original container in which the DEF Buzzers 0 91. was kept at the time of purchase. Do not warm up the DEF tank Also, if other containers are used, When DEF Freezes using a burner, heater, etc.
  • Page 195 Driving and Operating Selective Catalytic Reduction Continuing to drive for too long after Do not relocate or modify the (SCR) System these lights come on will result in exhaust pipe, muffler, DPF, SCR, additional warnings, more engine or DEF tank, which may affect the The Selective Catalytic Reduction power reduction and will eventually exhaust gas cleaning performance.
  • Page 196 Driving and Operating Diesel Exhaust Fluid (DEF) Low These warning and indicator lights Level Warning will go out automatically and engine power will be restored to normal Diesel Exhaust Fluid (DEF) is a after the SCR system detects that required fluid for the operation of the DEF tank is refilled with DEF.
  • Page 197 Driving and Operating DEF Tank Level is Low/Empty Stage Stage 1 Stage 2 Stage 3 Stage 4 DIC main display DEF gauge (DIC sub display 2) Solid (amber) Blinking (amber) Solid (red) Solid (red)
  • Page 198 Driving and Operating DEF Tank Level is Low/Empty (cont'd) Stage Stage 1 Stage 2 Stage 3 Stage 4 Solid Slow blinking Fast blinking Fast blinking Indicator light(s) Warning buzzer 1 short beep 3 short beeps *3 3 quick beeps *4 Continuous beeping Vehicle speed is Vehicle speed is...
  • Page 199 Driving and Operating DEF Tank Level is Low/Empty (cont'd) Stage Stage 1 Stage 2 Stage 3 Stage 4 CAUTION This message indicates incorrect DEF or an SCR system malfunction. Immediately contact your dealer to have your vehicle serviced *2 Remarks: DEF tank low stages are as follows: begin blinking.
  • Page 200 Driving and Operating further on (approximately long after these lights come on may 8 km (5 miles)) or when the engine eventually result in a severe vehicle is restarted. speed limitation. Stage 4 : The DEF gauge is red, The following is a summary of the the indicator light is blinking and the warning lights, indicator lights and buzzer is beeping continuously...
  • Page 201 Driving and Operating Incorrect DEF/SCR System Malfunction (Type A) Warnings Stage Stage 1 Stage 2 Stage 3 Stage 4 DIC main display DEF gauge (DIC sub Various Various Various Various display 2) Slow blinking Fast blinking Fast blinking Indicator light(s)
  • Page 202 Driving and Operating Incorrect DEF/SCR System Malfunction (Type A) Warnings (cont'd) Stage Stage 1 Stage 2 Stage 3 Stage 4 Indicator light(s) Warning buzzer 1 short beep 3 short beeps *1 3 quick beeps *2 Continuous beeping Vehicle speed: Vehicle speed: Vehicle speed: Vehicle speed: Restriction...
  • Page 203 Driving and Operating Stage 1 : When incorrect DEF or an Stage 4 : DEF indicator light is SCR system malfunction (Type A) is blinking quickly, the other warning detected, the warning and indicator lights are on and the buzzer is lights will come on as shown in the beeping continuously indicates the table and engine power will be...
  • Page 204 Driving and Operating SCR System Malfunction (Type B) Warning Stage Stage 1 Trigger SCR system malfunction detected DIC main display DEF gauge (DIC sub Various display 2)
  • Page 205 Driving and Operating SCR System Malfunction (Type B) Warning (cont'd) Stage Stage 1 Indicator light(s) Warning buzzer 1 short beep Restriction...

  • Page 206: Automatic Transmission

    Driving and Operating When the exhaust system warning 4. If the buzzer does not stop, Automatic light comes on, promptly have the return the engine control switch Transmission vehicle inspected and serviced at a back to the LOCK position and dealer.
  • Page 207 Driving and Operating Furthermore, the higher the engine While the air conditioner is Caution (Continued) speed, the stronger the creep and running. the greater the vehicle's tendency During the diesel particulate filter Failure to observe this precaution to move. (DPF) regeneration. can lead to faulty operation of the Starting electrical system.
  • Page 208 Driving and Operating Practice operating the selector lever Even if you plan to move only a Warning (Continued) between the N and D without short distance, sit in the correct pressing the push button. driving position and make sure you When you move the selector lever can firmly press the brake and Do not operate the selector lever...
  • Page 209 Driving and Operating To start your vehicle: On a steep slope: Normal Driving 1. Firmly press the brake pedal. Make sure that the shift indicator When you move the selector lever After making sure the selector indicates the correct gear (D for from P into D, shifting takes place in lever is placed into P or N, that forward movement, or R for...
  • Page 210 Driving and Operating You can easily accelerate to the Driving Uphill or Downhill required speed when overtaking Uphill driving: other vehicles or when joining traffic With the selector lever in D, if you on a highway. In order to maintain press down on the accelerator speed when driving on an uphill pedal, kickdown (change to a low...
  • Page 211 Driving and Operating Select 2 position during low speed Driving conditions Selector lever position operation under 36 km/h (22 MPH). Normal uphill road D (overdrive off switch ON) See Automatic Transmission Fluid Steep uphill, steep slope, mountain Temperature Warning Light 0 78. 2 or 1 road with many sharp curves To Stop Your Vehicle...
  • Page 212 Driving and Operating To Start After Stopping If you cannot move the selector Warning (Continued) lever from the P position after To start again after stopping your starting the engine, perform the vehicle, visually check that the When parking on a slope, move following necessary checks: selector lever is in D, and gradually the selector lever in the P position...
  • Page 213 Driving and Operating When Parking Your Vehicle If you cannot move the selector Releasing the Shift Lock in an lever from the P position after Emergency The key cannot be removed unless starting the engine, perform the the selector lever is securely placed If moving of the selector lever from following checks: in the P position (key interlock...
  • Page 214 Driving and Operating Actions that Can Lead to a Breakdown with an Automatic Transmission Actions that can lead to a breakdown Breakdown symptoms Stopping the vehicle on an uphill road with the selector lever in a position other than R, N, or P, the accelerator pedal pressed, and the brakes not applied.

  • Page 215: Selector Lever

    Driving and Operating Selector Lever N (Neutral) : Can be used when Warning starting the engine, but for safety, Move the selector lever (2) to make get in the habit of starting the When pulling away, always a shift into each gear position. engine in the P position.

  • Page 216: Overdrive Off

    Driving and Operating For safety reasons, the shift lock mountain roads or through city system operates to prevent shifting centers, release the overdrive. of the selector lever to any position Doing so will reduce the number other than P unless the brake pedal of gear changes making the ride is pressed and the starter switch is smoother.

  • Page 217: Antilock Brake

    Driving and Operating Overdrive Off Indicator Light Indicator light Function Usage conditions 6-Speed (4-speed + overdrive) automatic Goes Off. Use under normal driving conditions. change (Overdrive ON). Used when a light engine brake is required. 4-speed automatic change, but no change to Doing so will reduce the number of gear Comes On.
  • Page 218 Driving and Operating Driving in sand or on a muddy road When ABS is operating, Warning (Continued) may adversely affect the brakes and vibration is felt on the brake ABS sensors. Wash the vehicle to pedal and steering wheel and driving habits and drive the remove sand and mud after you may hear the system...
  • Page 219 Driving and Operating ABS Operation Indications and If the ABS warning light comes Warning (Continued) on during driving Signs The light does not come on when When braking suddenly, do not the engine control switch is pump the brakes (pushing and placed into the "ON"...
  • Page 220 Driving and Operating load due to acceleration or Warning (Continued) Warning (Continued) deceleration, thus preventing premature locking of the rear When tire chains are used. If powerful engine braking is wheels. applied on a very slippery icy When driving over road road, the drive wheels may be joints or bumps such as Warning...

  • Page 221: Parking Brake

    Driving and Operating Parking Brake Warning Warning Parking Brake Lever Although the parking brake Do not use the parking brake When parking or stopping your indicator light will come on if the while the vehicle is in motion vehicle, engage the parking brake parking brake is engaged while except in an emergency.
  • Page 222 Driving and Operating Operation of Parking Brake The parking brake indicator light in be checked by a qualified the instrument panel will come on technician. Adjustment may be when the lever is pulled up. Before required due to parking brake shoe you leave the driver's seat, follow wear.

  • Page 223: Exhaust Brake

    Driving and Operating If the number of notches is not The exhaust brake will disengage within the standard value range when the accelerator pedal or brake below, adjust it to the standard pedal is pressed. Releasing the value. Lever stroke is 6 to 8 pedal reengages the exhaust brake.

  • Page 224: Cruise Control

    Driving and Operating Conditions for Inoperable Exhaust It is advisable to operate the Cruise Control Brake exhaust brake when descending a The cruise control function allows slope or when stop and go driving is Under the following conditions, the you to drive the vehicle at a involved.
  • Page 225 Driving and Operating At the same time the cruise set indicator light comes on. Accelerating during Cruise Control Driving If you want to accelerate temporarily 1. Press the cruise control main to pass another vehicle while driving 2. Use the accelerator pedal to switch to turn it on.
  • Page 226 Driving and Operating When Increasing Vehicle Speed When Increasing Vehicle Speed at the decreased vehicle speed. Slightly If you want to decrease the speed quickly, press the brake pedal to If the cruise control resume switch is cancel cruise control and decelerate operated and released immediately, to the desired vehicle speed.
  • Page 227 Driving and Operating When Canceling Cruise Control When the vehicle speed may have to brake or shift to a lower decreases more than 20% below gear to keep your speed down. Of your set speed. course, applying the brake takes you out of cruise control.

  • Page 228: Fuel For Diesel Engines

    Driving and Operating If the cruise control is turned back The maximum slope angle at which Fuel on while the vehicle speed exceeds the system can control the vehicle what is set prior to the cancellation speed increase is different Fuel for Diesel Engines of cruise control, the set vehicle depending on the load the vehicle is...

  • Page 229: Biodiesel

    Driving and Operating damage, such fuel can also 1-D fuel (if available) or use a Biodiesel affect emission control. Before "winterized" Number 2-D (a blend of Biodiesel, may also be referred to using any diesel fuel, check with Number 1-D and Number 2-D). This as FAME blended (Fatty-acid methyl the service station operator to blended fuel is usually called...
  • Page 230 Driving and Operating fuel. Storage at hot ambient Fuels improperly blended for cold Caution temperatures will accelerate temperature operation may result in biodiesel degradation. restricted fuel filters and degraded Do not use blends containing vehicle performance. The vehicle is Owners who use very little fuel, more than 20% biodiesel.

  • Page 231: Cold Weather Operation

    Driving and Operating Blends up to B5 must meet ASTM To reduce the risk of poor quality D975 (Grades No. 2-D or No. 1-D fuel, purchase biodiesel blends from S15 Ultra Low Sulfur Diesel). When a fuel supplier or fueling station refueling with a biodiesel blend which sells BQ-9000 certified above B5, one of the following...

  • Page 232: Water In Fuel

    Driving and Operating At low temperatures, wax flakes are Water in Fuel Warning (Continued) more likely to form in Number 2-D During refueling, it is possible for fuel than in Number 1-D (or Be sure you do not overfill the water (and other contaminants) to "winterized"...
  • Page 233 Driving and Operating from your dealer, service stations, Fuel will be mixed in the drained Caution parts stores and other automotive water. Dispose of it in a method places. See your authorized dealer conforming to the regulatory Remaining water that is not for advice on using biocides in your requirements in your state.

  • Page 234: Running Out Of Fuel

    Driving and Operating 2. Loosen the drain plug and Running Out of Fuel move the priming pump (1) up When the Fuel Tank is Empty and down by hand between 10 and 20 times. 3. Fully tighten the drain plug (2) and move the priming pump (1) several times.
  • Page 235 Driving and Operating 2. Select the correct fuel (See Before Starting the Engine 4. Fully retighten the air bleed "Diesel Fuel Requirement and plug (2) and wipe off any fuel Fuel System"). Follow any that may have adhered to the posted safety rules.

  • Page 236: Filling The Tank

    Driving and Operating Insufficient air bleeding can result in Warning Warning (Continued) faulty engine operation. Be sure, therefore, to always carry out the Fuel vapor is highly flammable. He/she could pick up another previous steps under "After starting charge of static electricity by the engine".

  • Page 237: Conversions And Add-Ons

    Driving and Operating Conversions and Warning Add-Ons Fuel may be under pressure. Be sure to slowly open the fuel tank Add-On Electrical filler cap. If you open it quickly, Equipment fuel may spurt out. You and others could be seriously injured. Installing Electrical Equipment Warning Caution...

  • Page 238: Power Take-Off (Pto)

    Driving and Operating and other systems, resulting in a Installations, or alterations to the vehicle breakdown or in a original equipment vehicle or malfunction of electronic equipment. chassis, as manufactured and Consult your dealer if you wish to assembled by General Motors, are install radio equipment.
  • Page 239 Driving and Operating Optional PTO switches are available from your dealer to ease installation of a PTO. The optional PTO main switch and PTO engine speed control switch can be used increase the engine idle r/min without additional programming. Pressing the PTO main switch once will activate the PTO mode and raise the idle up speed up to the preset 800 r/min.

  • Page 240: Vehicle Care

    Vehicle Care Vehicle Care Fuel Filter ....270 Wheels and Tires Rear Axle (Gear Oil Viscosity Wheels and Tires ... . . 295 Chart) .

  • Page 241: General Information

    Vehicle Care General Information See Battery - North America 0 269 Accessories and and Jump Starting - North America Modifications Your authorized dealer has trained 0 311 and the back cover. technicians and genuine parts to Factory-Approved Accessories service your vehicle properly. For California Perchlorate Your dealer can furnish a wide expert advice and quality service,...

  • Page 242: Vehicle Checks

    Vehicle Care Vehicle Checks Warning (Continued) Warning (Continued) Doing Your Own personal injury, or damage to the Performing maintenance work on vehicle or its equipment. If you a truck or chassis can be Service Work have any questions about dangerous. In trying to do some Precautions for Checking and carrying out some service, have jobs, you can be seriously injured.
  • Page 243 Vehicle Care chock the wheels. It would be very Oils, brake fluid and engine coolant refuse from coming in contact with dangerous if the vehicle started have lubrication, cooling and rust parts or materials that have been to move. prevention functions. If these liquids removed when changing or deteriorate through loss or replenishing them.

  • Page 244: Cab Tilting

    Vehicle Care Cab Tilting Tilting the Cab 1. Check that all personnel are Before Tilting the Cab (Single Cab clear of the cab. Model) Warning To help avoid personal injury and property damage: Park the vehicle on level ground and check that there is enough space in front of and above the cab.

  • Page 245: Engine Compartment

    Vehicle Care 4. Raise the cab fully and be sure 3. Hold the assist handle (3) and Engine Compartment the cab support (5) is locked by unlock the cab support by Overview the support lock lever (7). pulling the support rearward while pressing the support lock 5.

  • Page 246: Engine Cover

    Vehicle Care Engine Cover Engine Inspection Sub Cover Engine Coolant Reserve Tank (Crew Cab Model) Inspection Cover (Crew Cab Engine Inspection Cover (Crew Model) Cab Model) To gain access to the engine compartment, pull the lock lever To gain access to the engine To gain access to the engine, coolant reserve tank, remove the (red) (1) on the driver s seat...
  • Page 247 Vehicle Care and the oil should be changed Access to the Engine Checking the Engine Oil Level regularly according to the Single Cab Model Maintenance Schedule. Access to the engine oil dipstick is The engine oil performs the located on the engine left side after following important functions: tilting the cab.
  • Page 248 Vehicle Care The engine oil level must be kept at The oil level cannot be checked the right level to help assure proper correctly when the engine is lubrication of your vehicle's engine. running. It is the owner's responsibility to If the engine has been running, wait check the oil level at regular at least 30 minutes before checking.
  • Page 249 Vehicle Care Prevent dirt from entering the filler Consequently, the maintenance Caution port when adding the oil. If foreign interval of the DPF filter will be matter mixes with the oil, it could reduced. When adding oil, be careful not to damage the engine.
  • Page 250 Vehicle Care Change Intervals Engine Oil Additives Engine Oil The oil and oil filter change intervals Engine oils contain a variety of Engine oil viscosity (thickness) has for your engine are based on the additives. Your engine should not an effect on fuel economy and use of recommended oil quality and need any extra additives if you use cold-weather starting.
  • Page 251 Vehicle Care Failure to use the recommended engine oil could result in engine or DPF breakdown, or in poor fuel efficiency. Be sure to use the recommended engine oil. Engine oil change precaution: When adding oil, remove the dipstick. After adding oil, wait for at least 5 minutes before starting the engine.

  • Page 252: Automatic Transmission

    Vehicle Care or bodies of water. Instead, recycle Too much or too little transmission Position of the Dipstick it by taking it to a used oil collection oil could damage your transmission. facility which may be found in your Too much could cause your community.
  • Page 253 Vehicle Care automatic transmission fluid should reach a temperature of approximately 70 - 80 °C (158 - 176 °F). During the winter when temperatures are low, adjust the amount of driving time according to the actual conditions. 2. Park the vehicle on level ground, and firmly apply the parking brake.

  • Page 254: Engine Air Cleaner/Filter

    Vehicle Care Dipstick H (HOT) Be sure to use a genuine air cleaner Warning Transmission fluid element. If a different air cleaner temperature Approx. 70 - element is used, it may cause the Be extremely careful not to burn 80 °C (158 - 176 °F). sensor to output a wrong signal.
  • Page 255 Vehicle Care Engine Coolant in Cold overflows into the reserve tank. Warning When the system cools, engine Weather coolant is drawn back into the To prevent the engine damage due Check, replenish or change the radiator. to freezing of the engine coolant, engine coolant only after the The engine cooling system has mix the coolant and water at the...
  • Page 256 Vehicle Care corrosion, use a mixture of the (262 °F). Periodic replacement Warning (Continued) recommended type antifreeze and of engine coolant is needed to water. If the engine of the vehicle is replenish the anticorrosion eyes are still irritated or otherwise at 30 °C ( 22 °F) or above, the additives that wear out with use.
  • Page 257 Vehicle Care Using coolant at any coolant Warning concentration other than that specified may reduce anti-freezing For storage, close the cap of performance, and engine coolant coolant container securely and may freeze. keep it in a place inaccessible to If the engine coolant decreases children.
  • Page 258 Vehicle Care stains on the ground showing leaks where the vehicle is parked. Contact your dealer if you discover leaks. Using the vehicle when there are leaks can lead to engine seizure. Adding Engine Coolant Crew Cab Model The radiator cap (1) opens and closes in double action.
  • Page 259 Vehicle Care engine coolant to provide for Thermostat required cooling, freezing, and The engine coolant temperature is corrosion protection. controlled by thermostat(s). The 3. Run the engine until the engine thermostats stop engine coolant coolant temperature rises to flow through the radiator until a normal level, and idle the preset temperature is reached.

  • Page 260: Engine Overheating

    Vehicle Care Engine Overheating HEAT message displayed. Take the If Steam Is Coming from the following corrective actions Engine Compartment When the Engine Overheats immediately. Warning The engine cooling system may Warning overheat if the engine coolant level If the engine coolant temperature is too low, if there is a sudden loss To help avoid being burned: gauge shows an overheat...
  • Page 261 Vehicle Care If Steam Is Not Coming from the If the engine coolant temperature When the cooling fan for the Engine Compartment gauge shows an overheat condition, radiator is not turning, turn off or you have reason to suspect the the engine immediately.
  • Page 262 Vehicle Care 4. If no steam or engine coolant started. Make sure the fan 5. Inspect to see if there is any can be seen or heard from the blade and pulleys are not dirt, etc. attached to the front engine compartment: broken.

  • Page 263: Power Steering Fluid

    Vehicle Care Power Steering Fluid Checking the Power Steering Warning Fluid Level The power steering fluid level must Before adding fluid, clean the be checked and it must be changed area around the cap and pour according to the Maintenance fluid from a clean jug or filler.

  • Page 264: Brakes

    Vehicle Care properly wiped. At this time, also Refilling Windshield Washer Follow the instructions provided with check the spraying condition of the the windshield washer fluid Fluid windshield washer. regarding the ratio for mixing with tap water. Inspect the washer fluid level regularly, especially during bad Poor quality products, engine weather conditions.
  • Page 265 Vehicle Care Follow the recommendations for 2. Check for the noisy sound of utilizes hydraulic pressure from the brake checks in the Maintenance the electric vacuum pump HBB pump integral with the power Schedule. inside the instrument panel at steering pump. the same time as vacuum GM replacement brake lining If the brake booster warning light...
  • Page 266 Vehicle Care Another characteristic of the HBB Vacuum or hydraulic power Caution (Continued) system is that the brake pedal may assisted brakes be pressed easily to the floor with If the engine stops, do not pump the hosing. Eventual leakage of HBB the vehicle at a stop.
  • Page 267 Vehicle Care lead to dragging brakes or other This is of particular importance The hydro-booster fluid level is major brake problems. As such, when removing components such correct if it is between the "MAX" mixing of these two fluids can as the accumulator or pressure and "MIN"...
  • Page 268 Vehicle Care floor (that is, the distance between Brake pad wear Free play (measured at the tip of the brake pedal bracket (2) and the pedal) Brake pads are about to wear brake pedal arm). out. If this happens, have your 5 - 10 mm (0.20 - 0.39 in) Clearance between the brake vehicle inspected at the nearest...

  • Page 269: Brake Fluid

    Vehicle Care free of any type of damage. Check Remove the inspection cover (1) on Caution the right front brake hose and pipe the left- hand side of the instrument in the same way. The rear left and panel by turning it with your fingers. The pad has an embedded wear right brake hoses and pipes should Check that the fluid level in the...

  • Page 270: Battery - North America

    Vehicle Care Never mix the specified brake fluid Battery - North America Danger (Continued) with fluids of another brand. Working Near Battery Be careful not to spill brake fluid when working on or near the onto painted surfaces or to let it battery.

  • Page 271: Fuel Filter

    Vehicle Care Remember to check and recharge Fuel Filter Warning the battery as necessary, as well as Change the fuel filter in accordance keep connection clean. WARNING: Battery posts, with the Maintenance Schedule or The hydrometer (green-eye test terminals, and related when the fuel filter indicator light indicator) in the top of each battery accessories contain lead and lead...

  • Page 272: Chart)

    Vehicle Care Rear Axle (Gear Oil Viscosity Chart) Gear Oil Viscosity Chart Select appropriate gear oil in accordance with the table below. It is important to select the viscosity appropriate for the temperature at which your vehicle operates. Use the following table for making correct selections.

  • Page 273: Rear Axle

    Vehicle Care Rear Axle (Oil Level Checking the Oil Level 2. Check that the oil level (1) is 0 mm to 10 mm (0 to 0.4 in) Check) below the bottom edge of the oil level plug hole (2). If the oil Rear Axle Differential Gear Oil level is too low, add oil through The rear axle differential gear oil...
  • Page 274 Vehicle Care particular part, component or TAMPERING WITH NOISE Insulation: system of the vehicle manufactured CONTROL SYSTEM Removal of the noise shields or any by General Motors. Defects in PROHIBITED underhood insulation. design, assembly or in any part, Federal law prohibits the following component or system of the vehicle Engine: acts or the causing thereof:...

  • Page 275: Automatic Transmission Shift Lock Control Function

    Vehicle Care Automatic Transmission 3. Remove the selector lever cover by removing the four Shift Lock Control screws and lifting it up. Function Check When the Selector Lever Cannot be Moved From the "P" Position Perform the following when the selector lever cannot be moved from the "P"...

  • Page 276: Wiper Blade Replacement

    Vehicle Care Wiper Blade Replacement 1. Pull the wiper arm up to the Installation vertical position. 2. While pressing the wiper-blade Caution hook toward the arm, slide the Allowing the wiper arm to touch blade downward toward the the windshield when no wiper base of the arm.
  • Page 277 Vehicle Care Replacement of Wiper Rubber Installation Insert Removal 2. With the blade and arm oriented in the same direction, push up the blade until it locks 1. Insert a new wiper rubber into place on the arm. insert into the wiper blade. Whenever a wiper blade has been 1.

  • Page 278: Headlamp Aiming

    Vehicle Care 2. Continue pushing in the wiper Headlamp Aiming Bulb Replacement rubber insert until the wiper blade's hook engages with the Caution hole in it, and then confirm that the rubber insert is securely Do not replace incandescent held in place. bulbs with aftermarket LED 3.
  • Page 279 Vehicle Care flasher unit will continue to operate. When one bulb of a pair of lamps, Check the turn signal lamps visually such as a headlamp blows out, the before the vehicle is used. other bulb is approaching the end of its useful life.
  • Page 280 Vehicle Care Bulb Wattage Position Lights Bulb Wattage (12V) Qty. Front Headlight Highbeam/Lowbeam 60/55W Front Turn Signal Lamp 27W (Amber) Parking Lamp Cornering Lamp Side Turn Signal Lamp 5W (Amber) Sidemarker Lamp 5W (Amber) Rear Taillamp and Stoplamp 8/27W Turn Signal Lamp Back-Up Lamp License Plate Lamp 7.5W...

  • Page 281: Signal

    Vehicle Care Headlamps and Front Turn Signal Replacing the Headlamps When the bulb has blown out, replace it with a bulb of the specified wattage. Be careful not to excessively tighten the mounting screws when replacing the headlamp bulbs. Do not replace a bulb with other than the specified wattage.
  • Page 282 Vehicle Care 4. Disconnect the connector (1) for the turn signal lamp from the socket (2) and then remove the lamp. 3. Tilt the turn signal lamp unit 7. Disconnect the headlamp down toward the front of the connector (5) and the parking vehicle and remove it.
  • Page 283 Vehicle Care If the rubber boot is not firmly in place, water could get inside the headlamp and lead to a breakdown. Replacing Parking Lamps 1. Refer to Replacing the Headlamps and remove the headlamp assembly. 8. Remove the rubber boot (2). 9.
  • Page 284 Vehicle Care Replacing a Front Turn Signal Lamp 3. To install the lamps, perform 2. Disconnect the connector for the same sequence of the turn signal light and then operations in reverse, taking remove the socket. care to turn the connector Do not replace a bulb with other clockwise to lock it securely.

  • Page 285: Roofmarker Lamps

    Vehicle Care 3. Pull the bulb from the socket 2. Remove the bulb (3) from the and replace it with a new one. socket (4) and replace it with a new one. 4. To install the lamps, perform the same sequence of 3.
  • Page 286 Vehicle Care 2. Slide the cornering lamp (3) 4. Loosen the socket by turning it and the side turn signal lamp counterclockwise. forward relative to the vehicle. Disconnect the clip (1) on the lamp s rear side from the door panel (2) and pull out the lamp.

  • Page 287: Lamps

    Vehicle Care Taillamps, Turn Signal, License Plate Lamp Stoplamps, and Back-Up Lamps D. Open the front door, tighten the nut from the inside of the door, and install the 1. Bulb rubber cap. 2. Lens 3. Screw 1. Turn Signal Lamp 4.

  • Page 288: Interior Lamps

    Vehicle Care Interior Lamps Electrical System Fuses : In case of an electrical overload, the fuse will blow and stop the flow of current in the circuit Electrical System before electrical components Overload become damaged. The cause of the circuit overload Electrical System must be identified and corrected Following the after-delivery service,...
  • Page 289 Vehicle Care The Location of Fuses and Relays Replacing Fuses 1. Before replacing fuses, firmly apply the parking brake, move the selector lever to the P (Park) position, and turn the engine control switch to the LOCK position. 2. The fuse puller is stored in the fuse box inside the cab.
  • Page 290 Vehicle Care Replacing Relays Warning Before replacing the relays, contact the nearest dealer. Always use fuses specified for the vehicle. Using fuses with a rating The vehicle may not be equipped other than that specified, or using with all of the fuses, relays, and wire or tin foil, etc., could result in features shown.
  • Page 291 Vehicle Care Fuse locations: Fuse and Relay Location Cab Interior Description Rating RR P / WINDOW ROOM LAMP, AUDIO DOOR LOCK TRAILER BRAKE P/ WINDOW WIPER H / LAMP LO (LH) LAMPS (BATT) H / LAMP LO (RH) BRAKE LAMPS STARTER H / LAMP HI (LH)
  • Page 292 Vehicle Care Description Rating Description Rating H / LAMP HORN HI (RH) TURN, HAZARD 15A MIRROR TAIL LAMPS HEATER IGNITION 2 IGNITION 1 ILLUMINATIONS 10A 29 CORNERING LAMPS 10A 30 AIR CONDITIONER 10A 31 D-1 CIGAR 20A D-2 ACCESSORIES SOCKET 15A METER D-3 POWER SOURCE 20A D-4 ECU (BATT)
  • Page 293 Vehicle Care Relay locations: Description STOP LAMP DAYTIME RUNNING LAMP KEY ON PARKING/NEUTRAL WIPER MAIN HORN WIPER HI LO TRAILER BRAKE POWER WINDOW POWER WINDOW HEAD LAMP LO VACUUM PUMP HEAD LAMP HI Relay Location TAIL LAMP CIGAR LIGHTER CORNERING LAMP...
  • Page 294 Vehicle Care Fuse and Relay Location Cab Exterior Description POWER ACC BLOWER MOTOR Fuse and Relay Location Fuse locations (2): Description Rating Description Rating PM SENSOR MARKER LIGHT 20A RR DOME TAIL MAIN LIGHT ECM MAIN CONDENSER...
  • Page 295 Vehicle Care When Slow-blow Fuses Blow Out Inspection Description Rating Relay locations (1): Description STARTER ECM MAIN NOX & DEF SENSOR A/C COMPRESSOR CONDENSER FAN RR DOME LIGHT Slow-blow fuses protect the When the headlights and other electrical circuits, and they are devices in the electrical system do SCR HEATER installed so that they can be quickly...

  • Page 296: Wheels And Tires

    Vehicle Care It is not necessary to open or close Wheels and Tires Warning the cover unless trouble is found. The operating load and cold inflation The relay box structure makes it Always use fuses specified by the pressure on the rim and wheel must difficult for water to enter.
  • Page 297 Vehicle Care rims, refer to the Tire and Rim See Tire Load and Inflation Table Be sure to install the tire inflation Association Inc. Yearbook , or your under Tire Pressure 0 307. valve caps to prevent dirt and tire dealer. moisture from getting into the valve In no case should the front or rear core, which could cause air leakage.
  • Page 298 Vehicle Care occurs, reverse the position of the when needed. (See the To reduce the chance of traction tires to equalize wear and get better Maintenance Schedule for more loss, follow these tips: tire life. information.) Improper alignment will Slow down during rainstorms or not cause the vehicle to vibrate;...
  • Page 299 Vehicle Care Use of any other size or type tire Warning (Continued) may affect load carrying capacity, ride, handling, speedometer/ Consult your dealer before odometer calibration, vehicle ground replacing wheels. Never use clearance and tire clearance to the wheels that are not designed for chassis.
  • Page 300 Vehicle Care Recommended replacement tire for Greenhouse Gas (GHG) emissions Tire size Tire maker Tire name Rolling resistance BRIDGESTONE CORPORATION Duravis R250 LRRA LT215/85R16E THE YOKOHAMA RUBBER CO., LTD. TY213A MC2 LRRA BRIDGESTONE CORPORATION M895Z LRRA 225/70R19.5F THE YOKOHAMA RUBBER CO., LTD. TY287 MC2 LRRA If the original equipment tires are...
  • Page 301 Vehicle Care Checking Tires As the tire air pressure varies Warning depending on the vehicle model and Air Pressure tire size, refer to the VIN, Weight Consult your dealer before Rating, and Greenhouse Gas replacing wheels. Never use (GHG) Emissions Plate on the wheels that are not designed for driver's door opening frame or the the vehicle.
  • Page 302 Vehicle Care Tire size Tire air pressure kPa (psi) kg (lb.) Front Rear Front Rear 6 577 LT215/85R16E LT215/85R16E 550 (80) 550 (80) (14,500) 7 258 225/70R19.5F 225/70R19.5F 590 (85) 590 (85) (16,000) 8 142 225/70R19.5F 225/70R19.5F 620 (90) 620 (90) (17,950) 8 845 225/70R19.5F...
  • Page 303 Vehicle Care Cracks and Other Damage When checking tires, pay special Warning (Continued) attention to: low air pressure; pebbles or nails in tread grooves; and could burst. Always keep the cracks or other damage on tire tires of your vehicle adjusted at surfaces;...
  • Page 304 Vehicle Care Use of Low Aspect Ratio Tires Warning Tires with excessively shallow tread grooves will increase the chance of skidding and, when driving at high speeds, hydroplaning. You and others could be seriously injured. Tread Wear Indicator (Example) Hydroplaning occurs when a vehicle 1.
  • Page 305 Vehicle Care Damaged Tires Danger (Continued) Danger (Continued) Danger If the tire looks as if it may start moving when the be underinflated, stand to engine power is transmitted It is dangerous to mount the the side and check whether to the rear axle even when wrong size tire on a wheel.
  • Page 306 Vehicle Care Wheel Nut Torque Danger (Continued) Danger (Continued) Warning Note that taking off and Tire mounting or repair can mounting tires on wheels result in serious personal Never use oil or grease on studs requires proper tools, safety injury or death, if not or nuts.
  • Page 307 Vehicle Care tighten wheel stud nuts and rim Warning (Continued) clamp nuts with a torque wrench after installing any wheel. that wheel should be replaced. In addition, nut tightness on all A loose running wheel may cause wheels should be set with a torque only one stud to break but wrench every 10 400 km (6,500 mi).

  • Page 308: Tire Pressure

    Vehicle Care Tire Pressure Tire Load and Inflation Table Tire Load and Inflation Table TIRES FOR VEHICLES IN HIGHWAY SERVICE TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES Tire Size Designation Cold Inflation Pressure (psi) LT215/85R16E Dual (lbs) 2470 Single 2680 225/70R19.5F Dual...
  • Page 309 Vehicle Care The difference in diameter of the Retightening Wheel Nuts Warning (Continued) tires for a dual-tire wheel should be Check the wheel nuts to make sure within the limit specified in the table they are tightened to the specific tires may get loaded beyond their below.
  • Page 310 Vehicle Care Single Tire Retightening of nuts on left rear dual-tire wheel Dual Tire 2. Tighten the inner wheel nuts of the same wheel to the specified torque. 1. Left side tire 2. Right side tire 1. Inner Nut Turn the wheel nuts in the tightening direction to the specified torque.

  • Page 311: If A Tire Goes Flat

    Vehicle Care 3. Next, tighten the outer wheel When replacing a tire with a new Warning nuts to the specified torque. one, use only a tire of the same type and size as the replaced tire; If you continue to drive on a flat otherwise, driving safety could be Warning tire, undue force will be applied to...

  • Page 312: Jump Starting

    Vehicle Care Jump Starting Danger (Continued) Danger (Continued) Jump Starting - North at least 5 minutes. Following this, Batteries produce explosive you should seek medical gases, contain corrosive acid, America assistance. and supply levels of electrical When the Battery is current high enough to cause When using tools or other metal Discharged...
  • Page 313 Vehicle Care Danger (Continued) Warning (Continued) Warning (Continued) Dilute sulfuric acid is used as the Never tow the vehicle to start Do not disconnect a battery battery fluid. Special care must be because a surge forward when terminal with the engine running. taken to ensure that this fluid the engine starts could cause a It could cause a breakdown in the...
  • Page 314 Vehicle Care the negative ( ) terminal which Make sure the cables are not is grounded (attached to the on or near pulleys, fans or engine block, or frame rail). other parts that will move when the engine is started. 2.
  • Page 315 Vehicle Care 7. If the engine in the disabled vehicle starts, remove the jumper cables in the reverse sequence as they were connected. 5. After connecting the cables, 6. Slightly rev up the engine of start the engine of the vehicle the vehicle with the booster with the booster battery.

  • Page 316: Towing The Vehicle

    Vehicle Care Towing the Vehicle Front End Towing (Front Wheels Ensure towing chains do not come Off Ground) into contact with the horns or the Consult your dealer or a bumper. (If towing chains contact To prepare a disabled vehicle for professional towing service if the the bumper, then remove the front end towing with front wheels...
  • Page 317 Vehicle Care Front End Towing (All Wheels On To prepare a disabled vehicle for After Towing the Ground) front end towing with all wheels on After towing the vehicle, block the the ground, the following steps are Your vehicle may be towed on all rear wheels and install axle shafts necessary: wheels provided the steering is...

  • Page 318: Appearance Care

    Vehicle Care 3. No vehicle should ever be Appearance Care conditions such as high-pressure towed over 88 km/h (55 mph). car washers may cause water to enter inside the vehicle. If the 4. Loose or protruding parts of Exterior Care vehicle is operated with foreign damaged vehicles should be material adhering to the exterior,...
  • Page 319 Vehicle Care To wash the vehicle: electronic control units and electrical Warning (Continued) components, or in rusting of the cab 1. Fully turn on the tap, and wash floor. Do not apply water from a out the undercarriage and volatile cleaning solvents, such as high-pressure washer nozzle suspension.
  • Page 320 Vehicle Care this precaution can lead to heat Vehicle Storage Polishing and Waxing deformation and breakage of plastic In order to maintain your vehicle's Periodic polishing and waxing is components, or to water leaks into attractive appearance as long as recommended to remove built-up the cab.
  • Page 321 Vehicle Care The application of wax to rubber lubricant should be applied using a Clean the outside of the windshield component surfaces can result in clean cloth. Weatherstrip lubricant with a non-abrasive cleaner. Your permanent whitening. application will lengthen windshield is clean if beads do not weatherstrip life, help sealing, and form when rinsing with water.
  • Page 322 Vehicle Care can cause serious damage to the This can also cause corrosion of engine and its components, these cores. Wash the radiator core particularly the fuel supply pump. with tap water every 24 months. Make sure to turn the engine off and Handling the Radiator and remove the key from the engine Charge Air Cooler...
  • Page 323 Vehicle Care Corrosion Protection Foreign Material Deposits Calcium chloride and other salts, Your vehicle has been designed and ice-melting agents, road oil and tar, built to resist corrosion. Special tree sap, bird droppings, chemicals materials and protective finishes from industrial chimneys and other were used on most parts of your foreign matter may damage vehicle vehicle when it was built to help...

  • Page 324: Interior Care

    Vehicle Care Underbody Maintenance cleaner, and gently wipe surfaces Warning (Continued) clean using a cloth wet with warm or Corrosive materials used for ice and cold water. snow removal, and dust control can life-threatening injuries could collect on the underbody. If these result.
  • Page 325 Vehicle Care Air fresheners (liquid, solid, gel, spots, spot rings, or setting of stains Warning (Continued) or plate types) must not come into or soilage all of which are more direct contact with, or spill onto, difficult to remove in a second use carbon tetrachloride, interior components such as the air cleaning.
  • Page 326 Vehicle Care Follow specific instructions on suede, raise nap with a dry scrub feathering towards the center. cleaner labels. brush and vacuum to remove any Keep changing to a clean final traces of residue. section of cloth. General Cleaning of Soiled or When you clean a stain from Spot Cleaning Fabric Type Water Spotted Fabric Type...
  • Page 327 Vehicle Care Carefully scrape off excess Finally, if needed, clean lightly off as quickly as possible and stain; then use solvent type with Fabric Cleaner the area cleaned with a clean cleaner. (Solvent type). cloth dampened with solvent type vinyl leather cleaner. Shoe polish, wax crayons, tar, Combination Stains Includes...

  • Page 328: Service And Maintenance

    Service and Maintenance Service and Maintenance vehicle with peace of mind. They also extend the vehicle's Schedule Maintenance service life. For safe and economical driving, we Caution recommend that you have your Maintenance Schedule vehicle inspected and serviced Damage caused by improper Maintenance Schedule .
  • Page 329 Service and Maintenance training of dealer technicians The schedule includes general vehicles), or vehicles operated for throughout the country and is maintenance which you or a frequent short trips, will require supported with a continuous qualified technician should perform more frequent vehicle maintenance. follow-up of publications and other periodically.
  • Page 330 Service and Maintenance Frequent short trips of less than be emphasized as critical to Maintenance Schedule Table 16 kilometers (10 miles) in sub- malfunction but each is dependent Letters Used to Indicate freezing temperatures upon the other. For example, if a Maintenance Service Types vehicle is repeatedly overloaded, Frequent and extended low-...
  • Page 331 Service and Maintenance Service intervals months or kilometers (miles) whichever No. Service Interval occurs first (1) Engine noise check or every Valve lash 12 months or every Engine oil and oil filter (2) 12 months or every Fuel filter 24 months Pre-fuel filter/water or every separator...
  • Page 332 Service and Maintenance Service intervals months or kilometers (miles) whichever No. Service Interval occurs first (1) or every Engine cooling system 12 months Every 12 months: I Engine coolant Every 24 months: R (when dealer recommended coolant is used) Exhaust system or every DPF (clean filter) 3,000 hours...
  • Page 333 Service and Maintenance Service intervals months or kilometers (miles) whichever No. Service Interval occurs first (1) Brake drum and rotor for or every wear and damage 12 months Brake electric or every vacuum pump 12 months or every 12 months: I Brake fluid or every 12 months: R...
  • Page 334 Service and Maintenance Service intervals months or kilometers (miles) whichever No. Service Interval occurs first (1) or every Differential gear oil 24 months or every Power steering fluid 24 months or every Power steering oil hoses 24 months Steering wheel free Every 10 400 km (6,500 miles): I play (4) or every...
  • Page 335 Service and Maintenance Service intervals months or kilometers (miles) whichever No. Service Interval occurs first (1) Wheel nut torque (4) Every 10 400 km (6,500 miles) or every King pin 12 months Wheel hub bearing grease or every - Front (5) 24 months Air conditioner blower Cleaned once a month...
  • Page 336 Service and Maintenance maintenance intervals and may Service Interval Maintenance procedure cause a problem with engine Engine Inspect sound absorption materials for durability. Every 16 000 km (10,000 miles) tears, broken out sections or (3) Refer to "Air Cleaner Indicator attachment.
  • Page 337 Service and Maintenance 3. Engine Oil and Oil Filter : 5. Pre-Fuel Filter/Water mounting, and injectors to correct Change at interval noted below separator : Replace the fuel filter torque every 80 000 km depending upon driving conditions. every 24 000 km (15,000 miles) or (50,000 miles).
  • Page 338 Service and Maintenance Engine Coolant 0 253. Have the 16. DPF (Pressure Difference When the truck is in motion, the Engine Coolant replaced by your Sensor Hose) : Inspect the sensor sound may be constant or it may authorized dealer. hose every 160 000 km come and go.
  • Page 339 Service and Maintenance 21. Brake Fluid : Check the fluid in engine oil change and replace fluid 30. Steering Gear Box Torque : the brake fluid reservoir every every 48 000 km (30,000 miles). Do Retighten the attaching bolts of the 16 000 km (10,000 miles).
  • Page 340 Service and Maintenance 33. Leaf Spring U-bolt Torque : 40. Starter : The color displayed by Wheel nut tightening torque Tighten the U-Bolt nuts to the the starter indicator light will change (362 lb·ft) specified torque after the first from green to amber when the 1 040 km (650 miles), thereafter number of times remaining is 0 or every 16 000 km (10,000 miles).
  • Page 341 Service and Maintenance Owner Checks and seat belt. The passengers are also Checking Condition of the Engine required to buckle up the seat belts. at Low Speeds and during Services Acceleration Adjust the positions of the steering wheel and mirrors. Lock the doors. 1.
  • Page 342 Service and Maintenance Recommended Daily 2. Checks performed at the Steering wheel position and engine free play (Pre-operation) Inspections Fan belt looseness and Operation of horn and turn These checks are in addition to, not damage signal lights instead of, any legally required daily inspections.
  • Page 343 Service and Maintenance Mounting condition of all Electrical System Warning (Continued) wheel nuts Following the after-delivery service, 6. Checks performed after the it is the owner's responsibility to For proper pedal operation, it is engine startup check all wiring periodically for also essential to lay floor mats cracked, chafed or oil-soaked properly.
  • Page 344 Service and Maintenance Greasing Chassis Components The type (characteristics) of the grease specified for use with a chassis component differs from that of the grease specified for use with another component. Be sure to use only the specified grease for each component and perform greasing according to the Maintenance Schedule.
  • Page 345 Service and Maintenance Driveshaft splines (4500/5500) Driveshaft universal joint (Single-piece shaft) Center bearing (4500/5500) Driveshaft universal joint (Two-piece shaft) Single-piece driveshaft: 2 points; Two-piece driveshaft: 3 points Each driveshaft universal joint must be greased heavily until grease oozes at the 4 needle bearing oil seal locations.
  • Page 346 Service and Maintenance Lubrication Chart...
  • Page 347 Service and Maintenance Additional A: Parking Brake : Park on a fairly to turn or has too much free play, steep hill and hold the vehicle with or when there are strange sounds Maintenance and Care the parking brake only. This checks when turning or parking.
  • Page 348 Service and Maintenance one side, unusual sounds when I: Defroster : Turn the outlet mirrors, headlamps, parking lamps, braking, increased brake pedal selector knob to "Defroster" and the identification and clearance lamps, travel or harder pedal. The front and fan speed control knob to the fully taillights, brake lamps, turn signals, rear brakes are attached to an auto clockwise position.
  • Page 349 Service and Maintenance a while. If you notice diesel fumes or Checking Components that fluid at any time, have the cause Showed Abnormalities during found and corrected at once. Previous Operation S: Underbody : Corrosive materials Check the components that showed used for ice removal, snow removal abnormalities during the previous and dust control can collect on the...
  • Page 350 Service and Maintenance Recommended Fluids, Lubricants, and Parts Recommended Fluids and Lubricants Fluids and lubricants identified below by name, part number, or specification can be obtained from your dealer. Usage Fluid/Lubricant Automatic Transmission Automatic Transmission Fluid (GM Part No. 19354076). Battery Terminals Petroleum Jelly (outer surfaces) Brake Fluid...
  • Page 351 Service and Maintenance Usage Fluid/Lubricant Engine Oil Engine oils with the letters CK-4 are required for your vehicle. The CK-4 designation can appear either alone or in combination with other American Petroleum Institute (API) designations, such as API CK-4/SL. These letters show API levels of quality.
  • Page 352 Service and Maintenance Be sure to use the LSD gear oil Maintenance additive mentioned above in Replacement Parts vehicles equipped with limited slip differentials, and ensure there is an Replacement Parts appropriate amount of the LSD gear Please contact your dealer for oil additive, otherwise a chattering genuine GM parts.
  • Page 353 Service and Maintenance 5.2L Diesel Part GM Part Number Engine Air Cleaner 97780479 Engine Oil Filter 98298404 Fuel Filter: Engine Side 98147525 Fuel Filter: Chassis Side 98037481 Replacement Fasteners Warning During vehicle maintenance, any fasteners used to replace older This vehicle is primarily ones must have the same dimensioned in the metric system.

  • Page 354: Technical Data

    Technical Data Technical Data Vehicle Identification VIN and Weight Rating Plate Vehicle Identification Vehicle Identification Number (VIN) Vehicle Identification The VIN and engine number are Number (VIN) ....353 necessary for registering your Vehicle Data vehicle.
  • Page 355 Technical Data ratings (GAWRs), as well as the VIN and emissions information for your vehicle. This plate is located on the left side rear pillar panel below the striker (single cab) or on the left center pillar panel beside the shoulder seat belt anchor (crew cab).
  • Page 356 Technical Data Section Description World Manufacturer Identifier (WMI) JAL: ISUZU GVWR and Brake System C: 14,001-16,000 lbs. hydraulic brake system E: 16,001-19,500 lbs. hydraulic brake system Series Code 4: 4500HD/4500XD 5: 5500HD/5500XD Cab Type Code W: Steel tilt single cab, 71 inch bumper to back of cab (BBC) J: Non-tilt crew cab, 110 inch bumper to back of cab (BBC) Chassis Type Code 1: 4 x 2...
  • Page 357 Technical Data Section Description Plant Code 7: Fujisawa Model Code 0: 4500HD 3: 5500XD 9: 5500HD K: 4500XD Sequence Numbers Interpretation of the VIN may differ depending on the vehicle. For further details, please ask your dealer. The engine number is stamped on the right side front part of the engine block.
  • Page 358 Technical Data Vehicle Data Capacities and Specifications These specifications are given here for information only. Before using them, see the Cautions and other instructions throughout this manual the index may help you locate such items. For more information, see the Service Manual covering the chassis or body part in question.
  • Page 359 Technical Data Valve clearance Both intake and exhaust valves: 0.6 mm (0.024 in) in cold engine Idling speed 550 600 r/min Fan belt tension New belt: 5 7 mm (0.20 0.28 in)/184 206 Hz When used: 8 9 mm (0.31 0.35 in)/158 170 Hz Oil filter Cartridge (spin on) type Engine oil capacity...
  • Page 360 Technical Data Service Specifications Weights Axle weight rating : Front 4500HD: 2431 kg (5,360 lb) 4500XD: 3007 kg (6,630 lb) 5500HD: 3098 kg (6,830 lb) 5500XD: 3300 kg (7,275 lb) Engine Oil Engine oil capacity When changing oil and filter: 11.0 L (11.6 qt) Engine Cooling System Capacity 19.6 L (20.7 qt)
  • Page 361 Technical Data Limited slip differential 4500HD/4500XD: lubricant additive 0.5 L (1.06 pt) 5500HD/5500XD: 0.6 L (1.27 pt) Fuel Fuel tank capacity 113 L (30.0 gal) 125 L (33.0 gal) Diesel Exhaust Fluid (DEF) DEF tank capacity 16.0 L (4.23 gal) Steering Steering wheel free play 10 50 mm (0.39 1.97 in)
  • Page 362 Technical Data Disc Brakes Model 4500HD 4500XD/5500HD/5500XD Brake size (Diameter x 293 x 40 mm ( 11.54 x 1.57 in) 363 x 42 mm ( 14.29 x 1.65 in) Thickness) Rotor thickness [Standard Value] 40.0 mm (1.575 in) 42.0 mm (1.654 in) [Usable Limit] 37.0 mm (1.457 in) 39.0 mm (1.535 in)
  • Page 363 Technical Data Parking Brake Lever effective stroke 6 8 notches (Under pull force of approx. 147 N (15 kg/33 lb) Electrical System Battery type [BCI size] 31T (160 750) x 2 (RC-CCA) x No. of units Starter 12 V/3.0 kw Alternator 12 V/140 amp Tightening Torque...
  • Page 364 Technical Data Engine Drive Belt Routing The air conditioning drive belt, Name if equipped, must be adjusted Fan Belt and Air Conditioning Alternator after fan belt adjustment. If the Compressor Belt belt is not adjusted properly, the If your air conditioning system is A/C belt may experience See the Maintenance Schedule functioning properly, it is not...

  • Page 365: Customer Information

    Offices ..... . 365 operation of the Chevrolet chassis, Customer Assistance for Text or upfitted rear body will be resolved Telephone (TTY) Users .

  • Page 366: Offices

    U.S. can communicate with following information available to assistance. However, if a customer Chevrolet by dialing: give the Customer Assistance wishes to write or e-mail Chevrolet, representative: 1-800-833-2438. the letter should be addressed to: Your name, address, and Online Owner Center United States daytime phone number.
  • Page 367 : View maintenance schedules, (Canada) alerts, and Vehicle Diagnostic Reimbursement Program www.chevroletowner.ca Information. Schedule service appointments. Visit the Chevrolet Owner Centre: : View and print dealer-recorded Chat live with online help service records and self-recorded representatives. service records. Locate owner resources such as...

  • Page 368: Program

    New Vehicle Limited Warranty. Legal fines. General Motors North America and When calling Roadside Assistance, Mounting, dismounting, Chevrolet reserve the right to make have the following information or changing of snow tires, any changes or discontinue the ready: chains, or other traction devices.

  • Page 369: Collision Damage Repair

    Customer Information of your transportation needs, your Collision Parts Aftermarket collision parts are also dealer can help minimize your available. These are made by Genuine GM Collision parts are new inconvenience. companies other than GM and may parts made with the same materials not have been tested for the vehicle.
  • Page 370 Customer Information Insuring the Vehicle parts. Read the lease carefully, as Vehicle make, model, and you may be charged at the end of model year. Protect your investment in the GM the lease for poor quality repairs. Vehicle Identification vehicle with comprehensive and Number (VIN).

  • Page 371: Publication Ordering

    Customer Information Insurance pays the bill for the repair, Publication Ordering Current and Past Models but you must live with the repair. Information Service manuals and customer Depending on your policy limits, literature are available for many your insurance company may Service Manuals current and past model year GM initially value the repair using...

  • Page 372: Reporting Safety Defects

    Motors. a safety defect exists in a group Call 1-800-862-4389, or write: of vehicles, it may order a recall Chevrolet Motor Division and remedy campaign. Chevrolet Customer Assistance However, NHTSA cannot Center become involved in individual P.O.

  • Page 373: Privacy

    Customer Information Vehicle Data GM and its affiliates may also download and retrieve stored Recording and information from your vehicle for motor vehicle research and Privacy development, safety and vehicle Your vehicle, like other modern improvement purposes. motor vehicles, has a number of sophisticated computer systems that monitor and control several aspects of the vehicle performance.

  • Page 374: Index

    Index Index Audio Players CD ......102 Accessories and Automatic Modifications ....240 Transmission .
  • Page 375 Index Brakes ......263 California Control of a Vehicle ... . . 139 Coolant Antilock .
  • Page 376 Index Devices Engines Diesel Fuel ....227 Auxiliary ..... . .117 Electrical Equipment, Exhaust Brake .
  • Page 377 Index Fuel Glove Box ..... . . 55 Biodiesel ..... 228 GM Mobility Reimbursement Idle Shutdown .
  • Page 378 Index Lamps (cont'd) Lights (cont'd) License Plate ....286 High/Low Beam Changer ..93 New Vehicle Break-In ... 165 Malfunction Indicator (Check Idle Shutdown .
  • Page 379 Index Phone Rear Axle ....271, 272 Bluetooth ..... 121 Rear Seats .
  • Page 380 Index Shift Lock Control Function Sun Visors ..... . . 37 Turn and Lane-Change System Check, Automatic Signals ......94 Noise Control .
  • Page 381 Index Wait to Start Light ....79 Warning Brake System Light ... . . 74 Caution and Danger ... . . 3 Warning Buzzers .
  • Page 382 84445126 A...

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