2005duramaxmanual like s10 diesel engines.pdf

7/27/2019 2005DuramaxManual like s10 diesel engines.pdf

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Features and Controls ..................................... 2-1Starting and Operating Your Vehicle ............. 2-2

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

Warning Lights, Gages and Indicators ........... 3-2

Service and Appearance Care .......................... 5-1Diesel Fuel Requirements and Fuel System ... 5-2Checking Things Under the Hood ............... 5-14Capacities and Specifications ..................... 5-36

Maintenance Schedule ..................................... 6Maintenance Schedule ................................ 6

Index................................................................

2005 DURAMAX Diesel Engine M


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General Motors, GM, GMC, CHEVROLET, the GMEmblem, the GMC Truck Emblem, the CHEVROLETEmblem, and the names SIERRA and SILVERADO areregistered trademarks of General Motors Corporation.

This manual contains information that pertains tothe operation of your diesel engine. It also contains your

Diesel Maintenance Schedule. The sections in thismanual correspond to the sections in your ownermanual. This manual, along with your owner manual,will assist you in the proper use and maintenanceof your vehicle.

Keep this manual with the owner manual in yourvehicle, so it will be there if you ever need it while youare on the road. If you sell your vehicle, leave thismanual and the owner manual with the vehicle.

This manual includes the latest information at the time itwas printed. We reserve the rights to make changesin the product after that time without notice.

Canadian Owners

A French language copy of this manual can be obtainedfrom your dealer or from:

Helm, IncorporatedP.O. Box 07130Detroit, MI 48207

Litho in U.S.A.Part No. 15101364 A First Edition 2004 General Motors Corporation. All Rights Reserved.

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Starting and Operating Your Vehicle .................2-2Starting Your Diesel Engine ...... ...... ...... ...... .....2-2Winter Cover ..... ...... ...... ...... ..... ...... ...... ...... ...2-5

Engine Coolant Heater ...... ...... ...... ...... ..... ...... .2-7

Section 2 Features and Controls

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Starting and Operating YourVehicle

Starting Your Diesel Engine

Your diesel engine starts differently than a gasolineengine.

Automatic Transmission

Move your shift lever to PARK (P) or NEUTRAL (N).Your engine wont start in any other position thats asafety feature. To restart when youre already moving,use NEUTRAL (N) only.

Notice: Do not try to shift to PARK (P) if yourvehicle is moving. If you do, you could damage thetransmission. Shift to PARK (P) only when yourvehicle is stopped.

Manual Transmission

Move your shift lever to neutral and hold the clutch pedalto the floor while starting the engine. Your vehicle wontstart if the clutch pedal is not all the way down thats a

safety feature.

Starting Your Engine

1. Turn your ignition key to RUN.

Observe the wait to start light. See Wait to StartLight on page 3-6. This light may not come on if theengine is hot.

2. As soon as the wait to start light goes off,immediately turn the ignition key to START.When the engine starts, let go of the key.

Your engine has a fast warm-up glow plug system.The wait to start light will illuminate for a muchshorter time than most diesel engines, due to therapid heating of the glow plug system.

Notice: Holding your key in START for longer than

15 seconds at a time will cause your battery tobe drained much sooner. And the excessive heatcan damage your starter motor.

Notice: If the wait to start light stays on afterstarting your vehicle, your vehicle may not runproperly. Have your vehicle serviced right away.

3. If the engine does not start after 15 secondsof cranking, turn the ignition key to OFF. Waitone minute for the starter to cool, then try the

same steps again.

If youre trying to start your engine after youve run outof fuel, follow the steps in Running Out of Fuel onpage 5-9.

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When your engine is cold, let it run for a few minutesbefore you move your vehicle. This lets oil pressurebuild up. Your engine will sound louder when its cold.

Notice: If you are not in an idling vehicle andthe engine overheats, you would not be there to seethe overheated engine indication. This could

damage your vehicle. Do not let your engine runwhen you are not in your vehicle.

Cold Weather Starting (Diesel Engine)

The following tips will help you get good starting incold weather.

Use the recommended engine oil when the outsidetemperature drops below freezing. See Engine Oil on

page 5-16. When the outside temperature dropsbelow 0F (18C), use of the engine coolant heateris recommended.

If you experience longer cranking times, notice anunusual amount of exhaust smoke or are at higheraltitudes (over 7,000 ft. or 2 135 m), you may use yourengine coolant heater. See Engine Coolant Heateron page 2-7.

See Diesel Fuel Requirements and Fuel System on

page 5-2 for information on what fuel to use incold weather.

If Your Diesel Engine Wont Start

If youve run out of fuel, look at Running Out of Fuel opage 5-9. See Diesel Fuel Requirements and FuelSystem on page 5-2.

If youre not out of fuel, and your engine wont start,

do this:Turn your ignition key to RUN. Immediately after the wato start light goes off, turn the ignition key to START.

If the light doesnt go off, wait a few seconds, then trystarting your engine again. See your dealer as soonas you can for a starting system check.

If the light comes on and then goes off and you knowyour batteries are charged, but your engine still

wont start, your vehicle needs service.If the light does not come on when the engine is cold,your vehicle needs service.

If your batteries dont have enough charge to start youengine, see Battery in the owners manual Index.

Be sure you have the right oil for your engine, and thayouve changed the oil at the proper times. If youuse the wrong oil, your engine may be harder to start.

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Be sure you are using the proper fuel for existingweather conditions. See Diesel Fuel Requirements andFuel System on page 5-2.

If the engine starts, runs a short time, then stops, yourvehicle needs service.

{CAUTION:

Do not use gasoline or starting aids, such as

ether, in the air intake. They could damage

your engine. There could also be a fire, whichcould cause serious personal injury.

Elevated Idle/Exhaust Restrictor

The engine has a cold temperature high idle and exhaustrestrictor feature which elevates the engines idle speedfrom 680 to 1200 rpms, and restricts the exhaust gasflow, when outside temperatures are below 32F (0C),and the engine coolant temperature is below150F (65C.) This feature enhances heater performanceby raising the engine coolant temperature faster.

This feature can be turned off and on using the DICsteering wheel control buttons. If your vehicle isnot equipped with the DIC steering wheel controlbuttons, doing the following to turn on this feature:

1. Turn the ignition to RUN, with the vehicle off.

2. Press the accelerator pedal to the floor and holdwhile quickly pressing the brake pedal three timesin less than eight seconds.

3. Release the accelerator pedal and start the engine.

When the engine is started, it will slowly ramp up tothe high idle speed after a delay of a few seconds up toapproximately two minutes. For this method to workproperly there must be no throttle or brake pedal faults.

The engine idle speed will return to normal once the

following conditions are met:

Once engine coolant temperature reaches150F (65C).

Air intake temperature reaches 32F (0C).

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The high idle speed will be temporarily interrupted andthe engine speed will return to normal if any of thefollowing conditions occur:

The brake pedal is applied.

The accelerator pedal is pressed.

The automatic transmission is shifted outof PARK (P) or NEUTRAL (N).

The clutch pedal on the manual transmissionis pressed.

Vehicle speed is detected.

Once these inputs are removed, the engine idle speedwill slowly ramp back up to high idle after the normaldelay, if the conditions for engine coolant temperature

and air intake temperature are still met.

Winter Cover

If your vehicle includes a winter cover, it will enhanceheater performance and will reduce the amount of timetakes to warm the inside of your vehicle in extremelycold conditions (below 0F (18C)). The winter

cover installs over the front bumper of your vehicle andrestricts the air flowing to the engine compartmentby covering the radiator grille.

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Usage Guidelines

The winter cover should only be used while operatingyour vehicle in extremely cold temperatures. Inthese temperatures, the vehicle does not need a largeamount of air to properly cool the engine. During periodsof operation when more airflow is required to cool thevehicle, the winter cover should not be used. Thefollowing usage guidelines will allow adequate airflow forproper radiator grille and air cooler performance:

Do not use the winter cover when temperatures areexpected to be above 32F (0C). Use of the coverin these conditions could cause your vehicle tooverheat. If this happens while the cover is beingused, remove the cover.

Do not use the winter cover if towing a trailer. Theadded power needed to tow a trailer requires theradiator grille to have full airflow under all conditions.Your vehicle may overheat if the cover is usedwhile towing a trailer.

Do not modify the cover. The winter cover does notcover some sections of the front of the vehiclebecause these openings are needed to provideenough airflow to the radiator grille and air cooler inextremely cold temperatures.

When the winter cover is used, the temperaturesensor found on the inside rearview mirror willnot function properly. The temperature that is shownwill be incorrect.

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Installation Instructions

The following instructions explain how to install andremove your vehicles winter cover. When installing orremoving the cover please refer to the UsageGuidelines mentioned previously. When you first try tofit the cover it may appear to be undersized. This isdue to the nature of the special vinyl, which will stretchduring installation to ensure a tight fit. For this reason,the initial installation of the cover is best performed whenthe winter cover is warm. If you are required to use afront license plate, simply cut the black stitches onthe back of the patch.

Grille Cover Installation

1. Pre-bend all the small black tabs into the shape of

a J.2. Remove the four push pins and slide them through

each of the pre-punched tabs.

3. Install the four push pins into the grille.

4. Hook all the tabs to the edge of the grille.

5. Fasten the snaps.

Lower Cover Installation

1. Pre-bend all of the small black tabs into the shapeof a J.

2. Fasten each tab toedge of the bumper,as illustrated.

To remove the winter cover, reverse the steps listedpreviously.

Engine Coolant Heater

In very cold weather, 0F (18C) or colder, the enginecoolant heater can help. Youll get easier startingand better fuel economy during engine warm-up.Usually, the coolant heater should be plugged in aminimum of four hours prior to starting your vehicle.

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To Use the Engine Coolant Heater

1. Turn off the engine.

2. Open the hood and unwrap the electrical cord. Thecord is located in the engine compartment, on thepassengers side of the vehicle, near the right

side engine mount.3. Plug it into a normal, grounded 110-volt AC outlet.

{CAUTION:

Plugging the cord into an ungrounded outletcould cause an electrical shock. Also, the

wrong kind of extension cord could overheatand cause a fire. You could be seriouslyinjured. Plug the cord into a properly grounded

three-prong 110-volt AC outlet. If the cord will

not reach, use a heavy-duty three-prongextension cord rated for at least 15 amps.

4. Before starting the engine, be sure to unplug andstore the cord as it was before to keep it awayfrom moving engine parts. If you dont, it couldbe damaged.

How long should you keep the coolant heater pluggedin? The answer depends on the outside temperature.You may wish to use your coolant heater to improveease of starting at temperatures between 0F (18C)and 20F (29C). Keep the coolant heater plugged infor a minimum of four hours. At temperatures below20F (29C), the coolant heater should remainplugged in for at least eight hours. It will not harm eitherthe coolant heater or the vehicle to leave the coolantheater plugged in longer than the times stated. Be sureto remove and store the cord before starting theengine. See Diesel Fuel Requirements and Fuel Systemon page 5-2 for information on what fuel to use incold weather.

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Warning Lights, Gages and Indicators ...............3-2Instrument Panel Cluster ...... ...... ...... ...... ..... ....3-2Malfunction Indicator Lamp ... ... ... ... ... ... ... ... ... ...3-3

Oil Pressure Gage ..........................................3-5

Wait to Start Light ..........................................3Fuel Gage .....................................................3Driver Information Center (DIC) ... ... ... ... ... ... ... ...3

Section 3 Instrument Panel

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Warning Lights, Gages and Indicators

Instrument Panel Cluster

United States Version shown, Canada similar.

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Your instrument cluster is designed to let you know at aglance how your vehicle is running. Youll know howfast youre going, about how much fuel you haveand many other things youll need to know to drive safelyand economically.

Malfunction Indicator LampCheck Engine Light

Your vehicle is equippedwith a computer whichmonitors operation of thefuel, timing, and emissioncontrol systems.

This system is called OBD II (On-BoardDiagnostics-Second Generation) and is intended toassure that emissions are at acceptable levels for thelife of the vehicle, helping to produce a cleanerenvironment. The Check Engine light comes on toindicate when service is required. Malfunctions often will

be indicated by the system before any problem isapparent. This may prevent more serious damage toyour vehicle. This system is also designed to assist yourservice technician in correctly diagnosing anymalfunction.

Notice: If you keep driving your vehicle with thislight on, after awhile, your emission controlsmay not work as well, your fuel economy may notbe as good, and your engine may not run assmoothly. This could lead to costly repairs that manot be covered by your warranty.

Notice: Modifications made to the engine,transmission, exhaust, intake, or fuel system ofyour vehicle or the replacement of the original tireswith other than those of the same Tire PerformanceCriteria (TPC) can affect your vehicles emissioncontrols and may cause this light to come on.Modifications to these systems could lead to costlyrepairs not covered by your warranty. This mayalso result in a failure to pass a required Emission

Inspection/Maintenance test.

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If the Light Comes On

This light should come on, as a check to show you it isworking, when the ignition is on and the engine isnot running. If it does not, have it repaired. This light willalso come on if an emission control system malfunctionhas been detected on your vehicle. Diagnosis and

service may be required.

You also may be able to correct the emission systemmalfunction by considering the following:

Did you just drive through a deep puddle of water?

If so, your electrical system may be wet. The conditionwill usually be corrected when the electrical systemdries out. A few driving trips should turn the light off.

Are you low on fuel?As your engine starts to run out of fuel, your engine maynot run as efficiently as designed since small amounts ofair are sucked into the fuel line. The system can detectthis. Adding fuel should correct this condition. It will take afew driving trips to turn the light off.

If none of the above steps have made the light turn off,your dealer can check the vehicle. Your dealer has theproper test equipment and diagnostic tools to fix any

mechanical or electrical problems that may havedeveloped.

Emissions Inspection and MaintenancePrograms

Some state/provincial and local governments have ormay begin programs to inspect the emission controlequipment on your vehicle. Failure to pass this

inspection could prevent you from getting a vehicleregistration.

Here are some things you need to know in order to helpyour vehicle pass an inspection:

Your vehicle will not pass this inspection if the CheckEngine light is on or not working properly.

Your vehicle will not pass this inspection if the OBD(on-board diagnostic) system determines that criticalemission control systems have not been completelydiagnosed by the system. The vehicle would beconsidered not ready for inspection. This can happen ifyou have recently replaced your battery or if your batteryhas run down. The diagnostic system is designed toevaluate critical emission control systems during normaldriving. This may take several days of routine driving.If you have done this and your vehicle still does not passthe inspection for lack of OBD system readiness, yourGM dealer can prepare the vehicle for inspection.

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Oil Pressure Gage

The oil pressure gage shows the engine oil pressure in

psi (pounds per square inch) when the engine isrunning. Canadian vehicles indicate pressure inkPa (kilopascals).

Oil pressure may vary under different driving conditionsand oil types. The DURAMAX engine may generateoil pressure in excess of 80 psi (548 kPa) under certainconditions, especially in cold temperatures. This is anormal operating range.

{CAUTION:

Do not keep driving if the oil pressure is low. If

you do, your engine can become so hot that it

catches fire. You or others could be burned.Check your oil as soon as possible and have

your vehicle serviced.

Notice: Lack of proper engine oil maintenance madamage the engine. The repairs would not becovered by your warranty. Always follow themaintenance schedule in this manual for changingengine oil.

United States Canada

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Wait to Start Light

Your diesel engine has aglow plug system to aid instarting your vehicle.

An instrument panel wait to start indicator light showsthat the system is functioning properly and tells youwhen the engine is ready to be started.

Your vehicle has a fast warm-up glow plug system. TheWait To Start Light will illuminate for a considerablyshorter time than most diesel engines due to the rapidheating of the glow plug system.

For more information, see Starting Your Diesel Engineon page 2-2.

Fuel Gage

When the ignition is on,the fuel gage shows youapproximately howmuch fuel you have left in

your tank.

The gage will first indicate E (empty) before you are out

of fuel, but you should get more fuel as soon aspossible.

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Listed are four situations you may experience with yourfuel gage:

At the gas station, the fuel pump shuts off beforethe gage reads F (full).

It takes a little more or less fuel to fill up than thefuel gage indicated. For example, the gage mayhave indicated the tank was half full, but it actuallytook a little more or less than half the tankscapacity to fill the tank.

The gage moves a little when you turn a corner orspeed up.

The gage doesnt go back to E (empty) when youturn off the ignition.

None of these indicate a problem with the fuel gage.

For information on how to fill your fuel tank, see FillingYour Tank on page 5-11.

Your vehicle also has a fuel cooler. To clean,powerwash the bottom of the vehicle.

Driver Information Center (DIC)

The Driver Information Center (DIC) is located on theinstrument panel cluster above the steering wheel. ThDIC comes on when the ignition is on. After a shortdelay the DIC will display the current driver andthe information that was last displayed before the enginwas last turned off.

If a problem is detected, a warning message will appeaon the display. Pressing the select button on the DICsteering wheel buttons, or the trip odometer reset stemfor vehicles without DIC steering wheel buttons, willacknowledge any current warning or service messages

Some messages that your DURAMAX diesel mayshow are:

ELEVATED IDLE DISABLED

On diesel engines, this message will appear when theelevated idle/exhaust restrictor feature has beenturned off. For more information on the elevatedidle/exhaust restrictor feature, see Starting Your DieseEngine on page 2-2.

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ELEVATED IDLE ENABLED

On diesel engines, this message will appear when theelevated idle/exhaust restrictor feature has beenturned on. For more information on the elevatedidle/exhaust restrictor feature, see Starting Your DieselEngine on page 2-2.

REDUCED ENGINE POWER

A computer monitors the operation of the electricaccelerator. If the REDUCED ENGINE POWERmessage comes on while you are driving, the computeris indicating that your vehicle has a problem. Youshould take your vehicle in for service soon.

WATER IN FUEL

This message will come on to warn you if there is waterin the diesel fuel system. For more information onhow this message works, see Diesel Fuel Requirementsand Fuel System on page 5-2.

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Diesel Fuel Requirements and Fuel System .......5-2Diesel Engine Fuel .........................................5-2What Fuel to Use ...........................................5-2

Very Cold Weather Operation ...........................5-4Water in Fuel .................................................5-5Water in Fuel Light Chart ................................5-6Running Out of Fuel .......................................5-9Fuel Filter Replacement ...... ..... ...... ...... ...... ....5-10Filling Your Tank ..........................................5-11Filling a Portable Fuel Container .....................5-13

Checking Things Under the Hood ....................5-14Engine Compartment Overview .......................5-14Engine Oil ...................................................5-16

Engine Oil Life System ..................................5-1Engine Air Cleaner/Filter ................................5-2Automatic Transmission Fluid ... ... ... ... ... ... ... ... .5-2

Engine Coolant .............................................5-2Coolant Surge Tank Pressure Cap ..................5-2Engine Overheating ...... ...... ...... ..... ...... ...... ....5-2Cooling System ............................................5-3

Capacities and Specifications ..........................5-3

Section 5 Service and Appearance Care

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Diesel Fuel Requirements andFuel SystemSome states and provinces have restrictions on thepurchase of diesel fuel for light-duty vehicles and requireyou to buy permits or pay special taxes. Some of

these restrictions apply only to residents, and othersapply to both residents and visitors. These restrictionscan change. To learn the current restrictions in anystate or province, contact your auto club, the police orother officials.

Diesel Engine Fuel

Notice: Diesel fuel or fuel additives not

recommended in this manual could damage yourfuel system and engine. Your warranty wouldnot cover this damage. And:

Diesel fuel that has been mixed with engine oilor automatic transmission fluid could damageyour engine and emission controls.

Aftermarket diesel fuel additives are not testedby General Motors. Some additives, particularlythose which contain alcohol or wateremulsifiers, may damage your fuel system.If you believe that unique circumstances call fora fuel additive to be used, consult your dealerfor advice.

If you ever run out of diesel fuel, it can bedifficult to restart your engine. To avoid all this,never let your tank get empty.

If you run out of fuel, Running Out of Fuel on page 5-9tells you how to restart your engine.

What Fuel to UseIn the United States, for best results use Number 2-Ddiesel fuel year-round (above and below freezingconditions) as oil companies blend Number 2-D fuel toaddress climate differences. Number 1-D diesel fuelmay be used in very cold temperatures (when it staysbelow 0F or 18C); however, it will produce apower and fuel economy loss. Avoid the use of Number

1-D diesel fuel in warm or hot climates. It may resultin stalling, poor starting when the engine is hot and maydamage the fuel injection system.

At a minimum, the diesel fuel you use should meetspecifications ASTM D975-03 (Grade Low Sulfur) in theUnited States. In addition, the Engine ManufacturersAssociation (EMA) has identified properties of animproved diesel fuel for better engine performance anddurability. Diesel fuels corresponding to the EMA

Recommended Guideline on Premium Diesel Fuel(FQP-1A) could provide better starting, less noise andbetter vehicle performance. If there are questionsabout the fuel you are using, contact your fuel supplier.

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It is acceptable to use diesel fuel containing up to5% biodiesel (B5), but the final blended fuel must meetthe same specification, ASTM D975-03 (Grade LowSulfur), as other fuels used in your vehicle, andthe biodiesel used for making this fuel must meet theASTM D6751-03 specification. Biodiesel is producedfrom vegetable oils or animal fat that have been

chemically modified to reduce the possibility of damageto your fuel system and engine. Higher concentration(i.e., greater than B5) biodiesel-containing fuels orthe use of unmodified bio-oils blended into diesel fuel atany concentration is not recommended and coulddamage your fuel system and engine. Such damagewould not be covered by your warranty. If thereare questions about the biodiesel-containing fuels youare using, contact your fuel supplier.

Diesel fuel may foam when you fill your tank. This cancause the automatic pump nozzle to shut off, eventhough your tank is not full. If this happens, just wait forthe foaming to stop and then continue to fill your tank.

{CAUTION:

Heat coming from the engine may cause the

fuel to expand and force the fuel out of your

tank. If something ignites the fuel, a fire couldstart and people could be burned. To help

avoid this, fill your fuel tank only until the

automatic nozzle shuts off. Do not try totop it off.

What Fuel to Use in Canada

Canadian fuels are blended for seasonal changes.Diesel Type A fuel is blended for better cold weatherstarting (below 0F or 18C); however, you maynotice some power and fuel economy loss. If Type Afuel is used in warmer temperatures, stalling andhard starting may occur. Diesel Type B fuel is blendefor temperatures above 0F (18C). The emissioncontrol system requires the use of diesel fuel withlow-sulfur (0.05% by weight) content. Both low- andhigher-sulfur fuels will be available in Canada.

Only low-sulfur diesel fuels are available in the UnitedStates.

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It is important that diesel-powered trucks are refueledonly with low-sulfur fuel. Use of fuels with higher-sulfurcontent will affect the function of the emissioncomponents and may cause reduced performance,excessive smoke and unpleasant odor.

At a minimum, the diesel fuel you use should meet

specifications CAN/CGSB-3.517-2000 (Low SulfurDiesel) in Canada. In addition, the Engine ManufacturersAssociation (EMA) has identified properties of animproved diesel fuel for better engine performance anddurability (FQP-1A). Diesel fuels corresponding tothe EMA description could provide better starting, lessnoise and better vehicle performance. If there arequestions about the fuel you are using, contact yourfuel supplier.

It is acceptable to use diesel fuel containing up to5% biodiesel (B5), but the final blended fuel must meetthe same specification, CAN/CGSB-3.517-2000(Low Sulfur Diesel) in Canada, as other fuels used inyour vehicle, and the biodiesel used for making thisfuel must meet the ASTM D6751-03 specification.Biodiesel is produced from vegetable oils or animalfat that have been chemically modified to reduce thepossibility of damage to your fuel system and engine.

Higher concentration (i.e., greater than B5)biodiesel-containing fuels or the use of unmodifiedbio-oils blended into diesel fuel at any concentration isnot recommended and could damage your fuelsystem and engine. Such damage would not be coveredby your warranty. If there are questions about thebiodiesel-containing fuels you are using, contact your

fuel supplier.

Very Cold Weather Operation

Follow the instructions listed previously under theheading What Fuel to Use.

Notice: Never use home heating oil or gasoline inyour diesel engine. They can cause engine

damage.In cold weather, your fuel filter may becomeclogged (waxed). To unclog it, move the vehicle to awarm garage area and warm the filter to between32F and 50F (0C to 10C). You will not need toreplace it. Additional information on the fuel filter follows.

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Water in Fuel

{CAUTION:

Diesel fuel containing water is still flammable.You could be burned. If you ever try to drain

water from your fuel, keep sparks, flames andsmoking materials away from the mixture.

Notice: If there is water in your diesel fuel and theweather is warm or humid, fungus and bacteriacan grow in the fuel. They can damage yourfuel system. A diesel fuel biocide can be used tosterilize your fuel system. However, your fuel systemmay still need to be cleaned. Your dealer canadvise you of the appropriate solution.

If your fuel tank needs to be purged to removewater, see your dealer or a qualified technician.Improper purging can damage your fuel system.

Sometimes, water can be pumped into your fueltank along with your diesel fuel. This can happen if aservice station doesnt regularly inspect and clean

its fuel tanks, or if it gets contaminated fuel from itssuppliers.

If this happens, a WATER IN FUEL message willappear on the Driver Information Center (DIC). If it doethe water must be drained. Your dealer can show youhow to do this.

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Water in Fuel Light Chart

If the WATER IN FUEL message comes on, usethis chart.

Water In Fuel Light Chart

Problem Recommended Action

Light comes onintermittently.

Drain water from fuelfilter.

Light stays on:

At temperaturesabove freezing.

Drain fuel filterimmediately. If no watercan be drained and lightstays on, see your dealerfor assistance.

At temperaturesbelow freezing.

Drain fuel filterimmediately. If no watercan be drained watermay be frozen in waterdrain system. Water maybe frozen in the fuel lines.Move the vehicle to awarm location to thawout, and then drain filtersystem.

Water In Fuel Light Chart (contd)

Problem Recommended Action

Immediately afterrefueling, largeamount of waterpossibly pumped intofuel tank.

Fuel tank purgingrequired. See your dealerfor assistance.

Notice: If you drive when this warning indicator ison, you can damage your fuel injection systemand your engine. If the indicator comes on right afteryou refuel, it means water was pumped into yourfuel tank. Turn off your engine immediately.

Then, have the water drained at once.Hard starting, hesitation or flat performance at highspeed or during hard acceleration may be an indicationof premature fuel filter plugging due to dirty orcontaminated fuel. The filter element may need to bechanged if this happens. See Fuel Filter Replacementon page 5-10.

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To drain water, do the following:

1. Stop and park the vehicle in a safe place.Turn off the engine and apply the parking brake.

2. Remove the fuel cap.

3. Place a fuel-resistant container under the fuel filter.The filter drain valve is located in the engine, on thepassengers side of the vehicle, on the bottom ofthe fuel filter.

4. Open the drain valve byturning two to threeturns. When fuelempties from the valve,all the water has beendrained. Close thevalve hand tight.

To help remove all thewater, press the primingpump several times.

5. Remove the fuel-resistant container and properlydispose of the contaminated fuel. To find out how

to properly dispose of contaminated diesel fuel, seeWhat to Do With Used Oil under Engine Oil onpage 5-16.

6. Install the fuel cap.

7. Start the engine and let it run for a few minutes.If the engine stalls, the fuel system may need tobe primed. While draining the water from thefuel filter, air may enter the fuel system. If air hasentered the fuel system the fuel system will need t

be primed.If the WATER IN FUEL message comes on again aftedriving a short distance or the engine runs rough orstalls, a large amount of water has probably beenpumped into the fuel tank. The fuel tank should bepurged.

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Fuel Priming

In order for the fuel system to work properly, the fuellines must be full of fuel and contain no air. If airgets into the fuel lines, it will be necessary to prime thefuel lines, to eliminate air before operating the vehicle.

Q: How does air get into the fuel lines?

A: One of the following may have happened: The vehicle ran out of fuel

The fuel filter was removed for servicing orreplacement

The fuel lines were removed or disconnected forservicing

The fuel filter water drain valve was opened whilethe engine was running

If one or more of the above occur, it is very likely that airhas entered your fuel system and that you will need toprime the fuel system before operating the vehicle. Air inthe fuel lines will not harm the engine or the vehicle.

However, the engine may not be able to start until thefuel system is primed and the air is removed.

Q: How do I prime the vehicle?

A: Your vehicle is equipped with a priming pumpwhich is part of the engine mounted fuel filter.The priming pump is hand operated and is designedto bring fuel to the engine to eliminate any airthat may be in the fuel lines. To prime the engine,do the following:

1. You must correct the condition which caused theloss of prime by making sure there is fuel in thetank.

2. Make sure the fuel filter has been installed andproperly tightened.

3. Make sure the fuel lines are properly connectedand the fuel filter is cool enough to touch.

4. Remove any dirt from the fuel filter head and ventvalve by wiping with a cloth.

5-8


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5. Open the fuel filter ventvalve by turning thescrew counterclockwiseseveral full turns.The vent valve islocated on top of thefuel filter housing.

6. Repeatedly push downon the fuel filter priming

pump with the palmof your hand. Thepump is located on topof the fuel filterhousing. Let the pumpreturn upwardbetween pushes.

7. Operate the priming pump until a small amount offuel seeps from the vent valve. When you see thefuel, the filter is now full of fuel and the systemshould be primed.

8. Close the vent valve. Clean any fuel whichaccumulated on the fuel filter. Start the engine andlet idle for a few minutes. Check the filter for leaks.

Running Out of Fuel

If the engine stalls and you think that youve run out offuel, do this to restart your engine:

{CAUTION:

Diesel fuel is flammable. It could start a fire if

it gets on hot engine parts. You could be

burned. Do not let too much fuel flow from theair bleed valve, and wipe up any spilled fuel

with a cloth.

1. If youre parked on a level surface, add at least two

gallons of fuel. However, if youre parked on a slopeyou may need to add up to five gallons of fuel.

2. Follow the fuel priming procedure earlier in thissection to prime the fuel filter.

5


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3. Close the air bleed valve.

4. Turn the ignition key to START for 10 to 15 secondsat a time until your engine starts. If the engine triesto run, but does not run smoothly, increase therpm a little using the accelerator pedal. This will helpforce air through the system.

Fuel Filter Replacement

If you want to change the fuel filter yourself, heres howto do it:

{CAUTION:

Diesel fuel is flammable. It could start a fire ifsomething ignites it, and you could be burned.Do not let it get on hot engine parts, and keep

matches or other ignition sources away.

First, drain any water from the filter following theprocedure for draining water listed previously.

Your vehicles engine should be off until the end of this

procedure.

The fuel filter is located in the engine compartment onthe passengers side of the vehicle, or on the driversside frame rail in front of the fuel tank.

1. Apply the parking brake.

2. Unplug the watersensor wire connected

to the fuel filter andunscrew the filterelement.

3. Remove the filter element. If there is any dirt on thefilter sealing surface, clean it off. Remove andreuse the water sensor float switch located on thebottom of the fuel filter.

4. Install the new filter element.

5. Reinstall and tighten the filter container and

reconnect the water sensor wire to the filter.6. Use the fuel filter priming procedure earlier in this

section to prime the fuel filter.

5-10


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7. Tighten the air bleed valve by turning it clockwiseuntil hand tight.

8. Start your engine and let it idle for five minutes.Check your fuel filter and air bleed valve for leaks.

Filling Your Tank

{CAUTION:

Fuel vapor burns violently and a fuel fire can

cause bad injuries. To help avoid injuries toyou and others, read and follow all the

instructions on the pump island. Turn off your

engine when you are refueling. Do not smokeif you are near fuel or refueling your vehicle.

Keep sparks, flames and smoking materials

away from fuel. Do not leave the fuel pumpunattended when refueling your vehicle this

is against the law in some places. Keep

children away from the fuel pump; never letchildren pump fuel.

The fuel cap is located behind a hinged door on the

drivers side of the vehicle.For chassis-cab models, refuel the front tank first,or in instances when only a partial fuel fill is desired.An automatic transfer mechanism will maintainapproximately equal fuel levels in both tanks, so noswitching is required by the operator.

5-


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To remove the fuel cap, turn it slowly to theleft (counterclockwise).

{CAUTION:

If you spill fuel and then something ignites it,you could be badly burned. Fuel can spray out

on you if you open the fuel cap too quickly.

This spray can happen if your tank is nearlyfull, and is more likely in hot weather. Open

the fuel cap slowly and wait for any hiss noise

to stop. Then unscrew the cap all the way.

Be careful not to spill diesel fuel. Dont top off or overfillyour tank, and wait a few seconds after youve finishedpumping before you remove the nozzle. Clean fuel frompainted surfaces as soon as possible. See Cleaning theOutside of Your Vehicle in your owners manual. Whenyou put the fuel cap back on, turn it to the right(clockwise) until you hear a clicking sound. Make sure

you fully install the cap. The diagnostic system candetermine if the fuel cap has been left off or improperlyinstalled. This would allow fuel to evaporate into theatmosphere. See Malfunction Indicator Lamponpage 3-3.

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{CAUTION:

If a fire starts while you are refueling, do not

remove the nozzle. Shut off the flow of fuel by

shutting off the pump or by notifying thestation attendant. Leave the area immediately.

Notice: If you need a new fuel cap, be sure to getthe right type. Your dealer can get one for you.If you get the wrong type, it may not fit properly.This may cause your malfunction indicator lamp tolight and may damage your fuel tank and emissionssystem. See Malfunction Indicator Lamp on

page 3-3.

Filling a Portable Fuel Container

{CAUTION:

Never fill a portable fuel container while it is in

your vehicle. Static electricity discharge from

the container can ignite the gasoline vapor.You can be badly burned and your vehicle

damaged if this occurs. To help avoid injury to

you and others:

Dispense gasoline only into approvedcontainers.

Do not fill a container while it is inside a

vehicle, in a vehicles trunk, pickup bed oron any surface other than the ground.

Bring the fill nozzle in contact with theinside of the fill opening before operatingthe nozzle. Contact should be maintaineduntil the filling is complete.

Do not smoke while pumping gasoline.

5-


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Checking Things Under the Hood

Engine Compartment Overview

When you open the hood on the 6.6L DURAMAX Diesel Engine, youll see:

5-14

A E i Ai Cl /Fil I P S i Fl id R i


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A. Engine Air Cleaner/Filter

B. Coolant Surge Tank

C. Battery

D. Engine Air Cleaner/Filter Restriction Indicator

E. Engine Oil Dipstick

F. Automatic Transmission Dipstick (If Equipped)

G. Engine Oil Fill Cap

H. Engine Fan

I. Power Steering Fluid Reservoir

J. Remote Negative () Terminal

K. Remote Positive (+) Terminal

L. Brake Fluid Reservoir

M. Clutch Fluid Reservoir (If Equipped)

N. Underhood Fuse Block

O. Windshield Washer Fluid Reservoir

5-

E i Oil Wh t Add E i Oil


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Engine Oil

Checking Engine Oil

It is a good idea to check your engine oil level everytime you get fuel.

The engine oil dipstick handle is a yellow loop. SeeEngine Compartment Overview on page 5-14 forthe location of the engine oil dipstick.

In order to get an accurate reading, the oil must bewarm (at normal operating temperature) and the vehiclemust be on level ground.

1. Turn off the engine and give the oil at least fiveminutes to drain back into the oil pan. With acool engine, allow 30 minutes. If you do not do this,

the oil dipstick might not show the actual level.2. Pull out the dipstick and clean it with a paper towel

or a cloth, then push it back in all the way. Removeit again, keeping the tip down.

When to Add Engine Oil

If the oil is at or below the cross-hatched area at the tip ofthe dipstick, then you will need to add at least two quartsof oil. But you must use the right kind. This sectionexplains what kind of oil to use. For engine oil crankcasecapacity, see Specification Chartson page 5-36.

Notice: Do not add too much oil. If your engine has

so much oil that the oil level gets above thecross-hatched area that shows the proper operatingrange, your engine could be damaged.

5-16

See Engine Compartment Wh t Ki d f E i Oil t U


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See Engine CompartmentOverview on page 5-14 forthe location of theengine oil fill cap.

Be sure to add enough oil to put the level somewhere inthe proper operating range. Push the dipstick all theway back in when you are through.

What Kind of Engine Oil to Use

Look for these two things:

CI-4 or CH-4

Oils designated as API CI-4 or CH-4 arerecommended for your vehicle. The CI-4 or CH-4

designations may appear either alone, together or combination with other API designations, such asAPI CI-4/SL.

These letters show American PetroleumInstitute (API) levels of quality.

Notice: Use only engine oils that have one of thesdesignations CI-4 or CH-4 for the DURAMAX diesengine. Failure to use the recommended oils canresult in engine damage not covered by your

warranty.

5-

SAE 15W 40


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SAE 15W-40

As shown in the viscosity chart, SAE 15W-40 isbest for your vehicle. However, you can useSAE 10W-30 at temperatures above 0F (18C).When it is very cold, below 0F (18C), you shoulduse SAE 5W-40 to improve cold starting.

These numbers on the oil container show itsviscosity, or thickness. Do not use other viscosityoils such as SAE 10W-40 or SAE 20W-50.

This doughnut-shapedlogo (symbol) is used onmost oil containers tohelp you select the correctoil. It means that the oilhas been certified by

the American PetroleumInstitute.

You should look for this on the oil container, and useonly those oils that display this logo.

GM Goodwrench oil of the recommended viscositygrades meets all the requirements for your vehicle.

5-18

Engine Oil Additives genuine GM parts and reset the system It is also


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Engine Oil Additives

Do not add anything to your oil. The recommended oilswith the API service symbol are all you will need forgood performance and engine protection.

Engine Oil Life System

When to Change Engine Oil

Your vehicle has a computer system that lets you knowwhen to change the engine oil and filter. This isbased on engine timing, engine load, and enginetemperature, and not on mileage. Based on drivingconditions, the mileage at which an engine oil changewill be indicated can vary considerably. For the oillife system to work properly, you must reset the systemevery time the oil is changed.

When the system has calculated that oil life has beendiminished, it will indicate that an oil change isnecessary. A CHANGE ENGINE OIL message willcome on. Change your oil as soon as possible withinthe next 600 miles (1 000 km). It is possible that, if youare driving under the best conditions, the oil lifesystem may not indicate that an oil change is necessaryfor over a year. However, your engine oil and filtermust be changed at least once a year and at this timethe system must be reset. Your dealer has GM-trainedservice people who will perform this work using

genuine GM parts and reset the system. It is alsoimportant to check your oil regularly and keep it at theproper level.

If the system is ever reset accidentally, you mustchange your oil at 3,000 miles (5 000 km) since yourlast oil change. Remember to reset the oil life systemwhenever the oil is changed.

How to Reset the Engine Oil LifeSystem

The Engine Oil Life System calculates when to changeyour engine oil and filter based on vehicle use.Anytime your oil is changed, reset the system so it cancalculate when the next oil change is required. If asituation occurs where you change your oil prior to a

CHANGE ENGINE OIL message being turned on,reset the system.

To reset the Engine Oil Life System, do the following:

1. Turn the ignition key to RUN with the engine off.

2. Fully press and release the accelerator pedal thretimes within five seconds.

If the OIL LIFE RESET message flashes for10 seconds, the system is resetting.

3. Turn the key to LOCK.

5-

If the CHANGE ENGINE OIL message comes back on Engine Air Cleaner/Filter


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If the CHANGE ENGINE OIL message comes back onwhen you start your vehicle, the engine oil life systemhas not reset. Repeat the procedure. If it still doesnot reset, see your dealer for service.

What to Do with Used Oil

Used engine oil contains certain elements that may be

unhealthy for your skin and could even cause cancer.Do not let used oil stay on your skin for very long. Cleanyour skin and nails with soap and water, or a goodhand cleaner. Wash or properly throw away clothing orrags containing used engine oil. See the manufacturerswarning about the use and disposal of oil products.

Used oil can be a threat to the environment. If youchange your own oil, be sure to drain all the oil from thefilter before disposal. Never dispose of oil by putting it

in the trash, pouring it on the ground, into sewers, or intostreams or bodies of water. Instead, recycle it bytaking it to a place that collects used oil. If you have aproblem properly disposing of your used oil, askyour dealer, a service station or a local recycling centerfor help.

Engine Air Cleaner/Filter

The air cleaner/filterassembly may have an aircleaner/filter restrictionindicator that lets you knowwhen the engine aircleaner/filter is dirty andneeds to be serviced.

The air cleaner/filter restriction indicator islocated on the air cleaner cover.

When to Inspect

Inspect the air cleaner/filter every 15,000 miles(25 000 km) and replace the filter if necessary.

How to Inspect

When the restriction indicator turns black, or is inthe red/orange change zone, replace the filter andreset the restriction indicator.

5-20

To inspect and replace the filter and reset the


39/78

To inspect and replace the filter and reset therestriction indicator, do the following:

The air cleaner/filter assembly is located on the frontcorner of the engine compartment on the passengersside of the vehicle.

1. Loosen the screws on the cover of the housing an

lift up the cover.2. Remove the air cleaner/filter from the housing. Ca

should be taken to dislodge as little dirt as possibl

3. Clean the filter sealing surface and the housing.

4. Install the new engine air cleaner/filter.

5. Reinstall the cover and tighten the screws.

6. Reset the air cleaner/filter restriction indicator,

if equipped, by pressing the top button on theindicator.

5-

See Scheduled Maintenance on page 6-4 to determine Automatic Transmission Fluid


40/78

See Scheduled Maintenance on page 6 4 to determinewhen to replace the engine air cleaner/filter.

{CAUTION:

Operating the engine with the air cleaner/filteroff can cause you or others to be burned. The

air cleaner not only cleans the air; it helps to

stop flame if the engine backfires. If it is notthere and the engine backfires, you could be

burned. Do not drive with it off, and be

careful working on the engine with the aircleaner/filter off.

Notice: If the air cleaner/filter is off, a backfire cancause a damaging engine fire. And, dirt caneasily get into your engine, which will damage it.Always have the air cleaner/filter in place when youare driving.

Automatic Transmission Fluid

When to Check and Change

A good time to check your automatic transmission fluidlevel is when the engine oil is changed.

Change both the fluid and filter every 25,000 miles

(41 500 km) if the vehicle is mainly driven under one ormore of these conditions:

In heavy city traffic where the outside temperatureregularly reaches 90F (32C) or higher.

In hilly or mountainous terrain.

When doing frequent trailer towing.

Uses such as found in taxi, police or delivery

service.If you do not use your vehicle under any of theseconditions, change the fluid and filter every50,000 miles (83 000 km).

See Scheduled Maintenance on page 6-4.

5-22

How to Check Checking the Fluid Level


41/78

How to Check

Because this operation can be a little difficult, you maychoose to have this done at the dealership servicedepartment.

If you do it yourself, be sure to follow all the instructionshere, or you could get a false reading on the dipstick.

Notice: Too much or too little fluid can damageyour transmission. Too much can mean that someof the fluid could come out and fall on hot enginepart or exhaust system parts, starting a fire.Too little fluid could cause the transmission tooverheat. Be sure to get an accurate reading if youcheck your transmission fluid.

Wait at least 30 minutes before checking the

transmission fluid level if you have been driving: When outside temperatures are above 90F (32 C).

At high speed for quite a while.

In heavy traffic especially in hot weather.

While pulling a trailer.

Checking the Fluid Level

Prepare your vehicle as follows:

Park your vehicle on a level place. Keep the enginrunning.

With the parking brake applied, place the shift levein PARK (P).

With your foot on the brake pedal, run the enginefor at least one minute and shift to DRIVE (D).Then shift to NEUTRAL (N) and then REVERSE (Rto fill the hydraulic system. Then, put the shiftlever in PARK (P).

Allow the engine to run at idle (500 800 rpm).Slowly release the brake pedal.

Then, without shutting off the engine, follow these step

Cold Check Procedure

The purpose of the cold check is to determine if thetransmission has enough fluid to be operated safely una hot check can be made. The fluid level rises as fluidtemperature increases. DO NOT fill above the COLDCHECK band if the transmission fluid is below normaloperating temperatures.

1. Pull out the dipstick and wipe it with a clean rag opaper towel.

2. Push it back in all the way, wait three seconds anthen pull it back out again.

5-

3. Check the fluid level reading. Repeat the check 4. Safe operating level is within the HOT RUN band


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g pprocedure to verify the reading.

4. If the fluid level is within the COLD CHECK band,the transmission may be operated until the fluid ishot enough to perform a hot check. If the fluidlevel is not within the COLD CHECK band, add ordrain fluid as necessary to bring the level into

the middle of the COLD CHECK band.

5. Perform a hot check at the first opportunity after thenormal operating temperature of 160F (71C) to200F (93C) is reached.

6. If the fluid level is in the acceptable range, push thedipstick back in all the way.

Hot Check Procedure

The fluid must be hot to ensure an accurate check. Thefluid level rises as temperature increases.

1. Operate the transmission in DRIVE (D) until thenormal operating temperature of 160F (71C) to200F (93C) is reached.

2. Pull out the dipstick and wipe it with a clean rag orpaper towel.

3. Push it back in all the way, wait three seconds andthen pull it back out again. Repeat the checkprocedure to verify the reading.

p gon the dipstick. The width of the HOT RUN bandrepresents approximately 1.06 quart (1.0 liter)of fluid at normal operating temperature.

5. If the fluid level is not within the HOT RUN band,add or drain fluid as necessary to bring the fluidlevel to within the HOT RUN band.

6. If the fluid level is in the acceptable range, push thedipstick back in all the way.

Consistency of Readings

Always check the fluid level at least twice using theprocedures described previously. Consistency(repeatable readings) is important to maintaining properfluid level. If inconsistent readings persist, check thetransmission breather to be sure it is clean and

unclogged. If readings are still inconsistent, contactyour dealer.

5-24

How to Add Fluid Engine Coolant


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Refer to the Maintenance Schedule to determine whatkind of transmission fluid to use. See RecommendedFluids and Lubricants on page 6-13.

Add fluid only after checking the transmission fluid whileit is hot. A cold check is used only as a reference.

If the fluid level is low, add only enough of the properfluid to bring the level up to the HOT area for a hotcheck. It doesnt take much fluid, generally less thanone pint (0.5 L). Dont overfill.

Notice: We recommend you use only fluid labeledDEXRON-III, Approved for the H-Specification,because fluid with that label is made especially foryour automatic transmission. Damage causedby fluid other than DEXRON-III, Approved for the

H-Specification, is not covered by your new vehiclewarranty.

After adding fluid, recheck the fluid level asdescribed under How to Check.

When the correct fluid level is obtained, push thedipstick back in all the way.

Engine Coolant

The cooling system in your vehicle is filled withDEX-COOL engine coolant. This coolant is designedto remain in your vehicle for 5 years or 150,000 miles(240 000 km), whichever occurs first, if you addonly DEX-COOL extended life coolant.

The following explains your cooling system and how toadd coolant when it is low. If you have a problemwith engine overheating, see Engine Overheating onpage 5-28.

A 50/50 mixture of clean, drinkable water andDEX-COOL coolant will:

Give freezing protection down to 34F (37C)

Give boiling protection up to 265F (129C)

Protect against rust and corrosion

Help keep the proper engine temperature

Let the warning lights and gages work as they shou

Notice: Using coolant other than DEX-COOL maycause premature engine, heater core or radiatorcorrosion. In addition, the engine coolant mayrequire changing sooner, at 30,000 miles (50 000 km

or 24 months, whichever occurs first. Any repairswould not be covered by your warranty. Always usDEX-COOL (silicate-free) coolant in your vehicle.

5-

What to Use Notice: If you use an improper coolant mixture,i ld h d b b dl d d


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Use a mixture of one-half clean, drinkable water andone-half DEX-COOL coolant which wont damagealuminum parts. If you use this coolant mixture,you dont need to add anything else.

{CAUTION:

Adding only plain water to your coolingsystem can be dangerous. Plain water, or

some other liquid such as alcohol, can boil

before the proper coolant mixture will. Yourvehicles coolant warning system is set for the

proper coolant mixture. With plain water or the

wrong mixture, your engine could get too hotbut you would not get the overheat warning.

Your engine could catch fire and you or others

could be burned. Use a 50/50 mixture of clean,drinkable water and DEX-COOL coolant.

your engine could overheat and be badly damaged.The repair cost would not be covered by yourwarranty. Too much water in the mixture can freezeand crack the engine, radiator, heater core andother parts.

If you have to add coolant more than four times a year,

have your dealer check your cooling system.

Notice: If you use the proper coolant, you do nothave to add extra inhibitors or additives which claimto improve the system. These can be harmful.

5-26

Checking Coolant The vehicle must be on a level surface. When youri i ld th l t l l h ld b t th FULL


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g

The coolant surge tank islocated in the enginecompartment on thepassengers side of thevehicle. See Engine

Compartment Overview onpage 5-14 for moreinformation on its location.

{CAUTION:

Turning the surge tank pressure cap when the

engine and radiator are hot can allow steam

and scalding liquids to blow out and burn youbadly. Never turn the surge tank pressure

cap even a little when the engine and

radiator are hot.

engine is cold, the coolant level should be at the FULLCOLD mark.

If your vehicle is equipped with a low coolant sensor,and the LOW COOLANT LEVEL message comeson and stays on, it means youre low on engine coolan

See DIC Warnings and Messages in the Index ofyour owners manual for more information.

5-

Adding Coolant Coolant Surge Tank Pressure Cap


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If you need more coolant, add the proper DEX-COOL

coolant mixture at the surge tank, but only when theengine is cool. If the surge tank is empty, see EngineOverheating on page 5-28 for the proper fill procedure.

{CAUTION:

You can be burned if you spill coolant on hot

engine parts. Coolant contains ethylene glycol,and it will burn if the engine parts are hot

enough. Do not spill coolant on a hot engine.

When replacing the pressure cap, make sure it ishand-tight.

g p

The surge tank pressurecap must be tightlyinstalled.

Notice: If the pressure cap is not tightly installed,coolant loss and possible engine damage may

occur. Be sure the cap is properly and tightlysecured.

Engine Overheating

You will find a coolant temperature gage on theinstrument cluster. In addition, the Driver InformationCenter (DIC) has the following warnings that mayappear: LOW COOLANT LEVEL and ENGINEOVERHEATED. See your owners manual for moreinformation.

5-28

If Steam Is Coming From Your Engine If No Steam Is Coming From Your


47/78

{CAUTION:

Steam from an overheated engine can burn

you badly, even if you just open the hood. Stayaway from the engine if you see or hear steam

coming from it. Just turn it off and geteveryone away from the vehicle until it cools

down. Wait until there is no sign of steam or

coolant before you open the hood.

If you keep driving when your engine isoverheated, the liquids in it can catch fire. You

or others could be badly burned. Stop yourengine if it overheats, and get out of thevehicle until the engine is cool.

Notice: If your engine catches fire because youkeep driving with no coolant, your vehicle canbe badly damaged. The costly repairs would not becovered by your warranty.

Engine

An overheat warning, along with a low coolant conditionor LOW COOLANT LEVEL message, if equipped, canindicate a serious problem. For more information, seeDriver Information Center (DIC) in your owners manua

If you get an engine overheat warning and dont have alow coolant condition, or LOW COOLANT LEVELmessage, if equipped, but see or hear no steam, theproblem may not be too serious. Sometimes the engincan get a little too hot when you:

Climb a long hill on a hot day.

Stop after high-speed driving.

Idle for long periods in traffic.

Tow a trailer. See Driving on Grades in theowners manual index.

5-

If you get the overheat warning with no sign of steam,try this for a minute or so:

Cooling System


48/78

try this for a minute or so:

1. In heavy traffic, let the engine idle in NEUTRAL (N)while stopped. If it is safe to do so, pull off the road,shift to PARK or NEUTRAL (N), and let theengine idle.

2. If your air conditioner is on, turn it off.

3. Turn on your heater to full hot at the highest fanspeed and open the window as necessary.

If you no longer have the overheat warning, you candrive. Just to be safe, drive slower for about 10 minutes.If the warning doesnt come back on, you can drivenormally.

If the warning continues, pull over, stop, and park yourvehicle right away.

If theres still no sign of steam and your vehicle isequipped with an engine driven cooling fan, push downthe accelerator until the engine speed is about twiceas fast as normal idle speed for at least three minuteswhile youre parked. If there is no sign of steam andyour vehicle is equipped with an electric cooling fan, idlethe engine for three minutes while youre parked. Ifyou still have the warning, turn off the engine and geteveryone out of the vehicle until it cools down.

You may decide not to lift the hood but to get servicehelp right away.

When you decide its safe to lift the hood, heres whatyoull see:

A. Coolant Surge Tank

B. Coolant Surge Tank Pressure Cap

C. Engine Fan

If the coolant inside the coolant surge tank is boiling,dont do anything else until it cools down. The vehicleshould be parked on a level surface.

5-30

The coolant level shouldbe at or above the FULL

If there seems to be no leak, start the engine again.If your vehicle is equipped with an engine driven coolin


49/78

be at or above the FULLCOLD mark. If it isnt,you may have a leak at thepressure cap or in theradiator hoses, heaterhoses, radiator, water

pump or somewhere elsein the cooling system.

{CAUTION:

Heater and radiator hoses, and other engineparts, can be very hot. Do not touch them. If

you do, you can be burned.

Do not run the engine if there is a leak. If you

run the engine, it could lose all coolant. Thatcould cause an engine fire, and you could be

burned. Get any leak fixed before you drive the

vehicle.

If your vehicle is equipped with an engine driven coolinfan, the engine cooling fan speed should increasewhen idle speed is doubled by pushing the acceleratorpedal down. If it doesnt, your vehicle needs service.Turn off the engine.

Notice: Engine damage from running your engine

without coolant is not covered by your warranty.

Notice: Using coolant other than DEX-COOL maycause premature engine, heater core or radiatorcorrosion. In addition, the engine coolant mayrequire changing sooner, at 30,000 miles (50 000 kmor 24 months, whichever occurs first. Any repairswould not be covered by your warranty. Always usDEX-COOL (silicate-free) coolant in your vehicle.

5-

How to Add Coolant to the CoolantS T k

If no coolant is visible in the surge tank, add coolant asfollows:


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Surge Tank

Notice: The diesel engine has a specific coolant fillprocedure. Failure to follow this procedure couldcause your engine to overheat and be severelydamaged.

If you havent found a problem yet, check to see ifcoolant is visible in the surge tank. If coolant is visiblebut the coolant level isnt at or above the FULLCOLD mark, add a 50/50 mixture of clean, drinkablewater and DEX-COOL coolant at the coolantsurge tank, but be sure the cooling system, includingthe coolant surge tank pressure cap, is cool before youdo it. See Engine Coolant on page 5-25 for moreinformation.

follows:

{CAUTION:

Steam and scalding liquids from a hot coolingsystem can blow out and burn you badly. They

are under pressure, and if you turn the coolant

surge tank pressure cap even a little theycan come out at high speed. Never turn the

cap when the cooling system, including the

coolant surge tank pressure cap, is hot. Waitfor the cooling system and coolant surge tank

pressure cap to cool if you ever have to turn

the pressure cap.

5-32

{CAUTION {CAUTION


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{CAUTION:

Adding only plain water to your cooling

system can be dangerous. Plain water, or

some other liquid such as alcohol, can boil

before the proper coolant mixture will. Yourvehicles coolant warning system is set for the

proper coolant mixture. With plain water or thewrong mixture, your engine could get too hot

but you would not get the overheat warning.

Your engine could catch fire and you or otherscould be burned. Use a 50/50 mixture of clean,

drinkable water and DEX-COOL coolant.

Notice: In cold weather, water can freeze and crackthe engine, radiator, heater core and other parts.Use the recommended coolant and the propercoolant mixture.

{CAUTION:

You can be burned if you spill coolant on hot

engine parts. Coolant contains ethylene glycol

and it will burn if the engine parts are hot

enough. Do not spill coolant on a hot engine.

Park the vehicle on a levesurface. You can removethe coolant surge tankpressure cap whenthe cooling system,including the coolant surg

tank pressure cap andupper radiator hose, is nolonger hot.

1. Turn the pressure cap slowly counterclockwise (leftuntil it first stops. Dont press down while turning thepressure cap. If you hear a hiss, wait for that to stop

A hiss means there is still some pressure left.2. Then keep turning the cap, but now push down as

you turn it. Remove the pressure cap.

5-


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3. After the engine cools, open the air bleed valve onthe thermostat housing.

Fill with the proper mixture. Add coolant until yousee a steady stream of coolant coming fromthe bleed valve.

4. Close the bleed valve.

5. Rinse or wipe the spilled coolant from the engineand compartment.

6. Then fill the coolant surge tank with the propermixture, to slightly above the fill mark.

5-34

7. With the coolant surge tank pressure cap off, startthe engine and let it run until you can feel the upp


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g y ppradiator hose getting hot. Watch out for theengine cooling fan.

By this time, the coolant level inside the coolantsurge tank may be lower. If the level is lower, addmore of the proper mixture to the coolant surge tan

until the level reaches the FULL COLD mark.8. Then replace the pressure cap.

5-

Capacities and Specifications


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Engine Specification

Engine VIN Code Type

6.6L V8 Turbo Diesel 2 V8

Capacities

Application

Capacities

English Metric

Cooling SystemAutomatic Transmission

Manual Transmission

24.0 quarts

24.0 quarts

23.0 L

23.0 L

Engine Oil With Filter6.6L V8

10.0 quarts 9.5 L

All quantities are approximate. When adding, be sure to fill to the appropriate level, as recommended in thismanual. Recheck fluid level after filling. See Recommended Fluids and Lubricants on page 6-13 for moreinformation.

5-36

Section 6 Maintenance Schedule


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Maintenance Schedule ......................................6-2Introduction ...... ...... ...... ...... ..... ...... ...... ...... ....6-2Maintenance Requirements ..............................6-2Your Vehicle and the Environment ....................6-2

Using Your Maintenance Schedule ....................6-2Scheduled Maintenance ...................................6-4Additional Required Services ............................6-6Maintenance Footnotes ...... ...... ...... ...... ...... .....6-8

Owner Checks and Services ...... ...... ...... ..... ...6-At Each Fuel Fill ...... ...... ...... ..... ...... ...... ...... .6-At Least Once a Month .................................6-1At Least Once a Year ...................................6-1

Recommended Fluids and Lubricants . ... ... ... ... ..6-Normal Maintenance Replacement Parts .. .. .. .. ..6-Maintenance Record ...... ...... ...... ..... ...... ...... ..6-

6

Maintenance Schedule Your Vehicle and the EnvironmentP hi l i t t l h l t k


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Introduction

Important: Keep engine oil at the proper level andchange as recommended.

Have you purchased the GM Protection Plan? The Plan

supplements your new vehicle warranties. See yourWarranty and Owner Assistance booklet or your dealerfor details.

Maintenance Requirements

Notice: Maintenance intervals, checks, inspections,replacement parts and recommended fluids andlubricants as prescribed in this manual arenecessary to keep your vehicle in good workingcondition. Any damage caused by failure to followscheduled maintenance may not be covered bywarranty.

Proper vehicle maintenance not only helps to keep yourvehicle in good working condition, but also helps theenvironment. All recommended maintenance isimportant. Improper vehicle maintenance can evenaffect the quality of the air we breathe. Improper fluidlevels or the wrong tire inflation can increase the level ofemissions from your vehicle. To help protect ourenvironment, and to keep your vehicle in good condition,be sure to maintain your vehicle properly.

Using Your Maintenance Schedule

We at General Motors want to help you keep yourvehicle in good working condition. But we do not knowexactly how you will drive it. You may drive very

short distances only a few times a week. Or you maydrive long distances all the time in very hot, dustyweather. You may use your vehicle in making deliveries.Or you may drive it to work, to do errands or in manyother ways.

Because of all the different ways people use theirvehicles, maintenance needs vary. You may need morefrequent checks and replacements. So please readthe following and note how you drive. If you have any

questions on how to keep your vehicle in good condition,see your GM Goodwrench dealer.

6-2

This schedule is for vehicles that:

carry passengers and cargo within recommended {CAUTION:


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y p g glimits. You will find these limits on the tire andloading information label. See Loading YourVehicle in your owner manual.

are driven on reasonable road surfaces within legaldriving limits.

are driven off-road in the recommended manner.See Off-Road Driving or Off-Road Driving withYour Four-Wheel-Drive Vehicle in your ownermanual.

use the recommended fuel. See Diesel Engine Fuelon page 5-2.

The services in Scheduled Maintenance on page 6-4should be performed when indicated. See AdditionalRequired Services on page 6-6 and MaintenanceFootnotes on page 6-8 for further information.

{CAUTION:

Performing maintenance work on a vehicle can

be dangerous. In trying to do some jobs, you

can be seriously injured. Do your own

maintenance work only if you have therequired know-how and the proper tools and

equipment for the job. If you have any doubt,see your GM Goodwrench dealer to have a

qualified technician do the work.

Some maintenance services can be complex. So,unless you are technically qualified and have the

necessary equipment, you should have your GMGoodwrench dealer do these jobs.

When you go to your GM Goodwrench dealer for youservice needs, you will know that GM-trained andsupported service technicians will perform the workusing genuine GM parts.

If you want to purchase service information, seeService Publications Ordering Information in yourowner manual.

6

Owner Checks and Services on page 6-10 tells youwhat should be checked, when to check it and what youcan easily do to help keep your vehicle in good

If the engine oil life system is ever reset accidentally,you must service your vehicle within 3,000 miles(5 000 km) since your last service Remember to reset


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can easily do to help keep your vehicle in goodcondition.

The proper replacement parts, fluids and lubricants touse are listed in Recommended Fluids and Lubricantson page 6-13 and Normal Maintenance Replacement

Parts on page 6-16. When your vehicle is serviced,make sure these are used. All parts should be replacedand all necessary repairs done before you or anyoneelse drives the vehicle. We recommend the use ofgenuine GM parts.

Scheduled Maintenance

When the CHANGE ENGINE OIL message comes on, it

means that service is required for your vehicle. Haveyour vehicle serviced as soon as possible within the next600 miles (1 000 km). It is possible that, if you aredriving under the best conditions, the engine oillife system may not indicate that vehicle service isnecessary for over a year. However, your engine oil andfilter must be changed at least once a year and atthis time the system must be reset. Your GMGoodwrench dealer has GM-trained service technicianswho will perform this work using genuine GM parts

and reset the system.

(5 000 km) since your last service. Remember to resetthe oil life system whenever the oil is changed. SeeEngine Oil Life System on page 5-19 for information onthe Engine Oil Life System and resetting the system.

When the CHANGE ENGINE OIL message appears,

certain services, checks and inspections are required.Required services are described in the following forMaintenance I and Maintenance II. Generally,it is recommended that your first service beMaintenance I, your second service be Maintenance IIand that you alternate Maintenance I and Maintenance IIthereafter. However, in some cases, Maintenance IImay be required more often.

Maintenance I Use Maintenance I if the CHANGE

ENGINE OIL message comes on within 10 months sincethe vehicle was purchased or Maintenance II wasperformed.

Maintenance II Use Maintenance II if the previousservice performed was Maintenance I. Always useMaintenance II whenever the message comes on10 months or more since the last service or if themessage has not come on at all for one year.

6-4

Scheduled Maintenance

Service Maintenance I Maintenance


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Change engine oil and filter. See Engine Oil on page 5-16. Reset oil lifesystem. See Engine Oil Life System on page 5-19. An Emission ControlService.

Allison transmission only: Replace external control-main filter only at the first

maintenance service performed on the vehicle.Lubricate chassis components. See footnote #.

Visually check for any leaks or damage. See footnote (j).

Inspect engine air cleaner filter change indicator. If necessary, replace filter.See Engine Air Cleaner/Filter on page 5-20. An Emission Control Service.See footnotes and (n).

Rotate tires and check inflation pressures and wear. See Tires in yourowners manual.

Inspect brake system. See footnote (a).

Check engine coolant and windshield washer fluid levels and add fluid asneeded.

Perform any needed additional services. See Additional Required Services inthis section.

Inspect suspension and steering components. See footnote (b).

Inspect engine cooling system. See footnote (c).

Inspect wiper blades. See footnote (d).

Inspect restraint system components. See footnote (e).

6

Scheduled Maintenance (contd)

Service Maintenance I Maintenance II


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Lubricate body components. See footnote (f).

Check transmission fluid level and add fluid as needed.

Replace fuel filter. An Emission Control Service. See footnote .

Inspect shields and underhood insulation. See footnote (h).

Check air intake system. See footnote (k).

Additional Required Services

The following services should be performed at the first maintenance service (I or II) after the indicatedmiles (kilometers) shown for each item.

Additional Required Services

Service and Miles (Kilometers)25,000

(41 500)50,000

(83 000)75,000

(125 000)100,000

(166 000)125,000

(207 500)150,000

(240 000)

Inspect fuel system for damageor leaks.

Inspect exhaust system for looseor damaged components.

6-speed manual transmissiononly: Change clutch fluid. Seefootnote (l).

6-6

Additional Required Services (contd)

S i d Mil (Kil )25,000

(41 500)50,000

(83 000)75,000

(125 000)100,000

(166 000)125,000

(207 500)150,000

(240 000)


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Service and Miles (Kilometers) (41 500) (83 000) (125 000) (166 000) (207 500) (240 000)

Change automatic transmissionfluid and filter (severe service). Seefootnote (m).

Change automatic transmissionfluid and filter (normal service).

Four-wheel drive with automatictransfer case only: Change transfercase fluid. See footnote (g).

Engine cooling system service (orevery 5 years, whichever occursfirst). An Emission Control Service.See footnote (i).

Inspect engine accessory drive belt.An Emission Control Service.

5-speed manual transmission only:Change manual transmission fluid.

6

Maintenance Footnotes

The U.S. Environmental Protection Agency or the

(c) Visually inspect hoses and have them replaced if theyare cracked, swollen or deteriorated. Inspect all pipes,fittings and clamps; replace with genuine GM parts as


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The U.S. Environmental Protection Agency or theCalifornia Air Resources Board has determined that thefailure to perform this maintenance item will not nullifythe emission warranty or limit recall liability prior tothe completion of the vehicles useful life. We, however,urge that all recommended maintenance services beperformed at the indicated intervals and themaintenance be recorded.

# Lubricate the front suspension, ball joints, steeringlinkage, transmission shift linkage and parkingbrake cable guides. Ball joints should not be lubricatedunless their temperature is 10F (-12C) or higher,or they could be damaged. Vehicles used under severecommercial operating conditions require lubricationon a regular basis every 3,000 miles (5 000 km).

(a) Visually inspect brake lines and hoses for properhook-up, binding, leaks, cracks, chafing, etc. Inspectdisc brake pads for wear and rotors for surfacecondition. Inspect other brake parts, including calipers,parking brake, etc.

(b) Visually inspect front and rear suspension andsteering system for damaged, loose or missing parts,signs of wear or lack of lubrication. Inspect power

steering lines and hoses for proper hook-up, binding,leaks, cracks, chafing, etc. Visually check constantvelocity joints, rubber boots and axle seals for leaks.

fittings and clamps; replace with genuine GM parts asneeded. To help ensure proper operation, a pressure testof the cooling system and pressure cap and cleaning theoutside of the radiator and air conditioning condenser isrecommended at least once a year.

(d) Visually inspect wiper blades for wear or cracking.Replace blade inserts that appear worn or damagedor that streak or miss areas of the windshield.

(e) Make sure the safety belt reminder light and all yourbelts, buckles, latch plates, retractors and anchoragesare working properly. Look for any other loose ordamaged safety belt system parts. If you see anythingthat might keep a safety belt system from doing its

job, have it repaired. Have any torn or frayed safety belts

replaced. Also look for any opened or broken airbagcoverings, and have them repaired or replaced.(The airbag system does not need regular maintenance.)

(f) Lubricate all key lock cylinders, body door hinges,hood latch assembly, secondary latch, pivots, springanchor, release pawl, tailgate hinges, tailgate linkage,tailgate handle pivot points, latch bolt, fuel doorhinge, locks and folding seat hardware. More frequentlubrication may be required when exposed to a corrosive

environment. Applying silicone grease on weatherstripswith a clean cloth will make them last longer, sealbetter and not stick or squeak.

6-8

(g) Check vent hose at transfer case for kinks andproper installation.

(h) Inspect shields and underhood insulation for damage

(l) Change clutch fluid (or every 24 months, whicheveroccurs first).

(m) Change automatic transmission fluid and filter if th


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(h) Inspect shields and underhood insulation for damageor looseness. Adjust or replace as required. This is aNoise Emission Control Service. Applicable only tovehicles sold in the United States.

(i) Drain, flush and refill cooling system. This service

can be complex; you should have your dealer performthis service. See Engine Coolant on page 5-25 forwhat to use. Inspect hoses. Clean radiator, condenser,pressure cap and filler neck. Pressure test the coolingsystem and pressure cap.

(j) A fluid loss in any vehicle system could indicate aproblem. Have the system inspected and repaired andthe fluid level checked. Add fluid if needed.

(k) Check the air intake system installation to assurethat gaskets are properly sealed and that all hoseconnections, fasteners and other components are tight.Also check to be sure that the air cleaner housing isproperly seated and the cover fits tightly. Tightenconnections and fasteners or replace damaged parts asnecessary. This is a Noise Emission Control Service.Applicable only to vehicles sold in the United States.

(m) Change automatic transmission fluid and filter if thvehicle is mainly driven under one or more of theseconditions:

In heavy city traffic where the outside temperaturregularly reaches 90F (32C) or higher.

In hilly or mountainous terrain.

When doing frequent trailer towing.

Uses such as found in taxi, police or deliveryservice.

(n) If you drive regularly under dusty conditions, inspecthe filter change indicator at each engine oil change.

6

Owner Checks and Services

These owner checks and services should be performed

Engine Coolant Level Check

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