duramax diesel manual - chevrolet

2k15_misc_duramax_diesel_22948873A.ai

(Modern Bridge - Level 2 / #23321109)

Spine = Saddle Stitch

(Image set @ 60% Transparency

Color = Black

Date = 11/06/13

2015

22948873 A

Duramax Diesel

Black plate (1,1)Chevrolet/GMC Duramax Diesel Supplement (GMNA Localizing-U.S./Canada-7132827) - 2015 - crc - 6/5/14

2015 Chevrolet/GMC Duramax Diesel Supplement M

In Brief . . . . . . . . . . . . . . . . . . . . . . . . 1-1Initial Drive Information . . . . . . . . 1-1Performance andMaintenance . . . . . . . . . . . . . . . . . 1-2

Instruments and Controls . . . . 5-1Warning Lights, Gauges, andIndicators . . . . . . . . . . . . . . . . . . . . 5-2

Information Displays . . . . . . . . . . 5-11Vehicle Messages . . . . . . . . . . . . 5-12Vehicle Personalization . . . . . . . 5-16

Driving and Operating . . . . . . . . 9-1Starting and Operating . . . . . . . . . 9-1Diesel Particulate Filter . . . . . . . 9-11Diesel Exhaust Fluid . . . . . . . . . 9-13Brakes . . . . . . . . . . . . . . . . . . . . . . . 9-20Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21Towing . . . . . . . . . . . . . . . . . . . . . . . 9-38Conversions and Add-Ons . . . 9-43

Vehicle Care . . . . . . . . . . . . . . . . . 10-1General Information . . . . . . . . . . 10-1Vehicle Checks . . . . . . . . . . . . . . . 10-3

Service and Maintenance . . . 11-1General Information . . . . . . . . . . 11-1Maintenance Schedule . . . . . . . 11-3Special ApplicationServices . . . . . . . . . . . . . . . . . . . . 11-7

Recommended Fluids . . . . . . . . 11-8Maintenance Records . . . . . . . 11-12

Technical Data . . . . . . . . . . . . . . . 12-1Vehicle Data . . . . . . . . . . . . . . . . . . 12-2

Index . . . . . . . . . . . . . . . . . . . . . i-1


ii Introduction

The names, logos, emblems,slogans, vehicle model names, andvehicle body designs appearing inthis manual including, but not limitedto, GM, the GM logo, CHEVROLET,GMC, the CHEVROLET and GMCTruck Emblems, SILVERADO,SIERRA, DENALI, EXPRESS,SAVANA, and Duramax aretrademarks and/or service marks ofGeneral Motors LLC, itssubsidiaries, affiliates, or licensors.

For vehicles first sold in Canada,substitute the name “GeneralMotors of Canada Limited” for GMCand Chevrolet Motor Divisionwherever it appears in this manual.

This manual describes features thatmay or may not be on the vehiclebecause of optional equipment thatwas not purchased on the vehicle,

model variants, countryspecifications, features/applicationsthat may not be available in yourregion, or changes subsequent tothe printing of this owner manual.

Refer to the purchasedocumentation relating to yourspecific vehicle to confirm thefeatures.

This manual contains informationthat pertains to the operation of yourdiesel engine. It also contains yourDiesel Maintenance Schedule. Thesections in this manual correspondto the sections in your ownermanual. This manual, along withyour owner manual, will assist youin the proper use and maintenanceof your vehicle.

Keep this manual in the vehicle forquick reference.

Canadian Vehicle Owners

Propriétaires Canadiens

A French language manual can beobtained from your dealer, atwww.helminc.com, or from:

On peut obtenir un exemplaire dece guide en français auprès duconcessionnaire ou à l'adressesavant:

Helm, IncorporatedAttention: Customer Service47911 Halyard DrivePlymouth, MI 48170

Using this SupplementThis supplement containsinformation specific to the uniquecomponents of the vehicle. It doesnot explain everything you need toknow about the vehicle. Read thissupplement along with the ownermanual to learn about the vehicle'sfeatures and controls.

Litho in U.S.A.Part No. 22948873 B-2 Second Printing ©2014 General Motors LLC. All Rights Reserved.


Introduction iii

Index

A good place to look for what youneed is the Index in back of thissupplement. It is an alphabetical listof what is in the supplement, andthe page number where you willfind it.


iv Introduction

2 NOTES


In Brief 1-1

In Brief

Initial Drive InformationTransmission . . . . . . . . . . . . . . . . . . 1-1

Performance and MaintenanceEngine Oil Life System . . . . . . . . 1-2Diesel Particulate Filter . . . . . . . 1-2Diesel Exhaust Fluid . . . . . . . . . . 1-3

Initial DriveInformation

TransmissionCold Operation

When temperatures are very cold,the transmission will prevent certainoperations to protect againstdamage. The information belowshows shift range availability basedon transmission oil temperature:. All shift ranges available

at −25°C (−13°F) or above.. 2 (Second) and 3 (Third) shift

ranges only at −35°C (−31°F) to−25°C (−13°F).

. 2 (Second) shift range only at−35°C (−31°F) or lower.

Torque converter clutch operationwill also be prevented when air ortransmission oil temperatures arebelow certain levels.

For areas where ambienttemperatures are below −40°C(−40°F), use synthetic transmissionfluid approved to AllisonTransmission® specificationTES-295. See RecommendedFluids and Lubricants on page 11-8and Automatic Transmission Fluidon page 10-9.

Adaptive Shift Controls

The shift quality of a new vehiclemay not be ideal because theAdaptive Shift Control process maynot have determined the bestsettings for a particular shift orcondition. Shift quality will improvewith continued driving.

Low Traction Mode

Low Traction Mode aids in vehicleacceleration on slippery roadsurfaces such as ice or snow. Byselecting 2 (Second) using RangeSelection Mode while at a stop, thetransmission will limit torque to thedrive wheels to prevent slippage.


1-2 In Brief

Heater Performance Mode

When cold weather conditions aredetected, the transmission raisespart throttle upshift points after the1 (First) to 2 (Second) upshift toincrease engine speed. This featureshortens engine and cab warm uptimes.

When the transmission is in thismode, upshifts may be delayed.This is normal and does not indicatean operational problem.

Four-Wheel Drive

When operating in 4 ↓(Four-Wheel-Drive Low), there is avery deep gear reduction. Theresulting shifts will feel exaggerated.

Performance andMaintenance

Engine Oil Life SystemThe engine oil life system calculatesengine oil life based on vehicle useand displays the CHANGE ENGINEOIL SOON message when it is timeto change the engine oil and filter.The oil life system should be resetto 100% only following an oilchange. See “Engine Oil LifeSystem” in the owner manual.

Diesel Particulate FilterThe Duramax engine is equippedwith a Diesel Particulate Filter (DPF)that, by design, will filter or trapparticulates. The DPF is locatedunder the vehicle in the exhaustsystem.

Depending on a number of factorsmonitored by the engine computer,the DPF will need to be cleaned ofaccumulated solids. When acleaning is needed, the engine

computer will initiate a cleaningaction by warming the exhaust gastemperature. This feature has beendesigned to operate automatically,with limited operator involvement orawareness.

Cleaning the DPF (ExhaustFilter)

While the DPF cleaning isautomatically controlled by theengine computer, the vehicle willneed to operate continuously untilthe CLEANING EXHAUST FILTERKEEP DRIVING UNTIL MESSAGEIS CLEARED message is no longerdisplayed. Cleaning occurs mosteffectively above 48 km/h (30 mph).If the vehicle is returned to idleduring the cleaning process, thedriver may notice a slightly differentsound or a slightly elevated engineidle speed. This is normal. No actionis required on the part of the driverduring a regular DPF cleaning. SeeDiesel Particulate Filter onpage 9-11.


In Brief 1-3

Special DPF Driver Messages

If the vehicle is used for numerousshort trips or extended slow-speedoperation, the engine computer maynot be able to adequately heat upthe exhaust system to clean theDPF effectively. The enginecomputer has been designed tocontinuously monitor the conditionof the DPF. When the enginecomputer detects that the DPF isnearly full of particulates and thatthe vehicle is not being operated ina manner that would allow effectiveautomatic DPF cleaning, the DriverInformation Center will display themessage CLEANING EXHAUSTFILTER KEEP DRIVING UNTILMESSAGE IS CLEARED.

If the vehicle continues to be drivenin a manner that prevents effectiveDPF cleaning, the DPF will becomeplugged with particulates. If thisoccurs, the engine computer willturn on the service engine soon lightin the instrument cluster and theDIC will display the messageENGINE POWER IS REDUCED.

See Diesel Particulate Filter onpage 9-11 and Engine PowerMessages on page 5-13.

Fuel

Use Ultra Low Sulfur DieselFuel (ULSD)

Use ULSD only. The emissioncontrol hardware used on thevehicle may be damaged by usingfuel with high sulfur levels. Use onlyfuel that is dispensed from pumpsbearing the ULSD label.

Do Not Use Low Sulfur DieselFuel (LSD)

Do not use fuel that is dispensedfrom pumps bearing the LSD label.

Do Not Use Non-Highway Fuel

Fuel labeled as off road ornon-highway is typically very high insulfur content and will damage theemission control system.Non-highway fuel is not intended foruse in on-highway vehicles and

does not have the fuel propertiesneeded by the DPF-equippedDuramax diesel.

In addition:. Use the correct engine oil.. Do not add gasoline to

diesel fuel.. Do not modify the induction or

exhaust systems.

See Fuel for Diesel Engines onpage 9-21 and Engine Oil onpage 10-6.

Diesel Exhaust FluidDiesel Exhaust Fluid (DEF) is usedwith diesel engines to reduce theamount of regulated emissionsproduced. The DEF system must bemaintained for the vehicle to runproperly.


1-4 In Brief

Locating Diesel Exhaust Fluid

DEF can be purchased at aChevrolet or GMC dealer. It canalso be purchased at authorizedvehicle and truck dealerships.Additionally, some diesel truckfueling stations or retailers mayhave DEF for purchase. Forvehicles with an active OnStar®

subscription, OnStar can help tolocate a DEF retailer. See“Customer Assistance Offices” inthe owner manual for phonenumbers to assist you in contactinga GM dealer. See RecommendedFluids and Lubricants on page 11-8.

As the DEF tank becomes low onfluid, warnings begin withapproximately 1600 km (1,000 mi) ofremaining range. These warningswill increase in intensity as the tankbecomes empty. Once the tank isempty, the vehicle speed will belimited. If there is an issue with thequality of the fluid or the exhaustfluid system, warnings will bedisplayed in the Driver InformationCenter (DIC). See Diesel ExhaustFluid on page 9-13.


Instruments and Controls 5-1

Instruments andControls

Warning Lights, Gauges, andIndicatorsInstrument Cluster . . . . . . . . . . . . 5-2Fuel Gauge . . . . . . . . . . . . . . . . . . . 5-6Engine Oil Pressure Gauge . . . 5-7Malfunction Indicator Lamp . . . 5-8Wait-to-Start Light . . . . . . . . . . . 5-10Diesel Exhaust Fluid (DEF)Warning Light . . . . . . . . . . . . . . 5-11

Power Take-Off Light . . . . . . . . 5-11

Information DisplaysDriver InformationCenter (DIC) . . . . . . . . . . . . . . . . 5-11

Vehicle MessagesVehicle Messages . . . . . . . . . . . 5-12Engine Cooling SystemMessages . . . . . . . . . . . . . . . . . . 5-12

Engine Oil Messages . . . . . . . . 5-13Engine Power Messages . . . . 5-13Fuel System Messages . . . . . . 5-13Diesel Exhaust FluidMessages . . . . . . . . . . . . . . . . . . 5-13

Diesel Particulate FilterMessages . . . . . . . . . . . . . . . . . . 5-14

Service Vehicle Messages . . . 5-14Starting the VehicleMessages . . . . . . . . . . . . . . . . . . 5-14

Vehicle Speed Messages . . . . 5-15

Vehicle PersonalizationVehicle Personalization (TruckModels) . . . . . . . . . . . . . . . . . . . . 5-16

Vehicle Personalization (VanModels) . . . . . . . . . . . . . . . . . . . . 5-18


5-2 Instruments and Controls

Warning Lights, Gauges, and Indicators

Instrument Cluster

English Base Level Pickup Shown, Metric Similar



English Uplevel Pickup Shown, Metric Similar



English Denali Pickup Shown, Metric Similar



English Van Shown, Metric Similar



See the owner manual for warninglights and gauges not listed in thissupplement.

Fuel Gauge

Metric Pickup Models

English Pickup Models

Metric Van Models

English Van Models

When the ignition is on, the fuelgauge shows approximately howmuch fuel the vehicle has left in thetank. The gauge will first indicateE (Empty) before the vehicle is outof fuel, but the vehicle's fuel tankshould be filled soon.

An arrow on the fuel gaugeindicates the side of the vehicle thefuel door is on.



Listed are four situations customersmay experience with the fuel gauge:. At the gas station, the fuel pump

shuts off before the gauge readsF (Full).

. It takes a little more or less fuelto fill up than the fuel gaugeindicated. For example, thegauge may have indicated thetank was half full, but it actuallytook a little more or less thanhalf the tank's capacity to fillthe tank.

. The gauge moves a little whileturning a corner or speeding up.

. The gauge does not go back toE (Empty) when the ignition isturned off.

None of these indicate a problemwith the fuel gauge.

For information on how to fill the fueltank, see Filling the Tank onpage 9-36.

Engine Oil PressureGauge

Metric Pickup Models

English Pickup Models

Metric Van Models



English Van Models

{ Caution

Lack of proper engine oilmaintenance can damage theengine. Driving with the engineoil low can also damage theengine. The repairs would not becovered by the vehicle warranty.Check the oil level as soon aspossible. Add oil if required, but ifthe oil level is within the operatingrange and the oil pressure is still

(Continued)

Caution (Continued)

low, have the vehicle serviced.Always follow the maintenanceschedule for changing engine oil.

The engine oil pressure gaugereads in kPa (kilopascals) or psi(pounds per square inch) when theengine is running. Oil pressure mayvary with engine speed, outsidetemperature, and oil viscosity.

If readings are outside the normaloperating range, the low oilpressure message may display onthe Driver Information Center (DIC),or for vehicles without DIC the oilpressure light will come on. If the oilpressure message or light comeson, check the oil level immediately.Do not operate the engine with theoil pressure warning light on or anENGINE OIL LOW ADD OILmessage displayed.

MalfunctionIndicator LampA computer system called OBD II(On-Board Diagnostics-SecondGeneration) monitors the operationof the vehicle to ensure emissionsare at acceptable levels, helping tomaintain a clean environment. Themalfunction indicator lamp comeson when the vehicle is placed inON/RUN as a check to show it isworking. If it does not, have thevehicle serviced by your dealer. See“Ignition Positions” in the ownermanual.

If the malfunction indicator lampcomes on while the engine isrunning, this indicates that there isan OBD II problem and diagnosisand service might be required.



This light may also come on whenthe Diesel Exhaust Fluid (DEF)management system is not working.See Diesel Exhaust Fluid onpage 9-13.

Malfunctions often are indicated bythe system before any problem isapparent. Being aware of the lightcan prevent more serious damageto the vehicle. This system alsoassists the service technician incorrectly diagnosing anymalfunction.

{ Caution

If the vehicle is continually drivenwith this light on, the emissioncontrols might not work as well,the vehicle fuel economy mightnot be as good, and the enginemight not run as smoothly. Thiscould lead to costly repairs thatmight not be covered by thevehicle warranty.

{ Caution

Modifications made to the engine,transmission, exhaust, intake,or fuel system of the vehicle orthe replacement of the originaltires with other than those of thesame Tire Performance Criteria(TPC) can affect the vehicle'semission controls and can causethis light to come on.Modifications to these systemscould lead to costly repairs notcovered by the vehicle warranty.This could also result in a failureto pass a required EmissionInspection/Maintenance test. SeeAccessories and Modifications onpage 10-1.

When the light is on, an emissioncontrol system malfunction hasbeen detected on the vehicle.Diagnosis and service might berequired.

An emission system malfunctionmight be corrected by using goodquality fuel. Poor fuel quality causesthe engine not to run as efficientlyas designed and may cause: stallingafter start-up, stalling when thevehicle is changed into gear,misfiring, hesitation on acceleration,or stumbling on acceleration. Theseconditions might go away once theengine is warmed up. See Fuel forDiesel Engines on page 9-21.

If this does not make the light turnoff, your dealer can check thevehicle. The dealer has the propertest equipment and diagnostic toolsto fix any mechanical or electricalproblems that might havedeveloped.

Emissions Inspection andMaintenance Programs

Depending on where you live, yourvehicle may be required toparticipate in an emission controlsystem inspection and maintenanceprogram. For the inspection, the



emission system test equipment willlikely connect to the vehicle's DataLink Connector (DLC).

The DLC is under the instrumentpanel to the left of the steeringwheel. See your dealer if assistanceis needed.

The vehicle may not passinspection if:. The malfunction indicator lamp is

on with the engine running, or ifthe light does not come on whenthe ignition is turned to ON/RUNwhile the engine is off. See yourdealer for assistance in verifyingproper operation of themalfunction indicator lamp.

. The OBD II (On-BoardDiagnostics) system determinesthat critical emission controlsystems have not beencompletely diagnosed. Thevehicle would be considered notready for inspection. This canhappen if the 12-volt battery hasrecently been replaced or rundown. The diagnostic system isdesigned to evaluate criticalemission control systems duringnormal driving. This can takeseveral days of routine driving.If this has been done and thevehicle still does not pass theinspection for lack of OBD IIsystem readiness, your dealercan prepare the vehicle forinspection.

Wait-to-Start Light

If the wait-to-start light comes on,the glow plug system is requiredand operating. Wait until the lightturns off before starting the engine.This light may not come on in warmtemperatures.

The fast warm-up glow plug systemmakes the wait-to-start light stay onfor a shorter amount of time thanmost diesel engines.

See Starting the Diesel Engine onpage 9-1.



Diesel Exhaust Fluid(DEF) Warning Light

This light, a Driver InformationCenter (DIC) message, and a chimecome on when there is an issue withthe Diesel Exhaust Fluid.

See Diesel Exhaust Fluid Messageson page 5-13 for information on thespecific message displaying with thelight.

If the DEF fluid level has not beencorrected, the light will continue toflash when the vehicle is started.The vehicle's speed may also belimited.

Also see Diesel Exhaust Fluid onpage 9-13.

Power Take-Off Light

Non-Denali Pickups

The vehicle may have a PowerTake-Off (PTO) light. Under normaloperating conditions, the PTO lightwill remain on throughout the PTOoperating cycle. If all conditionsrequired to engage PTO have notbeen met when enabling PTO, thePTO light will turn on, then turn offafter one second. See PowerTake-Off (PTO) on page 9-43.

Information Displays

Driver InformationCenter (DIC)The DIC is in the instrument cluster.The DIC comes on when the ignitionis on.

A Duramax diesel vehicle may havethe following additional DIC menuitems.

EXHAUST FLUID LEVEL

The EXHAUST FLUID LEVEL willbe displayed as either OK, XX%,or LOW.

When LOW appears on the display,add diesel exhaust fluid as soon aspossible. See Diesel Exhaust Fluidon page 9-13.



FUEL FILTER LIFE REMAINING

This display shows an estimate ofthe fuel filter's remaining useful life.If you see 90% FUEL FILTER LIFEREMAINING on the display, itmeans 90% of the current fuel filterlife remains. The fuel filter lifesystem will alert you to change thefuel filter on a schedule consistentwith your driving conditions.

When the remaining fuel filter life islow, the CHANGE FUEL FILTERmessage will appear on the display.Change the fuel filter as soon aspossible.

FUEL FILTER LIFE RESET

You must reset the FUEL FILTERLIFE REMAINING display after eachfuel filter change. It will not resetitself. Also, be careful not to resetthe FUEL FILTER LIFE REMAININGdisplay at any time other than whenthe fuel filter has just been changedbecause it cannot be resetaccurately until the next fuel filterchange. The fuel filter life willchange to 100% when the systemhas been reset. To reset the system,press and hold the set/reset button,or the trip odometer reset stem ifthere are no DIC buttons, fortwo seconds while FUEL FILTERLIFE REMAINING is displayed onthe DIC.

Vehicle MessagesThe Driver Information Center (DIC)will display warning messages if aproblem is detected. Pressing theselect button or the set/reset buttonfor vehicles with DIC buttons, or thetrip odometer reset stem for vehicleswithout DIC buttons, willacknowledge some current warningor service messages. Othermessages are more urgent andcannot be cleared from the displayuntil the issue is corrected.

The following are some additionalmessages that the Duramax dieselvehicle can display.

Engine Cooling SystemMessages

COOLANT LEVEL LOW ADDCOOLANT

This message will appear on theDIC if the engine coolant level islow. Adding coolant to the coolantrecovery tank will clear the



message. For pickups only,remember to check the coolant inboth sides of the reservoir. See“Engine Coolant” in the ownermanual.

Engine Oil Messages

ENGINE OIL LOW ADD OIL

This message only displays whenthe ignition key is turned to ON/RUNand the oil level in the vehicle is low.Check the oil level and correct it asnecessary. You may need to let thevehicle cool or warm up and cyclethe ignition to be sure this messageclears.

This message clears itself after10 seconds, until the next ignitioncycle. See Engine Oil on page 10-6.

Engine Power Messages

ENGINE POWER IS REDUCED

A computer monitors the operationof the engine. If the ENGINEPOWER IS REDUCED messagecomes on while driving, there will be

a reduction in performance andacceleration. You should take thevehicle in for service.

Fuel System Messages

CHANGE FUEL FILTER

This message will appear on theDIC for 10 seconds when a fuel filterchange is required. See Fuel FilterReplacement on page 9-33.

WATER IN FUEL SERVICEREQUIRED

This message will come on to warnyou if there is water in the dieselfuel system. For more informationon how this message works, seeWater in Fuel on page 9-28.

Diesel Exhaust FluidMessagesFor more information on thesemessages, see “Exhaust Fluid Low”or “Exhaust Fluid Quality Poor” inDiesel Exhaust Fluid on page 9-13.

EXHAUST FLUID RANGE:XXXX KM (MI)

When the exhaust fluid is gettinglow, the range will be displayed ineither kilometers or miles. It isnormal for the EXHAUST FLUIDRANGE to vary based on vehicleand environmental drivingconditions. When this message firstdisplays at approximately 1 600 km(1,000 mi) of fluid range remaining,the fluid is approximately 11 L(3 gal) low.

EXHAUST FLUID LOW SPEEDLIMITED SOON

When the exhaust fluid range is lessthan 120 km (75 mi) this messagewill be displayed.

EXHAUST FLUID EMPTYREFILL NOW

This message will be displayedwhen the exhaust fluid is empty.This message may be accompaniedby other messages that providemore information.



EXHAUST FLUID QUALITYPOOR SEE OWNERSMANUAL NOW

This message displays when theexhaust fluid is of poor quality or thewrong fluid was added. Thismessage may be accompanied byother messages that provide moreinformation.

Diesel Particulate FilterMessages

CLEANING EXHAUST FILTERCONTINUE DRIVING (UplevelCluster) or DIESEL PARTICFILTER IS FULL CONTINUEDRIVING (Base Level Cluster)

This message will appear on theDIC when an exhaust particulatefilter cleaning is required. To cleanthe filter, drive the vehicle above50 km/h (30 mph) until the warningmessage goes off. This will takeabout 30 minutes.

If the filter is not cleaned, themalfunction indicator lamp will comeon and the ENGINE POWER ISREDUCED message will bedisplayed. Vehicle performance willbe limited. See Diesel ParticulateFilter on page 9-11.

Service Vehicle Messages

SERVICE EXHAUST FLUIDSYSTEM SEE OWNERSMANUAL NOW

This message displays when theexhaust fluid system needs service.This message may be accompaniedby other messages that providemore information. See “ServiceExhaust Fluid System” in DieselExhaust Fluid on page 9-13.

SERVICE EMISSION SYSTEMSEE OWNERS MANUAL NOW

This message displays when theemission system needs service.Take the vehicle to your dealer. See“Service Emission System” in DieselExhaust Fluid on page 9-13.

Starting the VehicleMessages

ELEVATED IDLE OFF

This message will appear when theelevated idle/exhaust restrictorfeature has been turned off. See“Elevated Idle” under Starting theDiesel Engine on page 9-1.

ELEVATED IDLE ON

This message will appear when theelevated idle/exhaust restrictorfeature has been turned on. See“Elevated Idle” under Starting theDiesel Engine on page 9-1.

FAST IDLE ON (Van Models)

If your vehicle has this feature, thismessage displays when the fast idlefeature is on. See “Fast Idle Control”under Starting the Diesel Engine onpage 9-1.



Vehicle Speed MessagesFor more information on thesemessages, see Diesel Exhaust Fluidon page 9-13.

XXX KM (MI) UNTIL 105 KM/H(65MPH) MAX SPEED

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR, SERVICEEMISSION SYSTEM, or SERVICEEXHAUST FLUID SYSTEM. Thevehicle speed will be limited to105 km/h (65 mph) when thecountdown is over.

XXX KM (MI) UNTIL 88 KM/H(55MPH) MAX SPEED

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR, SERVICEEMISSION SYSTEM, or SERVICEEXHAUST FLUID SYSTEM. The

vehicle speed will be limited to88 km/h (55 mph) when thecountdown is over.

XXX KM (MI) UNTIL 7 KM/H(4 MPH) MAX SPEED

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR,or SERVICE EXHAUST FLUIDSYSTEM. The vehicle speed will belimited to 7 km/h (4 mph) when thecountdown is over.

SPEED LIMITED TO 105 KM/H(65MPH)

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR, SERVICEEMISSION SYSTEM, or SERVICEEXHAUST FLUID SYSTEM. Whenthis message is displayed, thevehicle speed is being limited to105 km/h (65 mph).

SPEED LIMITED TO 88 KM/H(55MPH)

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR, SERVICEEMISSION SYSTEM, or SERVICEEXHAUST FLUID SYSTEM. Whenthis message is displayed, thevehicle speed is being limited to88 km/h (55 mph).

SPEED LIMITED TO7KM/H (4 MPH)

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR,or SERVICE EXHAUST FLUIDSYSTEM. When this message isdisplayed, the vehicle speed isbeing limited to 7 km/h (4 mph).



TRANSITIONING TO XXKM/H(XXMPH) MAX SPEED

This message will be displayedalong with other messages. Thesemessages include EXHAUST FLUIDEMPTY REFILL NOW, EXHAUSTFLUID QUALITY POOR, SERVICEEMISSION SYSTEM, or SERVICEEXHAUST FLUID SYSTEM. Whenthis message is displayed, the endof the countdown has been reachedand the vehicle speed is beinglimited.

VehiclePersonalization

Vehicle Personalization(Truck Models)Use the audio system controls toaccess the personalization menusfor customizing vehicle features.

The following features may beavailable on some vehicles with adiesel engine. See “VehiclePersonalization” in the ownermanual for additional vehiclepersonalizations.

System Controls

1. Turn the ignition to ON/RUNwithout the engine running andplace the vehicle in P (Park).

To avoid excessive drain on thebattery, turn the headlamps off.

2. Press the MENU knob on theradio.

3. Turn the MENU knob to scroll toSETTINGS, then press theMENU knob.

4. Turn the MENU knob to scroll toVehicle, then press theMENU knob.

5. Turn the MENU knob to scroll tothe desired menu, then pressthe MENU knob.

Vehicle

Select and the following maydisplay:. Climate and Air Quality. Power Take-Off (PTO)

Climate and Air Quality

Select and the following maydisplay:. Elevated Idle (If Equipped)

Elevated Idle (If Equipped)

This allows the feature to be turnedon and off. See “Elevated Idle” inStarting the Diesel Engine onpage 9-1.



Select Off, or On.

Power Take-Off (PTO)

There may be additional featuresthat can be customized for thePower Take-Off (PTO). See PowerTake-Off (PTO) on page 9-43. Seeyour dealer to enable thesefeatures.

Feature Settings Menu Items

Press the MENU knob to select thedesired setting.. Standby Speed. Set 1 Speed. Set 2 Speed. Tap Step Speed. Shutdown Time

Turn the MENU knob to scroll toone of the following menuselections:

PTO STANDBY SPEED

This feature allows for modifying thePTO Standby Speed.

Turn the MENU knob to the desiredsetting. Press the MENU knob toselect the desired setting.

PTO SET 1 SPEED

This feature is available if thevehicle is configured for StationaryPreset PTO, and allows theselection of the PTO 1 set speed.

Turn the MENU knob to the desiredPTO Standby Set 1 setting. Pressthe MENU knob to select thedesired setting.

PTO SET 2 SPEED

This feature is available if thevehicle is configured for StationaryPreset PTO, and allows theselection of the PTO 2 set speed.

Turn the MENU knob to the desiredPTO Standby Set 2 setting. Pressthe MENU knob to select thedesired setting.

PTO TAP STEP SPEED

This feature is available if thevehicle is configured for StationaryVariable or Mobile PTO, and allowsthe selection of the PTO tap stepspeed.

Turn the MENU knob to the desiredPTO Tap Step Speed setting. Pressthe MENU knob to select thedesired setting.

PTO SHUTDOWN TIME

This feature is available if thevehicle is configured for StationaryPreset or Stationary Variable PTO,and allows the selection of the PTOshutdown time.

Turn the MENU knob to the desiredPTO Shutdown Time setting. Pressthe MENU knob to select thedesired setting.



Vehicle Personalization(Van Models)Your Duramax diesel vehicle mayhave additional customizablefeatures for Power Take-Off (PTO).See Power Take-Off (PTO) onpage 9-43. These features mayneed to be enabled by your dealer.

Entering the FeatureSettings Menu

1. Turn the ignition to ON/RUNwithout the engine running andplace the vehicle in P (Park).

To avoid excessive drain on thebattery, it is recommended thatthe headlamps are turned off.

2. Press the customization DICbutton on the instrument panelto scroll through the availablecustomizable options.

Feature Settings Menu Items

PTO STANDBY SPEED

This feature allows you to select thePTO standby speed.

Press the customization button untilthe PTO STANDBY SPEED screenappears on the DIC display. Pressthe set/reset button once to accessthe settings for this feature. Thenpress the customization button toscroll through the following choices:. 800 RPM. 900 RPM. 1000 RPM. 1100 RPM. 1200 RPM. 1300 RPM. 1400 RPM. 1500 RPM. NO CHANGE

To select a setting, press the set/reset button while the desiredsetting is displayed on the DIC.

PTO SET 1 SPEED

This feature, available if the vehicleis configured for Stationary PresetPTO, allows you to select the PTO 1set speed.

Press the customization button untilthe PTO SET 1 SPEED screenappears on the DIC display. Pressthe set/reset button once to accessthe settings for this feature. Thenpress the customization button toscroll through the following choices:. 1000 RPM. 1200 RPM. 1400 RPM. 1600 RPM. 1800 RPM. 2000 RPM. 2200 RPM. 2400 RPM. NO CHANGE




PTO SET 2 SPEED

This feature, available if the vehicleis configured for Stationary PresetPTO, allows you to select the PTO 2set speed.

Press the customization button untilthe PTO SET 2 SPEED screenappears on the DIC display. Pressthe set/reset button once to accessthe settings for this feature. Thenpress the customization button toscroll through the following choices:. 1800 RPM. 2000 RPM. 2200 RPM. 2400 RPM. 2600 RPM. 2800 RPM. 3000 RPM

. 3200 RPM

. NO CHANGE


PTO TAP STEP

This feature, available if the vehicleis configured for Stationary Variableor Mobile PTO, allows you to selectthe PTO tap step.

Press the customization button untilthe PTO TAP STEP screen appearson the DIC display. Press the set/reset button once to access thesettings for this feature. Then pressthe customization button to scrollthrough the following choices:. 25 RPM. 75 RPM. 100 RPM. 150 RPM. 200 RPM

. 250 RPM

. 350 RPM

. NO CHANGE


PTO SHUTDOWN TIME

This feature, available if the vehicleis configured for Stationary Presetor Stationary Variable PTO, allowsyou to select the PTOshutdown time.

Press the customization button untilthe PTO SHUTDOWN TIME screenappears on the DIC display. Pressthe set/reset button once to accessthe settings for this feature. Thenpress the customization button toscroll through the following choices:. OFF. 20 MINUTES. 35 MINUTES. 50 MINUTES



. 65 MINUTES

. 80 MINUTES

. 95 MINUTES

. 110 MINUTES

. NO CHANGE


Black plate (1,1)Chevrolet/GMC Duramax Diesel Supplement (GMNA Localizing-U.S./Canada-7132827) - 2015 - CRC - 6/5/14

Driving and Operating 9-1

Driving andOperating

Starting and OperatingStarting the Diesel Engine . . . . 9-1Winter Cover . . . . . . . . . . . . . . . . . . 9-5Engine Heater . . . . . . . . . . . . . . . . . 9-9Fuel OperatedHeater (FOH) . . . . . . . . . . . . . . . 9-10

Parking over ThingsThat Burn . . . . . . . . . . . . . . . . . . 9-11

Diesel Particulate FilterDiesel Particulate Filter . . . . . . 9-11

Diesel Exhaust FluidDiesel Exhaust Fluid . . . . . . . . . 9-13

BrakesExhaust Brake . . . . . . . . . . . . . . . 9-20

FuelFuel for Diesel Engines . . . . . . 9-21What Fuel to Use inThe U.S. . . . . . . . . . . . . . . . . . . . 9-21

What Fuel to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . 9-26

Cold Weather Operation . . . . . 9-27Water in Fuel . . . . . . . . . . . . . . . . 9-28Running Out of Fuel . . . . . . . . . 9-32Fuel Filter Replacement . . . . . 9-33Filling the Tank . . . . . . . . . . . . . . 9-36Filling a Portable FuelContainer . . . . . . . . . . . . . . . . . . . 9-37

TowingTrailer Towing . . . . . . . . . . . . . . . . 9-38

Conversions and Add-OnsPower Take-Off (PTO) . . . . . . . 9-43

Starting andOperating

Starting the DieselEngineThe diesel engine starts differentlythan a gasoline engine.

{ Caution

If the steering wheel is turneduntil it reaches the end of itstravel, and is held in that positionwhile starting the vehicle, damagemay occur to the hydraulic powersteering system and there may beloss of power steering assist.

Move the shift lever to P (Park) orN (Neutral). To restart the enginewhen the vehicle is already moving,use N (Neutral) only.


9-2 Driving and Operating

{ Caution

Do not try to shift to P (Park) if thevehicle is moving. If you do, youcould damage the transmission.Shift to P (Park) only when thevehicle is stopped.

Starting the Engine

1. Turn the ignition key to ON/RUN.

Observe the WAIT-TO-STARTlight. See Wait-to-Start Light onpage 5-10. This light may notcome on if the engine is warm.

2. If the WAIT-TO-START light isilluminated, wait until this lightgoes off to. Then turn theignition key to START. When theengine starts, let go of the key.

The engine has a fast warm-upglow plug system. Thewait-to-start light will illuminatefor a much shorter time than

most diesel engines, due to therapid heating of the glow plugsystem.

{ Caution

If the wait-to-start light stays onafter starting the vehicle, thevehicle may not run properly.Have the vehicle servicedright away.

3. If the engine does not start after15 seconds of cranking, turn theignition switch to LOCK/OFF.Wait one minute for the crankingmotor to cool, then try the samesteps again.

If you are trying to start the engineafter you have run out of fuel, followthe steps in Running Out of Fuel onpage 9-32.

When the engine is cold, let it runfor a few minutes before driving.This lets oil pressure build up. Theengine will sound louder when itis cold.

Cold Weather Starting (DieselEngine)

Use the recommended engine oilwhen the outside temperature dropsbelow freezing. See Engine Oil onpage 10-6. When the outsidetemperature drops below –18°C(0° F), use of the engine coolantheater is recommended.

If you experience longer crankingtimes, notice an unusual amount ofexhaust smoke, or are at higherelevations (over 2 135 m or 7,000 ft),you may use the engine coolantheater. See Engine Heater onpage 9-9.

See Fuel for Diesel Engines onpage 9-21 for information on whatfuel to use in cold weather.



If the Diesel Engine Will NotStart

If you have run out of fuel, seeRunning Out of Fuel on page 9-32.

If the vehicle is not out of fuel, andthe engine will not start:

Turn the ignition key to ON/RUN.After the WAIT-TO-START lightgoes off, turn the ignition key toSTART.

If the light does not go off, wait afew seconds, then try starting theengine again. See your dealer assoon as you can for a startingsystem check.

If the light comes on and then goesoff and you know the batteries arecharged, but the engine still will notstart, the vehicle needs service.

If the light does not come on whenthe engine is cold, the vehicleneeds service.

If the batteries do not have enoughcharge to start the engine, see“Battery” in the owner manual.

Check that the correct engine oilhas been used and changed atappropriate intervals. If the wrong oilis used, the engine may be harderto start.

Be sure you are using the properfuel for existing weather conditions.See Fuel for Diesel Engines onpage 9-21.

If the engine starts, runs a shorttime, then stops, the vehicle needsservice.

{ Warning

Do not use gasoline or startingaids, such as ether, in the airintake. They could damage theengine, which may not becovered by the vehicle warranty.They could also cause a fire,which could cause seriouspersonal injury.

Engine Idle Variations

Under certain conditions the engineidle speed can vary or be elevated.Change in idle speed is normal anddoes not indicate a problem. Normalconditions that can raise idle speedare low voltage, DPF regeneration,air conditioning compressor loads,and engine warmup. These speedscan range from approximately 600to 1000 rpm.

Elevated Idle

The engine has a cold temperaturehigh idle feature which elevates theengine idle speed from base idle to1050 rpm for pickup models or1200 rpm for van models whenoutside temperatures are below0°C (32°F), and the engine coolanttemperature is below 65°C (150°F).This feature enhances heaterperformance by raising the enginecoolant temperature faster. For truckmodels, there may be two methodsof activating the elevated idle.



To turn this feature on or off:

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

2. Press the accelerator pedal tothe floor and hold while quicklypressing the brake pedal threetimes in less than eight seconds.

3. Release the accelerator pedaland start the engine.

If this method is not available, seethe alternate method under TruckModels in Vehicle Personalization(Truck Models) on page 5-16 orVehicle Personalization (VanModels) on page 5-18.

On van models, this feature canalso be turned on and off using theDIC buttons.

When the engine is started, it willslowly ramp up to the high idlespeed after a delay of a fewseconds up to approximatelytwo minutes. For this method towork properly there must be nothrottle or brake pedal faults.

The engine idle speed will return tonormal once the following conditionsare met:. Engine coolant temperature

reaches 65°C (150°F).. Air intake temperature reaches

0°C (32°F).

The high idle speed will betemporarily interrupted and theengine speed will return to normal ifany of the following conditionsoccur:. The brake pedal is applied.. The accelerator pedal is

pressed.. The transmission is shifted out

of P (Park) or N (Neutral).. Vehicle speed is detected.

Once these inputs are removed, theengine idle speed will slowly rampback up to high idle after the normaldelay, if the conditions for enginecoolant temperature and air intaketemperature are still met.

Fast Idle Control

The vehicle may have this systemwhich can be used to increase theengine idle speed.

Fast Idle control will be enabledwhen the following conditionsare met:. The parking brake is set.. The transmission is in P (Park)

or N (Neutral).. The vehicle speed is about

0 km/h (0 mph).. The cruise control Set switch is

pressed and released for PresetFast Idle Speed (1200 rpm).

Fast Idle control will be disabledwhen one or more of the followingconditions occur:. The cruise control Set switch is

pressed and released. See“Cruise Control” in the ownermanual.

. The cruise control Cancel switchis pressed.



. The brake pedal is pressed.

. The transmission is shifted outof P (Park) or N (Neutral).

. The parking brake is released.

. The vehicle speed is not0 km/h (0 mph).

On vans, when fast idle is active, aFAST IDLE ON message will bedisplayed in the DIC. See Startingthe Vehicle Messages onpage 5-14.

Winter CoverIf equipped, the winter cover can beused to enhance heaterperformance in extremely coldconditions below −18°C (0°F). Thewinter cover installs over the grilleand restricts airflow to the enginecompartment.

For vehicles that did not come witha winter cover, a GM winter covercan be purchased. See your dealerfor additional information.

When the winter cover is in use, theHeater, Ventilation, and AirConditioning AUTO mode may notfunction properly. Use the manualsettings for comfort.

Usage Guidelines

The winter cover should only beused while operating the vehicle inextremely cold temperatures or inheavy snow for extended periods. Inthese temperatures, the vehicledoes not need a large amount of airto properly cool the engine. Whenmore airflow is required to cool thevehicle, the winter cover should notbe used. The following usageguidelines will allow adequateairflow for proper radiator and aircooler performance:. Do not use the winter cover if

towing a trailer. The vehicle mayoverheat if the radiator iscovered while towing.

. Do not use the winter cover if asnow plow is mounted on thetruck.

. Do not cover the opening in thefront bumper.

. Do not modify the cover. Thewinter cover does not coversome sections of the front of thevehicle to provide enoughairflow.

. When the winter cover is used,the outside air temperaturedisplay may not functionproperly.



. Keep the underside of the wintercover as clean as possible.Remove monthly or asnecessary and clean away dustand debris.

. Use only a mild soap to clean.Do not use harsh soap, strongdetergents, or vinyl protectant/sealant type products as theymay damage the special finish.Allow the winter cover to drycompletely before reinstalling.

Installation Instructions

When first trying to fit the cover, itmay appear to be undersized butwill stretch during installation toensure a tight fit. The initialinstallation of the cover is bestperformed when the winter coveris warm.

Installation (Chevrolet Pickup)

1. The white label must be at thetop and back of the cover.



2. Starting in the middle, attachfastening points as illustrated.

3. To remove, reverse the stepslisted previously.

Installation (GMC Pickup)

1. The white label must be at thetop and back of the cover.



2. Starting in the middle, attachfastening points as illustrated.

3. To remove, reverse the stepslisted previously.

Installation (Van Models)

1. Open the hood and secure itwith the prop rod.



2. Hook the five J-clips to thebottom edge of the grille.

3. Hook the top center J-clip by thehood latch.

4. Attach the metal hooks, oneeach at the top corners.

5. To remove the winter cover,reverse the steps listedpreviously.

Engine HeaterThe engine coolant heater canprovide easier starting and betterfuel economy during enginewarm-up in cold weather conditionsat or below −18°C (0°F). The enginecoolant heater should be plugged inat least four hours before starting.

To Use the Engine Heater

1. Turn off the engine.

2. Open the hood and unwrap theelectrical cord. The cord islocated in the enginecompartment, on the passengerside of the vehicle, near thebattery.

3. Plug it into a normal, grounded110-volt AC outlet.



{ Warning

Plugging the cord into anungrounded outlet could cause anelectrical shock. Also, the wrongkind of extension cord couldoverheat and cause a fire. Youcould be seriously injured. Plugthe cord into a properly groundedthree-prong 110-volt AC outlet.If the cord will not reach, use aheavy-duty three-prong extensioncord rated for at least 15 amps.

4. Before starting the engine, besure to unplug and store thecord as it was before to keep itaway from moving engine parts,and prevent damage.

The length of time the heater shouldremain plugged in depends on theoutside temperature. You may wishto use the coolant heater to improveease of starting at temperaturesbetween −18°C (0°F) and −29°C(−20°F). Keep the coolant heaterplugged in for a minimum of four

hours. At temperatures below −29°C(−20°F), the coolant heater shouldremain plugged in for at least eighthours. It will not harm either thecoolant heater or the vehicle toleave the coolant heater plugged inlonger than the times stated. Besure to store the cord before startingthe engine. See Fuel for DieselEngines on page 9-21 forinformation on what fuel to use incold weather.

Fuel OperatedHeater (FOH)

If the vehicle includes an FOH, it willenhance heater performance andwill reduce the amount of time it

takes to warm the inside of thevehicle in cold conditions below orequal to 4°C (39°F). The FOH isinstalled on the frame rail on thedriver side of the vehicle and usesdiesel fuel to heat the enginecoolant, which warms up thepassenger cabin air.

The FOH will turn on if all of thefollowing conditions exist:. Outside air temperature is below

or equal to 4°C (39°F).. Fuel level is greater or equal to

12.5% of the total fuel tankvolume.

. The engine is running.

. Coolant temperature is less than75°C (167°F).



Parking over ThingsThat Burn

{ Warning

Things that can burn could touchhot exhaust parts under thevehicle and ignite. Do not parkover papers, leaves, dry grass,or other things that can burn.

Diesel ParticulateFilterThe vehicle has a Diesel ParticulateFilter (DPF) as part of the exhaustsystem to reduce vehicle emissions.The DPF requires a unique exhausttailpipe with an exhaust cooler. Theexhaust cooler mixes air with theexhaust to lower the temperaturebefore it leaves the tailpipe.

The DPF, the tailpipe, or otherexhaust system components mustnot be altered. Inspect regularly andclean any mud or dirt from theexhaust cooler, especially where theexhaust cooler connects to thetailpipe and the openings wherefresh air enters the cooler.

The DPF will clean itself as part ofnormal operation. Several factorsincluding fuel consumed, hours ofengine operation and miles drivenare monitored by the Engine ControlModule (ECM). The self-cleaningoccurs approximately once per tankof fuel.

{ Caution

Permanent damage can occur tothe DPF or related components ifthe required Ultra Low SulfurDiesel (15 ppm sulfur maximum)or low ash CJ-4 engine oil is notused. This damage would not becovered by the vehicle warranty.

Under certain driving conditions,such as stop-and-go traffic, the filtercannot clean itself. The CLEANINGEXHAUST FILTER KEEP DRIVINGUNTIL MESSAGE IS CLEAREDmessage comes on when the DPFis dirty and needs to perform a selfcleaning.

For the filter to clean itself, thevehicle must be driven above50 km/h (30 mph) until theCLEANING EXHAUST FILTERKEEP DRIVING UNTIL MESSAGEIS CLEARED message goes off.This will take about 30 minutes.



{ Warning

During DPF self cleaning orduring extended idling in P (Park),the exhaust system and exhaustgases are very hot. Things thatburn could touch hot exhaustparts under the vehicle and ignite.You or others could be burned.Do not park, or idle for anextended period of time, near orover papers, leaves, dry grass,or other things that can burn.Keep the exhaust area clear ofmaterial that could ignite or burn.See Parking over Things ThatBurn on page 9-11 for moreinformation.

{ Caution

Extended idle should be avoidedbecause the DPF system is notcapable of self cleaning at idle.

(Continued)

Caution (Continued)

During extended idle operation,monitor the instrument paneltelltale lights and DriverInformation Center for messagesand take appropriate indicatedaction. Continued idling with thewarning light/message on couldcause irreversible damage to theDPF requiring repair and possiblereplacement that might not becovered by the vehicle warranty.

You will also notice a change in theexhaust sound and engine idlespeed. This is normal. See VehicleMessages on page 5-12.

If you continue to drive with theDPF warning message on and theexhaust filter is not cleaned asrequired, the malfunction indicatorlamp and the ENGINE POWER ISREDUCED message will come onand dealer service is necessary.

See Malfunction Indicator Lamp onpage 5-8 and Engine PowerMessages on page 5-13.

Vehicles with DPF have specific fueland engine oil requirements. SeeWhat Fuel to Use in The U.S. onpage 9-21 or What Fuel to Use inCanada and Mexico on page 9-26and Engine Oil on page 10-6 formore information on thoserequirements.

Extended idling in P (Park) cancause exhaust parts and gases tobecome very hot. Keep the exhaustarea clear of material that couldignite or burn. See Parking overThings That Burn on page 9-11.

For vehicles with Power Take-Off(PTO), monitor the instrument panelcluster for lights related to the DPF.

See Accessories and Modificationson page 10-1 for importantinformation if you are consideringadding accessories or modifyingthe vehicle.



Diesel Exhaust Fluid

{ Warning

Diesel Exhaust Fluid (DEF) iscorrosive. Do not allow it to comein contact with your skin, eyes,or the finished surfaces of thevehicle. If exposed, it may causeskin and eye irritation. Wear skinand eye protection whenhandling. Inhalation may causeirritation to the upper respiratorytract. Store in a cool,well-ventilated area. For moresafety information, see the labelof the Diesel Exhaust Fluidcontainer.

DEF is used with diesel engines toreduce the amount of regulatedemissions produced. The fluid levelin the DEF tank must be maintainedfor the vehicle to run correctly.The capacity of the DEF tank is20.1 L (5.3 gal).

Locating Diesel Exhaust Fluid

DEF can be purchased at aChevrolet or GMC dealer. It canalso be purchased at authorizedvehicle and truck dealerships.Additionally, some diesel truckfueling stations or retailers mayhave DEF for purchase. Forvehicles with an active OnStarsubscription, OnStar can help tolocate a DEF retailer. See“Customer Assistance Offices” inthe owner manual for phonenumbers to assist in contacting aGM dealer. See RecommendedFluids and Lubricants on page 11-8.

Filling the DEF Tank

{ Caution

Use only exhaust fluid that is GMapproved, or fluid containing theAPI certified or ISO 22241 label.The use of other fluids coulddamage the system, requiringcostly repairs that will not becovered by the vehicle warranty.

When adding DEF to an empty orvery low tank, always add at least7.6 L (2 gal) of fluid to release thevehicle from speed limitation.

Do not overfill the DEF tank. Whenfluid reaches the top of the fill pipe,stop filling. Do not top off the DEFtank. When the EXHAUST FLUIDRANGE XXXX KM (MI) message inthe Driver Information Center (DIC)displays at approximately 1600 km(1,000 mi) of fluid range remaining,about 11 L (3 gal) of DEF havebeen used.

If you spill DEF on the vehicle whilefilling the tank, rinse the area withwater and wipe the surface with adamp cloth.



DEF Fill - Vans

For vans, the DEF fill is behind thefuel fill door. The DEF cap is blue,and the diesel cap is green.

The fill tube location for chassis-caband cutaway vans finished by anupfitter will vary. Check the upfittermanual.

DEF Fill - Pickups

For full-size pickups, the DEF fill isunder the hood, on the passengerside, at the back of the enginecompartment. The DEF cap is blue.

Exhaust Fluid Low

A full DEF tank will last for severalthousand kilometers (miles),depending on vehicle usage. As theexhaust fluid level drops, warningswill automatically be displayed in theDIC. Exhaust fluid level status isavailable on the DIC under thevehicle Information button.

See “Exhaust Fluid Level” in DriverInformation Center (DIC) onpage 5-11.

To avoid vehicle speed limitations,the DEF tank should be refilled atthe first opportunity after a lowwarning indication. If DEF is addedbefore the EXHAUST FLUIDEMPTY REFILL NOW messageappears, it may take several km/mifor the DIC message to update.

If the vehicle speed has beenlimited and DEF has been added, itmay take up to 30 seconds afterengine start with the vehiclestopped for the EXHAUST FLUIDEMPTY REFILL NOW message toclear. If the vehicle is driven prior tothe DIC message clearing, thevehicle speed will still be limited.If the DIC message clears whiledriving, the speed limitation will beremoved gradually.



If DEF is added under freezingconditions, additional time may berequired to remove speed limitationsand may require less fluid to fill theDEF tank.

The following actions describestrategies required by the U.S.Environmental Protection Agency(EPA) and the California AirResource Board (CARB). The DEFmessages relate to these strategies.

The DIC message EXHAUSTFLUID RANGE: XXXX KM (MI)displays at approximately 1600 km(1,000 mi) of fluid range remaining.This message appears again atapproximately 500 km (300mi) ofremaining range before the exhaustfluid tank becomes empty.

Below 500 km (300 mi) of rangeremaining, these messages willappear every time the vehicle isstarted.

If these warnings are ignored andthe DEF tank becomes empty, theDIC message displays:. EXHAUST FLUID EMPTY

REFILL NOW - 644 KM (400 MI)UNTIL 105 KM/H (65 MPH) MAXSPEED.

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, EXHAUST FLUIDEMPTY REFILL NOW - 998 KM(620 MI) UNTIL 105 KM/H(65 MPH) MAX SPEED.

The displayed mileage will decreaseas driving continues. A warning lightalso comes on.

When the mileage countdown iszero, the DIC message EXHAUSTFLUID EMPTY REFILL NOW -TRANSITIONING TO 105 KM/H(65 MPH) MAX SPEED displays.A warning light and a chime alsocome on. Vehicle speed will bereduced to a maximum speed limitof 105 km/h (65 mph).

After the transition to 105 km/h(65 mph) is complete, the DICmessage displays:. EXHAUST FLUID EMPTY

REFILL NOW - SPEED LIMITEDTO 105 KM/H (65 MPH) –120 KM (75 MI) UNTIL 89 KM/H(55 MPH) MAX SPEED.

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, EXHAUST FLUIDEMPTY REFILL NOW - SPEEDLIMITED TO 105 KM/H(65 MPH) – 933 KM (580 MI)UNTIL 89 KM/H (55 MPH) MAXSPEED.

The displayed mileage will decreaseas driving continues. A warning lightand a chime also come on.

When the mileage countdown iszero, the DIC message EXHAUSTFLUID EMPTY REFILL NOW -TRANSITIONING TO 89 KM/H(55 MPH) MAX SPEED displays.



A flashing warning light and a chimealso come on. Vehicle speed will bereduced to a maximum speed limitof 89 km/h (55 mph).

After the transition to 89 km/h(55 mph) is complete, the DICmessage EXHAUST FLUID EMPTYREFILL NOW - SPEED LIMITEDTO 89 KM/H (55 MPH) – 120 KM(75 MI) UNTIL 7 KM/H (4 MPH) MAXSPEED displays. The displayedmileage will decrease as drivingcontinues. A flashing warning lightand a chime also come on.

When the mileage countdown iszero, the DIC message EXHAUSTFLUID EMPTY REFILL NOW -TRANSITIONING TO 7 KM/H(4 MPH) MAX SPEED displays.A flashing warning light and a chimealso come on. Vehicle speed will bereduced to a maximum speed limitof 7 km/h (4 mph).

After the transition to 7 km/h (4 mph)is complete, the DIC messageEXHAUST FLUID EMPTY REFILLNOW - SPEED LIMITED TO 7 KM/H

(4 MPH) displays. A flashingwarning light and a chime alsocome on.

Add at least 7.6 L (2 gal) of fluid torelease the vehicle from speedlimitation from a very low or emptytank. The capacity of the DEF tankis 20.1 L (5.3 gal).

See Diesel Exhaust Fluid Messageson page 5-13, Diesel Exhaust Fluid(DEF) Warning Light on page 5-11,and Recommended Fluids andLubricants on page 11-8.

Exhaust Fluid Quality Poor

Use only exhaust fluid that is GMapproved, or fluid containing the APIcertified or ISO 22241 label.

All DEF has an expiration date.If the system detects poor quality,or contaminated or diluted DEF, theDIC message displays:. EXHAUST FLUID QUALITY

POOR - SEE OWNERSMANUAL NOW – 160 KM(99 MI) UNTIL 105 KM/H(65 MPH) MAX SPEED.

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, EXHAUST FLUIDQUALITY POOR - SEEOWNERS MANUAL NOW –998 KM (620 MI) UNTIL 105 KM/H (65 MPH) MAX SPEED.

The displayed mileage will decreaseas driving continues. A warning lightalso comes on. Adding fresh DEF tothe system may resolve theproblem, depending on severalfactors. If the DIC message persists,see your dealer or additional DICmessages may display.

When the mileage countdown iszero, a DIC message EXHAUSTFLUID QUALITY POOR - SEEOWNERS MANUAL NOW -TRANSITIONING TO 105 KM/H(65 MPH) MAX SPEED displays.A warning light and a chime alsocome on. Vehicle speed will bereduced to a maximum speed limitof 105 km/h (65 mph).



After the transition to 105 km/h(65 mph) is complete, the DICmessage displays:. EXHAUST FLUID QUALITY

POOR - SEE OWNERSMANUAL NOW - SPEEDLIMITED TO 105 KM/H(65 MPH) – 120 KM (75 MI)UNTIL 89 KM/H (55 MPH) MAXSPEED .

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, EXHAUST FLUIDQUALITY POOR - SEEOWNERS MANUAL NOW -SPEED LIMITED TO 105 KM/H(65 MPH) – 933 KM (580 MI)UNTIL 89 KM/H (55 MPH) MAXSPEED .


When the mileage countdown iszero, the DIC message EXHAUSTFLUID QUALITY POOR - SEEOWNERS MANUAL NOW -TRANSITIONING TO 89 KM/H

(55 MPH) MAX SPEED displays.A flashing warning light and a chimealso come on. Vehicle speed will bereduced to a maximum speed limitof 89 km/h (55 mph).

After the transition to 89 km/h(55 mph) is complete, a DICmessage EXHAUST FLUIDQUALITY POOR - SEE OWNERSMANUAL NOW - SPEED LIMITEDTO 89 KM/H (55 MPH) – 120 KM(75 MI) UNTIL 7 KM/H (4 MPH) MAXSPEED displays. The displayedmileage will decrease as drivingcontinues. A flashing warning lightand a chime also come on.

When the mileage countdown iszero, a DIC message EXHAUSTFLUID QUALITY POOR - SEEOWNERS MANUAL NOW -TRANSITIONING TO 7 KM/H(4 MPH) MAX SPEED displays.A flashing warning light and a chimealso come on. Vehicle speed will bereduced to a maximum speed limitof 7 km/h (4 mph).

After the transition to 7 km/h (4 mph)is complete, a DIC messageEXHAUST FLUID QUALITY POOR- SEE OWNERS MANUAL NOW -SPEED LIMITED TO 7 KM/H(4 MPH) displays. A flashingwarning light and a chime alsocome on.

Service Exhaust Fluid System

If a problem occurs with the DEFsystem, the DIC message displays:. SERVICE EXHAUST FLUID

SYSTEM - SEE OWNERSMANUAL NOW – 160 KM(99 MI) UNTIL 105 KM/H(65 MPH) MAX SPEED.

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, SERVICE EXHAUSTFLUID SYSTEM - SEEOWNERS MANUAL NOW –998 KM (620 MI) UNTIL 105 KM/H (65 MPH) MAX SPEED.

The displayed mileage will decreaseas driving continues. A warning lightalso comes on. In some cases this



message will clear itself, indicatingthat the DEF system was able tocorrect the condition. If the DICmessage persists, see your dealeror additional DIC messages maydisplay.

When the mileage countdown iszero, the DIC message SERVICEEXHAUST FLUID SYSTEM - SEEOWNERS MANUAL NOW -TRANSITIONING TO 105 KM/H(65 MPH) MAX SPEED displays.A warning light and a chime alsocome on. Vehicle speed will bereduced to a maximum speed limitof 105 km/h (65 mph).

After the transition to 105 km/h(65 mph) is complete, a DICmessage displays:. SERVICE EXHAUST FLUID

SYSTEM - SEE OWNERSMANUAL NOW - SPEEDLIMITED TO 105 KM/H(65 MPH) – 120 KM (75 MI)UNTIL 89 KM/H (55 MPH) MAXSPEED.

. For emergency vans with RPOYF2 or emergency pickups withRPO ANM, SERVICE EXHAUSTFLUID SYSTEM - SEEOWNERS MANUAL NOW -SPEED LIMITED TO 105 KM/H(65 MPH) – 933 KM (580 MI)UNTIL 89 KM/H (55 MPH) MAXSPEED.


When the mileage countdown iszero, the DIC message SERVICEEXHAUST FLUID SYSTEM - SEEOWNERS MANUAL NOW -TRANSITIONING TO 89 KM/H(55 MPH) MAX SPEED displays.A flashing warning light and a chimealso come on. Vehicle speed will bereduced down to a maximum speedlimit of 89 km/h (55 mph).

After the transition to 89 km/h(55 mph) is complete, the DICmessage SERVICE EXHAUSTFLUID SYSTEM - SEE OWNERSMANUAL NOW - SPEED LIMITEDTO 89 KM/H (55 MPH) – 120 KM

(75 MI) UNTIL 7 KM/H (4 MPH) MAXSPEED displays. The displayedmileage will decrease as drivingcontinues. A flashing warning lightand a chime also come on.

When the mileage countdown iszero, the DIC message SERVICEEXHAUST FLUID SYSTEM - SEEOWNERS MANUAL NOW -TRANSITIONING TO 7 KM/H(4 MPH) MAX SPEED displays.A flashing warning light and a chimealso come on. Vehicle speed will bereduced to a maximum speed limitof 7 km/h (4 mph).

After the transition to 7 km/h (4 mph)is complete, the DIC messageSERVICE EXHAUST FLUIDSYSTEM - SEE OWNERSMANUAL NOW - SPEED LIMITEDTO 7 KM/H (4 MPH) displays.A flashing warning light and a chimealso come on.



Service Emission System

These restrictions are not applicableto emergency vans with RPO YF2or emergency pickups withRPO ANM.

If a problem occurs with the vehicleemission system, the DIC messageSERVICE EMISSION SYSTEM -SEE OWNERS MANUAL NOW –282 KM (175 MI) UNTIL 105 KM/H(65 MPH) MAX SPEED displays.The displayed mileage will decreaseas driving continues. In some casesthis message will clear itself,indicating that the emission systemwas able to correct the condition.If the DIC message persists, seeyour dealer or additional DICmessages may display.

When the mileage countdown iszero, the DIC message SERVICEEMISSION SYSTEM - SEEOWNERS MANUAL NOW -TRANSITIONING TO 105 KM/H(65 MPH) MAX SPEED displays.A chime also comes on. Vehiclespeed will be reduced to amaximum speed limit of 105 km/h(65 mph).

After the transition to 105 km/h(65 mph) is complete, the DICmessage SERVICE EMISSIONSYSTEM - SEE OWNERSMANUAL NOW - SPEED LIMITEDTO 105 KM/H (65 MPH) – 120 KM(75 MI) UNTIL 89 KM/H (55 MPH)MAX SPEED displays. Thedisplayed mileage will decrease asdriving continues. A chime alsocomes on.

When the mileage countdown iszero, the DIC message SERVICEEMISSION SYSTEM - SEEOWNERS MANUAL NOW -TRANSITIONING TO 89 KM/H(55 MPH) MAX SPEED displays.A chime also comes on. Vehiclespeed will be reduced to amaximum speed limit of 89 km/h(55 mph).

After the transition to 89 km/h(55 mph) is complete, the DICmessage SERVICE EMISSIONSYSTEM - SEE OWNERSMANUAL NOW - SPEED LIMITEDTO 89 KM/H (55 MPH) displays.A chime also comes on.



Brakes

Exhaust BrakeThe heavy duty diesel pickups havean exhaust brake to enhance thevehicle brake system, and reducebrake lining wear.

A switch is used to activate thesystem, and is located below theclimate controls in the center of thevehicle instrument panel. The switchmust be pressed at each vehiclestart for the system to be active.

A light in the switch will come onwhen the exhaust brake isactivated.

The Driver Information Center (DIC)displays the message EXHAUSTBRAKE ON for approximately10 seconds, then clears.

To turn the brake off, press theexhaust brake switch a second time.The DIC displays the messageEXHAUST BRAKE OFF forapproximately 10 seconds, thenclears.

Downshifts may be automaticallyselected to increase engine speed,which increases the effectiveness ofthe exhaust brake. The number ofdownshifts selected is determinedby the length of time the brakes areapplied, and the rate the vehicle isslowing. The system delivers thecorrect amount of braking to assistin vehicle control. The heavier thevehicle load, the more active theengine exhaust brake will be. Use ofthe exhaust brake will help maintain

vehicle speed when used withcruise control. See “Cruise Control”in the owner manual.

Automatic downshifts will not occurif the vehicle is in Range SelectionMode. See “Manual Mode” in theowner manual.

The exhaust brake only activateswhen the transmission torqueconverter is locked. This can varybased on vehicle speed, gear, andload. The exhaust brake will bemore active when in Tow/Haul Mode.



Fuel

Fuel for Diesel EnginesThis vehicle is approved to usediesel fuel with no more than15 ppm sulfur content and biodieselup to 20% by volume. Both dieseland biodiesel blends must meet allthe requirements as defined in themost current versions of the localfuel standards. Please see therecommended fuels for individualcountries, as described in thefollowing sections.

{ Caution

Engine damage may occur andthe damage would not be coveredby the warranty if:

. Gasoline is added to the fueltank. Gasoline should neverbe added to the fuel tank.

(Continued)

Caution (Continued)

. Diesel fuel has been mixedwith engine oil, vegetable oil,or automatic transmissionfluid.

. Marine diesel fuel; fuel oils;diesel fuels that are entirelyor partially plant based, suchas rape seed oil or bio-diesel;Aquazole®; or similardiesel-water emulsionsare used.

. Diesel fuel or fuel additivesthat are not recommendedare used.

. Aftermarket diesel fueladditives, particularly thosethat contain alcohol or wateremulsifiers, are used. Consultyour dealer before using afuel additive.

Some conditions, such as dirty fuel,may decrease fuel filter life and aCHANGE FUEL FILTER messagemay come on in the DriverInformation Center (DIC).

What Fuel to Use inThe U.S.Use only diesel fuel with ultra lowsulfur content (15 ppm, maximum).Look for dispensers with this label.



Use diesel fuel that meets ASTMspecification D 975, Grades No. 2-Dor No. 1-D S15, also known as UltraLow Sulfur Diesel. Contact a fuelsuppler for any questions.

{ Caution

Use of diesel fuel other than UltraLow Sulfur Diesel (15 ppm sulfurmaximum) will cause damage tothe exhaust after-treatmentsystem. This damage would notbe covered by the vehiclewarranty. Do not use marine,locomotive, or boiler distillate fuelsince it may contain higher sulfurlevels.

Diesel Fuel Grades

For best results use No. 2-D dieselfuel year-round because it isblended for seasonal temperaturedifferences, both above and belowfreezing conditions. No. 1-D dieselfuel can be used in very coldtemperatures (below -18°C or 0°F);

however, it will reduce power andfuel economy. Avoid using No. 1-Ddiesel fuel in warm or hot climates.It can result in stalling, poor startingwhen the engine is hot, and damageto the fuel injection system.The fuels industry usually willautomatically modify the fuel for theappropriate seasonal blend. If indoubt, please confirm with yourlocal fuel supplier.

Premium Diesel Fuel

Premium Diesel Fuel (FQP-1A)corresponding to the EngineManufacturers Association (EMA)Recommended Guideline mayprovide less noise, better starting,and better vehicle performance, butis not required.

Biodiesel

Biodiesel is a renewable fuelproduced from vegetable oils oranimal fats that have beenchemically modified for normalperformance.

{ Caution

Do not use home-made biodieselor home test kits because thequality cannot be verified byapproved scientific methods. Donot use raw vegetable oil or otherunmodified bio-oils, fats,or blends of vegetable oil withdiesel. They could damage thefuel system and engine, anddamages would not be coveredby the vehicle warranty.



Biodiesel blends

Use biodiesel blends that meet theASTM specification D6751.. Retail pumps dispensing blends

containing up to 5% biodiesel(B5) are not required to belabeled with the concentration ofbiodiesel. Blends up to B5 mustmeet ASTM D975 (Grades No.2-D or No. 1-D S15 Ultra LowSulfur Diesel).

{ Caution

Do not use blends containingmore than 20% biodiesel. Anyengine, fuel system, or exhaustafter-treatment system damagewould not be covered by thevehicle warranty.

Pumps dispensing more than5% and up to 20% biodiesel arerequired to be labeled with theconcentration of biodiesel. Whenrefueling with a biodiesel blendabove B5, one of the followinglabels should appear on thedispenser:

. Blends containing more than 5%and up to 20% biodiesel mustmeet ASTM specification D7467(Biodiesel blend, B6 - B20).



Biodiesel quality can vary widely.To reduce the risk of poor qualityfuel, purchase biodiesel blendsfrom a BQ-9000 certifiedmarketer. See www.bq-9000.orgfor a list of certified marketers.

As a renewable fuel, biodieselprovides some environmentalbenefits. However, biodiesel hasunique properties and needs to behandled differently than diesel fuel.Its use presents additional risks andmay not be appropriate in allsituations. Certain vehicle operatingmodes increase these risks andshould be avoided. Read further todetermine if your driving habits arecompatible with the use of biodiesel.

. Biodiesel fuel quality degradeswith time and exposure to hightemperature quicker than UltraLow Sulfur Diesel fuel. Morefrequent refueling provides thebest opportunity to have asupply of fresh fuel. Storage athot ambient temperatures willaccelerate biodieseldegradation.

Owners who use very little fuel,or who have vehicles stored forextended periods of time, shouldavoid the use of biodieselblended fuels above 5% byvolume. When vehicles arestored for longer than onemonth, they should be run out ofbiodiesel to below one-quartertank, refueled with Ultra LowSulfur Diesel fuel, and drivenseveral miles before storage.

. At temperatures below 32°F (0°C), it is recommended to switchto Ultra Low Sulfur Diesel fuelwith no biodiesel content, or toblends with biodiesel containingless than 5% by volume. Atthese extreme coldtemperatures, biodiesel blendshigher than 5% by volume maycause fuel filter plugging andsystem gelling, which can leadto vehicle operability problems.

Fuels improperly blended forcold temperature operation mayresult in restricted fuel filters anddegraded vehicle performance.The vehicle is equipped with afuel heating system to provide alevel of protection against filterplugging from gelling or waxingof conventional diesel fuel andbiodiesel blends. If the operatingtemperature is far below thetemperature at which gelling orwaxing of the fuel occurs thesystem will not prevent all casesof filter plugging.



. Vehicles operated for extendedperiods of time on Ultra LowSulfur Diesel fuel and thenswitched to biodiesel blendsmay experience premature fuelfilter clogging and require morefrequent fuel filter service.

With long-term use of Ultra LowSulfur Diesel fuel, gum andvarnish may be deposited withinthe tank and fuel system. Thesedeposits, while not problematicwith the use of Ultra Low SulfurDiesel fuel, may becomeloosened with a sudden switchto biodiesel blends and causefuel filter plugging.

If the vehicle experiences a fuelfilter restriction, the on-boardmonitoring system will alert thedriver that the fuel filter requiresservice. The fuel filter, however,will not prevent all damagecaused by poor quality biodiesel.

Refueling

Diesel fuel can foam when filling thetank. This can cause the automaticpump nozzle to shut off, even if thetank is not full. If this happens, waitfor the foaming to stop, and then fillthe tank more slowly. See Filling theTank on page 9-36.

{ Warning

Heat coming from the engine cancause the fuel to expand andforce the fuel out of the tank.If something ignites the fuel, a firecould start. To help avoid this, fillthe tank slowly and only until thenozzle shuts off. Do not top it off.Clean up any spilled fuel.

Accidental Refueling withGasoline

{ Caution

If the vehicle is accidentallyrefueled with gasoline, do notcontinue driving the vehicleexcept to get to a location whereit can be stopped safely. Drivingthe vehicle will damage the fuelsystem. Have the vehicle towedto a qualified technician to havethe gasoline removed from thetank, preferably until the fuelgauge reads near E (Empty).Refuel with Ultra Low SulfurDiesel fuel.



What Fuel to Use inCanada and MexicoUse only diesel fuel with ultra lowsulfur content (15 ppm maximum).

What Fuel to Use in Canada

Use diesel fuel that meets CAN/CGSB-3.517 specification inCanada. Contact a fuel supplier forquestions about fuel.

{ Caution

Use of diesel fuel other than UltraLow Sulfur Diesel (15 ppm sulfurmaximum) will cause damage tothe exhaust after-treatmentsystem. This damage would notbe covered by the vehiclewarranty. Do not use marine,locomotive, or boiler distillate fuelsince it may contain higher sulfurlevels.

Diesel Fuel Types

Fuels are blended for seasonalchanges. Diesel Type A fuel isblended to ensure vehicles operatein extreme cold temperatures. Thisfuel, however, may cause somepower and fuel economy losses.Diesel Type B fuel is blended forhigher temperatures experiencedduring most of the year. Avoid usingDiesel Type A fuel in warm or hotclimates. Doing so can result installing, poor starting when theengine is hot, and damage to thefuel injection system.

Premium Diesel Fuel

If available, premium diesel fuel(FQP-1A) corresponding to theEngine Manufacturers Association(EMA) Recommended Guidelinecould provide better starting andvehicle performance with less noise.

Biodiesel

Biodiesel is a renewable fuelproduced from vegetable oils oranimal fats that have beenchemically modified for normalengine performance.

{ Caution

Do not use home-made biodieselor home test kits because thequality cannot be verified byapproved scientific methods. Donot use raw vegetable oil or otherunmodified bio-oils, fats,or blends of vegetable oil withdiesel. They could damage thefuel system and engine, anddamages would not be coveredby the vehicle warranty.

Biodiesel blends

Biodiesel blends that meet the CAN/CGSB-3.522 specifications up to20% (B20) can be used. Avoid theuse of biodiesel blends above 20%,as they may damage the engine



and fuel system. For detailedinformation on the use of biodiesel,see What Fuel to Use in The U.S.on page 9-21.

Refueling

Diesel fuel can foam when filling thetank. This can cause the automaticpump nozzle to shut off, even if thetank is not full. If this happens, waitfor the foaming to stop, and then fillthe tank more slowly. See Filling theTank on page 9-36.

{ Warning

Heat coming from the engine cancause the fuel to expand andforce the fuel out of the tank.If something ignites the fuel, a firecould start. To help avoid this, fillthe tank slowly and only until thenozzle shuts off. Do not top it off.Clean up any spilled fuel.

Accidental Refueling withGasoline

{ Caution

If the vehicle is accidentallyrefueled with gasoline, do notcontinue driving the vehicleexcept to get to a location whereit can be stopped safely. Drivingthe vehicle will damage the fuelsystem. Have the vehicle towedto a qualified technician to havethe gasoline removed from thetank, preferably until the fuelgauge reads near E (Empty).Refuel with Ultra Low SulfurDiesel fuel.

What Fuel to Use in Mexico

Use diesel fuel specificationNOM-086 Pemex UBA, which meetsthe Ultra Low Sulfur Diesel fuelrequirement of 15 ppm sulfurmaximum. This fuel is not availablein all regions of Mexico.

{ Caution

Use of diesel fuel other than UltraLow Sulfur Diesel (15 ppm sulfurmaximum) will damage theexhaust after-treatment system.This damage would not becovered by the vehicle warranty.

Cold Weather OperationIn cold weather, the fuel filter maybecome clogged by wax naturallypresent in the fuel. To unclog it,move the vehicle to a warm garagearea and allow the filter to warm up.The fuel filter may need to bereplaced. See Fuel FilterReplacement on page 9-33.

At temperatures below 0°C (32°F), itis recommended to avoid usingbiodiesel blends above (5% blend)which may cause fuel filter plugging,system gelling, and freezing thatmay affect vehicle starting.



It is recommended to use Ultra LowSulfur No. 1-D diesel fuel or a blendof No. 1-D and No. 2-D diesel fuel toenhance vehicle operation in coldweather at temperatures below (0°C(32F). Use of No. 1-D diesel fuelmay lower the fuel economy.

Water in FuelImproper fuel tank inspection orcleaning, or contaminated fuel fromsuppliers, can cause water to bepumped into the fuel tank along withthe diesel fuel. If a WATER IN FUELmessage displays, the water mustbe drained immediately.

{ Warning

Diesel fuel containing water is stillcombustible. You or others couldbe burned. If the fuel needs to bedrained, keep sparks, flames, andsmoking materials away from themixture.

{ Caution

Water in the diesel fuel cancorrode internal components ofthe fuel system and lead tosevere damage. It can alsosupport fungus or bacteriagrowth, which can damage thefuel system and fuel operatedheater (FOH) (if equipped). Evenwith a diesel fuel biocide, the fuelsystem may still need to becleaned. Your dealer can adviseof the appropriate solution.

If the fuel tank needs to bepurged to remove water, see yourdealer or a qualified technician.Improper purging can damage thefuel system and block the FOH.

Water in Fuel Troubleshooting

If the WATER IN FUEL SERVICEREQUIRED message comes on:

ProblemRecommended

Action

Messagedisplays butgoes off duringthe ignitioncycle.

The fuel filter isapproximatelyhalf full of water.Drain the waterimmediately.See "RemovingWater from FuelFilter" later inthis section.



ProblemRecommended

Action

Messagedisplays andstays on.

Drain the fuelfilterimmediately.If no water canbe drained, andthe temperatureis belowfreezing, thenwater may befrozen in thefilter. Move thevehicle to awarm location tothaw, then drainthe fuel. If stillno water drains,see your dealer.

ProblemRecommended

Action

Immediatelyafter refueling,messagedisplays andstays on.

A large amountof water is in thefuel tank. Drainthe fuel filterimmediately.If the messagestays on,or comes backon again withoutrefueling, fueltank purging isrequired. Seeyour dealer.If the messagedisplays and thevehicle stalls orhas roughriding, do notdrive until thewatercontaminatedfuel is drained.

{ Caution

Driving with this message on candamage the fuel injection systemand the engine. If the messagecomes on right after a refuel,water was pumped into the fueltank. Turn off the engine anddrain the water immediately.

Removing Water from FuelFilter

To drain water:

1. Turn the engine off and applythe parking brake.

2. Remove the fuel cap.



Pickup

Van

3. Place a container under the filterdrain valve. The filter drain valveis on the bottom of the fuel filter.For pickup models, the filterdrain valve is on the passengerside of the engine compartment.For van models, the filter drainvalve is under the vehicle on thedriver side, inside the frame rail.

4. For pickup models, open thedrain valve by turning it two tothree turns. Pump the primeruntil fuel empties from the valveand all of the water has beendrained. Close the valve handtight.

For van models, open the fuelfilter drain valve by turning it twoto three turns. Allow the filter todrain until all of the water hasbeen removed. Close the valvehand tight.

5. Properly dispose of the watercontaminated fuel.

6. Install the fuel cap.

7. Start the engine and let it run fora few minutes. During thedraining process, air may haveentered the fuel system. If theengine stalls, the fuel systemmay need to be primed. See“Fuel Priming” following.

Fuel Priming

For the fuel system to work properly,the fuel lines must be full of fuel.If air gets in, the fuel lines need tobe primed before operating thevehicle and the fuel operatedheater (FOH).

If air is present, the following mayhave happened:. The vehicle ran out of fuel.. The fuel filter was removed.. The fuel lines were removed or

disconnected.. The fuel filter water drain valve

was opened while the enginewas running.



. The FOH pump and FOH fuellines were removed ordisconnected.

The system is not harmed by air inthe fuel lines; however, the engineand/or the FOH may not start untilthe fuel system is primed and the airis removed.

To Prime Pickup Models

The priming pump is part of theengine fuel filter and will bring fuelto the engine to eliminate air in thefuel lines. To prime the engine:

1. Correct any condition thatcaused the loss of prime.

2. Check that the fuel filter isinstalled and properly tightened,and cool enough to touch.

3. Check that the fuel lines areproperly connected.

4. Remove any dirt from the fuelfilter head and vent valve.

5. Locate the fuel filter vent valveon top of the fuel filter housing.Turn the valve screwcounterclockwise several fullturns to open.

6. Locate the fuel filter primingpump on top of the fuel filterhousing. Push down and let itreturn up several times.

7. Continue priming the pump untila small amount of fuel comesfrom the vent valve. Thisindicates the filter is full of fueland the system should beprimed.

8. Close the vent valve. Clean anyfuel off the fuel filter. Try to startthe engine. If the engine stalls,operate the priming pumpseveral times in between starting



attempts. Allow the engine toidle for a few minutes after itstarts. Check the filter for leaks.

To Prime Van Models

There is an electric priming pumpthat will bring fuel to the engine andeliminate air in the fuel lines.To prime the engine:

1. Correct any condition thatcaused the loss of prime.

2. Turn the ignition to ON/RUN for30 seconds. Do not start theengine. The fuel pump will startpriming.

3. Turn the ignition off, then back tostart, and crank the engine for15 seconds.

4. If the engine does not start,repeat Steps 2 and 3 until theengine starts.

If the engine does not start afterrepeating Steps 2 and 3 threetimes, turn the ignition key off for60 seconds.

5. Repeat the above steps until theengine starts.

6. If the engine starts, but does notrun smoothly, increase theengine speed slightly.

7. If the engine starts and runs butstalls again, turn the ignition offfor 60 seconds.

8. When the engine starts, let it idlefor a few minutes and check thefilter for any leaks.

To Prime the Fuel Operated Heater(FOH) Fuel Lines (Van Models)

See your dealer or qualifiedtechnician if the FOH fuel lines needto be primed.

Running Out of Fuel

Pickup Models

{ Warning

Diesel fuel is combustible. It couldstart a fire if it gets on hot engineparts. You could be burned. Catchany fuel from the air bleed valve,and wipe up any spilled fuel witha cloth.

If the engine has stalled due torunning out of fuel, try the followingsteps to restart it:

1. If parked on a level surface, addat least 7.6 L (2 gal) of fuel. Upto 18.9 L (5 gal) may be neededif parked on a slope.

2. Follow the fuel primingprocedure earlier in this sectionto prime the fuel filter.

3. Turn the ignition key to STARTfor 10 to 15 seconds at a timeuntil the engine starts. If the



engine tries to run, but does notrun smoothly, increase the rpmslightly by using the acceleratorpedal. This will help force airthrough the system.

4. Return to Step 2 if the enginestalls and will not restart.

5. After a few attempts, if theengine still does not start, seeyour dealer.

Van Models

If the engine has stalled due torunning out of fuel, try to restart it:

1. If parked on a level surface, addat least 3.8 L (1 gal) of fuel. Upto 18.9 L (5 gal) may be neededif parked on a slope.

2. Follow the vehicle fuel systempriming procedure earlier in thissection to re-prime the systemand restart the engine.

If the check engine light comes ondue to running out of fuel, it maytake a few drive cycles to clear.

The fuel operated heater (FOH)stops automatically when the fueltank volume is less than or equal to10% of the total tank. The FOH fuellines will not need to be primed ifthe vehicle runs out of fuel.

Fuel Filter ReplacementPickup Models

{ Warning

Diesel fuel is flammable. It couldstart a fire if something ignites it,and people could be burned. Donot let it get on hot engine parts,and keep matches or otherignition sources away.

The fuel filter is located in theengine compartment on thepassenger side of the vehicle.

1. Drain any water from the filter.See “Removing Water from Fuel”in Water in Fuel on page 9-28.

Keep the engine off until theprocedure is completed.

2. Apply the parking brake.

3. Access the fuel filter through thepassenger side wheel houseopening. Remove only thenecessary fasteners to allow therear of the wheel liner to belowered enough for fuel filteraccess.



4. Unplug the water sensor wireconnected to the fuel filter andunscrew the filter element.

5. Clean the fuel filter area on theengine before removing thefuel filter.

{ Caution

Failure to cover the fuel filter witha clean cloth to keep out debriswhen replacing may cause dirt toget into the engine. This couldcause engine damage. Keep thefuel filter covered with a cleancloth when replacing.

6. Remove the filter element.If there is any dirt on the filtersealing surface, clean it off.Remove and reuse the watersensor float switch on thebottom of the fuel filter.

7. Install the new filter element.

8. Reinstall and tighten the filtercontainer and reconnect thewater sensor wire to the filter.

9. Reposition the wheel liner.

10. Install and tighten thefasteners.

11. Use the fuel filter primingprocedure earlier in this sectionto prime the fuel filter.

12. Start the engine and let it idlefor five minutes. Check the fuelfilter and air bleed valve forleaks.

13. Reset the fuel filter monitor.See Fuel System Messages onpage 5-13.

Van Models

If the fuel operated heater (FOH) isnot working, the FOH line requirespriming. See your dealer for service.See Fuel Operated Heater (FOH) onpage 9-10.

{ Warning

Diesel fuel is flammable. It couldstart a fire if something ignites it,and people could be burned. Donot let it get on hot engine parts,and keep matches or otherignition sources away.

The fuel filter and fuel pump screenare on the driver side frame rail infront of the fuel tank.

The fuel pump screen should beinspected and cleaned if necessaryat each fuel filter inspection orreplacement.

The fuel level must be less thanthree-quarters full.

1. Drain any water from the filter.See “Removing Water FromFuel” in Water in Fuel onpage 9-28.

2. Keep the engine off until theprocedure is completed.



Fuel Filter


2. Unplug the water sensor wireconnected to the fuel filter(lowest wire) and unscrew thefilter cap.

3. Remove the filter element.If there is any dirt on the filtersealing surface, clean it off.

4. Install the new filter element.

5. Reinstall and tighten the filtercap and reconnect the watersensor wire to the filter.

6. Follow the vehicle fuel systempriming procedure earlier in thissection to re-prime the system.

7. Start the engine and let it idle forfive minutes.

Fuel Pump Screen


2. Unscrew the fuel pumpscreen bowl.

3. Remove the filter element.If there is any dirt on the filtersealing surface, clean it off.

4. Clean the fuel pump screen andfuel pump screen bowl o-ring.

5. Inspect the screen and o-ring fordamage. Replace as necessary.

6. Install the fuel pump screen ando-ring.

7. Install the fuel pumpscreen bowl.

8. Follow the vehicle fuel systempriming procedure earlier in thissection to re-prime the system.

9. Start the vehicle and let it idle forfive minutes.



Filling the Tank

{ Warning

Fuel vapors and fuel fires burnviolently and can cause injury ordeath.

. To help avoid injuries to youand others, read and followall the instructions on the fuelpump island.

. Turn off the engine whenrefueling.

. Keep sparks, flames, andsmoking materials awayfrom fuel.

. Do not leave the fuel pumpunattended.

. Do not reenter the vehiclewhile pumping fuel.

(Continued)

Warning (Continued)

. Keep children away from thefuel pump and never letchildren pump fuel.

. Fuel can spray out if the fuelcap is opened too quickly.This spray can happen if thetank is nearly full, and ismore likely in hot weather.Open the fuel cap slowly andwait for any hiss noise to stopthen unscrew the cap allthe way.

Van Shown, Pickup Similar

The green fuel cap is behind ahinged door on the driver side of thevehicle. On van models, the bluediesel exhaust fluid cap is alsobehind the fuel door. Do not removeboth caps at the same time.

For chassis-cab models, refuel thefront tank first, or in instances whenonly a partial fuel fill is desired. Anautomatic transfer mechanism willmaintain approximately equal fuellevels in both tanks, so no switchingis required by the operator.



To remove the fuel cap, turn itslowly to the left (counterclockwise).

Be careful not to spill diesel fuel. Donot top off or overfill your tank, andwait a few seconds after you havefinished pumping before you removethe nozzle. Clean fuel from paintedsurfaces as soon as possible. See“Washing the Vehicle” in the ownermanual. When you put the fuel capback on, turn it to the right(clockwise) until you hear a clickingsound. Make sure you fully installthe cap.

{ Warning

If a fire starts while you arerefueling, do not remove thenozzle. Shut off the flow of fuel byshutting off the pump or bynotifying the station attendant.Leave the area immediately.

{ Caution

If a new fuel cap is needed, besure to get the right type of capfrom your dealer. The wrong typeof fuel cap might not fit properlyand could damage the fuel tankand emissions system.

{ Caution

If your vehicle has beenaccidentally filled with gasoline,do not run the engine or severeengine damage can occur.Contact your dealer to have thefuel system flushed.

Filling a Portable FuelContainer

{ Warning

Filling a portable fuel containerwhile it is in the vehicle can causefuel vapors that can ignite eitherby static electricity or othermeans. You or others could bebadly burned and the vehiclecould be damaged. Always:

. Use approved fuelcontainers.

. Remove the container fromthe vehicle, trunk, or pickupbed before filling.

. Place the container on theground.

(Continued)



Warning (Continued)

. Place the nozzle inside the fillopening of the containerbefore dispensing fuel, andkeep it in contact with the fillopening until filling iscomplete.

. Fill the container no morethan 95% full to allow forexpansion.

. Do not smoke, light matches,or use lighters whilepumping fuel.

. Avoid using cell phones orother electronic devices.

Towing

Trailer TowingWhen towing at high elevation onsteep uphill grades, consider thefollowing:

Engine coolant at higher elevationwill boil at a lower temperature thanat or near sea level. If the engine isturned off immediately after towingat high elevation on steep uphillgrades, the vehicle may show signssimilar to engine overheating. Toavoid this, let the engine run whileparked (preferably on level ground)with the transmission in P (Park)and the parking brake applied for atleast five minutes before turning theengine off. If the overheat warningcomes on, see Engine Overheatingon page 10-23.

Use the following chart to determinehow much the vehicle can weigh,based upon your vehicle modeland options.



Vehicle Axle Ratio Max. Trailer Wt.8 GCWR *

C-2500 Pickup Models – 2WD

Pickup Model Double CabStandard Box 1

3.73 7 983 kg (17,600 lb) 11113 kg (24,500 lb)

Pickup Model Crew Cab StandardBox 1

3.73 7 893 kg (17,400 lb) 11113 kg (24,500 lb)

Pickup Model Regular Cab LongBox 1

3.73 8 119 kg (17,900 lb) 11113 kg (24,500 lb)

Pickup Model Double Cab LongBox 1

3.73 7 938 kg (17,500 lb) 11113 kg (24,500 lb)

Pickup Model Crew Cab LongBox 1

3.73 7 847 kg (17,300 lb) 11113 kg (24,500 lb)

K-2500 Pickup Models – 4WD

Pickup Model Double CabStandard Box 1

3.73 7 847 kg (17,300 lb) 11113 kg (24,500 lb)

Pickup Model Crew Cab StandardBox 1

3.73 7 757 kg (17,100 lb) 11113 kg (24,500 lb)

Pickup Model Regular Cab LongBox 1

3.73 7 983 kg (17,600 lb) 11113 kg (24,500 lb)

Pickup Model Double Cab LongBox 1

3.73 7 802 kg (17,200 lb) 11113 kg (24,500 lb)




Pickup Model Crew Cab LongBox 5

3.73 7 439 kg (16,400 lb) 11113 kg (24,500 lb)

C-3500 Pickup Model Double Cab Long Box – 2WD

Single Rear Wheels 1 3.73 7 938 kg (17,500 lb) 11113 kg (24,500 lb)

Dual Rear Wheels 3 3.73 10 433 kg (23,000 lb) 13 835 kg (30,500 lb)

C-3500 Pickup Model Crew Cab Standard Box – 2WD


C-3500 Pickup Model Crew Cab Long Box – 2WD



K-3500 Pickup Model Regular Cab – 4WD



K-3500 Pickup Model Double Cab Long Box – 4WD






K-3500 Pickup Model Crew Cab Standard Box – 4WD


K-3500 Pickup Model Crew Cab Long Box – 4WD


Dual Rear Wheels7 3.73 10 251 kg (22,600 lb) 13 835 kg (30,500 lb)

C/K-3500 Chassis Cab – 2WD/4WD

All 3.73 9 13 835 kg (30,500 lb)

Van Models – 2WD

G2500 Cargo Van ShortWheelbase

3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G2500 Cargo Van LongWheelbase

3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G3500 Cargo Van ShortWheelbase

3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G3500 Cargo Van LongWheelbase

3.54 4 536 kg (10,000 lb) 8 391 kg (18,500 lb)

G3500 Passenger Van ShortWheelbase

3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)




G3500 Passenger Van LongWheelbase

3.54 4 400 kg (9,700 lb) 7 711 kg (17,000 lb)

G3500 Cutaway Van 159”Wheelbase

3.54 9 7 257 kg (16,000 lb)

G3500 Cutaway Van 139”Wheelbase

3.54 9 7 711 kg (17,000 lb)

G3500 Cutaway Van 155” and159” Wheelbase

3.73 9 8 391 kg (18,5000 lb)

*The Gross Combination Weight Rating (GCWR) is the total allowable weight of the completely loaded vehicle andtrailer including any passengers, cargo, equipment, and conversions. The GCWR for the vehicle should not beexceeded.1Trailer rating limited to 5 897 kg (13,000 lb) with conventional hitch.2Trailer rating limited to 7 257 kg (16,000 lb) with conventional hitch.3Trailer rating limited to 7 484 kg (16,500 lb) with conventional hitch.4Trailer rating limited to 8 165 kg (18,000 lb) with conventional hitch.5Trailer rating limited to 6 577 kg (14,500 lb) with conventional hitch.6Trailer rating limited to 6 804 kg (15,000 lb) with conventional hitch.7Trailer rating limited to 8 896 kg (19,600 lb) with conventional hitch.8For chassis cab and pickup box delete vehicles, choose an appropriate hitch and load the truck and trailer withinthe limits of GCWR, GVWR, and RGAWR.9Maximum Trailer Weight cannot be provided because total vehicle weight is unknown.

See “Towing a Trailer” in the owner manual for kingpin weight and trailer tongue weight information.



Conversions andAdd-Ons

Power Take-Off (PTO)The PTO is an upfitter integratedsystem that allows the user tocreate an auxiliary power source forrunning add-on equipment, such assalt spreaders, snow plows,winches, and lift buckets. The PTOsystem controls engine speed tovalues higher than normal base idle,PTO load relay engagement, andremote starting and shutdown of theengine.

Primary PTO Operating Modes

PTO modes of operation include:. Preset PTO Mode (Stationary

operation only). Variable PTO Mode (Stationary

and mobile operation)

The PTO stationary mode providesboth in-cab and remote controls.The in-cab controls are enabled as

the factory preset. The remotecontrols are disabled. This factorypreset configuration can beprogrammed to enable the remotecontrols, and/or disable the in-cabPTO controls. See your dealer formore information.

PTO Sub-Modes

The primary PTO modes have thefollowing sub-modes:. Engine speed control, PTO load

relay engagement/disengagement

. Remote engine start andshutdown (Stationaryoperation only)

PTO Engage/DisengageConditions

Engage Conditions –Stationary PTO

To engage stationary PTOoperation, the following conditionsmust be met:. The engine must be running.

. The vehicle cannot be movingand the parking brake mustbe set.

. The shift lever must be inP (Park).

. The brake pedal must not bepressed.

For in-cab PTO operation:

Press and release the PTO switchlocated below the climate controls inthe center of the vehicle instrumentpanel. The PTO indicator light, onthe tachometer, will blink fast untilthe PTO load becomes engaged.The indicator light will then be onsteady. The SET– and +RES cruisecontrol buttons can then be used toestablish the desired PTO operatingspeed.

For remote PTO operation:

Press and release the PTO remotearm switch, then withinfive seconds, press and release thePTO remote engine start/shutdownswitch. The PTO remote set switchcan then be used to establish the



desired PTO operating speed.Additional information is available inthe service manual for the correctwiring configuration andprogramming of the remote PTOenable and set switches. Theseswitch connections are accessedthrough the PTO upfitter connector,located on the chassis frame,behind the vehicle compartment.

Enabling Conditions – Mobile PTO

To engage mobile PTO operation,the following conditions must be metprior to turning on PTO:. The engine must be running.. The vehicle speed must be less

than the PTO top vehicle speedlimit. The default setting is94 km/h (58 mph). This limit canbe adjusted by a servicetechnician.

. The shift lever may be in M1, M2or M3. When placed in M2 orM3, the vehicle will upshiftaccording to engine RPM setpoint and vehicle speed.

. The brake must be pressed andthen released. The brake mustthen remain released.

. Cruise control cannot beenabled or active.

. Engine speed must be less thanthe maximum allowed PTOengage speed of 1500 rpm.

. Press and release the PTO incab switch. The PTO indicatorlight will blink fast until the PTOload becomes engaged, at whichpoint the indicator light will be onsteady. The SET– and +REScruise control buttons can thenbe used to establish the desiredPTO operating speed. See“Variable PTO Mode” and “PTOSwitch Operation” later in thissection.

DIC WARNING MESSAGES

One or more of the following DriverInformation Center (DIC) messagesmay appear if the PTO will not

engage. The operator must take theaction indicated, then attempt tore-enable PTO.. PTO: SHIFT TO PARK OR

NEUTRAL (Stationary only). PTO: SET PARK BRAKE

(Stationary only). PTO: PRESS & RELEASE

BRAKE (Mobile only). PTO: RELEASE BRAKE. PTO: REDUCE VEHICLE

SPEED. PTO: REDUCE ENGINE SPEED. PTO: DISENGAGE CRUISE

CONTROL (Mobile only)

In addition to these messages, thePTO indicator light will indicatewhen all conditions required toengage PTO have not been met.When enabling PTO, the indicatorlight will turn on, then off afterone second. Under normaloperating conditions, the PTOindicator light will remain onthroughout the PTO operating cycle.



PTO Disengage Conditions

To disengage the stationary ormobile PTO operation, do one of thefollowing:. Press the brake. PTO will

disengage immediately. ThePTO indicator light will blinkslowly, indicating that the PTOset speed is stored in memory.Pressing the +RES switch willrestore engine speed to thestored PTO set speed. PTO canalso be programmed toreengage at PTO standby speedupon releasing the brake pedal.

. Press and release the PTOin-cab switch. The engine speedwill return to normal engine idle.The PTO indicator light will gooff indicating the PTO load relayhas been disengaged and PTOset speed has been cleared frommemory.

. From the remote PTO controls,Press and release theemergency stop switch. PTO is

disengaged and the engine isshut down simultaneously.(Stationary remote PTO only)

. From the remote PTO controls,press and release the remoteengine start/shutdown switch.PTO is disengaged and theengine is shut downsimultaneously. (Stationaryremote PTO only)

The mobile PTO mode will alsodisengage if the following conditionsare detected by the vehicleelectronics:. The PTO load becomes

disengaged. (See servicemanual.)

. Vehicle speed exceeds 94 km/h(58 mph).

. Engine speed exceeds themaximum allowed PTOoperating speed of 3100 rpm(factory setting 2100 rpm).

. The PTO control system willattempt to limit accelerator pedaland PTO switch input as the

vehicle approaches the aboveoperational limits. There aresome vehicle conditions, suchas downhill acceleration, thatmay cause vehicle speed and/orengine speed limits to beexceeded. Under theseconditions, PTO is disengaged.

The stationary PTO mode will alsodisengage if any of the followingconditions are detected by thevehicle electronics:. Movement of the vehicle.. The parking brake is released.. The transmission is shifted from

P (Park) or N (Neutral) toD (Drive) or R (Reverse).

. The PTO load becomesdisengaged. (See servicemanual.)

. Cruise control is enabled.

Preset PTO Mode

Preset PTO can only be used whenthe vehicle is not moving. Thismode provides both in-cab and



remote controls. The in-cab controlsare enabled as the factory preset.The remote controls are disabled.This factory preset configuration canalso be reprogrammed to enable theremote controls, and disable thein-cab PTO controls. See yourdealer for more information.

For in-cab PTO mode, the enginespeed is initially set to a stand-byengine speed (900 rpm) by pressingthe PTO in-cab switch.

For remote PTO mode, with theengine off, press and release thePTO remote arm switch and within5 seconds press and release thePTO remote start/shutdown switch.The engine speed is initially set to astand-by engine speed (900 rpm).The stand-by engine speed can beset to a higher speed by a servicetechnician.

Choose one of two factory presetsby pressing the SET– (speed 1) or+RES (speed 2) switches, or PTOremote SET switch. Speed 1 andSpeed 2 are programmable by a

service technician from base engineidle rpm to max PTO operationspeed (3100 rpm).. Speed 1: Pressing the −/SET

position of the PTO switchresults in a preset speed of1200 rpm.

. Speed 2: Pressing the +/RESposition of the PTO switchresults in a preset speed of1900 rpm.

Pressing and releasing the PTOin-cab switch will return the enginespeed back to normal idle. The PTOload relay is also disengaged. IN theremote mode, pressing andreleasing the PTO remote start/shutdown switch will disengage theload and shut down the engine.

Maximum PTO Operating Speed:To protect the PTO fromover-speed, the PTO system willdisengage when the engine speedexceeds 3100 rpm. The factorypreset maximum PTO operating

speed is 2100 rpm. This can bereprogrammed by a servicetechnician.

Variable PTO Mode

In this mode, the vehicle can beprogrammed for stationary or mobileoperation.

The variable PTO mode controlsengine speed, and PTO loadengagement is selected by eitherthe PTO in-cab or remote switches.Engine speed selection is variablebetween base engine idle speedand a maximum of 3100 rpm(factory setting 2100 rpm).

In the mobile PTO mode, thevehicle will operate at a vehiclespeed resulting from the currentPTO engine speed request andcurrent transmission gear rangeselected.

Vehicle speed stability is greatlyimproved by operating thetransmission in manual modebecause upshifts are limited. MobilePTO is only available in M1, M2,



and M3. This reduces the maximumvehicle speed while allowing highengine speed operation.

PTO Switch Operation

To engage PTO, press and releasethe in-cab PTO switch or, press andrelease the remote PTO arm switch,then within five seconds, press andrelease the PTO remote start/shutdown switch. The vehicle willincrease engine speed to a factorypreset engine speed (900 rpm). ThisPTO stand-by speed is not intendedto be an operational PTO speed, butallows the engagement of the PTOat lower initial start-up rpm to matchwith the engagement of the PTOload relay.

The initial stand-by speed can beadjusted by holding the acceleratorto the desired engine speed, thenpressing and releasing the in-cabPTO switch. The current enginespeed will become the new stand-byspeed. This adjustment can only bedone once at the initial engagementof PTO. The initial stand-by speed

adjustment must be between enginebase idle speed and 1500 rpm(maximum PTO engage speed).

Press and release the in-cab switch.The engine speed will be reduced tothe base idle speed and the PTOload relay will be disengaged. Inremote mode, press and release thePTO remote start/shutdown switch.

PTO Operational Speed Control

SET: Press and hold theaccelerator to obtain the desiredengine speed, then press andrelease the SET– switch. Thecurrent engine speed will bemaintained. This action can berepeated as desired to a higher rpmvalue. The PTO set speed cannotexceed 3100 rpm.

TAP-DOWN: Press and release theSET– switch to reduce the enginespeed by increments of 100 rpm.This increment can be adjusted by aservice technician.

COAST: Press and hold the SET–switch to reduce the rpm by 150 rpmper second until the desired enginespeed is reached or until the initialPTO standby speed is reached.

RESUME: When a PTO set speedhas been achieved, press andrelease the brake pedal. Enginespeed will reduce to basic idlespeed. The PTO indicator light willblink slowly indicating the previousPTO set speed has been retained inmemory. Press and release the+RES switch to resume the previousPTO set speed.

TAP-UP: Press and release the+RES switch to increase the enginespeed by increments of 100 rpm.This increment can be adjusted by aservice technician.

ACCEL: Press and hold the +RESswitch to increase the rpm by150 rpm per second until the desiredengine speed is reached or until themaximum allowable PTO set speedis reached.



Remote Engine Start Control

The vehicle’s PTO system allowsthe engine to be remotely startedwhile operating in the stationaryPTO mode. The vehicle wiringsystem provides for connections toa remote start arming switch andremote engine start switch. Theseconnections are accessed throughthe upfitter connector.

The remote start function is initiatedby a sequence of switch actions, inaddition to several vehicleconditions. The vehicle ignition keycan be in any position or removedfrom the ignition. The followingconditions must be met beforeattempting to remote start theengine:. The vehicle must be configured

for stationary PTO operation bya qualified dealer.

. The parking brake must be set.

. The transmission shift lever mustbe in P (Park).

. The vehicle hood must beclosed.

Once the above conditions are met,continue the remote start by doingthe following steps using the remotePTO controls:

1. Press and release the remotearm switch.

2. Within five seconds of releasingthe remote arm switch, pressand hold the remote enginestart/shutdown switch for abouttwo seconds (horn will sound)until the engine starts. The PTOsystem will raise engine rpm tostandby speed and engage thePTO load.

Remote Engine ShutdownControl

The vehicle’s PTO system allows forremote engine shutdown whileoperating in the stationary PTOmode. This feature has the followingfunctions:. Engine shutdown using the

operator remote switch: Thevehicle wiring system providesremote engine shutdown switchconnections, which areaccessed through the PTOupfitter connector.

. Timed auto-engine shutdown:The timed auto-engine shutdownfeature provides the means toshut down the engineautomatically after a predefinedtime. PTO must be operationalfor this function to be active.



. Engine shutdown based oncritical engine conditions: Theengine will be shut down whenPTO is operating if a criticalengine condition is detected bythe vehicle system (i.e., low oil,low oil pressure, hot engine, hottransmission, low fuel, dieselparticulate filter regeneration).If PTO operation is continuedwhen critical engine conditionsare present, a horn chirpwarning will occur after two tofive minutes. The engine will beshut down two minutes after thehorn warning. The operator canre-start the engine with theignition key. The above hornwarning and engine shutdownwill again occur if the criticalengine condition is still present.

Prolonged or Extended PTOOperation

While operating the vehicle instationary PTO mode, the DieselParticulate Filter (DPF) will continueto filter the exhaust and accumulatesoot. The engine control system,depending on the speed and loadbeing applied by the PTO, may notbe able to generate enough energyor adequate heat needed to clean orregenerate the DPF. Continuedoperation under conditions that donot allow effective regeneration orcleaning will eventually plug theDPF and result in reduced power.The ENGINE POWER ISREDUCED Driver InformationCenter (DIC) message andmalfunction indicator lamp will bedisplayed, and dealer service will berequired to return the vehicle tonormal, full power operation.

To prevent this from occurring,frequently monitor the vehicle duringPTO operation. If the DIC messageis displayed during PTO operation,see Diesel Particulate Filter onpage 9-11 for information on how toclean or regenerate the DPF. Alsosee “Remote Engine ShutdownControl” earlier in this section.

Factory Preset Parameters

The following table lists the factorypreset parameters. These may bealtered by the service technician toconfigure the various PTO features.



ProgrammableParameters

Factory Setting Minimum Value Maximum Value

PTO In-cab Control ENABLED DISABLED ENABLED

PTO Remote Control DISABLED DISABLED ENABLED

Type of Set SwitchOperation

MOMENTARY MOMENTARY LATCHING

Press ON Then Go To Set1 Speed

DISABLED DISABLED ENABLED

Remote Engine Start DISABLED DISABLED ENABLED

Remote Engine Shutdown DISABLED DISABLED ENABLED

Load Feedback DISABLED DISABLED ENABLED

Engage Relay DISABLED DISABLED ENABLED

Keep Relay EngagedDuring Braking

DISABLED DISABLED ENABLED

Action After Brake IsReleased

RETURN TO BASEIDLE RPM

RETURN TO BASEIDLE RPM

RETURN TOSTANDBY RPM

Set Low Fuel Level forEngine Shutdown

15% 0 25%

Engine Run Time WhilePTO is Active – Timer

420 min 0 minutes 58 hours





Max. PTO Engine Speed 2100 RPM 500 RPM 3100 RPM

Max. PTO Engage Speed 1500 RPM 0 RPM 1500 RPM

PTO Standby RPM 900 RPM 500 RPM Normal engineidle will override if higherthan Standby Speed

1500 RPM

PTO Set Speed 1 1200 RPM 500 RPM PTO Set Speed 1cannot be set below PTO

Standby speed

3100 RPM

PTO Set Speed 2 1900 RPM 500 RPM PTO Set Speed 2cannot be set below PTO

Standby speed

3100 RPM

Tap Step 100 RPM 4 RPM 500 RPM

Ramp Rate 150 RPM 4 RPM 150 RPM

Maximum Vehicle Speed 94 km/h 30 km/h 94 km/h

Minimum RemotePotentiomete Threshold

5% 0% 50%

Maximum RemotePotentiomete Threshold

95% 50% 100%





Remote Set SwitchTransition to LowVoltage (<1.66 V)

SET SPEED 1 STANDBY SPEED, SET SPEED 1, or SET SPEED 2

Remote Set SwitchTransition to Open State

(>1.66 V, <3.33 V)

PTO STANDBY STANDBY SPEED, SET SPEED 1, or SET SPEED 2

Remote Set SwitchTransition to HighVoltage (>3.33 V)

SET SPEED 2 STANDBY SPEED, SET SPEED 1, or SET SPEED 2

If the PTO factory presetparameters do not match thesettings described above, then theymay have already been altered inorder to satisfy the requirements ofthe installed PTO system and bodyequipment.

See www.gmupfitter.com for moreinformation on the installation ofwiring and programming for PTOaftermarket equipment.


Vehicle Care 10-1

Vehicle Care

General InformationAccessories andModifications . . . . . . . . . . . . . . . 10-1

Vehicle ChecksEngine CompartmentOverview . . . . . . . . . . . . . . . . . . . 10-3

Engine Oil . . . . . . . . . . . . . . . . . . . 10-6Engine Oil Life System . . . . . . 10-9Automatic TransmissionFluid . . . . . . . . . . . . . . . . . . . . . . . 10-9

Engine Air Cleaner/Filter . . . . 10-15Cooling System . . . . . . . . . . . . 10-17Engine Coolant . . . . . . . . . . . . . 10-18Engine Overheating . . . . . . . . 10-23

General Information

Accessories andModificationsAdding non-dealer accessories ormaking modifications to the vehiclecan affect vehicle performance andsafety, including such things asairbags, braking, stability, ride andhandling, emissions systems,aerodynamics, durability, andelectronic systems like antilockbrakes, traction control, and stabilitycontrol. These accessories ormodifications could even causemalfunction or damage not coveredby the vehicle warranty.

Damage to vehicle componentsresulting from modifications or theinstallation or use of non-GMcertified parts, including controlmodule or software modifications, isnot covered under the terms of thevehicle warranty and may affectremaining warranty coverage foraffected parts.

GM Accessories are designed tocomplement and function with othersystems on the vehicle. See yourdealer to accessorize the vehicleusing genuine GM Accessoriesinstalled by a dealer technician.

See the warranty manual.

Aftermarket EnginePerformance EnhancementProducts and Modifications

Some aftermarket engineperformance products andmodifications promise a way toincrease the horsepower and torquelevels of the vehicle's powertrain.You should be aware that theseproducts could have harmful effectson the performance and life of theengine, exhaust emission system,transmission, and drivetrain. Theengines, transmissions, anddrivetrains have been designed andbuilt to offer industry leadingdurability and performance in themost demanding applications.


10-2 Vehicle Care

Engine power enhancementproducts may enable the engine tooperate at horsepower and torquelevels that could damage, createfailure, or reduce the life of theengine, engine emission system,transmission, and drivetrain.Damage, failure, or reduced life ofthe engine, transmission, emissionsystem, drivetrain, or other vehiclecomponents caused by aftermarketengine performance enhancementproducts or modifications might notbe covered under the vehiclewarranty.


Vehicle Care 10-3

Vehicle Checks

Engine Compartment Overview

United States Pickup Models Shown, Canada Similar


10-4 Vehicle Care

1. Remote Positive (+) Terminal

2. Battery

3. Coolant Surge Tank andPressure Cap

4. Engine Air Cleaner/Filter

5. Diesel Exhaust Fluid (DEF)Fill Tube

6. Engine Oil Dipstick

7. Engine Oil Fill Cap

8. Engine Fan (Out of View)

9. Automatic Transmission Dipstick

10. Power Steering Fluid Reservoir

11. Brake Fluid Reservoir

12. Windshield Washer FluidReservoir

13. Auxiliary Battery

14. Underhood Fuse Block

15. Remote Negative (-) Terminal


Vehicle Care 10-5

United States Van Models Shown, Canada Similar


10-6 Vehicle Care

1. Battery

2. Coolant Surge Tank andPressure Cap

3. Automatic Transmission Dipstick

4. Engine Oil Dipstick

5. Engine Fan (Out of View)

6. Engine Oil Fill Cap

7. Engine Air Cleaner/Filter

8. Air Cleaner/Filter RestrictionIndicator

9. Power Steering Fluid Reservoir

10. Brake Fluid Reservoir

11. Windshield Washer FluidReservoir

Engine OilTo ensure proper engineperformance and long life, carefulattention must be paid to engine oil.Following these simple, butimportant steps will help protectyour investment:. Always use engine oil approved

to the proper specification and ofthe proper viscosity grade. See“Selecting the Right Engine Oil”in this section.

. Check the engine oil levelregularly and maintain theproper oil level. See “CheckingEngine Oil” and “When to AddEngine Oil” in this section.

. Change the engine oil at theappropriate time. See “EngineOil Life System” in the ownermanual.

. Always dispose of engine oilproperly. See “What to Do withUsed Oil” in this section.

Checking Engine Oil

It is a good idea to check the engineoil level at each fuel fill. In order toget an accurate reading, the oilmust be warm, at normal operatingtemperature, and the vehicle mustbe on level ground. The engine oildipstick handle is a loop. SeeEngine Compartment Overview onpage 10-3 for the location of theengine oil dipstick.

Obtaining an accurate oil levelreading is essential:

1. Turn off the engine and allow atleast five minutes for the oil todrain back into the oil pan. Witha cool engine, allow 30 minutes.Checking the oil level too soonafter engine shutoff will notprovide an accurate oil levelreading.


Vehicle Care 10-7

{ Warning

The engine oil dipstick handlemay be hot; it could burn you.Use a towel or glove to touch thedipstick handle.

2. Pull out the dipstick and wipe itwith a clean paper towel or acloth, then push it back in all theway. Remove it again, keepingthe tip down.

When to Add Engine Oil

If the oil is below the cross-hatchedarea at the tip of the dipstick, add1 L (1 qt) of the recommended oiland then recheck the level. See“Selecting the Right Engine Oil” inthis section for an explanation of

what kind of oil to use. For engineoil crankcase capacity, seeCapacities and Specifications onpage 12-2.

{ Caution

Do not add too much oil. Oillevels above or below theacceptable operating rangeshown on the dipstick are harmfulto the engine. If you find that youhave an oil level above theoperating range, i.e., the enginehas so much oil that the oil levelgets above the cross-hatchedarea that shows the properoperating range, the engine couldbe damaged. You should drainout the excess oil or limit drivingof the vehicle and seek a serviceprofessional to remove theexcess amount of oil.

See Engine Compartment Overviewon page 10-3 for the location of theengine oil fill cap.

Be sure to add enough oil to put thelevel somewhere in the properoperating range. Push the dipstickall the way back in when through.

Selecting the Right Engine Oil

Specification

Oils designated as API CJ-4 arerequired for the vehicle. The CJ-4designation can appear either aloneor in combination with otherAmerican Petroleum Institute (API)designations, such as API CJ-4/SL.These letters show API levels ofquality.


10-8 Vehicle Care

American Petroleum Institute (API)symbol

This doughnut-shaped logo(symbol) is used on most oilcontainers to help you select thecorrect oil. It means that the oil hasbeen certified by the AmericanPetroleum Institute.

Look for this on the oil container,and use only those oils that displaythis logo.

{ Caution

Use only engine oils that have thedesignation CJ-4 for the dieselengine. Failure to use therecommended oil can damage theDPF and result in engine damagenot covered by the vehiclewarranty.

Viscosity Grade

Use SAE 15W-40 viscosity gradeengine oil.

When it is very cold, below −18°C(0°F), use SAE 5W-40 to improvecold starting. These numbers on theoil container show its viscosity,or thickness.

When selecting an oil of theappropriate viscosity grade, alwaysselect an oil of the correctspecification. See “Specification”earlier in this section.


Vehicle Care 10-9

Engine Oil Additives/EngineOil Flushes

Do not add anything to the oil. Therecommended oils with the APIservice symbol are all that isneeded for good performance andengine protection.

Engine oil system flushes are notrecommended and could causeengine damage not covered by thevehicle warranty.

What to Do with Used Oil

Used engine oil contains certainelements that can be unhealthy foryour skin and could even causecancer. Do not let used oil stay onyour skin for very long. Clean yourskin and nails with soap and water,or a good hand cleaner. Wash orproperly dispose of clothing or ragscontaining used engine oil. See themanufacturer's warnings about theuse and disposal of oil products.

Used oil can be a threat to theenvironment. If you change yourown oil, be sure to drain all the oil

from the filter before disposal. Neverdispose of oil by putting it in thetrash or pouring it on the ground,into sewers, or into streams orbodies of water. Recycle it by takingit to a place that collects used oil.

Engine Oil Life SystemThe engine oil life system calculatesengine oil life based on vehicle useand displays the CHANGE ENGINEOIL SOON message when it is timeto change the engine oil and filter.The oil life system should be resetto 100% only following an oilchange. See “Engine Oil LifeSystem” in the owner manual.

Automatic TransmissionFluid

When to Check and Change(Pickup Models)

Change the fluid and filter at theintervals listed. See MaintenanceSchedule on page 11-3.

And be sure to use the transmissionfluid listed in Recommended Fluidsand Lubricants on page 11-8.

How to Check

Because this operation can be alittle difficult, the decision may bemade to have this done at thedealer.

If the decision is made to performthis operation, be sure to follow allthe instructions here, or a falsereading on the dipstick could result.

{ Caution

Too much or too little fluid candamage the transmission. Toomuch can mean that some of thefluid could come out and fall onhot engine parts or exhaustsystem parts, starting a fire. Toolittle fluid could cause thetransmission to overheat. Be sureto get an accurate reading ifchecking the transmission fluid.


10-10 Vehicle Care

Wait at least 30 minutes beforechecking the transmission fluid levelif the vehicle has been driven:. When outside temperatures are

above 32°C (90°F).. At high speed for quite a while.. In heavy traffic — especially in

hot weather.. While pulling a trailer.

Checking the Fluid Level

Prepare the vehicle as follows:. Park the vehicle on a level

place. Keep the engine running.. With the parking brake applied,

place the shift lever in P (Park).. With a foot on the brake pedal,

run the engine for at leastone minute and shift to D(Drive). Then shift to N (Neutral)and then R (Reverse) to fill thehydraulic system. Then, put theshift lever in P (Park).

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

Then, without shutting off theengine, follow these steps:

Cold Check Procedure

The purpose of the cold check is todetermine if the transmission hasenough fluid to be operated safelyuntil a hot check can be made. Thefluid level rises as fluid temperatureincreases. DO NOT fill above theCOLD band if the transmission fluidis below normal operatingtemperatures.

1. Pull out the dipstick and wipe itwith a clean rag or paper towel.The transmission dipstick islocated near the center of the

engine compartment. SeeEngine Compartment Overviewon page 10-3 for location.

2. Push it back in all the way, waitthree seconds, and then pull itback out again.

3. Check the fluid level reading.Repeat the check procedure toverify the reading.

4. If the fluid level is within theCOLD band, the transmissionmay be operated until the fluid ishot enough to perform a hotcheck. If the fluid level is notwithin the COLD band, add ordrain fluid as necessary to bringthe level into the middle of theCOLD band.

5. Perform a hot check at the firstopportunity after the normaloperating temperature of 71°C(160°F) to 93°C (200°F) isreached.

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


Vehicle Care 10-11

Hot Check Procedure

The fluid must be hot to ensure anaccurate check. The fluid level risesas temperature increases.

1. Operate the transmission in D(Drive) until the normal operatingtemperature of 71°C (160°F) to93°C (200°F) is reached.

2. Pull out the dipstick and wipe itwith a clean rag or paper towel.

3. Push it back in all the way, waitthree seconds and then pull itback out again. Repeat thecheck procedure to verify thereading.

4. Safe operating level is within theHOT band on the dipstick. Thewidth of the HOT bandrepresents approximately 1.0 L(1.06 qt) of fluid at normaloperating temperature.

5. If the fluid level is not within theHOT band, add or drain fluid asnecessary to bring the fluid levelto within the HOT band.

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

Consistency of Readings

Always check the fluid level at leasttwice using the proceduresdescribed previously. Consistency isimportant to maintaining proper fluidlevel. If inconsistent readingspersist, check the transmissionbreather to be sure it is clean andunclogged. If readings are stillinconsistent, contact the dealer.

How to Add Fluid

In cold operation, Allisonrecommends using SyntheticTransmission Fluid approved toAllison Transmission specificationTES-295 in areas where theminimum ambient temperatures arebelow −40°C (−40°F).

Refer to the Maintenance Scheduleto determine what kind oftransmission fluid to use. SeeRecommended Fluids andLubricants on page 11-8.

Add fluid only after checking thetransmission fluid while it is hot.A cold check is used only as areference. If the fluid level is low,add only enough of the proper fluidto bring the level up to the HOT areafor a hot check. It does not takemuch fluid, generally less than 0.5 L(1 pt). Do not overfill.

{ Caution

Use of the incorrect automatictransmission fluid may damagethe vehicle, and the damage maynot be covered by the vehiclewarranty. Always use theautomatic transmission fluid listedin Recommended Fluids andLubricants on page 11-8.

. After adding fluid, recheck thefluid level as described under“How to Check.”

. When the correct fluid level isobtained, push the dipstick backin all the way.


10-12 Vehicle Care

When to Check and Change(Van Models)

Change the fluid and filter at theintervals listed. See MaintenanceSchedule on page 11-3.

Use the transmission fluid listed inRecommended Fluids andLubricants on page 11-8.

How to Check

Because this operation can be alittle difficult, the decision may bemade to have this done at thedealership service department.

If the decision is made to performthis operation, be sure to follow allthe instructions here, or a falsereading on the dipstick could result.

{ Caution

Too much or too little fluid candamage the transmission. Toomuch can mean that some of thefluid could come out and fall on

(Continued)

Caution (Continued)

hot engine parts or exhaustsystem parts, starting a fire. Toolittle fluid could cause thetransmission to overheat. Be sureto get an accurate reading ifchecking the transmission fluid.

Wait at least 30 minutes beforechecking the transmission fluid levelif the vehicle has been driven:. When outside temperatures are

above 32° C (90°F).. At high speed for quite a while.. In heavy traffic — especially in

hot weather.. While pulling a trailer.

To get the right reading, the fluidshould be at normal operatingtemperature, which is 82°C to 93°C(180°F to 200°F). Get the vehiclewarmed up by driving about 24 km(15 mi) when outside temperaturesare above 10°C (50°F). If it is colder

than 10°C (50°F), drive the vehicleuntil the engine temperature gaugemoves and then remains steady for10 minutes.

A cold check can be made after thevehicle has been sitting for eighthours or more with the engine off,but this is used only as a reference.Let the engine run at idle forfive minutes if outside temperaturesare 10°C (50°F) or more. If it iscolder than 10°C (50°F), the enginemay have to idle longer. Should thefluid level be low during this coldcheck, the fluid must be checkedwhen hot before adding fluid.Checking the fluid hot will give youa more accurate reading of the fluidlevel.

Checking the Fluid Level

Prepare the vehicle as follows:. Park the vehicle on a level

place. Keep the engine running.. With the parking brake applied,

place the shift lever in P (Park).


Vehicle Care 10-13

. With a foot on the brake pedal,move the shift lever througheach gear range, pausing forabout three seconds in eachrange. Then, position the shiftlever in P (Park).

. Let the engine run at idle forthree minutes or more.

Then, without shutting off theengine, follow these steps:

The transmission dipstick is locatednear the center of the enginecompartment and will be labeledwith the graphic shown.

See Engine Compartment Overviewon page 10-3 for location.

1. Flip the handle up and then pullout the dipstick and wipe it witha clean rag or paper towel.

2. Push it back in all the way, waitthree seconds, and then pull itback out again.

Check both sides of the dipstick,and read the lower level. Thefluid level must be in the COLDarea for a cold check or in theHOT or cross-hatched area for ahot check. Be sure to keep thedipstick pointed down to get anaccurate reading.

3. If the fluid level is in theacceptable range, push thedipstick in all the way, then flipthe handle down to lock thedipstick in place.

What Transmission Fluidto Use

Cold Operation

When temperatures are very cold,the transmission will prevent certainoperations to protect againstdamage. The information belowshows shift range availability basedon transmission oil temperatures:. All shift ranges available at

−25°C (−13°F) or above.. 2 (Second) and 3 (Third) shift

ranges only at −35°C (−31°F) to−25°C (−13°F).

. 2 (Second) shift range only at−35°C (−31°F) or lower.

Torque converter clutch operationwill also be prevented when air ortransmission oil temperatures arebelow certain levels.

Transmission shifting might befirmer with a cold transmission. Thisdifference in shift quality is normal.


10-14 Vehicle Care

1. For areas where ambienttemperatures stay above −40°C(−40°F), regular transmissionfluid can be used. SeeRecommended Fluids andLubricants on page 11-8.

2. For areas where ambienttemperatures fall below −40°C(−40°F), synthetic transmissionfluid approved to AllisonTransmission Specificationshould be used. SeeRecommended Fluids andLubricants on page 11-8. The

synthetic transmission fluid canbe used for all temperatureranges.

How to Add Fluid

See Maintenance Schedule onpage 11-3 to determine what kind oftransmission fluid to use. SeeRecommended Fluids andLubricants on page 11-8.

Using a funnel, add fluid down thetransmission dipstick tube only afterchecking the transmission fluidwhile it is hot. A cold check is usedonly as a reference. If the fluid levelis low, add only enough of theproper fluid to bring the level up tothe HOT area for a hot check.It does not take much fluid,generally less than 0.5 L (1 pt). Donot overfill.

{ Caution

Use of the incorrect automatictransmission fluid may damagethe vehicle, and the damage maynot be covered by the vehiclewarranty. Always use theautomatic transmission fluid listedin Recommended Fluids andLubricants on page 11-8.

. After adding fluid, recheck thefluid level as described under“How to Check” earlier in thissection.

. When the correct fluid level isobtained, push the dipstick backin all the way. Then flip thehandle down to lock the dipstickin place.


Vehicle Care 10-15

Engine Air Cleaner/Filter

Pickup Models

The air cleaner/filter assembly is onthe front corner of the enginecompartment on the passenger sideof the vehicle.

When to Inspect the Engine AirCleaner/Filter

Inspect the air cleaner/filter every25 000 km (15,000 mi) and replacethe filter if necessary.

How to Inspect the Engine AirCleaner/Filter

To inspect the air cleaner/filter,remove the engine air cleaner/filterby following Steps 1-9. When theengine air cleaner/filter is removed,lightly shake it to release loose dustand dirt. If the engine air cleaner/filter remains covered with dirt, anew filter is required. Never usecompressed air to clean the filter.

1. Cover Screws

2. Cover Electrical Connectors

3. Clamp

To inspect and replace the filter:

1. Disconnect the harnessconnectors from the air cleanercover electrical connector (2).

2. Loosen the screw on theclamp (3) holding the air outletduct in place. Do not remove theclamp. Move the air duct aside.

3. Remove the two air cleanerhousing cover screws (1).

4. Raise the air cleaner housingcover and remove the aircleaner/filter from the air cleanerhousing. Take care to dislodgeas little dirt as possible.

5. Clean the filter sealing surfaceand the housing.

6. Install the new engine aircleaner/filter.

7. Lower the air cleaner housingcover and secure with the twoscrews.

8. Install the air duct and tightenthe screw on the clamp tosecure it to the air cleanerhousing.

9. Install the harness electricalconnectors.

See Maintenance Schedule onpage 11-3 to determine when toreplace the engine air cleaner/filter.


10-16 Vehicle Care

{ Warning

Operating the engine with the aircleaner/filter off can cause you orothers to be burned. The aircleaner not only cleans the air; ithelps to stop flames if the enginebackfires. Use caution whenworking on the engine and do notdrive with the air cleaner/filter off.

{ Caution

If the air cleaner/filter is off, dirtcan easily get into the engine,which could damage it. Alwayshave the air cleaner/filter in placewhen you are driving.

Van Models

The air cleaner/filter assembly mayhave an air cleaner/filter restrictionindicator that shows when theengine air cleaner/filter is dirty andneeds to be serviced.

The air cleaner/filter restrictionindicator is on the air cleanerresonator.

When to Inspect the Engine AirCleaner/Filter

See Maintenance Schedule onpage 11-3.

How to Inspect the Engine AirCleaner/Filter

When the restriction indicator is inthe red/orange “change” zone,replace the filter and reset therestriction indicator. The air cleaner/filter assembly is at the front of theengine compartment.

1. Cover Screws

2. Restriction Indicator


Vehicle Care 10-17

To inspect and replace the filter andreset the restriction indicator:

1. Loosen the screws (1) on thecover of the housing and lift upthe cover.

2. Remove the air cleaner/filterfrom the housing. Take care todislodge as little dirt as possible.

3. Clean the filter sealing surfaceand the housing.

4. Install the new engine aircleaner/filter.

5. Reinstall the cover and tightenthe screws.

6. Reset the air cleaner/filterrestriction indicator (2),if equipped, by pressing the topbutton on the indicator.

See Maintenance Schedule onpage 11-3 to determine when toreplace the engine air cleaner/filter.

{ Warning

Operating the engine with the aircleaner/filter off can cause you orothers to be burned. The aircleaner not only cleans the air; ithelps to stop flames if the enginebackfires. Use caution whenworking on the engine and do notdrive with the air cleaner/filter off.

{ Caution

If the air cleaner/filter is off, dirtcan easily get into the engine,which could damage it. Alwayshave the air cleaner/filter in placewhen you are driving.

Cooling SystemThe cooling system allows theengine to maintain the correctworking temperature.

Pickup Models

1. Coolant Surge Tank

2. Coolant Surge TankPressure Cap

3. Engine Cooling Fan (Outof View)


10-18 Vehicle Care

Van Models

1. Coolant Surge Tank

2. Coolant Surge TankPressure Cap

3. Engine Cooling Fan (Outof View)

{ Warning

Heater and radiator hoses, andother engine parts, can be veryhot. Do not touch them. If you do,you can be burned.

Do not run the engine if there is aleak. If you run the engine, itcould lose all coolant. That couldcause an engine fire, and youcould be burned. Get any leakfixed before you drive the vehicle.

{ Caution

Using coolant other thanDEX-COOL® can causepremature engine, heater core,or radiator corrosion. In addition,the engine coolant could requirechanging sooner. Any repairswould not be covered by the

(Continued)

Caution (Continued)

vehicle warranty. Always useDEX-COOL (silicate-free) coolantin the vehicle.

Engine CoolantThe cooling system in the vehicle isfilled with DEX-COOL® enginecoolant. This coolant is designed toremain in the vehicle for 5 years or240 000 km (150,000mi), whicheveroccurs first, if you add onlyDEX-COOL extended life coolant.

The following explains the coolingsystem and how to add coolantwhen it is low. If there is a problemwith engine overheating, see EngineOverheating on page 10-23.

A 50/50 mixture of clean, drinkablewater and DEX-COOL coolant will:. Give freezing protection down to

−37°C (−34°F).. Give boiling protection up to

129°C (265°F).


Vehicle Care 10-19

. Protect against rust andcorrosion.

. Help keep the proper enginetemperature.

. Let the warning lights andgauges work as they should.

{ Caution

Using coolant other thanDEX-COOL® can causepremature engine, heater core,or radiator corrosion. In addition,the engine coolant could requirechanging sooner. Any repairswould not be covered by thevehicle warranty. Always useDEX-COOL (silicate-free) coolantin the vehicle.

What to Use

Use a 50/50 mixture of clean,drinkable water and DEX-COOLcoolant which will not damage

aluminum parts. If using thismixture, nothing else needs to beadded.

{ Warning

Adding only plain water or someother liquid to the cooling systemcan be dangerous. Plain waterand other liquids, can boil beforethe proper coolant mixture will.The vehicle's coolant warningsystem is set for the propercoolant mixture. With plain wateror the wrong mixture, the enginecould get too hot but you wouldnot get the overheat warning. Theengine could catch fire and you orothers could be burned. Use a 50/50 mixture of clean, drinkablewater and DEX-COOL coolant.

If coolant has to be added morethan four times a year, have thedealer check the vehicle coolingsystem.

{ Caution

If improper coolant mixture,inhibitors, or additives are used inthe vehicle cooling system, theengine could overheat and bedamaged. Too much water in themixture can freeze and crackengine cooling parts. The repairswould not be covered by thevehicle warranty. Use only theproper mixture of engine coolantfor the cooling system. SeeRecommended Fluids andLubricants on page 11-8.

Never dispose of engine coolant byputting it in the trash, or by pouringit on the ground, or pouring intosewers, streams, or bodies of water.Have the coolant changed by anauthorized service center, familiarwith legal requirements regardingused coolant disposal. This will helpprotect the environment and yourhealth.


10-20 Vehicle Care

Checking Coolant (Pickup Models)

The coolant surge tank is in theengine compartment on thepassenger side of the vehicle. SeeEngine Compartment Overview onpage 10-3 for location.

The coolant surge tank is dividedinto two sides. The pressurized side(engine side) should be completelyfull, while the non-pressurized side(fender side) will be significantlylower, depending on the operatingtemperature.

{ Warning

Turning the surge tank pressurecap when the engine and radiatorare hot can allow steam andscalding liquids to blow out andburn you badly. Never turn thesurge tank pressure cap— even alittle—when the engine andradiator are hot.

The vehicle must be on a levelsurface. When the engine is cold,the coolant level should be at orabove the MIN mark.

Checking Coolant (Van Models)

The coolant surge tank is near thecenter of the engine compartment.See Engine Compartment Overviewon page 10-3 for location.

{ Warning

Turning the surge tank pressurecap when the engine and radiatorare hot can allow steam andscalding liquids to blow out andburn you badly. Never turn the

(Continued)


Vehicle Care 10-21

Warning (Continued)

surge tank pressure cap— even alittle—when the engine andradiator are hot.

The vehicle must be on a levelsurface. When the engine is cold,the coolant level should be at theCOLD FILL mark.

Adding Coolant (Pickup and VanModels)

{ Caution

If coolant is changed or added,always add enough to fill thesystem completely or enginedamage may occur.

If more coolant is needed, add theproper DEX-COOL coolant mixtureat the surge tank, but be careful notto spill it.

{ Warning

You can be burned if you spillcoolant on hot engine parts.Coolant contains ethylene glycoland it will burn if the engine partsare hot enough. Do not spillcoolant on a hot engine.

{ Caution

This vehicle has a specificcoolant fill procedure. Failure tofollow this procedure could causethe engine to overheat and beseverely damaged.

{ Warning

Steam and scalding liquids from ahot cooling system can blow outand burn you badly. They are

(Continued)

Warning (Continued)

under pressure, and if you turnthe coolant surge tank pressurecap— even a little— they cancome out at high speed. Neverturn the cap when the coolingsystem, including the coolantsurge tank pressure cap, is hot.Wait for the cooling system andcoolant surge tank pressure capto cool if you ever have to turnthe pressure cap.

If no coolant is visible in the surgetank, add coolant as follows:


10-22 Vehicle Care

1. Remove the coolant surge tankpressure cap when the coolingsystem, including the coolantsurge tank pressure cap andupper radiator hose, is nolonger hot.

Turn the pressure cap slowlycounterclockwise about one fullturn. If a hiss is heard, wait forthat to stop. A hiss means thereis still some pressure left.

2. Keep turning the pressure capslowly, and remove it.

3. Slowly fill the coolant surge tank.Do not let the coolant level goabove the seam in the tank untilafter the engine comes tooperating temperature in Step 4.

4. With the coolant surge tankpressure cap off, start theengine and let it run until theengine coolant temperaturegauge indicates approximately90°C (195°F).

By this time, the coolant levelinside the coolant surge tankmay be lower. If the level islower, slowly add more of theproper mixture to the coolantsurge tank until it reaches theproper level.

On pickup models, slowlycontinue to add coolant so itgoes into the non-pressurizedside (fender side) of the coolantsurge tank until it reachesone-third of the capacity.

Fill the coolant surge tank to thefollowing levels:. At or above the MIN mark

on the pickup.. To the COLD FILL mark on

the van.

5. Replace the pressure cap. Besure the pressure cap ishand-tight and fully seated.

6. Verify coolant level after theengine is shut off and thecoolant is cold. If necessary,repeat coolant fill procedureSteps 1–6.

If the coolant level is still low afterhaving followed these steps twice,have the coolant system checked bya certified technician at the dealerfor a possible leak.

{ Caution

If the pressure cap is not tightlyinstalled, coolant loss andpossible engine damage mayoccur. Be sure the cap is properlyand tightly secured.


Vehicle Care 10-23

Engine OverheatingThere is an engine coolanttemperature gauge on theinstrument panel cluster. See theowner manual.

If Steam Is Coming from theEngine Compartment

{ Warning

Steam from an overheated enginecan burn you badly, even if youjust open the hood. Stay awayfrom the engine if you see or hearsteam coming from it. Just turn itoff and get everyone away fromthe vehicle until it cools down.Wait until there is no sign ofsteam or coolant before you openthe hood.

If you keep driving when theengine is overheated, the liquidsin it can catch fire. You or otherscould be badly burned. Stop the

(Continued)

Warning (Continued)

engine if it overheats, and get outof the vehicle until the engineis cool.

{ Caution

Running the engine withoutcoolant may cause damage or afire. Vehicle damage would not becovered by the vehicle warranty.

If No Steam Is Coming fromthe Engine Compartment

A Driver Information Center (DIC)message, along with a low coolantcondition, can indicate a seriousproblem.

If there is an engine overheatwarning and the vehicle does nothave a low coolant condition, andno steam is heard or seen, theproblem may not be too serious.Sometimes the engine can get alittle too hot when the vehicle:. Climbs a long hill on a hot day.. Stops after high-speed driving.. Idles for long periods in traffic.. Tows a trailer. See “Driving on

Grades” in the owner manual.

If the DIC message comes on withno sign of steam, try this for aminute or so:

1. In heavy traffic, let the engineidle in N (Neutral) while stopped.If it is safe to do so, pull off theroad, shift to P (Park) orN (Neutral), and let theengine idle.

2. Turn on the heater to full hot atthe highest fan speed and openthe window as necessary.


10-24 Vehicle Care

If the vehicle no longer has theoverheat warning, the vehicle canbe driven. Just to be safe, driveslower for about 10 minutes. If thewarning does not come back on,drive normally and have the coolingsystem checked for proper fill andfunction.

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

If there is still no sign of steam andthe vehicle is equipped with anengine driven cooling fan, pushdown the accelerator until theengine speed is about twice as fastas normal idle speed for at leastfive minutes while the vehicle isparked. If the warning is still there,turn off the engine and get everyoneout of the vehicle until it cools down.

The decision may be made not to liftthe hood, but to get service helpright away.


Service and Maintenance 11-1

Service andMaintenance

General InformationGeneral Information . . . . . . . . . . 11-1

Maintenance ScheduleMaintenance Schedule . . . . . . . 11-3

Special Application ServicesSpecial ApplicationServices . . . . . . . . . . . . . . . . . . . . 11-7

Recommended FluidsRecommended Fluids andLubricants . . . . . . . . . . . . . . . . . . 11-8

Maintenance ReplacementParts . . . . . . . . . . . . . . . . . . . . . . 11-11

Maintenance RecordsMaintenance Records . . . . . . 11-12

General InformationThis maintenance section applies tovehicles with a diesel engine. Forgasoline engine vehicles, see themaintenance schedule section inthe owner manual.

Your vehicle is an importantinvestment. This section describesthe required maintenance for thevehicle. Follow this schedule to helpprotect against major repairexpenses resulting from neglect orinadequate maintenance. It mayalso help to maintain the value ofthe vehicle if it is sold. It is theresponsibility of the owner to haveall required maintenance performed.

Your dealer has trained technicianswho can perform requiredmaintenance using genuinereplacement parts. They haveup-to-date tools and equipment forfast and accurate diagnostics. Manydealers have extended evening andSaturday hours, courtesy

transportation, and onlinescheduling to assist with serviceneeds.

Your dealer recognizes theimportance of providingcompetitively priced maintenanceand repair services. With trainedtechnicians, the dealer is the placefor routine maintenance such as oilchanges and tire rotations andadditional maintenance items liketires, brakes, batteries, and wiperblades.

{ Caution

Damage caused by impropermaintenance can lead to costlyrepairs and may not be coveredby the vehicle warranty.Maintenance intervals, checks,inspections, recommended fluids,and lubricants are important tokeep the vehicle in good workingcondition.


11-2 Service and Maintenance

The Tire Rotation and RequiredServices are the responsibility of thevehicle owner. It is recommended tohave your dealer perform theseservices every 12 000 km/7,500 mi.Proper vehicle maintenance helps tokeep the vehicle in good workingcondition, improves fuel economy,and reduces vehicle emissions.

Because of the way people usevehicles, maintenance needs vary.There may need to be morefrequent checks and services. TheAdditional Required Services -Normal are for vehicles that:. Carry passengers and cargo

within recommended limits onthe Tire and Loading Informationlabel. See “Vehicle Load Limits”in the owner manual.

. Are driven on reasonable roadsurfaces within legal drivinglimits.

. Use the recommended fuel. SeeFuel for Diesel Engines onpage 9-21.

Refer to the information in theMaintenance Schedule AdditionalRequired Services - Normal chart.

The Additional Required Services -Severe are for vehicles that are:. Mainly driven in heavy city traffic

in hot weather.. Mainly driven in hilly or

mountainous terrain.. Frequently towing a trailer.. Used for high speed or

competitive driving.. Used for taxi, police, or delivery

service.

Refer to the information in theMaintenance Schedule AdditionalRequired Services - Severe chart.

{ Warning

Performing maintenance work canbe dangerous and can causeserious injury. Performmaintenance work only if therequired information, proper tools,and equipment are available.If they are not, see your dealer tohave a trained technician do thework. See “Doing Your OwnService Work” in the ownermanual.



MaintenanceScheduleOwner Checks and Services

At Each Fuel Stop. Check the engine oil level. See

Engine Oil on page 10-6.

Once a Month. Check the tire inflation

pressures. See “Tire Pressure”in the owner manual.

. Inspect the tires for wear. See“Tire Inspection” in the ownermanual.

. Check the windshield washerfluid level. See “Washer Fluid” inthe owner manual.

Engine Oil Change

When the CHANGE ENGINE OILSOON message displays, have theengine oil and filter changed withinthe next 1 000 km/600 mi. If drivenunder the best conditions, theengine oil life system might not

indicate the need for vehicle servicefor more than a year. The engine oiland filter must be changed at leastonce a year and the oil life systemmust be reset. Your trained dealertechnician can perform this work.If the engine oil life system is resetaccidentally, service the vehiclewithin 5 000 km/3,000 mi since thelast service. Reset the oil lifesystem when the oil is changed.See Engine Oil Life System onpage 10-9.

Tire Rotation and RequiredServices Every 12 000 km/7,500 mi

Rotate the tires, if recommended forthe vehicle, and perform thefollowing services. See “TireRotation” in the owner manual.. Check engine oil level and oil

life percentage. If needed,change engine oil and filter, andreset oil life system. See EngineOil on page 10-6 and Engine OilLife System on page 10-9.

. Check engine coolant level. SeeEngine Coolant on page 10-18.

. Check windshield washer fluidlevel. See “Washer Fluid” in theowner manual.

. Visually inspect windshield wiperblades for wear, cracking,or contamination. See “ExteriorCare” in the owner manual.Replace worn or damaged wiperblades. See “Wiper BladeReplacement” in the ownermanual.

. Check tire inflation pressures.See “Tire Pressure” in the ownermanual.

. Inspect tire wear. See “TireInspection” in the owner manual.

. Visually check for fluid leaks.

. Inspect engine air cleaner filter.See Engine Air Cleaner/Filter onpage 10-15.

. Inspect brake system.



. Visually inspect steering,suspension, and chassiscomponents for damaged, loose,or missing parts or signs ofwear. See “Exterior Care” in theowner manual. Lubricate thesuspension and steeringcomponents at least every otheroil change (If equipped withgrease fittings).

. Check restraint systemcomponents. See “SafetySystem Check” in the ownermanual.

. Visually inspect fuel system fordamage or leaks.

. Visually inspect exhaust systemand nearby heat shields forloose or damaged parts.

. Lubricate body components. See“Exterior Care” in the ownermanual.

. Check starter switch. See“Starter Switch Check” in theowner manual.

. Check automatic transmissionshift lock control function. See“Automatic Transmission ShiftLock Control Function Check” inthe owner manual.

. Check ignition transmission lock.See “Ignition Transmission LockCheck” in the owner manual.

. Check parking brake andautomatic transmission parkmechanism. See “Park Brakeand P (Park) Mechanism Check”in the owner manual.

. Check accelerator pedal fordamage, high effort, or binding.Replace if needed.

. Visually inspect gas strut forsigns of wear, cracks, or otherdamage. Check the hold openability of the strut. See yourdealer if service is required.

. Pickup models: Inspect sunrooftrack and seal, if equipped. See“Sunroof” in the owner manual.

. Pickup models: Verify spare tirekey lock operation and lubricateas needed. See “Tire Changing”in the owner manual.



Maintenance ScheduleAdditional RequiredServices - Normal

12000km/7,500mi

24000km/15,000mi

36000km/22,500mi

48000km/30,000mi

60000km/37,500mi

72000km/45,000mi

84000km/52,500mi

96000km/60,000mi

108000km/67,500mi

120000km/75,000mi

132000km/82,500mi

144000km/90,000mi

156000km/97,500mi

168000km/105,000mi

180000km/112,500mi

192000km/120,000mi

204000km/127,500mi

216000km/135,000mi

228000km/142,500mi

240000km/150,000mi

Rotate tires and perform Required Services.Check engine oil level and oil life percentage.Change engine oil and filter, if needed.

@ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @

Replace engine air cleaner filter. (1) @ @ @

Change automatic transmission fluid and filter.Filter is external on pickups and internal on vans. @

Change automatic transmission external filter -pickup only. @ @

Drain and fill engine cooling system. (2) @

Visually inspect accessory drive belts. (3) @

Replace brake fluid. (4) @

Footnotes — MaintenanceSchedule Additional RequiredServices - Normal

(1) Or every four years, whichevercomes first.

(2) Or every five years, whichevercomes first. See Cooling System onpage 10-17.

(3) Or every 10 years, whichevercomes first. Inspect for fraying,excessive cracking, or damage;replace, if needed.

(4) Or every 10 years, whichevercomes first.



Maintenance ScheduleAdditional RequiredServices - Severe

12000km/7,500mi

24000km/15,000mi

36000km/22,500mi

48000km/30,000mi

60000km/37,500mi

72000km/45,000mi

84000km/52,500mi

96000km/60,000mi

108000km/67,500mi

120000km/75,000mi

132000km/82,500mi

144000km/90,000mi

156000km/97,500mi

168000km/105,000mi

180000km/112,500mi

192000km/120,000mi

204000km/127,500mi

216000km/135,000mi

228000km/142,500mi

240000km/150,000mi

Rotate tires and perform Required Services.Check engine oil level and oil life percentage.Change engine oil and filter, if needed.

@ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @

Replace engine air cleaner filter. (1) @ @ @

Change automatic transmission fluid and filter.Filter is external on pickups and internal on vans. @ @ @

Change automatic transmission external filter -pickup only. @ @

Drain and fill engine cooling system. (2) @

Visually inspect accessory drive belts. (3) @

Replace brake fluid. (4) @

Footnotes — MaintenanceSchedule Additional RequiredServices - Severe

(1) Or every four years, whichevercomes first.

(2) Or every five years, whichevercomes first. See Cooling System onpage 10-17.

(3) Or every 10 years, whichevercomes first. Inspect for fraying,excessive cracking, or damage;replace, if needed.

(4) Or every 10 years, whichevercomes first.



Special ApplicationServices. Severe Commercial Use

Vehicles Only: Lubricate chassiscomponents every 5 000 km/3,000 mi.

. Have underbody flushing serviceperformed once a year.

For Pickups

Replace the fuel filter when theCHANGE FUEL FILTER message inthe Driver Information Center (DIC)comes on. See Fuel SystemMessages on page 5-13. If the fuelfilter has not been replaced, or if thevehicle has been driven 36 000 km/22,500 mi or more since the fuelfilter was last replaced, replace thefilter and reset the message. Thediesel fuel filter may need to bereplaced more frequently, based onbiodiesel usage, driving in severedust climate or off-road driving ortowing a trailer for extendedperiods. The fuel filter should bereplaced at least every 2 years.

For Vans

Replace the fuel filter when theCHANGE FUEL FILTER message inthe Driver Information Center (DIC)comes on. See Fuel SystemMessages on page 5-13. If the fuelfilter has not been replaced, or if thevehicle has been driven22,500 miles (36,000 KM) or moresince the fuel filter was lastreplaced, replace the filter and resetthe message. The diesel fuel filtermay need to be replaced morefrequently, based on biodieselusage, driving in severe dustclimate or off-road driving or towinga trailer for extended periods. Thefuel filter should be replaced at leastevery 2 years. Also, inspect andclean the fuel pump screen,if necessary, at each fuel filterinspection or replacement.



Recommended Fluids

Recommended Fluids and LubricantsFluids and lubricants identified below by name, part number, or specification can be obtained from your dealer.

Usage Fluid/Lubricant

Engine Oil Engine oils with the letters CJ-4 are required for your vehicle. The CJ-4designation can appear either alone or in combination with other AmericanPetroleum Institute (API) designations, such as API CJ-4/SL. These lettersshow API levels of quality. To determine the preferred viscosity for yourvehicle's diesel engine, see Engine Oil on page 10-6.

Engine Coolant 50/50 mixture of clean, drinkable water and use only DEX-COOL® coolant.See Engine Coolant on page 10-18.

Hydraulic Brake System DOT 3 Hydraulic Brake Fluid (GM Part No. 19299818, inCanada 19299819).

Windshield Washer Automotive windshield washer fluid that meets regional freeze protectionrequirements.

Diesel Exhaust AftertreatmentSystem

Diesel Exhaust Fluid (GM Part No. 19286291, in Canada 88862660) ordiesel exhaust fluid that meets ISO 22241-1 or displays the API DieselExhaust Fluid Certification Mark.

Van Models: Parking Brake CableGuides

Chassis Lubricant (GM Part No. 12377985, in Canada 88901242) orlubricant meeting requirements of NLGI #2, Category LB or GC-LB.

Power Steering System GM Power Steering Fluid (GM Part No. 89021185, in Canada 89021186).




Automatic Transmission DEXRON®-VI Automatic Transmission Fluid.Allison Transmission Only: For areas where ambient temperatures arebelow -40°C (-40°F) use Synthetic Transmission Fluid approved to AllisonTransmission specification TES-295 (GM Part No. 12378515, inCanada 88900701).

Key Lock Cylinders Multi-Purpose Lubricant, Superlube (GM Part No. 12346241, inCanada 10953474).

Pickup Models: Floor Shift Linkage Lubriplate Lubricant Aerosol (GM Part No. 89021668, in Canada 89021674)or lubricant meeting requirements of NLGI #2 Category LB or GC-LB.

Chassis Lubrication Chassis Lubricant (GM Part No. 12377985, in Canada 88901242) orlubricant meeting requirements of NLGI #2, Category LB or GC-LB.

Van Models: Front Wheel Bearings Wheel bearing lubricant meeting requirements of NLGI #2, Category GC orGC-LB (GM Part No. 1051344, in Canada 993037).

Front and Rear Axle SAE 75W-90 Synthetic Axle Lubricant (GM Part No. 89021677, inCanada 89021678).

Van Models: One-Piece PropshaftSlip Yoke Spline, Two-PiecePropshaft Slip-in-Tube Spline

Spline Lubricant, Special Lubricant (GM Part No. 19257121, inCanada 19257122).

Pickup Models: Front Axle PropshaftSpline

Spline Lubricant, Special Lubricant (GM Part No. 19257121, inCanada 19257122).




Pickup Models: Rear Driveline CenterSpline

Chassis Lubricant (GM Part No. 12377985, in Canada 88901242) orlubricant meeting requirements of NLGI #2, Category LB or GC-LB.

Hood Hinges Multi-Purpose Lubricant, Superlube (GM Part No. 12346241, inCanada 10953474).

Pickup Models: Body Door HingePins, Tailgate Hinge and Linkage,

and Fuel Door Hinge

Multi-Purpose Lubricant, Superlube (GM Part No. 12346241, inCanada 10953474).

Pickup Models: Tailgate Handle PivotPoints, Hinges, Latch Bolt, and

Linkage

Multi-Purpose Lubricant, Superlube (GM Part No. 12346241, inCanada 10953474).

Weatherstrip Conditioning Weatherstrip Lubricant (GM Part No. 3634770, in Canada 10953518) orDielectric Silicone Grease (GM Part No. 12345579, in Canada 10953481).

Weatherstrip Squeaks Synthetic Grease with Teflon, Superlube (GM Part No. 12371287, inCanada 10953437).



Maintenance Replacement PartsReplacement parts identified below by name, part number, or specification can be obtained from your dealer.

Part GM Part Number ACDelco Part Number

Engine Air Cleaner/Filter

Pickup Models 25945274 A3141C

Van Models 20815924 A3140C

Engine Fuel Filter 12646512 TP3012

Fuel Pump Screen Kit for Van Models 19259252 TP3017

Engine Oil Filter 88917036 PF2232

Use only the specified filters.



Maintenance RecordsAfter the scheduled services are performed, record the date, odometer reading, who performed the service, and thetype of services performed in the boxes provided. Retain all maintenance receipts.

DateOdometerReading

Serviced By Services Performed



DateOdometerReading



Technical Data 12-1

Technical Data

Vehicle DataCapacities andSpecifications . . . . . . . . . . . . . . 12-2

Engine Drive Belt Routing . . . 12-4


12-2 Technical Data

Vehicle Data

Capacities and SpecificationsThe following approximate capacities are given in metric and English conversions. See Recommended Fluids andLubricants on page 11-8.

Application

Capacities

Metric English

Cooling System (Pickup Models) 27.0 L 28.5 qt

Cooling System (Van Models)

Front Heat or AC Only 20.0 L 21.2 qt

Front Heat or AC Plus Fuel Operated Heater (FOH) 20.9 L 22.1 qt

Front and Rear Heat or AC Only 21.5 L 22.7 qt

Front and Rear Heat or AC Plus Fuel OperatedHeater (FOH)

22.4 L 23.7 qt

Diesel Exhaust Fluid (DEF) Tank*

Pickup Models 20.1 L 5.3 gal

Van Models 20.1 L 5.3 gal

Engine Oil with Filter 9.5 L 10.0 qt

Transmission Fluid (Pan Removal and Filter Replacement) 7.0 L 7.4 qt


Technical Data 12-3

Application

Capacities

Metric English

*Do not overfill the DEF tank. See Diesel Exhaust Fluid on page 9-13.

All quantities are approximate. When adding, be sure to fill to the appropriate level, as recommended in thismanual. Recheck fluid level after filling.

Engine Specifications

Engine VIN Code Type

6.6L V8 Turbo Diesel (LGH Engine) L V8

6.6L V8 Turbo Diesel (LML Engine) 8 V8


12-4 Technical Data

Engine Drive Belt Routing


INDEX i-1

AAccessories andModifications . . . . . . . . . . . . . . . . . 10-1

Air Cleaner/Filter, Engine . . . . . 10-15AutomaticTransmission Fluid . . . . . . . . . . .10-9

BBrakeExhaust . . . . . . . . . . . . . . . . . . . . . .9-20

CCanadian Vehicle Owners . . . . . . . . . iiCapacities andSpecifications . . . . . . . . . . . . . . . . 12-2

CheckEngine Light . . . . . . . . . . . . . . . . . . . 5-8

Cluster, Instrument . . . . . . . . . . . . . 5-2Cold Weather Operation . . . . . . . 9-27CoolantEngine . . . . . . . . . . . . . . . . . . . . . . 10-18

Cooling System . . . . . . . . . . . . . . . 10-17Engine Messages . . . . . . . . . . . .5-12

CoversWinter . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

DDieselStarting Your Engine . . . . . . . . . . . 9-1

Diesel Exhaust Fluid . . . . . . 1-3, 9-13Diesel Exhaust Fluid (DEF)Warning Light . . . . . . . . . . . . . . . . 5-11

Diesel Exhaust FluidMessages . . . . . . . . . . . . . . . . . . . . 5-13

Diesel Particulate Filter . . . . . . . . 9-11Diesel Particulate FilterMessages . . . . . . . . . . . . . . . . . . . . 5-14

Drive Belt Routing, Engine . . . . . 12-4Driver InformationCenter (DIC) . . . . . . . . . . . . . . . . . 5-11

EEngineAir Cleaner/Filter . . . . . . . . . . . 10-15Check and Service EngineSoon Light . . . . . . . . . . . . . . . . . . . 5-8

Compartment Overview . . . . . . .10-3Coolant . . . . . . . . . . . . . . . . . . . . . 10-18Cooling System . . . . . . . . . . . . . 10-17Cooling System Messages . . .5-12Drive Belt Routing . . . . . . . . . . . .12-4Heater . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Engine (cont'd)Oil Life System . . . . . . . . . . . . . . .10-9Oil Messages . . . . . . . . . . . . . . . . .5-13Oil Pressure Gauge . . . . . . . . . . . 5-7Overheating . . . . . . . . . . . . . . . . 10-23Power Messages . . . . . . . . . . . . .5-13Starting Your Diesel . . . . . . . . . . . 9-1

EnginesDiesel Fuel . . . . . . . . . . . . . . . . . . .9-21

Exhaust Brake . . . . . . . . . . . . . . . . . 9-20Exhaust FluidDiesel . . . . . . . . . . . . . . . . . . . . . . . .9-13

FFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11Replacement (Fuel) . . . . . . . . . . .9-33

Filter,Engine Air Cleaner . . . . . . . . . 10-15

FluidAutomatic Transmission . . . . . .10-9Diesel Exhaust . . . . . . . . . . . . . . . . 1-3

FuelCold Weather Operation . . . . . .9-27Diesel Engines . . . . . . . . . . . . . . .9-21Filling a Portable FuelContainer . . . . . . . . . . . . . . . . . . .9-37


i-2 INDEX

Fuel (cont'd)Filling the Tank . . . . . . . . . . . . . . .9-36Filter Replacement . . . . . . . . . . .9-33Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Operated Heater (FOH) . . . . . . .9-10Running out of Fuel . . . . . . . . . . .9-32System Messages . . . . . . . . . . . .5-13Water in Fuel . . . . . . . . . . . . . . . . .9-28What to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . .9-26

What to Use in the U.S. . . . . . .9-21Fuel for Diesel Engines . . . . . . . . 9-21

GGaugesEngine Oil Pressure . . . . . . . . . . . 5-7Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

General InformationService and Maintenance . . . . . 11-1

HHeaterEngine . . . . . . . . . . . . . . . . . . . . . . . . . 9-9Fuel Operated . . . . . . . . . . . . . . . .9-10

IInstrument Cluster . . . . . . . . . . . . . . 5-2Introduction . . . . . . . . . . . . . . . . . . . . . . . . ii

LLampsMalfunction Indicator . . . . . . . . . . 5-8

LightsPower Take-off . . . . . . . . . . . . . . . 5-11Wait to Start . . . . . . . . . . . . . . . . . .5-10

MMaintenanceRecords . . . . . . . . . . . . . . . . . . . . .11-12

Maintenance Schedule . . . . . . . . 11-3Recommended Fluids andLubricants . . . . . . . . . . . . . . . . . . . 11-8

Malfunction Indicator Lamp . . . . . 5-8MessagesDiesel Exhaust Fluid . . . . . . . . . .5-13Diesel Particulate Filter . . . . . . .5-14Engine Cooling System . . . . . . .5-12Engine Oil . . . . . . . . . . . . . . . . . . . .5-13Engine Power . . . . . . . . . . . . . . . .5-13Fuel System . . . . . . . . . . . . . . . . . .5-13

Messages (cont'd)Service Vehicle . . . . . . . . . . . . . . .5-14Starting the Vehicle . . . . . . . . . . .5-14Vehicle . . . . . . . . . . . . . . . . . . . . . . .5-12Vehicle Speed . . . . . . . . . . . . . . . .5-15

OOilEngine . . . . . . . . . . . . . . . . . . . . . . . .10-6Engine Oil Life System . . . . . . .10-9Engine Oil Pressure Gauge . . . . 5-7Messages . . . . . . . . . . . . . . . . . . . .5-13

Overheating, Engine . . . . . . . . . . 10-23

PParkingOver Things That Burn . . . . . . . 9-11

PersonalizationVehicle . . . . . . . . . . . . . . . . .5-16, 5-18

Power Take-Off (PTO) . . . . . . . . . 9-43Power Take-Off Light . . . . . . . . . . 5-11


INDEX i-3

RRecommended Fluids andLubricants . . . . . . . . . . . . . . . . . . . . 11-8

RecordsMaintenance . . . . . . . . . . . . . . . . .11-12

Replacement PartsMaintenance . . . . . . . . . . . . . . . . .11-11

Routing, Engine Drive Belt . . . . . 12-4Running out of Fuel . . . . . . . . . . . . 9-32

SServiceAccessories andModifications . . . . . . . . . . . . . . . .10-1

Engine Soon Light . . . . . . . . . . . . . 5-8Maintenance Records . . . . . . .11-12Maintenance, GeneralInformation . . . . . . . . . . . . . . . . . . 11-1

Vehicle Messages . . . . . . . . . . . .5-14ServicesSpecial Application . . . . . . . . . . . 11-7

Special Application Services . . . 11-7Specifications andCapacities . . . . . . . . . . . . . . . . . . . . 12-2

Starting the Diesel Engine . . . . . . 9-1

Starting the VehicleMessages . . . . . . . . . . . . . . . . . . . . 5-14

SupplementUsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

TTowingTrailer . . . . . . . . . . . . . . . . . . . . . . . .9-38

TrailerTowing . . . . . . . . . . . . . . . . . . . . . . . .9-38

TransmissionFluid, Automatic . . . . . . . . . . . . . .10-9

UUsing This Supplement . . . . . . . . . . . . ii

VVehicleCanadian Owners . . . . . . . . . . . . . . . iiMessages . . . . . . . . . . . . . . . . . . . .5-12Personalization . . . . . . . . .5-16, 5-18Speed Messages . . . . . . . . . . . . .5-15

WWait to Start Light . . . . . . . . . . . . . 5-10Warning LightDiesel Exhaust Fluid (DEF) . . . 5-11

Water in Fuel . . . . . . . . . . . . . . . . . . 9-28What Fuel to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . . . 9-26

What Fuel to Use inthe U.S. . . . . . . . . . . . . . . . . . . . . . . 9-21

Winter Cover . . . . . . . . . . . . . . . . . . . 9-5


i-4 INDEX

2 NOTES

duramax diesel manual - chevrolet

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