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Black plate (1,1)Chevrolet/GMC DURAMAX Diesel - 2013 - CRC - 3/29/12

2013 Chevrolet/GMC DURAMAX Diesel M

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

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

Information Displays . . . . . . . . . . . 5-9Vehicle Messages . . . . . . . . . . . . 5-10Vehicle Personalization . . . . . . . 5-15

Driving and Operating . . . . . . . . 9-1Starting and Operating . . . . . . . . . 9-1Diesel Particulate Filter . . . . . . . 9-10Diesel Exhaust Fluid . . . . . . . . . 9-12

Brakes . . . . . . . . . . . . . . . . . . . . . . . 9-18Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19Towing . . . . . . . . . . . . . . . . . . . . . . . 9-38Conversions and Add-Ons . . . 9-43

Vehicle Care . . . . . . . . . . . . . . . . . 10-1General Information . . . . . . . . . . 10-1Vehicle Checks . . . . . . . . . . . . . . . 10-3Electrical System . . . . . . . . . . . . 10-27

Service and Maintenance . . . 11-1General Information . . . . . . . . . . 11-1Maintenance Schedule . . . . . . . 11-3Special ApplicationServices . . . . . . . . . . . . . . . . . . . . 11-8

Additional Maintenanceand Care . . . . . . . . . . . . . . . . . . . . 11-8

Recommended Fluids . . . . . . . 11-12Maintenance Records . . . . . . . 11-16

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 marksof General Motors LLC, itssubsidiaries, affiliates, or licensors.

This manual describes features thatmay or may not be on your specificvehicle either because they areoptions that you did not purchase ordue to changes subsequent to theprinting of this owner manual.Please refer to the purchasedocumentation relating to yourspecific vehicle to confirm each ofthe features found on your vehicle.

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 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 copy of thismanual can be obtained from yourdealer or from:

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

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. 20955139 A First Printing ©2012 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 . . . . . . . 1-3Diesel Exhaust Fluid . . . . . . . . . . 1-4

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 11‑12and Automatic Transmission Fluidon page 10‑10.

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, on most vehicles, displays aDIC message when it is necessaryto change the engine oil and filter.The oil life system should be resetonly following an oil change.

Resetting the Oil Life System

To reset the Engine Oil Life Systemon van models:

1. Display the OIL LIFEREMAINING on the DIC.

2. Press and hold the SET/RESETbutton on the DIC for more thanfive seconds. The oil life willchange to 100%.

To reset the Engine Oil Life Systemon most pickup models:

1. Display the OIL LIFEREMAINING on the DIC. If thevehicle does not have DICbuttons, the vehicle must be inP (Park) to access this display.

2. Press and hold the SET/RESETbutton on the DIC, or the tripodometer reset stem if thevehicle does not have DICbuttons, for more thanfive seconds. The oil life willchange to 100%.

On all models, the Engine Oil LifeSystem can be reset as follows:

1. Turn the ignition to ON/RUN withthe engine off.

2. Fully press the accelerator pedalslowly three times withinfive seconds.

3. Display the OIL LIFEREMAINING on the DIC. If thedisplay shows 100%, the systemis reset.

4. Turn the key to LOCK/OFF.


In Brief 1-3

See Engine Oil Life System onpage 10‑9.

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 enginecomputer 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 forapproximately 30 minutes and atspeeds greater than 48 km/h(30 mph) to clean the DPFeffectively. If the vehicle is returnedto idle during the cleaning process,the driver may notice a slightlydifferent sound or a slightly elevatedengine idle speed. This is normal.No action is required on the part ofthe driver during a regular DPFcleaning. See Diesel ParticulateFilter on page 9‑10.

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 condition

of 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 9‑10 and Engine PowerMessages on page 5‑11.


1-4 In Brief

Fuel

Use Ultra-Low Sulfur DieselFuel (ULSD)

Use Ultra-Low Sulfur Diesel Fuel(ULSD) only. The emission controlhardware used on the vehicle maybe damaged by using fuel with highsulfur levels. Use only fuel that isdispensed from pumps bearing theULSD 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 anddoes 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 9‑19 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.

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. For

vehicles with an active OnStar®subscription, OnStar can help tolocate a DEF retailer. For moreinformation on locating DEF seewww.afdc.energy.gov/afdc/locator/def/. See “Customer AssistanceOffices” in the owner manual forphone numbers to assist you incontacting a GM dealer. SeeRecommended Fluids andLubricants on page 11‑12.

As the DEF tank becomes low onfluid, warnings begin withapproximately 1600 km(1,000 miles) of remaining range.These warnings will increase inintensity as the tank becomesempty. Once the tank is empty, thevehicle speed will be limited. If thereis an issue with the quality of thefluid or the exhaust fluid system,warnings will be displayed in theDriver Information Center (DIC).See Diesel Exhaust Fluid onpage 9‑12.


Instruments and Controls 5-1

Instruments andControls

Warning Lights, Gauges, andIndicatorsInstrument Cluster . . . . . . . . . . . . 5-2Fuel Gauge . . . . . . . . . . . . . . . . . . . 5-4Engine Oil Pressure Gauge . . . 5-5Malfunction Indicator Lamp . . . 5-6Wait-to-Start Light . . . . . . . . . . . . . 5-8Diesel Exhaust Fluid (DEF)Warning Light . . . . . . . . . . . . . . . . 5-8

Information DisplaysDriver InformationCenter (DIC) . . . . . . . . . . . . . . . . . 5-9

Vehicle MessagesVehicle Messages . . . . . . . . . . . 5-10Engine Cooling SystemMessages . . . . . . . . . . . . . . . . . . 5-10

Engine Oil Messages . . . . . . . . 5-10Engine Power Messages . . . . 5-11Fuel System Messages . . . . . . 5-11Diesel Exhaust FluidMessages . . . . . . . . . . . . . . . . . . 5-11

Diesel Particulate FilterMessages . . . . . . . . . . . . . . . . . . 5-12

Service Vehicle Messages . . . 5-12Starting the VehicleMessages . . . . . . . . . . . . . . . . . . 5-12

Transmission Messages . . . . . 5-13Vehicle Speed Messages . . . . 5-13

Vehicle PersonalizationVehicle Personalization . . . . . . 5-15


5-2 Instruments and Controls

Warning Lights, Gauges, and Indicators

Instrument Cluster

English 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

Notice: 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, butif the oil level is within theoperating range and the oilpressure is still low, have thevehicle serviced. Always followthe maintenance schedule forchanging 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 is outside the normaloperating range of 0-548 kPa(0-80 psi), check the oil levelimmediately. DO NOT operate theengine with the oil pressure warninglight on or an ENGINE OIL LOWADD OIL message 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 9‑12.

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.

Notice: If the vehicle iscontinually driven with this lighton, the emission controls mightnot work as well, the vehicle fueleconomy might not be as good,and the engine might not run assmoothly. This could lead tocostly repairs that might not becovered by the vehicle warranty.

Notice: Modifications made to theengine, transmission, exhaust,intake, or fuel system of thevehicle or the replacement of theoriginal tires with other than

those of the same TirePerformance Criteria (TPC) canaffect the vehicle's emissioncontrols and can cause this lightto come on. Modifications tothese systems could lead tocostly repairs not covered by thevehicle warranty. This could alsoresult in a failure to pass arequired Emission Inspection/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. These

conditions might go away once theengine is warmed up. See Fuel forDiesel Engines on page 9‑19.

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, theemission 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 can

happen 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 5‑11 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 9‑12.

Information Displays

Driver InformationCenter (DIC)The Driver Information Center (DIC)is located on the instrument panelabove the steering wheel. The DICcomes on when the ignition is on.

A Duramax Diesel vehicle may havethe following additional DIC menuitems.

EXHAUST FLUID LEVEL

If the vehicle has DIC buttons, pressthe vehicle information button untilEXHAUST FLUID LEVEL displays.If the vehicle does not have DICbuttons, press the trip stem untilEXHAUST FLUID LEVEL displays.The EXHAUST FLUID LEVEL willbe displayed as either OK, XX%,or LOW.

When LOW appears on the display,you should add diesel exhaust fluidas soon as you can. See DieselExhaust Fluid on page 9‑12.

FUEL FILTER LIFE REMAINING

If the vehicle has DIC buttons, pressthe vehicle information button untilFUEL FILTER LIFE REMAININGdisplays. If the vehicle does nothave DIC buttons, press the tripstem until FUEL FILTER LIFEREMAINING displays. This displayshows an estimate of the fuel filter'sremaining useful life. If you see90% 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.You should change the fuel filter assoon as you can.



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 stem if there are no DICbuttons, for two seconds whileFUEL FILTER LIFE REMAINING isdisplayed on the 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

Notice: Engine damage fromrunning your engine withoutcoolant is not covered by yourwarranty. See “Overheated

Engine Protection OperatingMode” in the owner manual forinformation on driving to a safeplace in an emergency.

This message will appear on theDIC if the engine coolant level islow. Adding coolant to the coolantrecovery tank will clear themessage. 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 bea 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 9‑27.

Diesel Exhaust FluidMessagesFor more information on thesemessages, see “Exhaust Fluid Low”or “Exhaust Fluid Quality Poor” inDiesel Exhaust Fluid on page 9‑12.

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 FILTERKEEP DRIVING UNTILMESSAGE IS CLEARED

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 9‑10.

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 9‑12.

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 9‑12.

Starting the VehicleMessages

ELEVATED IDLE OFF

If your vehicle does not have DICbuttons, this message will appearwhen the elevated idle/exhaustrestrictor feature has been turnedoff. This feature can be turned on oroff by pressing the pedals. For moreinformation on the elevated idle/exhaust restrictor feature, see“Elevated Idle” under Starting theDiesel Engine on page 9‑1.

If your vehicle has DIC buttons, thismessage will not be displayed. Theelevated idle can be turned on or offusing the customization menus.Press the customization button untilELEVATED IDLE appears on theDIC display. Press the set/resetbutton once to access the settingsfor this feature. Then press thecustomization button to scrollthrough the following settings: OFF,ON, or NO CHANGE. Choose one



of the available settings and pressthe set/reset button while it isdisplayed on the DIC to select it.

ELEVATED IDLE ON

If your vehicle does not have DICbuttons, this message will appearwhen the elevated idle/exhaustrestrictor feature has been turnedon. This feature can be turned on oroff by pressing the pedals. For moreinformation on the elevated idle/exhaust restrictor feature, see“Elevated Idle” under Starting theDiesel Engine on page 9‑1.

If your vehicle has DIC buttons, thismessage will not be displayed. Theelevated idle can be turned on or offusing the customization menus.Press the customization button untilELEVATED IDLE appears on theDIC display. Press the set/resetbutton once to access the settingsfor this feature. Then press thecustomization button to scrollthrough the following settings: OFF,ON, or NO CHANGE. Choose one

of the available settings and pressthe set/reset button while it isdisplayed on the DIC to select it.

FAST IDLE ON

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.

Transmission Messages

SHIFT INHIBITED SELECT NTO RESET (Pickup Models)

If the transmission is unable to shiftinto a selected gear, this messagewill appear on the DIC. Theelectronic shift position indicator onthe instrument panel cluster mayblink when this occurs. To make thevehicle shift to the requested gear,you may have to shift back toP (Park) or N (Neutral) and re-selectthe desired gear.

Vehicle Speed MessagesFor more information on thesemessages, see Diesel Exhaust Fluidon page 9‑12.

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.



VehiclePersonalizationYour 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 buttonto 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




2 NOTES


Driving and Operating 9-1

Driving andOperating

Starting and OperatingStarting the Diesel Engine . . . . 9-1Winter Cover . . . . . . . . . . . . . . . . . . 9-4Engine Heater . . . . . . . . . . . . . . . . . 9-9Fuel OperatedHeater (FOH) . . . . . . . . . . . . . . . 9-10

Parking over ThingsThat Burn . . . . . . . . . . . . . . . . . . 9-10

Diesel Particulate FilterDiesel Particulate Filter . . . . . . 9-10

Diesel Exhaust FluidDiesel Exhaust Fluid . . . . . . . . . 9-12

BrakesExhaust Brake . . . . . . . . . . . . . . . 9-18

FuelFuel for Diesel Engines . . . . . . 9-19What Fuel to Use inThe U.S. . . . . . . . . . . . . . . . . . . . 9-20

What Fuel to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . 9-24

Cold Weather Operation . . . . . 9-27

Water in Fuel . . . . . . . . . . . . . . . . 9-27Running Out of Fuel . . . . . . . . . 9-32Fuel Filter Replacement . . . . . 9-33Filling the Tank . . . . . . . . . . . . . . 9-36Filling a Portable FuelContainer . . . . . . . . . . . . . . . . . . . 9-38

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. The vehiclewill only start in the P (Park) or theN (Neutral) position.

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

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

Starting the Engine

1. Turn the ignition key to ON/RUN.

Observe the wait-to-start light.See Wait-to-Start Light onpage 5‑8. This light may notcome on if the engine is warm.


9-2 Driving and Operating

2. As soon as the wait-to-start lightgoes off, immediately 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 thanmost diesel engines, due to therapid heating of the glow plugsystem.

Notice: If the wait‐to‐start lightstays on after starting the vehicle,the vehicle 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 starter tocool, then try the same stepsagain.

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 you movethe vehicle. This lets oil pressurebuild up. The engine will soundlouder when it is cold.

Cold Weather Starting (DieselEngine)

The following tips will help with coldweather starting.

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 9‑19 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 theignition key to ON/RUN.Immediately after the wait-to-startlight goes 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.



Be sure you have the right oil for theengine, and that you have changedthe oil at the proper times. If youuse the wrong oil, the engine maybe harder to start.

Be sure you are using the properfuel for existing weather conditions.See Fuel for Diesel Engines onpage 9‑19.

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 warranty. Therecould also be a fire, which couldcause serious personal 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 1,000 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 below 0°C(32°F), and the engine coolanttemperature is below 65°C (150°F).This feature enhances heaterperformance by raising the enginecoolant temperature faster.

This feature can be turned on or offusing the DIC buttons. If the vehicleis not equipped with DIC buttons, dothe following to turn this feature onor 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.

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 reaches0°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 is in the On

position. See “Cruise Control” inthe owner manual.

. The cruise control Set switch ispressed and released for PresetFast Idle Speed (1200 rpm).

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

position.. 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).

When Fast Idle is active, a FASTIDLE ON message will be displayedin the Driver Information Center(DIC). See Starting the VehicleMessages on page 5‑12.

Winter CoverIf the vehicle includes a wintercover, it can be used to enhanceheater performance in extremelycold conditions below −18°C (0°F).The winter cover installs over thegrille and restricts airflow to theengine compartment.

For diesel powered vehicles that didnot come with a winter cover, a GMwinter cover can be purchased asan accessory. See your dealer foradditional information.



Usage Guidelines

The winter cover should only beused while operating the vehicle inextremely cold temperatures or inheavy snow for extended periods oftime. In these temperatures, thevehicle does not need a largeamount of air to properly cool theengine. When more airflow isrequired to cool the vehicle, thewinter cover should not be used.The following usage guidelines willallow adequate airflow for properradiator and air cooler performance:. Do not use the winter cover if

towing a trailer. The addedpower needed to tow a trailerrequires the radiator grille tohave full airflow under allconditions. The vehicle mayoverheat if the cover is usedwhile towing a trailer.

. Do not use the winter cover if asnow plow is mounted on thetruck. The addition of a snowplow requires the radiator grilleto have full airflow.

. Do not cover the opening in thefront bumper. This opening is toprovide enough airflow.

. Do not modify the cover. Thewinter cover does not coversome sections of the front of thevehicle because these openingsare needed to provide enoughairflow to the radiator grille andair cooler in extremely coldtemperatures.

. When the winter cover is used,the temperature sensor found onthe inside rearview mirror will not

function properly. Thetemperature that is shown will beincorrect.

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

. Use only a mild soap to cleanthe winter cover. Do not useharsh soap, strong detergents,or vinyl protectant/sealant typeproducts as they may destroythe special finish of the wintercover. Allow the winter cover todry completely before reinstallingon the vehicle.

Installation Instructions

When first trying to fit the cover, itmay appear to be undersized. Thisis due to the nature of the specialvinyl, which will stretch duringinstallation to ensure a tight fit. Forthis reason, the initial installation ofthe cover is best performed whenthe winter cover is warm.



Installation (Chevrolet Pickup)

1. Open the hood.

2. Slide the channels of the coverdown the back edge of the grilleon both sides.

3. Hook J-clips to the bottom of thegrille.

4. Hook J-clips to the top edge ofthe grille by the enginecompartment.



5. Hook J-clips to the side edge ofthe grille.

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

Installation (GMC Pickup)

1. Open the hood.

2. Slide the channels of the coverdown the back edge of the grilleon both sides.

3. Insert pockets between the grilleand the bumper.

4. Hook J-clips to the top edge ofthe grille by the enginecompartment.




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.


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 the rightside auxiliary battery.

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 fourhours. 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 9‑19 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 ittakes 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. See“Exhaust System Inspection” underMaintenance Schedule onpage 11‑3.

The DPF will clean itself as part ofnormal operation. Several factorsincluding fuel consumed, hours ofengine operation and miles drivenare monitored by the Engine Control



Module (ECM). The self-cleaningoccurs approximately once per tankof fuel.

Notice: Permanent damage canoccur to the DPF or relatedcomponents if the required UltraLow Sulfur Diesel (15 ppm sulfurmaximum) or low ash CJ‐4 engineoil is not used. This damagewould not be covered by thevehicle 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 9‑10 for moreinformation.

Notice: Extended idle should beavoided because the DPF systemis not capable of self cleaning atidle. During extended idleoperation, monitor the instrument

panel telltale 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 5‑10.

If you continue to drive with the DPFwarning 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 5‑6 and Engine PowerMessages on page 5‑11.



Vehicles with DPF have specific fueland engine oil requirements. SeeWhat Fuel to Use in The U.S. onpage 9‑20 or What Fuel to Use inCanada and Mexico on page 9‑24and 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 9‑10.

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 modifying thevehicle.

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 more safetyinformation, see the label of theDiesel Exhaust Fluid container.

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. Thecapacity of the DEF tank is 20.1 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. For moreinformation on locating DEF seewww.afdc.energy.gov/afdc/vehicles/diesels_fluid.html. See “CustomerAssistance Offices” in the ownermanual for phone numbers to assistin contacting a GM dealer. SeeRecommended Fluids andLubricants on page 11‑12.

Filling the DEF Tank

Notice: Use only exhaust fluidthat is GM approved, or fluidcontaining the API certified orISO 22241 label. The use of otherfluids could damage the system,



requiring costly repairs that willnot be covered by the vehiclewarranty.

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 message in theDriver 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 locatedbehind the fuel fill door. The DEFcap is blue, and the diesel cap isgreen.

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 islocated under the hood, on thepassenger side, at the back of theengine compartment. The DEF capis 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 5‑9.

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 EXHAUST FLUIDEMPTY REFILL NOW - 644 KM(400 MI) UNTIL 105 KM/H (65 MPH)MAX SPEED displays. Thedisplayed mileage will decrease asdriving 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 EXHAUST FLUID EMPTYREFILL 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 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 5‑11, Diesel Exhaust Fluid(DEF) Warning Light on page 5‑8,and Recommended Fluids andLubricants on page 11‑12.

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 EXHAUST FLUIDQUALITY POOR - SEE OWNERSMANUAL NOW – 160 KM (99 MI)UNTIL 105 KM/H (65 MPH) MAXSPEED displays. The displayedmileage will decrease as drivingcontinues. A warning light alsocomes on. Adding fresh DEF to thesystem may resolve the problem,depending on several factors. If theDIC message persists, see yourdealer or additional DIC messagesmay 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 EXHAUST FLUIDQUALITY POOR - 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 warning lightand a chime also come on.

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) MAX

SPEED 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 SERVICE EXHAUST FLUID SYSTEM- SEE OWNERS MANUAL NOW –

160 KM (99 MI) UNTIL 105 KM/H(65 MPH) MAX SPEED displays.The displayed mileage will decreaseas driving continues. A warning lightalso comes on. In some cases thismessage 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 SERVICE EXHAUSTFLUID SYSTEM - 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 warning lightand a chime also come on.

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

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 cases

this 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 usedto activate the system, and islocated below the climate controls inthe center of the vehicle instrumentpanel. The switch must be pressedat each vehicle start for the systemto be active. A light in the switch willcome on when the exhaust brake isactivated.

The Driver Information Center (DIC)displays the message EXHAUSTBRAKE ENABLED forapproximately 10 seconds, thenclears.

To turn the brake off, press theexhaust brake switch a second time.The DIC displays the messageEXHAUST BRAKE DISABLED 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 maintainvehicle 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 EnginesSome states and provinces haverestrictions on the purchase ofdiesel fuel for light-duty vehicles andrequire you to buy permits or payspecial taxes. Some of theserestrictions apply only to residents,and others apply to both residentsand visitors. These restrictions canchange. To learn the currentrestrictions in any state or province,contact your auto club, the police,or other officials.

Notice: Diesel fuel or fueladditives not recommended inthis manual could damage thefuel system, fuel‐operated heater(FOH) (Van models only), andengine. Your warranty would notcover this damage. And:. Diesel fuel that has beenmixed with engine oil orautomatic transmission fluidcould damage the engineand emission controls.

. We do not test aftermarketdiesel fuel additives. Someadditives, particularly thosewhich contain alcohol orwater emulsifiers, coulddamage the fuel system.If you believe that uniquecircumstances call for a fueladditive to be used, consultyour dealer for advice.

. If you ever run out of dieselfuel, it can be difficult torestart the engine. To avoidthis, never let the tank getempty.

If gasoline is ever accidentallyadded to the fuel tank, to avoidsevere engine damage, do notrun the engine until the fuel tankcan be drained.

Some conditions, such as dirty fuel,may decrease fuel filter life and achange filter message maycome on.

If you run out of fuel, Running Out ofFuel on page 9‑32 tells you how torestart the engine.



What Fuel to Use inThe U.S.Notice: Use of diesel fuel otherthan Ultra Low Sulfur Diesel(15 ppm sulfur maximum) willcause permanent damage to theexhaust after‐treatment system.This damage would not becovered by the vehicle warranty.

The emission control systemrequires the use of diesel fuel withultra low sulfur content (15 ppm or0.0015% by weight, maximum).Look for the following label on thedispenser to ensure you are fillingwith Ultra Low Sulfur Diesel fuel.

At a minimum, the diesel fuel youuse should meet the latest versionof ASTM specification D 975(Grades No. 2-D or No. 1-D S15,commonly known as Ultra LowSulfur Diesel) in the United States.If there are questions about the fuelyou are using, contact your fuelsupplier.

Diesel Fuel Grades

For best results use No. 2-D dieselfuel year-round (above and belowfreezing conditions) as oilcompanies blend No. 2-D fuel toaddress climate differences.

No. 1-D diesel fuel can be used invery cold temperatures (when itstays below −18°C or 0°F);however, it will produce a power andfuel economy loss. Avoid the use ofNo. 1-D diesel fuel in warm or hotclimates. It can result in stalling,poor starting when the engine is hot,and damage to the fuel injectionsystem.

Premium Diesel Fuel

Diesel fuel corresponding to theEngine Manufacturers Association(EMA) Recommended Guideline onPremium Diesel Fuel (FQP-1A)could provide better starting, lessnoise, and better vehicleperformance, but its use is notrequired.

Biodiesel

What is biodiesel?

Biodiesel is a fuel produced fromvegetable oils or animal fats thathave been chemically modified toreduce the possibility of damage tothe fuel system and engine.



Notice: Raw vegetable oil orother unmodified bio-oils or fatsare not biodiesel and must not beused in your vehicle as theycould damage the fuel systemand engine.

What not to use

Do not use home-made biodiesel inyour vehicle since its quality cannotbe verified by approved scientificmethods. Home test kits are notapproved scientific methods.

Notice: Any damage caused byraw, unmodified, or home-madebiodiesel would not be coveredby the vehicle warranty.

Biodiesel blends

It is acceptable to use diesel fuelcontaining up to 20% biodiesel(B20). The diesel fuel portion of theblend must meet the samespecification, ASTM D975 (GradesNo. 2-D or No. 1-D S15 commonlyknown as Ultra Low Sulfur Diesel),as other fuels used in your vehicle,and the biodiesel used for making

this fuel must meet the latestversion of ASTM specificationD6751.. Pump labeling — Retail pumps

dispensing blends containing upto 5% biodiesel (B5) are notrequired to be labeled with theconcentration of biodiesel.Blends up to B5 must meetASTM D975 (Grades No. 2-D orNo. 1-D S15 commonly knownas Ultra Low Sulfur Diesel).

Notice: Do not use blendscontaining more than 20%biodiesel. Any engine, fuelsystem, or exhaustafter-treatment system damagecaused by the use of such blendswould 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 blend

above B5, ensure one of thefollowing two labels appears onthe dispenser:



. Biodiesel quality — Blendscontaining more than 5% and upto 20% biodiesel must meet thelatest version of ASTMspecification D7467 (Biodieselblend, B6 - B20). Biodiesel is anemerging product, and its qualitycan vary widely. To reduce therisk of poor quality fuel, werecommend that biodieselusers purchase biodiesel blendsfrom a BQ-9000 certifiedmarketer. A listing of certifiedmarketers can be found atwww.bq-9000.org. If thereare questions about thebiodiesel-containing fuels youare using, contact your fuelsupplier.

Notice: Certain driving patternsare not compatible with biodieseluse. It is the operator’sresponsibility to ensure thatbiodiesel in the vehicle’s tankdoes not lead to engine, fuelsystem, or exhaust after‐treatment system damage.

We neither encourage nordiscourage the use of biodieselblends for vehicles. As a renewablefuel, biodiesel provides someenvironmental benefits. However,biodiesel has unique properties andneeds to be handled differently thandiesel fuel. Its use presentsadditional risks and may not beappropriate in all situations. Certainvehicle operating modes increasethese risks and should be avoided.Read further to determine if yourdriving habits are compatible withthe use of biodiesel.. Biodiesel fuel quality degrades

with time and exposure to hightemperature much more quicklythan conventional diesel fuel.More frequent refueling providesthe best opportunity to have asupply of fresh fuel.

Owners who have very low fuelusage or who have vehiclesstored for extended periods oftime should avoid the use ofbiodiesel. Storage at hot ambienttemperatures will acceleratebiodiesel degradation.

When vehicles will be stored forextended periods of time(greater than one month), theyshould be run out of biodiesel tobelow one-quarter tank, refueledwith conventional Ultra LowSulfur Diesel fuel, and drivenseveral miles before storage.

. Biodiesel gels sooner thanconventional diesel fuel at coldtemperature, and biodiesel fuelrequires proper blending forwinter time operation.



Fuels improperly blended forcold temperature operation mayresult in restricted fuel filters anddegraded vehicle performance.Your vehicle is equipped with afuel heating system to provide alevel of protection against filterplugging from gelling (waxing) ofconventional diesel fuel andbiodiesel blends. However, thesystem will not prevent all casesof plugged filters if the operatingtemperature is far below thetemperature at which gelling orwaxing of the fuel occurs (cloudpoint).

Use of biodiesel blends greaterthan B5 (5% blend) should beavoided in cold temperatures.

. Vehicles operated for extendedperiods of time on conventionaldiesel fuel and then switched tobiodiesel blends may experiencepremature fuel filter clogging andrequire more frequent fuel filterservice.

With long-term use ofconventional diesel fuel, gumand varnish may be depositedwithin the tank and fuel system.These deposits, while notproblematic with the use ofconventional diesel fuel, maybecome loosened with a suddenswitch to biodiesel blends andcause fuel filter plugging.

This vehicle is equipped with afuel filter restriction monitoringsystem that will alert you if thefuel filter requires service, but itwill not prevent damage causedby poor quality biodiesel.

. Use of biodiesel blends willdegrade the performance of yourvehicle’s water separator.Biodiesel reduces theeffectiveness of the vehicle’swater separator, and in the eventof water contamination of thefuel, increases the risk ofdamage to the fuel system.

Refueling

Diesel fuel can foam when you fillthe tank. This can cause theautomatic pump nozzle to shut off,even though the tank is not full.If this happens, wait for the foamingto stop, and then try filling the tankmore slowly. See Filling the Tank onpage 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 and people could beburned. To help avoid this, tryfilling the tank more slowly and fillthe fuel tank only until theautomatic nozzle shuts off. Do nottry to top it off.



Accidental Refueling withGasoline

Notice: If any amount of gasolineis added to the fuel tank, do notstart the engine until the fuel tankcan be drained and refilled withUltra Low Sulfur Diesel fuel. Yourdealer can perform thisprocedure. If this procedure isnot performed, the vehicle willrun very rough and have reducedpower. Severe engine damage willoccur and would not be coveredby the vehicle warranty.

What Fuel to Use inCanada and MexicoThe emission control systemrequires the use of diesel fuel withultra low sulfur content (15 ppm or0.0015% by weight, maximum).

What Fuel to Use in Canada

Notice: Use of diesel fuel otherthan Ultra Low Sulfur Diesel(15 ppm sulfur maximum) willcause permanent damage to the

exhaust after‐treatment system.This damage would not becovered by the vehicle warranty.

At a minimum, the diesel fuel youuse should meet the latest versionof specification CAN/CGSB-3.517(ULS) in Canada. If there arequestions about the fuel you areusing, contact your fuel supplier.

Diesel Fuel Types

Canadian fuels are blended forseasonal changes. Diesel Type “A”fuel is blended for better coldweather starting in extremeconditions; however, you mightnotice some power and fueleconomy loss. If Type “A” fuel isused in warmer temperatures,stalling and hard starting may occur.Diesel Type “B” fuel is blended forhigher temperatures experiencedduring most of the year.

Premium Diesel Fuel

Diesel fuels corresponding to theEngine Manufacturers Association(EMA) Recommended Guideline onPremium Diesel Fuel (FQP-1A)could provide better starting, lessnoise, and better vehicleperformance, but their use is notrequired.

Biodiesel

What is biodiesel?

Biodiesel is a fuel produced fromvegetable oils or animal fats thathave been chemically modified toreduce the possibility of damage tothe fuel system and engine.

Notice: Raw vegetable oil orother unmodified bio-oils or fatsare not biodiesel and must not beused in your vehicle as theycould damage the fuel systemand engine.



What not to use

Do not use home-made biodiesel inyour vehicle since its quality cannotbe verified by approved scientificmethods. Home test kits are notapproved scientific methods.

Notice: Any damage caused byraw, unmodified, or home-madebiodiesel would not be coveredby the vehicle warranty.

Biodiesel blends

It is acceptable to use diesel fuelcontaining up to 20% biodiesel(B20). For low level, under 5%,biodiesel blends (B1 to B5), the fuelyou use should meet the latestversion of specification CAN/CGSB-3.520 (ULS). At the time ofprinting of this manual, a CGSBstandard for B6-B20 is underdevelopment and has not beenpublished. Until a CGSB B6-B20specification is available, biodieselblends containing more than 5%and up to 20% biodiesel must meet

the latest version of ASTMspecification D7467 (Biodieselblend, B6-B20). If there arequestions about thebiodiesel-containing fuels you areusing, contact your fuel supplier.

Notice: Certain driving patternsare not compatible with biodieseluse. It is the operator’sresponsibility to ensure thatbiodiesel in the vehicle’s tankdoes not lead to engine, fuelsystem, or exhaust after‐treatment system damage.

We neither encourage nordiscourage the use of biodieselblends for vehicles. As a renewablefuel, biodiesel provides someenvironmental benefits. However,biodiesel has unique properties andneeds to be handled differently thandiesel fuel. Its use presentsadditional risks and may not beappropriate in all situations. Certainvehicle operating modes increasethese risks and should be avoided.

Read further to determine if yourdriving habits are compatible withthe use of biodiesel.. Biodiesel fuel quality degrades

with time and exposure to hightemperature much more quicklythan conventional diesel fuel.More frequent refueling providesthe best opportunity to have asupply of fresh fuel.

Owners who have very low fuelusage or who have vehiclesstored for extended periods oftime should avoid the use ofbiodiesel. Storage at hot ambienttemperatures will acceleratebiodiesel degradation.

When vehicles will be stored forextended periods of time(greater than one month), theyshould be run out of biodiesel tobelow one-quarter tank, refueledwith conventional Ultra LowSulfur Diesel fuel, and drivenseveral miles before storage.



. Biodiesel gels sooner thanconventional diesel fuel at coldtemperature, and biodiesel fuelrequires proper blending forwinter time operation.

Fuels improperly blended forcold temperature operation mayresult in restricted fuel filters anddegraded vehicle performance.Your vehicle is equipped with afuel heating system to provide alevel of protection against filterplugging from gelling (waxing) ofconventional diesel fuel andbiodiesel blends. However, thesystem will not prevent all casesof plugged filters if the operatingtemperature is far below thetemperature at which gelling orwaxing of the fuel occurs (cloudpoint).

Use of biodiesel blends greaterthan B5 (5% blend) should beavoided in cold temperatures.

. Vehicles operated for extendedperiods of time on conventionaldiesel fuel and then switched tobiodiesel blends may experiencepremature fuel filter clogging andrequire more frequent fuel filterservice.

With long-term use ofconventional diesel fuel, gumand varnish may be depositedwithin the tank and fuel system.These deposits, while notproblematic with the use ofconventional diesel fuel, maybecome loosened with a suddenswitch to biodiesel blends andcause fuel filter plugging.

This vehicle is equipped with afuel filter restriction monitoringsystem that will alert you if thefuel filter requires service, but itwill not prevent damage causedby poor quality biodiesel.

. Use of biodiesel blends willdegrade the performance of yourvehicle’s water separator.

Biodiesel reduces theeffectiveness of the vehicle’swater separator, and in the eventof water contamination of thefuel, increases the risk ofdamage to the fuel system.

What Fuel to Use in Mexico

Notice: Use of diesel fuel otherthan Ultra Low Sulfur Diesel (15ppm sulfur maximum) will causepermanent damage to the exhaustafter‐treatment system. Thisdamage would not be covered bythe vehicle warranty.

Ultra Low Sulfur Diesel fuel is notavailable in all regions of Mexico.

Refueling

Diesel fuel can foam when you fillthe tank. This can cause theautomatic pump nozzle to shut off,even though the tank is not full.If this happens, wait for the foamingto stop, and then try filling the tankmore slowly. See Filling the Tank onpage 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 and people could beburned. To help avoid this, tryfilling the tank more slowly and fillthe fuel tank only until theautomatic nozzle shuts off. Do nottry to top it off.

Accidental Refueling withGasoline

Notice: If any amount of gasolineis added to the fuel tank, do notstart the engine until the fuel tankcan be drained and refilled withUltra Low Sulfur Diesel fuel. Yourdealer can perform thisprocedure. If this procedure isnot performed, the vehicle willrun very rough and have reducedpower. Severe engine damage willoccur and would not be coveredby the vehicle warranty.

Cold Weather OperationFollow the instructions listedpreviously under the heading “WhatFuel to Use.”

Notice: Never use home heatingoil or gasoline in the vehicle.They can cause engine damagenot covered by the vehiclewarranty.

In cold weather, the fuel filter couldbecome clogged by wax naturallypresent in the fuel. To unclog it,move the vehicle to a warm garagearea and allow the filter to warm upto between 0°C (32°F) and 10°C(50°F). You will not need to replacethe filter. Additional information onthe fuel filter follows.

Use of biodiesel blends greater thanB5 (5% blend) should be avoided incold temperatures.

Water in Fuel

{ WARNING

Diesel fuel containing water is stillflammable. You could be burned.If you ever try to drain water fromthe fuel, keep sparks, flames, andsmoking materials away from themixture.

Notice: If there is water in thediesel fuel and the weather iswarm or humid, fungus andbacteria can grow in the fuel.They can damage the fuel systemand fuel operated heater (FOH) (ifequipped). A diesel fuel biocidecan be used to sterilize the fuelsystem. However, the fuel systemmay still need to be cleaned. Yourdealer can advise you of theappropriate 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.

Sometimes, water can be pumpedinto the fuel tank along with thediesel fuel. This can happen if aservice station does not regularlyinspect and clean its fuel tanks, or ifit gets contaminated fuel from itssuppliers.

If this happens, a WATER IN FUELSERVICE REQUIRED message willappear on the Driver InformationCenter (DIC). The water must bedrained.

Water in Fuel Message Chart

If the WATER IN FUEL SERVICEREQUIRED message comes on,use this chart.

ProblemRecommended

Action

Message comeson but does notremain on afteran ignitioncycle.

Water separatoris approximatelyhalf full. Drainwater as soonas possible.Water level maycontinue toincrease.

Message remains on after anignition cycle:

At temperaturesabove freezing.

Drain fuel filterimmediately.If no water canbe drained andmessage stayson, see yourdealer forassistance.

ProblemRecommended

Action

At temperaturesbelow freezing.

Drain fuel filterimmediately.If no water canbe drained,water may befrozen in waterdrain system orfuel lines. Movethe vehicle to awarm location tothaw out, andthen drain filtersystem.

Immediatelyafter refueling,large amount ofwater possiblypumped intofuel tank.

Fuel tankpurgingrequired. Seeyour dealer forassistance.

Notice: Driving when thiswarning indicator is on, candamage the fuel injection systemand the engine. If the indicatorcomes on right after a refuel, it



means water was pumped intothe fuel tank. Turn off the engineimmediately. Then, have the waterdrained at once.

To drain water:

1. Stop and park the vehicle in asafe place. Turn off the engineand apply the parking brake.

2. Remove the fuel cap.

Pickup

Van

3. Place a fuel-resistant containerunder the fuel filter. For pickupmodels, the filter drain valve islocated in the enginecompartment, on the passengerside of the vehicle, on thebottom of the fuel filter. For vanmodels, the filter drain valve islocated under the vehicle on thedriver side (inside frame rail), onthe bottom of the fuel filter.

4. For pickup models, open thedrain valve by turning it two tothree turns. Pump the primeruntil all of the water has beenremoved. When fuel emptiesfrom the valve, all the water hasbeen drained. Close the valvehand tight.

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. Remove the fuel-resistantcontainer and properly disposeof the contaminated fuel.

6. Install the fuel cap.



7. For pickup models, start theengine and let it run for a fewminutes. If the engine stalls, thefuel system may need to beprimed. While draining the waterfrom the fuel filter, air may enterthe fuel system. If air hasentered the fuel system, the fuelsystem will need to be primed.

For van models, start the engineand let it run for a few minutes.

If the WATER IN FUEL SERVICEREQUIRED message/warning lightcomes on again after driving a shortdistance or the engine runs rough orstalls, a large amount of water hasprobably been pumped into the fueltank. The fuel tank should bepurged.

Fuel Priming

In order for the fuel system to workproperly, the fuel lines must be fullof fuel and contain no air. If air getsinto the fuel lines, it will benecessary to prime the fuel lines to

eliminate air before operating thevehicle and the fuel operatedheater (FOH).

If air is in the fuel lines, one of thefollowing may have happened:. The vehicle ran out of fuel.. The fuel filter was removed for

servicing or replacement.. The fuel lines were removed or

disconnected for servicing.. The fuel filter water drain valve

was opened while the enginewas running.

. The fuel operated heater (FOH)pump and FOH fuel lines wereremoved or disconnected forservicing.

If one or more of the above occur, itis very likely that air has entered thefuel system and priming the fuelsystem is needed before operatingthe vehicle. Air in the fuel lines doesnot harm the engine, the FOH,or the vehicle.

However, the engine and/or theFOH may not be able to start untilthe fuel system is primed and the airis removed.

To Prime the Vehicle (PickupModels)

The vehicle is equipped with apriming pump which is part of theengine mounted fuel filter. Thepriming pump is hand operated andis designed to bring fuel to theengine to eliminate any air in thefuel lines. To prime the engine:

1. Correct the condition thatcaused the loss of prime bymaking sure there is fuel inthe tank.

2. Make sure the fuel filter hasbeen installed and properlytightened.

3. Make sure the fuel lines areproperly connected and the fuelfilter is cool enough to touch.

4. Remove any dirt from the fuelfilter head and vent valve bywiping with a cloth.



5. Open the fuel filter vent valve byturning the screwcounterclockwise several fullturns. The vent valve is locatedon top of the fuel filter housing.

6. Repeatedly push down on thefuel filter priming pump with thepalm of your hand. The pump islocated on top of the fuel filterhousing. Let the pump returnupward between pushes.

7. Operate the priming pump until asmall amount of fuel seeps fromthe vent valve. When fuel isseen, the filter is now full of fueland the system should beprimed.

8. Close the vent valve. Clean anyfuel that accumulated on the fuelfilter. Attempt to start the engine.

The engine may start and stall.If this occurs, operate thepriming pump several times inbetween starting attempts. Oncethe engine stays running, allow itto idle for a few minutes. Checkthe filter for leaks.

To Prime the Vehicle (Van Models)

The vehicle has an electric primingpump. The priming pump isoperated electrically and isdesigned to bring fuel to the engineto eliminate any air in the fuel lines.To prime the engine:

1. Correct the condition thatcaused the loss of prime bymaking sure there is fuel inthe tank.

2. Turn the ignition key on for30 seconds. The fuel pump willbe operating and starting thepriming process. Do not start theengine during the first30 seconds.



3. After completing the initial primein Step 2, turn the ignition off,then back to start, and crank theengine for 15 seconds.

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

5. If the engine does not run afterrepeating Steps 2 and 3 threetimes, turn the ignition key off for60 seconds, allowing theElectronic Control Module (ECM)to reset.

6. Repeat the above steps until theengine starts.

7. If the engine runs, but does notrun smoothly, increase theengine speed slightly bypressing the accelerator pedal.This will help to force out airthrough the system.

8. If the engine starts and runs butstalls again, turn the ignition keyoff for 60 seconds to reset theECM and repeat the stepsabove.

9. 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

If the engine stalls and you thinkthat you have run out of fuel, do thisto restart the engine:

{ WARNING

Diesel fuel is flammable. It couldstart a fire if it gets on hot engineparts. You could be burned. Donot let too much fuel flow from theair bleed valve, and wipe up anyspilled fuel with a cloth.

1. If parked on a level surface, addat least 7.6 L (2 gal) of fuel.However, if parked on a slope,up to 18.9 L (5 gal) of fuel mightneed to be added.

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 theengine tries to run, but does notrun smoothly, increase the rpm alittle using the accelerator pedal.This will help force air throughthe system.

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

Van Models

If the engine stalls and you thinkthat you may have run out of fuel,do this to restart the engine:

1. If parked on a level surface, addat least 3.8 L (1 gal) of fuel.However, if parked on a slope,up to 18.9 L (5 gal) of fuel mightneed to be added.

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

The check engine light may comeon if the vehicle has run out of fuel.This light may stay on for a fewdrive cycles after the condition iscorrected, but will eventually clearitself.

The fuel operated heater stopsautomatically when the fuel tankvolume is less or equal to 10% ofthe total tank volume. If the vehicleruns out of fuel, the FOH fuel lineswill not need to be primed becausethey will still have fuel remaining.

Fuel Filter ReplacementPickup Models

{ WARNING

Diesel fuel is flammable. It couldstart a fire if something ignites it,and you could be burned. Do notlet it get on hot engine parts, andkeep matches or other ignitionsources away.

Drain any water from the filterfollowing the procedure for drainingwater listed previously.

The vehicle's engine must be offuntil the end of this procedure.

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

1. Apply the parking brake. Accessthe fuel filter through thepassenger side wheel houseopening. It is not necessary toremove all of the wheel linerfasteners.

2. Remove only the necessaryfasteners to allow the rear of thewheel liner to be loweredenough for fuel filter access.



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

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

5. Install the new filter element.

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

7. Reposition the wheel liner.

8. Install and tighten fasteners.

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

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

11. Reset the fuel filter monitor.See Fuel System Messages onpage 5‑11.

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 you could be burned. Do notlet it get on hot engine parts, andkeep matches or other ignitionsources away.

Drain any water from the filterfollowing the procedure for drainingwater listed previously.

The vehicle's engine must be offuntil the end of this procedure.

The fuel filter and fuel pump screenare located on the driver side framerail in front of the fuel tank.



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

To minimize fuel siphoning from thefuel tank during fuel filterreplacement, be sure the fuel tank isless than three-quarters full.

Fuel Filter

1. Apply the parking brake.

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

1. Apply the parking brake.

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.

(Continued)

WARNING (CONTINUED)

. Do not reenter the vehiclewhile pumping fuel.

. 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 located behinda hinged door on the driver side ofthe vehicle. On van models, theblue diesel 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 Your 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.

Notice: If you need a new fuelcap, be sure to get the right type.Your dealer can get one for you.If you get the wrong type, it maynot fit properly.

Notice: 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 container fromvehicle, trunk, or pickup bedbefore filling.

. Place 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.

. Do not smoke whilepumping fuel.

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 10‑24.



Use the following chart to determine how much the vehicle can weigh, based upon your vehicle model and options.

Vehicle Axle Ratio Max. Trailer Wt. GCWR *

C-2500 Pickup Models — 2WD

Extended Cab Standard Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Extended Cab Standard Box — Fifth-Wheel Trailer 3.73 5 851 kg (12,900 lb) 11113 kg (24,500 lb)

Crew Cab Standard Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Crew Cab Standard Box — Fifth-Wheel Trailer 3.73 5 625 kg (12,400 lb) 11113 kg (24,500 lb)

Sierra Denali — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Sierra Denali — Fifth-Wheel Trailer 3.73 5 262 kg (11,600 lb) 11113 kg (24,500 lb)

Regular Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Regular Cab Long Box — Fifth-Wheel Trailer 3.73 6 532 kg (14,400 lb) 11113 kg (24,500 lb)

Extended Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Extended Cab Long Box — Fifth-Wheel Trailer 3.73 5 625 kg (12,400 lb) 11113 kg (24,500 lb)

Crew Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Crew Cab Long Box — Fifth-Wheel Trailer 3.73 5 307 kg (11,700 lb) 11113 kg (24,500 lb)

K-2500 Pickup Models — 4WD

Extended Cab Standard Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Extended Cab Standard Box — Fifth-Wheel Trailer 3.73 5 171 kg (11,400 lb) 11113 kg (24,500 lb)




Crew Cab Standard Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Crew Cab Standard Box — Fifth-Wheel Trailer 3.73 4 899 kg (10,800 lb) 11113 kg (24,500 lb)



Regular Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Regular Cab Long Box — Fifth-Wheel Trailer 3.73 5 761 kg (12,700 lb) 11113 kg (24,500 lb)

Extended Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Extended Cab Long Box — Fifth-Wheel Trailer 3.73 4 944 kg (10,900 lb) 11113 kg (24,500 lb)

Crew Cab Long Box — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Crew Cab Long Box — Fifth-Wheel Trailer 3.73 4 536 kg (10,000 lb) 11113 kg (24,500 lb)

C-3500 Pickup Model Extended Cab — 2WD

Single Rear Wheels — Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Single Rear Wheels — Fifth-Wheel Trailer 3.73 7 620 kg (16,800 lb) 11113 kg (24,500 lb)

Dual Rear Wheels — Conventional Trailer 3.73 7 484 kg (16,500 lb) 13 835 kg (30,500 lb)

Dual Rear Wheels — Fifth-Wheel Trailer 3.73 10 387 kg (22,900 lb) 13 835 kg (30,500 lb)

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

Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)




Fifth-Wheel Trailer 3.73 7 620 kg (16,800 lb) 11113 kg (24,500 lb)



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





Dual Rear Wheels — Sierra Denali — ConventionalTrailer

3.73 7 484 kg (16,500 lb) 13 835 kg (30,500 lb)

Dual Rear Wheels — Sierra Denali — Fifth-WheelTrailer

3.73 10 297 kg (22,700 lb) 13 835 kg (30,500 lb)

K-3500 Pickup Model Regular Cab — 4WD








K-3500 Pickup Model Extended Cab — 4WD





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

Conventional Trailer 3.73 5 897 kg (13,000 lb) 11113 kg (24,500 lb)

Fifth-Wheel Trailer 3.73 7 484 kg (16,500 lb) 11113 kg (24,500 lb)



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





Sierra Denali — Conventional Trailer 3.73 8 165 kg (18,000 lb) 13 835 kg (30,500 lb)

Sierra Denali — Fifth-Wheel Trailer 3.73 10 161 kg (22,400 lb) 13 835 kg (30,500 lb)




Van Models — 2WD

G2500 Cargo Van 3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G3500 Cargo Van Short Wheelbase 3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G3500 Cargo Van Long Wheelbase 3.54 4 536 kg (10,000 lb) 8 391 kg (18,500 lb)

G3500 Passenger Van Short Wheelbase 3.54 4 536 kg (10,000 lb) 7 711 kg (17,000 lb)

G3500 Passenger Van Long Wheelbase 3.54 4 400 kg (9,700 lb) 7 711 kg (17,000 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.

See “Towing a Trailer” in the ownermanual for kingpin weight and trailertongue 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 as

salt spreaders, snow plows,winches, and lift buckets. The PTOsystem controls engine speed tovalues higher than normal base idle,PTO load relay engagement, andshutdown of the engine.



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 asthe factory preset. The remotecontrols are disabled. This factory

preset 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 and

shutdown (Stationaryoperation only)

PTO load relay engagement/disengagement is disabled at thefactory. See “Factory PresetParameters” later in this section.

PTO Enabling/DisablingConditions

Enabling Conditions –Stationary PTO

To engage stationary PTOoperation, the following conditionsmust be met:. The engine must be running.. The vehicle cannot be moving

and the parking brake mustbe set.

. The shift lever must be inP (Park) or N (Neutral).

. The brake pedal must not bepressed.

. The engine speed must be lessthan the maximum allowed PTOengage speed of 1500 rpm. ThePTO engage speed can beadjusted by a service technician.



For in-cab PTO operation:

Press and release the R on the PTOswitch. The PTO indicator light willblink fast until the PTO loadbecomes engaged. The indicatorlight will then be on steady. The−/SET and +/RES switch positionscan then be used to establish thedesired PTO operating speed.

For remote PTO operation:

Press and release the remote PTOarming switch, then withinfive seconds, move the PTO enableswitch from OFF to ON (open toclosed). The remote indicator lightwill come on when the PTO Load isengaged. The PTO remote SETswitch can then be used to establishthe desired PTO operating speed.Additional information is available inthe service manual for the correctwiring configuration andprogramming of the remote PTOenable and set switches. Theseswitches are accessed through thePTO upfitter connector, locatedunder the passenger side door.

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 is80 km/h (50 mph). This limit canbe adjusted by a servicetechnician.

. The shift lever may be in anyposition.

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

. Cruise control cannot be active.

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

. Press and release the R on thePTO switch. The PTO indicatorlight will blink fast until the PTOload becomes engaged, at whichpoint the indicator light will be on

steady. The −/SET and +/RESswitch positions can then beused 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 on the instrument panelcluster if the PTO will not engage.The operator must take the actionindicated, then again press andrelease the R on the PTO switch.

. PTO: SHIFT TO PARK ORNEUTRAL (Stationary only)

. PTO: SET PARK BRAKE(Stationary only)

. PTO: PRESS & RELEASEBRAKE (Mobile only)

. PTO: RELEASE BRAKE

. PTO: REDUCE VEHICLESPEED

. PTO: REDUCE ENGINE SPEED



. PTO: DISENGAGE CRUISECONTROL (Mobile only)

. PTO: SPEED RANGE (ProgramECM to match PTO Mode)

In addition to these messages, thePTO switch indicator light willindicate when all conditions requiredto engage 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 load relay engagement/disengagement is disabled at thefactory. See “Factory PresetParameters” later in this section.

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 PTO

set speed is stored in memory.Pressing the +/RES switchposition will restore enginespeed to the stored PTO setspeed. PTO can also beprogrammed to reengage atPTO standby speed uponreleasing the brake pedal(mobile PTO only).

. Press and release the9 on thePTO in-cab switch. The enginespeed will return to normalengine idle. The PTO indicatorlight will go off indicating thePTO load relay has beendisengaged and PTO set speedhas been cleared from memory.

. From the remote PTO controls,move the speed enable switch tothe off position. The engine willreturn to normal idle. The PTOload relay is disengaged. PTOmemory speed is also cleared(Stationary PTO only).

. From the remote PTO controls,press the remote engineshutdown switch. PTO isdisengaged and the engine isshutdown simultaneously(Stationary remote 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 80 km/h(50 mph).

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

. The PTO control system willattempt to limit acceleratorpedal and PTO switch inputas the vehicle approachesthe above operational limits.



There are some vehicleconditions, such as downhillacceleration, which may causevehicle speed and/or enginespeed limits to be exceeded.Under these conditions, PTO isdisengaged.

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

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

. The PTO load becomesdisengaged. (See servicemanual.)

Preset PTO Mode

Preset PTO can only be used whenthe vehicle is not moving. Theengine speed is initially set to astand-by engine speed (850 rpm) bypressing the PTO in-cab switch R ,

or by pressing and releasing theremote arming switch. Then withinfive seconds, assert the remotePTO enable switch to on. Thisprovides an initial start-up enginespeed to match the engagement ofthe PTO load. The PTO standbyengine speed can be reprogrammedto a higher speed by your dealer.

Choose one of two factory presetsby pressing the PTO in-cab −/SETor +/RES switch positions or theremote PTO SET switch.Speed 1 and Speed 2 areprogrammable by a servicetechnician from base engine idlerpm to max PTO operation speed(3100 rpm).. Speed 1: Pressing the −/SET

position of the PTO switchresults in a preset speed of1250 rpm.

. Speed 2: Pressing the +/RESposition of the PTO switchresults in a preset speed of1700 rpm.

Pressing the9 switch position onthe PTO in-cab switch or moving theremote PTO enable switch to OFFresults in the return of the enginespeed back to normal idle. The PTOload relay is also disengaged.

Maximum PTO Operating Speed:During PTO operation, theaccelerator pedal can be pressed toadjust the engine speed. To protectthe PTO from over-speed, the PTOsystem will disengage when theengine speed exceeds 2100 rpm.

The Stationary PTO Mode providesboth in-cab and remote controls.The in-cab controls are enabled asthe factory preset. The remotecontrols are disabled. This factorypreset configuration can also bereprogrammed to enable the remotecontrols, and disable the in-cabPTO controls (i.e., PTO switch,accelerator pedal). See your dealerfor more information.



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 shifting into thetransmission manual mode becauseupshifts are limited. This reducesthe maximum vehicle speed whileallowing high engine speedoperation. Therefore, low vehicle

speed operation at 16–40 km/h(10–25mph) and high PTO enginespeed (1,500–2,000 rpm) can beachieved in the manual mode 1 and2 transmission ranges.

PTO Switch Operation

The In-cab PTO switch has fourpositions: R,9 , −/SET, and +/RES.

R : This is the PTO switch ONposition.

To engage PTO, press and releasethe in-cab switch R or, press andrelease the remote PTO armingswitch; then within five seconds,assert the remote enable switch toON. The vehicle will increaseengine speed to a factory presetengine speed (850 rpm). This PTOstand-by speed is not intended to bean 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 R. The current enginespeed will become the new stand-byspeed. This adjustment can only bedone once at the initial engagementof PTO. The initial stand-by speedadjustment must be between enginebase idle speed and 1800 rpm(maximum PTO engage speed).

9 : This is the PTO switch OFFposition.

Press and release the in-cab9switch position or assert the remoteenable switch to OFF to disengagePTO. The engine speed will bereduced to the base idle speed andthe PTO load relay will bedisengaged.



−/SET (SET/TAP-DOWN/COAST)

SET: Press and hold theaccelerator to obtain the desiredengine speed, then press andrelease the −/SET position of thePTO switch. The current enginespeed will be maintained.This action can be repeated asdesired to a higher rpm value. ThePTO set speed cannot exceed2100 rpm.

TAP-DOWN: Press and release the−/SET switch position on the PTOswitch to reduce the engine speedby increments of 100 rpm.

COAST: Press and hold the −/SETswitch position on the PTO switch toreduce the rpm by 200 rpm persecond until the desired enginespeed is reached or until the initialPTO standby speed is reached.

+/RES (RESUME/TAP-UP/ACCEL)

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 position to resume theprevious PTO set speed. The PTOset speed cannot exceed 2100 rpm.

TAP-UP: Press and release the+/RES position to increase theengine speed by increments of100 rpm.

ACCEL: Press and hold the +/RESposition to increase the rpm by200 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 remotestart arming switch.

2. Within five seconds of releasingthe remote start arming switch,press and hold the remoteengine start switch for abouttwo seconds (horn will sound)until the engine starts.

3. Release the remote engine startswitch.

To enable normal PTO operationafter remotely starting the vehicle:

1. Press and release the remotestart arming switch.

2. Within five seconds of releasingthe remote start arming switch,the PTO remote enable switchmust be moved from OFFto ON.

3. The PTO system will raiseengine rpm to standby speedand engage the PTO load.Press the remote PTO −/SET or+/RES switch to elevate PTO tothe desired engine operatingspeed.

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. Toprevent this from occurring,frequently monitor the vehicle duringPTO operation. If the DIC messageis displayed during PTO operation,see Diesel Particulate Filter onpage 9‑10 for information on how toclean or regenerate the DPF. Alsosee “Remote Engine ShutdownControl” earlier in this section.



Factory Preset ParametersThe following table lists the factory preset parameters. These may be altered by the service technician to configurethe various PTO features.

Programmable Parameters Factory Setting Minimum Value Maximum Value

PTO In-cab Control ENABLED DISABLED ENABLED

PTO Remote Control DISABLED DISABLED ENABLED

Type of Set Switch Operation MOMENTARY MOMENTARY LATCHING

Press ON Then Go To Set 1Speed

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 Engaged DuringBraking


Action After Brake IsReleased

RETURN TO BASEIDLE RPM

RETURN TO BASEIDLE RPM

RETURN TOSTANDBY RPM

Auto Engine Shutdown Timer ENABLED DISABLED ENABLED

Engine Shutdown Due ToFailure





Engine Shutdown Warning DISABLED DISABLED ENABLED

Set Low Fuel level For EngineShutdown

15% 0 25%

Engine Run Time While PTOis Active – Timer 7 Hours 4 minutes 7 hours

Min. PTO Engage Speed 500 RPM 500 RPM 1800 RPM

Max. PTO Engine Speed 1800 RPM 950 RPM 3100 RPM

PTO Standby RPM 850 RPM500 RPM Normal engineidle will override if higherthan Standby Speed

3100 RPM

PTO Set Speed 1 1250 RPM500 RPM PTO Set Speed 1cannot be set below PTO

Standby speed3100 RPM

PTO Set Speed 2 1700 RPM500 RPM PTO Set Speed 2cannot be set below PTO

Standby speed3100 RPM

Maximum Operating Speed 2100 RPM 500 RPM 3100 RPM

Tap Step 100 RPM 4 RPM 500 RPM

Ramp Rate 200 RPM 4 RPM 1000 RPM




Maximum Vehicle Speed 129 km/h (80 mph) 30 km/h (18 mph) 129 km/h (80 mph)

Minimum Remote AcceleratorVoltage

0.25 V 0.0 V 2.5 V

Maximum Remote AcceleratorVoltage 4.75 V 2.5 V 5.0 V

Wheel Speed Sensitivity HIGH LOW, MEDIUM, HIGH

Remote Set Switch Transitionto Low Voltage (<1.66 V)

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

Remote Set Switch Transitionto Open State

(>1.66 V, <3.33 V)PTO STANDBY STANDBY SPEED, SET SPEED 1, or SET SPEED 2

Remote Set Switch Transitionto High Voltage (>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 in

order 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 . . . . . . . . . . . . . . . . . . . . . . 10-10

Engine Air Cleaner/Filter . . . . 10-16Cooling System . . . . . . . . . . . . 10-18Engine Coolant . . . . . . . . . . . . . 10-20Engine Overheating . . . . . . . . 10-24Starter Switch Check . . . . . . . 10-25

Automatic Transmission ShiftLock Control FunctionCheck . . . . . . . . . . . . . . . . . . . . . 10-25

Ignition Transmission LockCheck . . . . . . . . . . . . . . . . . . . . . 10-26

Park Brake and P (Park)Mechanism Check . . . . . . . . 10-26

Electrical SystemEngine Compartment FuseBlock . . . . . . . . . . . . . . . . . . . . . 10-27

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.


10-2 Vehicle Care

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 your vehicle's Warranty bookletfor more information.

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.

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

A. Coolant Surge Tank andPressure Cap

B. Remote Positive (+) Terminal

C. Battery

D. Engine Air Cleaner/Filter

E. Diesel Exhaust Fluid (DEF)Fill Tube

F. Engine Air Cleaner/FilterRestriction Indicator (IfEquipped)

G. Engine Oil Dipstick

H. Engine Oil Fill Cap

I. Engine Fan (Out of View)

J. Automatic TransmissionDipstick

K. Power Steering Fluid Reservoir

L. Brake Fluid Reservoir

M. Auxiliary Battery

N. Underhood Fuse Block

O. Windshield Washer FluidReservoir

P. Remote Negative (-) Terminal


Vehicle Care 10-5

United States Van Models Shown, Canada Similar


10-6 Vehicle Care

A. Battery

B. Coolant Surge Tank andPressure Cap

C. Automatic TransmissionDipstick

D. Engine Oil Dipstick

E. Engine Fan (Out of View)

F. Engine Oil Fill Cap

G. Engine Air Cleaner/Filter

H. Air Cleaner/Filter RestrictionIndicator

I. Power Steering Fluid Reservoir

J. Brake Fluid Reservoir

K. 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 Engine OilLife System on page 10‑9.

. 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 clean itwith a paper towel or a cloth,then push it back in all the way.Remove it again, keeping thetip 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.

Notice: Do not add too much oil.Oil levels 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

Look for three things:. CJ-4

Oils designated as API CJ-4 arerequired for the vehicle. TheCJ-4 designation can appeareither alone or in combinationwith other American PetroleumInstitute (API) designations, suchas API CJ-4/SL. These lettersshow API levels of quality.


10-8 Vehicle Care

. SAE 15W-40

SAE 15W-40 is best for thevehicle. When it is very cold,below −18°C (0°F), useSAE 5W-40 to improve coldstarting. These numbers on theoil container show its viscosity,or thickness. Do not use otherviscosity oils such asSAE 10W-30, SAE 10W-40,or SAE 20W-50.

. 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.

Notice: Use only engine oils thathave the designation CJ-4 for thediesel engine. Failure to use therecommended oil can damage theDPF and result in engine damagenot covered by the vehiclewarranty.

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.


Vehicle Care 10-9

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 oilfrom 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 System

When to Change Engine Oil

This vehicle has a computer systemthat indicates when to change theengine oil and filter. This is basedon a combination of factors whichinclude engine revolutions, enginetemperature, and miles driven.Based on driving conditions, themileage at which an engine oilchange is indicated can varyconsiderably. For the oil life systemto work properly, the system mustbe reset every time the oil ischanged.

When the system has calculatedthat oil life has been diminished, itindicates that an oil change isnecessary. A CHANGE ENGINEOIL SOON message comes on.Change the oil as soon as possiblewithin the next 1 000 km (600 mi).It is possible that, if driving underthe best conditions, the oil lifesystem might indicate that an oilchange is not necessary for up to ayear. The engine oil and filter must

be changed at least once a yearand, at this time, the system mustbe reset. Your dealer has trainedservice people who will perform thiswork and reset the system. It is alsoimportant to check the oil regularlyover the course of an oil draininterval and keep it at the properlevel.

If the system is ever resetaccidentally, the oil must bechanged at 5 000 km (3,000 mi)since the last oil change.Remember to reset the oil lifesystem whenever the oil is changed.

How to Reset the Engine OilLife System

Reset the system whenever theengine oil is changed so that thesystem can calculate the nextengine oil change.

To reset the Engine Oil Life Systemon van models:

1. Display the OIL LIFEREMAINING on the DIC.


10-10 Vehicle Care

2. Press and hold the SET/RESETbutton on the DIC for more thanfive seconds. The oil life willchange to 100%.

To reset the Engine Oil Life Systemon most pickup models:

1. Display the OIL LIFEREMAINING on the DIC. If thevehicle does not have DICbuttons, the vehicle must be inP (Park) to access this display.

2. Press and hold the SET/RESETbutton on the DIC, or the tripodometer reset stem if thevehicle does not have DICbuttons, for more thanfive seconds. The oil life willchange to 100%.

On all models, the Engine Oil LifeSystem can be reset as follows:

1. Turn the ignition to ON/RUN withthe engine off.

2. Fully press the accelerator pedalslowly three times withinfive seconds.

3. Display the OIL LIFEREMAINING on the DIC. If thedisplay shows 100%, the systemis reset.

4. Turn the key to LOCK/OFF.

If the CHANGE ENGINE OIL SOONmessage comes back on when thevehicle is started, the engine oil lifesystem has not reset. Repeat theprocedure.

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 11‑12.

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.

Notice: Too much or too littlefluid can damage thetransmission. Too much canmean that some of the fluid couldcome out and fall on hot engineparts or exhaust system parts,starting a fire. Too little fluidcould cause the transmission tooverheat. Be sure to get anaccurate reading if checking thetransmission 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.


Vehicle Care 10-11

. In heavy traffic — especially inhot 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 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 CHECK band if thetransmission fluid is below normaloperating temperatures.

1. Pull out the dipstick and wipe itwith a clean rag or paper towel.The transmission dipstick islocated near the center of theengine 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 CHECK band, thetransmission may be operateduntil the fluid is hot enough toperform a hot check. If the fluidlevel is not within the COLDCHECK band, add or drain fluidas necessary to bring the levelinto the middle of the COLDCHECK 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.

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.


10-12 Vehicle Care

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 RUN band on the dipstick.The width of the HOT RUN bandrepresents approximately 1.0 L(1.06 qt) of fluid at normaloperating temperature.

5. If the fluid level is not within theHOT RUN band, add or drainfluid as necessary to bring thefluid level to within the HOTRUN 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 fluid

level. 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 11‑12.

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 pint). Do not overfill.

Notice: Use of the incorrectautomatic transmission fluid maydamage the vehicle, and thedamages may not be covered bythe vehicle warranty. Always usethe automatic transmission fluidlisted in Recommended Fluidsand Lubricants on page 11‑12.. After adding fluid, recheck the

fluid level as described under“How to Check.”

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

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 11‑12.


Vehicle Care 10-13

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.

Notice: Too much or too littlefluid can damage thetransmission. Too much canmean that some of the fluid couldcome out and fall on hot engineparts or exhaust system parts,starting a fire. Too little fluidcould cause the transmission tooverheat. Be sure to get anaccurate reading if checking thetransmission 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 inhot 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 colderthan 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).. With 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.


10-14 Vehicle Care

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.


Vehicle Care 10-15

A. For areas where ambienttemperatures stay above −40°C(−40°F), regular transmissionfluid can be used. SeeRecommended Fluids andLubricants on page 11‑12.

B. For areas where ambienttemperatures fall below −40°C(−40°F), synthetic transmissionfluid approved to AllisonTransmission Specificationshould be used. SeeRecommended Fluids andLubricants on page 11‑12.

The synthetic transmission fluidcan be used for all temperatureranges.

How to Add Fluid

Refer to the Maintenance Scheduleto determine what kind oftransmission fluid to use. SeeRecommended Fluids andLubricants on page 11‑12.

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 pint). Donot overfill.

Notice: Use of the incorrectautomatic transmission fluid maydamage the vehicle, and thedamages may not be covered bythe vehicle warranty. Always usethe automatic transmission fluidlisted in Recommended Fluidsand Lubricants on page 11‑12.. After adding fluid, recheck the

fluid 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.


10-16 Vehicle Care

Engine Air Cleaner/Filter

Pickup 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 located on the aircleaner box.

When to Inspect

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

How to Inspect

When the restriction indicator turnsblack, or is in the red/orange“change” zone, replace the filter andreset the restriction indicator. Theair cleaner/filter assembly is locatedon the front corner of the enginecompartment on the passenger sideof the vehicle.

To inspect and replace the filter andreset the restriction indicator:

A. Clamp

B. Cover Electrical Connector

C. Restriction Indicator

D. Cover Screws

1. Disconnect the harnessconnector from the air cleanercover electrical connector (B).

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


Vehicle Care 10-17

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

4. Raise the air cleaner housingcover and remove the aircleaner/filter from the air cleanerhousing. Care should be takento dislodge as little dirt aspossible.

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 electricalconnector.

10. Reset the air cleaner/filterrestriction indicator (C),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.

Notice: If the air cleaner/filter isoff, dirt can easily get into theengine, which could damage it.Always have the air cleaner/filterin place when 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 located on the aircleaner resonator.

When to Inspect

See Maintenance Schedule onpage 11‑3.


10-18 Vehicle Care

How to Inspect

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

To inspect and replace the filter andreset the restriction indicator:

A. Cover Screws

B. Restriction Indicator

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

2. Remove the air cleaner/filterfrom the housing. Care shouldbe taken to dislodge as little dirtas 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 (B),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; it

(Continued)

WARNING (CONTINUED)

helps to stop flames if the enginebackfires. Use caution whenworking on the engine and do notdrive with the air cleaner/filter off.

Notice: If the air cleaner/filter isoff, dirt can easily get into theengine, which could damage it.Always have the air cleaner/filterin place when you are driving.

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


Vehicle Care 10-19

Pickup Models

A. Coolant Surge Tank

B. Coolant Surge TankPressure Cap

C. Engine Cooling Fan (Outof View)

Van Models

A. Coolant Surge Tank

B. Coolant Surge TankPressure Cap

C. 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.

Notice: Using coolant other thanDEX-COOL® can cause prematureengine, heater core, or radiatorcorrosion. In addition, the enginecoolant could require changingsooner, at 50 000 km (30,000mi)or 24months, whichever occursfirst. Any repairs would not becovered by the vehicle warranty.Always use DEX-COOL(silicate-free) coolant in thevehicle.


10-20 Vehicle Care

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 10‑24.

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).. Protect against rust and

corrosion.. Help keep the proper engine

temperature.. Let the warning lights and

gauges work as they should.

Notice: Using coolant other thanDEX-COOL may cause prematureengine, heater core, radiator, andfuel operated heater (van modelsonly) corrosion. In addition, theengine coolant may requirechanging sooner, at 50 000 km(30,000 mi) or 24 months,whichever occurs first. Anyrepairs would not be covered bythe vehicle 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 damagealuminum parts. If using thismixture, nothing else needs to beadded.

{ WARNING

Adding only plain water or someother liquid to the cooling systemcan be dangerous. Plain water

(Continued)

WARNING (CONTINUED)

and 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.

Notice: If an improper coolantmixture is used, the engine couldoverheat and be badly damaged.The repair cost would not becovered by the vehicle warranty.Too much water in the mixturecan freeze and crack the engine,radiator, heater core, and otherparts.


Vehicle Care 10-21

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

Notice: If you use extra inhibitorsand/or additives in your vehicle'scooling system, you coulddamage your vehicle. Use onlythe proper mixture of the enginecoolant listed in this manual forthe cooling system. SeeRecommended Fluids andLubricants on page 11‑12.

Never dispose of engine coolant byputting it in the trash, pouring it onthe ground, or into sewers, streams,or bodies of water. Have the coolantchanged by an authorized servicecenter, familiar with legalrequirements regarding usedcoolant disposal. This will helpprotect the environment and yourhealth.

Checking Coolant (Pickup Models)

The coolant surge tank is located inthe engine 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.


10-22 Vehicle Care

Checking Coolant (Van Models)

The coolant surge tank is locatednear the center of the enginecompartment. See EngineCompartment Overview onpage 10‑3 for location.

{ WARNING

Turning the surge tank pressurecap when the engine and radiatorare hot can allow steam andscalding liquids to blow out and

(Continued)

WARNING (CONTINUED)

burn 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 theCOLD FILL mark.

Adding Coolant (Pickup and VanModels)

Notice: If coolant is changed oradded, always add enough to fillthe system 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.

Notice: This vehicle has aspecific coolant fill procedure.Failure to follow this procedurecould cause the engine tooverheat and be severelydamaged.

{ WARNING

Steam and scalding liquids from ahot cooling system can blow outand burn you badly. They areunder pressure, and if you turnthe coolant surge tank pressurecap— even a little— they cancome out at high speed. Never

(Continued)


Vehicle Care 10-23

WARNING (CONTINUED)

turn 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:

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.

Notice: If the pressure cap is nottightly installed, coolant loss andpossible engine damage mayoccur. Be sure the cap is properlyand tightly secured.


10-24 Vehicle Care

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.

Notice: If the engine catches firebecause of being driven with nocoolant, the vehicle can be badlydamaged. The costly repairswould not be covered by thevehicle warranty.

If No Steam Is Coming fromthe Engine Compartment

The COOLANT LEVEL LOW ADDCOOLANT Driver InformationCenter (DIC) message, along with alow coolant condition can indicate aserious problem.

If there is an engine overheatwarning and the vehicle does nothave a low coolant condition, andno steam is heard or seen, the

problem 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 COOLANT LEVEL LOW ADDCOOLANT Driver InformationCenter (DIC) message comes onwith no 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.

If the vehicle no longer has theoverheat warning, the vehicle canbe driven. Just to be safe, drive


Vehicle Care 10-25

slower for about 10 minutes. If thewarning does not come back on,drive normally.

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.

Starter Switch Check

{ WARNING

When you are doing thisinspection, the vehicle couldmove suddenly. If the vehiclemoves, you or others could beinjured.

1. Before starting this check, besure there is enough roomaround the vehicle.

2. Firmly apply both the parkingbrake and the regular brake.See “Parking Brake” in theowner manual.

Do not use the acceleratorpedal, and be ready to turn offthe engine immediately if itstarts.

3. Try to start the engine in eachgear. The vehicle should startonly in P (Park) or N (Neutral).

If the vehicle starts in any otherposition, contact your dealer forservice.

Automatic TransmissionShift Lock ControlFunction Check

{ WARNING

When you are doing thisinspection, the vehicle couldmove suddenly. If the vehiclemoves, you or others could beinjured.

1. Before starting this check, besure there is enough roomaround the vehicle. It should beparked on a level surface.

2. Firmly apply the parking brake.See “Parking Brake” in theowner manual.

Be ready to apply the regularbrake immediately if the vehiclebegins to move.


10-26 Vehicle Care

3. With the engine off, turn theignition to ON/RUN, but do notstart the engine. Withoutapplying the regular brake, try tomove the shift lever out ofP (Park) with normal effort. If theshift lever moves out of P (Park),contact your dealer for service.

Ignition TransmissionLock CheckWhile parked, and with the parkingbrake set, try to turn the ignition toLOCK/OFF in each shift leverposition.. The ignition should turn to

LOCK/OFF only when the shiftlever is in P (Park).

. The ignition key should comeout only in LOCK/OFF.

Contact your dealer if service isrequired.

Park Brake and P (Park)Mechanism Check

{ WARNING

When you are doing this check,the vehicle could begin to move.You or others could be injuredand property could be damaged.Make sure there is room in frontof the vehicle in case it begins toroll. Be ready to apply the regularbrake at once should the vehiclebegin to move.

Park on a fairly steep hill, with thevehicle facing downhill. Keepingyour foot on the regular brake, setthe parking brake.. To check the parking brake's

holding ability: With the enginerunning and the transmission inN (Neutral), slowly remove footpressure from the regular brakepedal. Do this until the vehicle isheld by the parking brake only.

. To check the P (Park)mechanism's holding ability:With the engine running, shift toP (Park). Then release theparking brake followed by theregular brake.

Contact your dealer if service isrequired.


Vehicle Care 10-27

Electrical System

Engine Compartment Fuse Block

Pickup Models

The underhood fuse block is locatedin the engine compartment, on thedriver side of the vehicle. Lift thecover to access the fuse block.

For vans equipped with a Duramaxengine, see “Engine CompartmentFuse Block” in the owner manual.

To remove fuses, hold the end ofthe fuse between your thumb andindex finger and pull straight out.

The vehicle may not be equippedwith all of the fuses and relaysshown.

Fuses Usage

1

Electronic StabilitySuspension Control,Automatic LevelControl Exhaust

2Left Trailer Stop/Turn Lamp

3 Engine Controls

4Right Trailer Stop/Turn Lamp

5 Front Washer

6 Fuel Heater

7Transmission ControlModule (Battery)

8Antilock BrakeSystem 2


10-28 Vehicle Care

Fuses Usage

9 Trailer Back-upLamps

10Left Low-BeamHeadlamp

11Engine ControlModule (Battery)

12Diesel ElectronicControl Module

13TransmissionIgnition 1

14Vehicle Back-upLamps

15Right Low-BeamHeadlamp

16Air ConditioningCompressor

17Electronic ControlModule/ThrottleControl

18 Fuel Pump

19Integrated TrailerBrake Control

Fuses Usage

20 Headlamp Washer

21Rear WindshieldWasher

22 Trailer Park Lamps

23 Left Park Lamps

24 Right Park Lamps

25 Fog Lamps

26 Horn

27Right High-BeamHeadlamp

28Daytime RunningLamps

29Left High-BeamHeadlamp

30Daytime RunningLamp 2

31 Sunroof

32Key Ignition System,Theft-DeterrentSystem

Fuses Usage

33 Windshield Wiper

34SEO B2 UpfitterUsage (Battery)

35Electric AdjustablePedals

36Climate Controls(Battery)

37Airbag System(Ignition)

38 Amplifier

39 Audio System

40Miscellaneous(Ignition), CruiseControl

41Tailgate Open/CloseAssist

42Airbag System(Battery)

43Instrument PanelCluster

44 Power Take-Off


Vehicle Care 10-29

Fuses Usage

45

Auxiliary ClimateControl (Ignition),Compass andTemperature Mirror

46Center High-MountedStoplamp (CHMSL)

47 Rear Defogger

48 Heated Mirrors

49SEO B1 UpfitterUsage (Battery)

50Cigarette Lighter,Auxiliary Power Outlet

51

Automatic LevelControl CompressorRelay, SEO UpfitterUsage

52Climate Controls(Ignition)

53Engine ControlModule, SecondaryFuel Pump (Ignition)

68 Fan

J-CaseFuses

Usage

54Automatic LevelControl Compressor

55Heavy Duty Anti-lockBrake System

56Antilock BrakeSystem 1

57 Starter

58Stud 2 (TrailerBrakes)

59Left Bussed ElectricalCenter 1

60Electric RunningBoards

61 Not Used

62Four-Wheel DriveSystem

63Stud 1 (TrailerConnector BatteryPower)

64Mid-Bussed ElectricalCenter 1

J-CaseFuses

Usage

65Climate ControlBlower

66Tailgate Open/CloseAssist

67Left Bussed ElectricalCenter 2

Relays Usage

FAN RLY Fan Relay

HDLPLO/HID

Low-Beam Headlamp

FOGLAMP

Front Fog Lamps

A/CCMPRSR

Air ConditioningCompressor

STRTR Starter

PWR/TRN Powertrain

FUELPMP

Fuel Pump


10-30 Vehicle Care

Relays Usage

PRKLAMP

Parking Lamps

REARDEFOG

Rear Defogger

RUN/CRNK

Switched Power


Service and Maintenance 11-1

Service andMaintenance

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

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

Special Application ServicesSpecial ApplicationServices . . . . . . . . . . . . . . . . . . . . 11-8

Additional Maintenanceand CareAdditional Maintenanceand Care . . . . . . . . . . . . . . . . . . . 11-8

Recommended FluidsRecommended Fluids andLubricants . . . . . . . . . . . . . . . . . 11-12

Maintenance ReplacementParts . . . . . . . . . . . . . . . . . . . . . . 11-15

Maintenance RecordsMaintenance Records . . . . . . 11-16

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.

Notice: Damage caused byimproper maintenance can lead tocostly repairs and may not becovered by the vehicle warranty.Maintenance intervals, checks,inspections, recommended fluids,and lubricants are important tokeep the vehicle in good workingcondition.

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.


11-2 Service and Maintenance

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. See“Recommended Fuel” in theowner manual.

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.

. Add diesel exhaust fluid. SeeDiesel Exhaust Fluid onpage 9‑12.

. Check engine coolant level. SeeEngine Coolant on page 10‑20.

. 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 10‑16.



. Inspect brake system.

. Visually inspect steering,suspension, and chassiscomponents for damaged, loose,or missing parts or signs ofwear. See “Exterior Care” in theowner manual.

. 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.



Footnotes — MaintenanceSchedule Additional RequiredServices — Normal

(1) Or every four years, whichevercomes first.

(2) Do not directly power wash thetransfer case output seals. Highpressure water can overcome theseals and contaminate the transfercase fluid. Contaminated fluid willdecrease the life of the transfercase and should be replaced.

(3) Or every five years, whichevercomes first. See Cooling System onpage 10‑18.

(4) Or every 10 years, whichevercomes first.

(5) Inspect for fraying, excessivecracking, or damage; replace,if needed.



Footnotes — MaintenanceSchedule Additional RequiredServices — Severe

(1) Extreme service. For vehiclesmainly driven off-road in four-wheeldrive or used in farming, mining,forestry, Department of NaturalResources (DNR), or snow plowing.

(2) Or every four years, whichevercomes first.

(3) Do not directly power wash thetransfer case output seals. Highpressure water can overcome theseals and contaminate the transfercase fluid. Contaminated fluid willdecrease the life of the transfercase and should be replaced.

(4) Or every five years, whichevercomes first. See Cooling System onpage 10‑18.

(5) Or every 10 years, whichevercomes first.

(6) Inspect for fraying, excessivecracking, or damage; replace,if needed.

Special ApplicationServices. Severe Commercial Use

Vehicles Only: Lubricate chassiscomponents every 5 000 km/3,000 mi.

. Have underbody flushing serviceperformed once a year.

. Replace the fuel filter when theCHANGE FUEL FILTERmessage in the DriverInformation Center (DIC) comeson. See Fuel System Messageson page 5‑11. The fuel filtershould be changed at leastevery two years. The PERCENTFUEL FILTER LIFE REMAININGcan be used to decide if the filtershould be changed duringroutine service.

On van models, inspect andclean the fuel pump screen ifnecessary at each fuel filterinspection or replacement.

AdditionalMaintenance and CareYour vehicle is an importantinvestment and caring for it properlymay help to avoid future costlyrepairs. To maintain vehicleperformance, additionalmaintenance services may berequired. It is recommendedthat your dealer perform theseservices — their trained dealertechnicians know your vehicle best.Your dealer can also perform athorough assessment with a multi‐point inspection to recommendwhen your vehicle may needattention. The following list isintended to explain the services andconditions to look for that mayindicate services are required.



Battery

The battery supplies power to startthe engine and operate anyadditional electrical accessories.. To avoid break‐down or failure to

start the vehicle, maintain abattery with full cranking power.

. Trained dealer technicians havethe diagnostic equipment to testthe battery and ensure that theconnections and cables arecorrosion‐free.

Belts. Belts may need replacing if they

squeak or show signs ofcracking or splitting.

. Trained dealer technicians caninspect the belts andrecommend replacement whennecessary.

Brakes

Brakes stop the vehicle and arecrucial to safe driving.. Signs of brake wear may include

chirping, grinding, or squealingnoises, or difficulty stopping.

. Trained dealer technicians haveaccess to tools and equipmentto inspect the brakes andrecommend quality partsengineered for the vehicle.

Fluids

Proper fluid levels and approvedfluids protect the vehicle’s systemsand components. SeeRecommended Fluids andLubricants on page 11‑12 for GMapproved fluids.. Engine oil and windshield

washer fluid levels should bechecked at every fuel fill.

. Instrument cluster lights maycome on to indicate that fluidsmay be low and need to befilled.

Hoses

Hoses transport fluids and shouldbe regularly inspected to ensurethat there are no cracks or leaks.With a multi‐point inspection, yourdealer can inspect the hoses andadvise if replacement is needed.

Lamps

Properly working headlamps,taillamps, and brake lamps areimportant to see and be seen onthe road.. Signs that the headlamps need

attention include dimming, failureto light, cracking, or damage.The brake lamps need to bechecked periodically to ensurethat they light when braking.



. With a multi‐point inspection,your dealer can check the lampsand note any concerns.

Shocks and Struts

Shocks and struts help aid in controlfor a smoother ride.. Signs of wear may include

steering wheel vibration, bounce/sway while braking, longerstopping distance, or uneventire wear.

. As part of the multi‐pointinspection, trained dealertechnicians can visually inspectthe shocks and struts for signsof leaking, blown seals,or damage, and can advisewhen service is needed.

Tires

Tires need to be properly inflated,rotated, and balanced. Maintainingthe tires can save money, fuel, andcan reduce the risk of tire failure.. Signs that the tires need to be

replaced include three or morevisible treadwear indicators; cordor fabric showing through therubber; cracks or cuts in thetread or sidewall; or a bulge orsplit in the tire.

. Trained dealer technicians caninspect and recommend the righttires. Your dealer can alsoprovide tire/wheel balancingservices to ensure smoothvehicle operation at all speeds.Your dealer sells and servicesname brand tires.

Vehicle Care

To help keep the vehicle looking likenew, vehicle care products areavailable from your dealer. Forinformation on how to clean andprotect the vehicle’s interior andexterior, see “Interior Care” and“Exterior Care” in the owner manual.

Wheel Alignment

Wheel alignment is critical forensuring that the tires deliveroptimal wear and performance.. Signs that the alignment may

need to be adjusted includepulling, improper vehiclehandling, or unusual tire wear.

. Your dealer has the requiredequipment to ensure properwheel alignment.



Windshield

For safety, appearance, and thebest viewing, keep the windshieldclean and clear.. Signs of damage include

scratches, cracks, and chips.. Trained dealer technicians can

inspect the windshield andrecommend proper replacementif needed.

Wiper Blades

Wiper blades need to be cleanedand kept in good condition toprovide a clear view.. Signs of wear include streaking,

skipping across the windshield,and worn or split rubber.

. Trained dealer technicians cancheck the wiper blades andreplace them when needed.



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 10‑20.

Hydraulic Brake SystemDOT 3 Hydraulic Brake Fluid (GM Part No. 12377967, inCanada 89021320).

Windshield WasherAutomotive windshield washer fluid that meets regional freeze protectionrequirements.

Diesel Exhaust AftertreatmentSystem

Diesel Exhaust Fluid (GM Part No. 88862659, 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. 89021184, 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 CylindersMulti-Purpose Lubricant, Superlube (GM Part No. 12346241, inCanada 10953474).

Pickup Models: Floor Shift LinkageLubriplate Lubricant Aerosol (GM Part No. 89021668, in Canada 89021674)or lubricant meeting requirements of NLGI #2 Category LB or GC-LB.

Chassis LubricationChassis 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 AxleSAE 75W-90 Synthetic Axle Lubricant (GM Part No. 89021677, inCanada 89021678).

Transfer Case DEXRON®-VI Automatic Transmission Fluid.

Van Models: One-Piece PropshaftSlip Yoke Spline, Two-PiecePropshaft Slip-in-Tube Spline

Spline Lubricant, Special Lubricant (GM Part No. 12345879, inCanada 10953511).

Pickup Models: Front Axle PropshaftSpline

Spline Lubricant, Special Lubricant (GM Part No. 12345879, inCanada 10953511).




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 HingesMulti-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 ConditioningWeatherstrip Lubricant (GM Part No. 3634770, in Canada 10953518) orDielectric Silicone Grease (GM Part No. 12345579, in Canada 10953481).

Weatherstrip SqueaksSynthetic 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 11‑12.

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 9‑12.

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 . . . . . 10-16AutomaticTransmission Fluid . . . . . . . . . 10-10

Automatic TransmissionShift Lock ControlFunction Check . . . . . . . . . . . 10-25

BBrakeExhaust . . . . . . . . . . . . . . . . . . . . . .9-18

CCanadian Vehicle Owners . . . . . . . . . iiCapacities andSpecifications . . . . . . . . . . . . . . . . 12-2

CheckEngine Light . . . . . . . . . . . . . . . . . . . 5-6IgnitionTransmission Lock . . . . . . . . 10-26

Cluster, Instrument . . . . . . . . . . . . . 5-2

Cold Weather Operation . . . . . . . 9-27CoolantEngine . . . . . . . . . . . . . . . . . . . . . . 10-20

Cooling System . . . . . . . . . . . . . . . 10-18Engine Messages . . . . . . . . . . . .5-10

CoversWinter . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

DDieselStarting Your Engine . . . . . . . . . . . 9-1

Diesel Exhaust Fluid . . . . . . 1-4, 9-12Diesel Exhaust Fluid (DEF)Warning Light . . . . . . . . . . . . . . . . . 5-8

Diesel Exhaust FluidMessages . . . . . . . . . . . . . . . . . . . . 5-11

Diesel Particulate Filter . . . . . . . . 9-10Diesel Particulate FilterMessages . . . . . . . . . . . . . . . . . . . . 5-12

Drive Belt Routing, Engine . . . . . 12-4Driver InformationCenter (DIC) . . . . . . . . . . . . . . . . . . 5-9

EElectrical SystemEngine CompartmentFuse Block . . . . . . . . . . . . . . . . 10-27

EngineAir Cleaner/Filter . . . . . . . . . . . 10-16Check and Service EngineSoon Light . . . . . . . . . . . . . . . . . . . 5-6

Compartment Overview . . . . . . .10-3Coolant . . . . . . . . . . . . . . . . . . . . . 10-20Cooling System . . . . . . . . . . . . . 10-18Cooling System Messages . . .5-10Drive Belt Routing . . . . . . . . . . . .12-4Heater . . . . . . . . . . . . . . . . . . . . . . . . . 9-9Oil Life System . . . . . . . . . . . . . . .10-9Oil Messages . . . . . . . . . . . . . . . . .5-10Oil Pressure Gauge . . . . . . . . . . . 5-5Overheating . . . . . . . . . . . . . . . . 10-24Power Messages . . . . . . . . . . . . . 5-11Starting Your Diesel . . . . . . . . . . . 9-1

EnginesDiesel Fuel . . . . . . . . . . . . . . . . . . .9-19

Exhaust Brake . . . . . . . . . . . . . . . . . 9-18Exhaust FluidDiesel . . . . . . . . . . . . . . . . . . . . . . . .9-12


i-2 INDEX

FFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10Replacement (Fuel) . . . . . . . . . . .9-33

Filter,Engine Air Cleaner . . . . . . . . . 10-16

FluidAutomatic Transmission . . . . 10-10Diesel Exhaust . . . . . . . . . . . . . . . . 1-4

FuelCold Weather Operation . . . . . .9-27Diesel Engines . . . . . . . . . . . . . . .9-19Filling a Portable FuelContainer . . . . . . . . . . . . . . . . . . .9-38

Filling the Tank . . . . . . . . . . . . . . .9-36Filter Replacement . . . . . . . . . . .9-33Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Operated Heater (FOH) . . . . . . .9-10Running out of Fuel . . . . . . . . . . .9-32System Messages . . . . . . . . . . . . 5-11Water in Fuel . . . . . . . . . . . . . . . . .9-27What to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . .9-24

What to Use in the U.S. . . . . . .9-20

Fuel for Diesel Engines . . . . . . . . 9-19FusesEngine CompartmentFuse Block . . . . . . . . . . . . . . . . 10-27

GGaugesEngine Oil Pressure . . . . . . . . . . . 5-5Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

General InformationService and Maintenance . . . . . 11-1

HHeaterEngine . . . . . . . . . . . . . . . . . . . . . . . . . 9-9Fuel Operated . . . . . . . . . . . . . . . .9-10

IIgnition Transmission LockCheck . . . . . . . . . . . . . . . . . . . . . . . 10-26

Instrument Cluster . . . . . . . . . . . . . . 5-2Introduction . . . . . . . . . . . . . . . . . . . . . . . . ii

LLampsMalfunction Indicator . . . . . . . . . . 5-6

LightsWait to Start . . . . . . . . . . . . . . . . . . . 5-8

MMaintenanceRecords . . . . . . . . . . . . . . . . . . . . .11-16

Maintenance ScheduleRecommended Fluidsand Lubricants . . . . . . . . . . . . .11-12

Malfunction Indicator Lamp . . . . . 5-6MessagesDiesel Exhaust Fluid . . . . . . . . . . 5-11Diesel Particulate Filter . . . . . . .5-12Engine Cooling System . . . . . . .5-10Engine Oil . . . . . . . . . . . . . . . . . . . .5-10Engine Power . . . . . . . . . . . . . . . . 5-11Fuel System . . . . . . . . . . . . . . . . . . 5-11Service Vehicle . . . . . . . . . . . . . . .5-12Starting the Vehicle . . . . . . . . . . .5-12Transmission . . . . . . . . . . . . . . . . .5-13Vehicle . . . . . . . . . . . . . . . . . . . . . . .5-10Vehicle Speed . . . . . . . . . . . . . . . .5-13


INDEX i-3

OOilEngine . . . . . . . . . . . . . . . . . . . . . . . .10-6Engine Oil Life System . . . . . . .10-9Engine Oil Pressure Gauge . . . . 5-5Messages . . . . . . . . . . . . . . . . . . . .5-10

Overheating, Engine . . . . . . . . . . 10-24

PParkingBrake and P (Park)Mechanism Check . . . . . . . . 10-26

Over Things That Burn . . . . . . .9-10PersonalizationVehicle . . . . . . . . . . . . . . . . . . . . . . .5-15

Power Take-Off (PTO) . . . . . . . . . 9-43

RRecommended Fluids andLubricants . . . . . . . . . . . . . . . . . . . 11-12

RecordsMaintenance . . . . . . . . . . . . . . . . .11-16

Replacement PartsMaintenance . . . . . . . . . . . . . . . . .11-15

Routing, Engine Drive Belt . . . . . 12-4Running out of Fuel . . . . . . . . . . . . 9-32

SServiceAccessories andModifications . . . . . . . . . . . . . . . .10-1

Engine Soon Light . . . . . . . . . . . . . 5-6Maintenance Records . . . . . . .11-16Maintenance, GeneralInformation . . . . . . . . . . . . . . . . . . 11-1

Vehicle Messages . . . . . . . . . . . .5-12Shift Lock Control FunctionCheck, AutomaticTransmission . . . . . . . . . . . . . . . . 10-25

Specifications andCapacities . . . . . . . . . . . . . . . . . . . . 12-2

Starter Switch Check . . . . . . . . . 10-25Starting the VehicleMesssages . . . . . . . . . . . . . . . . . . . 5-12

Starting Your Diesel Engine . . . . . 9-1SupplementUsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

TTowingTrailer . . . . . . . . . . . . . . . . . . . . . . . .9-38

TrailerTowing . . . . . . . . . . . . . . . . . . . . . . . .9-38

TransmissionFluid, Automatic . . . . . . . . . . . . 10-10Messages . . . . . . . . . . . . . . . . . . . .5-13

UUsing This Supplement . . . . . . . . . . . . ii

VVehicleCanadian Owners . . . . . . . . . . . . . . . iiMessages . . . . . . . . . . . . . . . . . . . .5-10Personalization . . . . . . . . . . . . . . .5-15Speed Messages . . . . . . . . . . . . .5-13


i-4 INDEX

WWait to Start Light . . . . . . . . . . . . . . 5-8Warning LightDiesel Exhaust Fluid (DEF) . . . . 5-8

Water in Fuel . . . . . . . . . . . . . . . . . . 9-27What Fuel to Use in Canadaand Mexico . . . . . . . . . . . . . . . . . . . 9-24

What Fuel to Use inthe U.S. . . . . . . . . . . . . . . . . . . . . . . 9-20

Winter Cover . . . . . . . . . . . . . . . . . . . 9-4

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