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Chevrolet 2500HD Supplementary Manual

Contents

1. 9 26 What Fuel to Use in Canada and Mexico 065 9 22 What Fuel to Use in the U S cee 9 17 Winter Cover 00 9 5
2. 9 31 Gage sirr Erron nE E EAn 5 4 Operated Heater FOH 9 10 Running Out of Fuel 9 30 System Messages 5 11 Fuel cont Water in Fuel 9 26 What to Use in Canada and Mexico 5 9 22 What to Use in the U S 9 17 Fuel for Diesel Engines 9 16 Fuses Engine Compartment Fuse Block 10 28 G Gauges Engine Oil Pressure 5 5 UCI iu teme vi ee bacee meee 5 4 General Information Service and Maintenance 11 1 H Heater ENQING c2cec0teae shieareenteas 9 9 Fuel Operated 9 10 Ignition Transmission Lock Check 0 00c cece e ee 10 27 Instrument Cluster 5 2 Introduction 0 cece eee ii L Lamps Malfunction Indicator 5 6 Lights Wait to Start 5 9 Maintenance Records c0eceeee ee 11 12 Maintenance Schedule Recommended Fluids and Lubricants 08 11 8 Scheduled Maintenance 11 2 Malfunction Indicator Lamp 5 6 Messages P S Diesel Exhaust Fluid 5 11 F Diesel Particulate Filter 5 12 es and P Park Aa es eeepc Engine Cooling System lt s FM Mechanism Check 10 27 Accessories and Engine Ol spepiientieunioree 5 11 Over Things That Burn 9 10 Modifications 10 1 Engine FONG setascenusebacrs FM Personalization Engine Soon Light 5 6 eve
3. If there is still no sign of steam and the vehicle is equipped with an engine driven cooling fan push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least five minutes while the vehicle is parked If the warning is still there turn off the engine and get everyone out of the vehicle until it cools down The decision may be made not to lift the hood but to get service help right away Starter Switch Check Z WARNING When you are doing this inspection the vehicle could move suddenly If the vehicle moves you or others could be injured 1 Before starting this check be sure there is enough room around the vehicle 2 Firmly apply both the parking brake and the regular brake See Parking Brake in the owner manual Do not use the accelerator pedal and be ready to turn off the engine immediately if it starts 3 Try to start the engine in each gear The vehicle should start only in P Park or N Neutral If the vehicle starts in any other position contact your dealer for service Automatic Transmission Shift Lock Control Function Check Z WARNING When you are doing this inspection the vehicle could move suddenly If the vehicle moves you or others could be injured 1 Before starting this check be sure there is enough room around the vehicle It should be parked on a level surface 2 Firmly apply the parking brake See
4. Cleaning the DPF Exhaust Filter While the DPF cleaning is automatically controlled by the engine computer the vehicle will need to operate continuously for approximately 30 minutes and at speeds greater than 48 km h 30 mph to clean the DPF effectively If the vehicle is returned to idle during the cleaning process the driver may notice a slightly different sound or a slightly elevated engine idle speed This is normal No action is required on the part of the driver during a regular DPF cleaning See Diesel Particulate Filter Exhaust Filter on page 9 10 1 4 In Brief Special DPF Driver Messages If the vehicle is used for numerous short trips or extended slow speed operation the engine computer may not be able to adequately heat up the exhaust system to clean the DPF effectively The engine computer has been designed to continuously monitor the condition of the DPF When the engine computer detects that the DPF is nearly full of particulates and that the vehicle is not being operated in a manner that would allow effective automatic DPF cleaning the Driver Information Center will display the message CLEANING EXHAUST FILTER KEEP DRIVING UNTIL MESSAGE IS CLEARED If the vehicle continues to be driven in a manner that prevents effective DPF cleaning the DPF will become plugged with particulates If this occurs the engine computer will turn on the Service Engine Soon Light in the instrument cluster and the DIC
5. DIC will display EXHAUST FLUID QUALITY POOR SEE OWNERS MANUAL NOW Adding fresh DEF to the system may resolve the problem depending on several factors If the DIC message persists see your dealer After 322 km 200 miles of driving without correcting the problem a DIC message 89 km h 55 mph MAX SPEED UPON RESTART will be displayed There will also be a warning light and chime The vehicle will be speed limited to 89 km h 55 mph at the next restart If the problem is not resolved after 805 km 500 miles of operation speed will be limited to 7 km h 4 mph after the next fuel fill Service Exhaust Fluid System If a problem occurs with the DEF system the DIC will display SERVICE EXHAUST FLUID SYSTEM SEE OWNERS MANUAL NOW In some cases this message will clear itself indicating that the DEF system was able to correct the condition If the DIC massage persists see your dealer After 322 km 200 miles of driving without correcting the problem a DIC message 89 km h 55 mph MAX SPEED UPON RESTART will be displayed There will also be a warning light and chime The vehicle will be speed limited to 89 km h 55 mph at the next restart If the problem is not resolved after 805 km 500 miles of operation speed will be limited to 7 km h 4 mph after the next fuel fill Driving and Operating 9 15 Brakes Exhaust Brake Pickup Models only The heavy duty diesel pickups have an exhaust bra
6. Do not try to shift to P Park if the vehicle is moving If you do you could damage the transmission 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 on page 5 9 This light may not come on if the engine is warm 9 2 Driving and Operating 2 As soon as the wait to start light goes off immediately turn the ignition key to START When the engine starts let go of the key The engine has a fast warm up glow plug system The wait to start light will illuminate for a much shorter time than most diesel engines due to the rapid heating of the glow plug system Notice If the wait to start light stays on after starting the vehicle the vehicle may not run properly Have the vehicle serviced right away 3 If the engine does not start after 15 seconds of cranking turn the ignition switch to LOCK OFF Wait one minute for the starter to cool then try the same steps again If you are trying to start the engine after you have run out of fuel follow the steps in Running Out of Fuel on page 9 30 When the engine is cold let it run for a few minutes before you move the vehicle This lets oil pressure build up The engine will sound louder when it s cold Notice If you are not in an idling vehicle and the engine overheats you would not be there to see the overheated engine indication This could
7. Immediately after refueling large amount of water possibly pumped into fuel tank Recommended Action Drain fuel filter immediately If no water can be drained water may be frozen in water drain system or fuel lines Move the vehicle to a warm location to thaw out and then drain filter system Fuel tank purging required See your dealer for assistance Driving and Operating Notice Driving when this warning indicator is on can damage the fuel injection system and the engine If the indicator comes on right after a refuel it means water was pumped into the fuel tank Turn off the engine immediately Then have the water drained at once To drain water 1 Stop and park the vehicle in a safe place Turn off the engine and apply the parking brake 2 Remove the fuel cap 3 Place a fuel resistant container under the fuel filter s For pickup models the filter drain valve is located in the engine compartment on the passenger side of the vehicle on the bottom of the fuel filter For van models the filter drain valves for 9 27 the primary and secondary fuel filters are located in the chassis inside frame rail compartment They are on the driver side of the vehicle below the fuel filters For pickup models open the drain valve by turning it two to three turns Pump the primer until all of the water has been removed When fuel empties from the valve all the water has been dr
8. RES switch position to resume the previous PTO set speed The PTO set speed cannot exceed 2100 rpm TAP UP Press and release the RES position to increase the engine speed by increments of 100 rpm ACCEL Press and hold the RES position to increase the rpm by 200 rpm per second until the desired engine speed is reached or until the maximum allowable PTO set speed is reached Remote Engine Start Control The vehicle s PTO system allows the engine to be remotely started while operating in the stationary PTO mode The vehicle wiring system provides for connections to a remote engine start arming switch and remote starting switch These connections are accessed through the upfitter connector Driving and Operating 9 45 The remote start function is initiated by a sequence of switch actions in addition to several vehicle conditions The vehicle ignition key can be in any position or removed from the ignition The following conditions must be met before attempting to remote start the engine e The vehicle must be configured for stationary PTO operation by a qualified dealer e The parking brake must be set e The transmission shift lever must be in P Park e The vehicle hood must be closed 9 46 Driving and Operating Once the above conditions are met continue the remote start by doing the following steps using the remote PTO controls 1 Press and release the remote start arming switch
9. change normal service Check vent hose at transfer case for kinks and proper installation Check to be sure vent hose is unobstructed clear and free of debris During any maintenance if a power washer is used to clean mud and dirt from the underbody care should be taken to not directly spray the transfer case output seals High pressure water can overcome the seals and contaminate the transfer case fluid Contaminated fluid will decrease the life of the transfer case and should be replaced First Engine Oil Change After Every 240 000 km 150 000 Miles e Engine cooling system drain flush and refill or every five years whichever occurs first See Engine Coolant on page 10 21 An Emission Control Service e Engine drive belts inspection for fraying excessive cracks or obvious damage or every 10 years whichever occurs first Replace if needed 11 8 Service and Maintenance Recommended Fluids Lubricants and Parts Recommended Fluids and Lubricants Fluids and lubricants identified below by name part number or specification can be obtained from your dealer Engine oils with the letters CJ 4 are required for your vehicle The CJ 4 designation can appear either alone or in combination with other American Engine Oil Petroleum Institute API designations such as API CJ 4 SL These letters show API levels of quality To determine the preferred viscosity for your vehicle s diesel engine see Engine Oil on page 1
10. Choose one of two factory presets by pressing the PTO In cab SET or RES switch positions or the remote PTO SET switch Speed 1 and Speed 2 are programmable by a service technician from base engine idle rpm to max PTO operation speed 3100 rpm e Speed 1 Pressing the SET position of the PTO switch results in a preset speed of 1250 rpm e Speed 2 Pressing the RES position of the PTO switch results in a preset speed of 1700 rpm Pressing the O switch position on the PTO in cab switch or moving the remote PTO enable switch to OFF results in the return of the engine speed back to normal idle The PTO load relay is also disengaged 9 43 Maximum PTO Operating Speed During PTO operation the accelerator pedal can be pressed to adjust the engine speed To protect the PTO from over speed the PTO system will disengage when the engine speed exceeds 2100 rpm The Stationary PTO Mode provides both in cab and remote controls The in cab controls are enabled as the factory preset The remote controls are disabled This factory preset configuration can also be reprogrammed to enable the remote controls and disable the in cab PTO controls i e PTO switch accelerator pedal See your dealer for more information Variable PTO Mode In this mode the vehicle can be programmed for stationary or mobile operation The variable PTO mode controls engine speed and PTO load engagement is selected by either the PTO i
11. Control 1 Module Throttle Control Vehicle Care 10 29 Fuses Usage Brake Control Washer 27 Right High Beam Headlamp 28 Daytime Running Lamps 29 Left High Beam Headlamp Daytime Running 30 Lamp 2 10 30 Vehicle Care Key Ignition System Theft Deterrent System Windshield Wiper SEO B2 Upfitter Usage Battery Electric Adjustable Pedals Climate Controls Battery Airbag System voninen a Audio System Miscellaneous Ignition Cruise Control Tailgate Open Close Assist System Battery Instrument Panel Cluster Power Take Off Auxiliary Climate Control Ignition Compass and Temperature Mirror Center High Mounted Stoplamp CHMSL Rear Defogger Heated Mirrors SEO B1 Upfitter Usage Battery Cigarette Lighter Auxiliary Power Outlet Automatic Level Control Compressor Relay SEO Upfitter Usage _Fuses_ Usas _ Controls Ignition Engine Control Module Secondary Fuel Pump Ignition Automatic Level Control Compressor Heavy Duty Anti lock Brake System Anti lock Brake System 1 Stud 2 oe Left e Electrical Center 1 Vehicle Care 10 31 Usage evs Usage retin Tage FAN RLY Fan Relay PRK P ikinai Lamps Electric Running HDLP LAMP g p LO HID Low Beam Headlamp REAR EETA Heated Windshield DEFOG 99 FOG Washer System Front Fog Lamps LAMP RUN Four Wheel Drive CRNK gt Witehed Power System A C Air Condi
12. Controls The fast warm up glow plug system makes the wait to start light stay on for a shorter amount of time than most diesel engines For more information see Starting the Diesel Engine on page 9 1 Diesel Exhaust Fluid DEF Warning Light AJIA This light a Driver Information Center DIC Message and a chime come on when there is an issue with the Diesel Exhaust Fluid 5 9 See Diesel Exhaust Fluid Messages on page 5 11 for information on the specific message displaying with the light If the DEF fluid level has not been corrected the light will continue to flash when the vehicle is started or after a fuel refill The vehicle s speed may also be limited Also see Diesel Exhaust Fluid on page 9 12 for more information 5 10 Information Displays Driver Information Center DIC The Driver Information Center DIC is located on the instrument panel above the steering wheel The DIC comes on when the ignition is on A Duramax Diesel vehicle may have the following additional DIC menu items FUEL FILTER LIFE REMAINING To access this display the vehicle must be in P Park If your vehicle has DIC buttons press the vehicle information button until FUEL FILTER LIFE REMAINING displays If your vehicle does not have DIC buttons press the trip stem until FUEL FILTER LIFE REMAINING displays This display shows an estimate of the fuel filter s remaining useful life If you see 90 FUEL FILT
13. Van Models If the fuel operated heater FOH is not working the FOH line requires priming See your dealer for service See Fuel Operated Heater FOH Van Models Only on page 9 10 for more information Driving and Operating If you want to change the fuel filter yourself here s how to do it Z WARNING Diesel fuel is flammable It could start a fire if something ignites it and you could be burned Do not let it get on hot engine parts and keep matches or other ignition sources away First drain any water from the filter following the procedure for draining water listed previously The vehicle s engine must be off until the end of this procedure The fuel filters are located on the driver side frame rail in front of the fuel tank To minimize fuel siphoning from the fuel tank during fuel filter replacement be sure the fuel tank is less than 3 4 full Primary Filter A 1 Apply the parking brake f n7 MS JI Unplug the water sensor wire connected to the fuel filter lowest wire and unscrew the filter s cap Remove the filter element If there is any dirt on the filter sealing surface clean it off Install the new filter element Reinstall and tighten the filter s cap and reconnect the water sensor wire to the filter 6 Follow the vehicle fuel system priming procedure earlier in this section to re prime the system 7 Start the engine and let it idle for five minute
14. Vehicle Speed Messages 89 KM H 55 MPH MAX SPEED UPON RESTART This message will be displayed along with other messages These messages include EXHAUST FLUID EMPTY REFILL NOW EXHAUST FLUID QUALITY POOR or SERVICE EXHAUST FLUID SYSTEM The vehicle speed will be limited to 89 KM H 55 MPH at the next restart 5 14 7 KM H 4MPH MAX SPEED NEXT FUEL FILL This message will be displayed along with other messages These messages include EXHAUST FLUID EMPTY REFILL NOW EXHAUST FLUID QUALITY POOR or SERVICE EXHAUST FLUID SYSTEM The vehicle speed will be limited to 7 KM H 4 MPH at the next fuel fill SPEED LIMITED TO 89 KM H 55 MPH This message will be displayed along with other messages These messages include EXHAUST FLUID EMPTY REFILL NOW EXHAUST FLUID QUALITY POOR or SERVICE EXHAUST FLUID SYSTEM When this message is displayed the vehicle speed is being limited to 89 KM H 55 MPH Instruments and Controls SPEED LIMITED TO 7 KM H 4 MPH This message will be displayed along with other messages These messages include EXHAUST FLUID EMPTY REFILL NOW EXHAUST FLUID QUALITY POOR or SERVICE EXHAUST FLUID SYSTEM When this message is displayed the vehicle speed is being limited to 7 KM H 4 MPH Vehicle Personalization Your Duramax Diesel vehicle may have additional customizable features for Power Take Off PTO See Power Take Off PTO on page 9 39 for more information Entering the Fe
15. When the engine is started it will slowly ramp up to the high idle speed after a delay of a few seconds up to approximately two minutes For this method to work properly there must be no throttle or brake pedal faults 9 4 Driving and Operating The engine idle speed will return to normal once the following conditions are met e Once engine coolant temperature reaches 65 C 150 F e Air intake temperature reaches 0 C 32 F The high idle speed will be temporarily interrupted and the engine speed will return to normal if any of the following conditions occur e The brake pedal is applied e The accelerator pedal is pressed e The transmission is shifted out of P Park or N Neutral e Vehicle speed is detected Once these inputs are removed the engine idle speed will slowly ramp back up to high idle after the normal delay if the conditions for engine coolant temperature and air intake temperature are still met Fast Idle Control The vehicle may have this system which can be used to increase the engine idle speed Fast Idle control will be enabled when the following conditions are met e The park brake is set e The transmission is in P Park or N Neutral e The vehicle speed is about 0 km h 0 mph e The cruise control is in the On position See Cruise Control in the Index of the vehicle owner manual e The cruise control Set switch is pressed and released for Preset Fa
16. a particular shift or condition Shift quality will improve with continued driving 1 2 In Brief Low Traction Mode Allison Transmission Low Traction Mode aids in vehicle acceleration on slippery road surfaces such as ice or snow By selecting 2 Second using Range Selection Mode while at a stop the transmission will limit torque to the drive wheels to prevent slippage Heater Performance Mode Allison Transmission When cold weather conditions are detected the transmission raises part throttle upshift points after the 1 First to 2 Second upshift to increase engine speed This feature shortens engine and cab warm up times When the transmission is in this mode upshifts may be delayed This is normal and does not indicate an operational problem Four Wheel Drive Allison Transmission When operating in 4 Four Wheel Drive Low there is a very deep gear reduction The resulting shifts will feel exaggerated Performance and Maintenance Engine Oil Life System The engine oil life system calculates engine oil life based on vehicle use and on most vehicles displays a DIC message when it is necessary to change the engine oil and filter The oil life system should be reset only following an oil change Resetting the Oil Life System To reset the Engine Oil Life System on van models 1 Display the OIL LIFE REMAINING on the DIC 2 Press and hold the SET RESET button on the DIC for mor
17. approximately 18 9 L 5 gal Locating Diesel Exhaust Fluid DEF can be purchased at a Chevrolet or GMC dealer It can also be purchased at authorized vehicle and truck dealerships Additionally some diesel truck fuelling stations or retailers may also have DEF for purchase For vehicles with an active OnStar subscription OnStar can help to locate a DEF retailer For more information on locating DEF see www afdc energy gov afdc vehicles diesels_fluid html See Customer Assistance Offices in the owner manual for phone numbers to assist you in contacting a GM dealer See Recommended Fluids and Lubricants on page 11 8 Filling the DEF Tank Notice Use only exhaust fluid that is GM approved or fluid containing the API certified or ISO 22241 label The use of other fluids could damage the system requiring costly repairs that will not be covered by the vehicle warranty When adding DEF to an empty or very low tank always add at least 3 78 liters one gallon of fluid to release the vehicle from speed limitation Do not over fill the DEF tank When fluid reaches the top of the fill pipe stop filling Do not top off the DEF tank If you spill DEF on the vehicle while filling the tank wipe the surface with a damp cloth DEF Fill Vans For vans the DEF fill is located behind the fuel fill door The DEF cap is blue and diesel cap is green Fill tube location for chassis cab and cutaway vans fini
18. backfires Use caution when working on the engine and do not drive with the air cleaner filter off Notice lf the air cleaner filter is off dirt can easily get into the engine which could damage it Always have the air cleaner filter in place when you are driving 10 20 Vehicle Care Cooling System Van Models Z WARNING The cooling system allows the engine to maintain the correct Heater and radiator hoses and working temperature other engine parts can be very hot Do not touch them If you do Pickup Models you can be burned Do not run the engine if there is a leak If you run the engine it could lose all coolant That could cause an engine fire and you could be burned Get any leak fixed before you drive the vehicle A Coolant Surge Tank B Coolant Surge Tank Pressure Cap C Engine Cooling Fan Out of View A Coolant Surge Tank B Coolant Surge Tank Pressure Cap C Engine Cooling Fan Out of View Notice Using coolant other than DEX COOL can cause premature engine heater core or radiator corrosion In addition the engine coolant could require changing sooner at 50 000 km 30 000 mi or 24 months whichever occurs first Any repairs would not be covered by the vehicle warranty Always use DEX COOL silicate free coolant in the vehicle Engine Coolant The cooling system in the vehicle is filled with DEX COOL engine coolant This coolant is designed to remai
19. be set below PTO 3100 RPM Standby speed 500 RPM PTO Set Speed 2 PTO Set Speed 2 1700 RPM cannot be set below PTO 3100 RPM Standby speed 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 9 50 Driving and Operating Programmable Factory Setting Minimum Value Maximum Value Parameters Maximum Vehicle Speed 129 km h 80 mph 30 km h 18 mph 129 km h 80 mph Minimum Remote Accelerator Voltage meee oe Maximum Remote Accelerator Voltage Se ies Wheel Speed Sensitivity HIGH LOW MEDIUM HIGH Remote Set Switch Transition to Low SET_SPEED 1 STANDBY SPEED SET SPEED_1 or SET SPEED 2 Voltage lt 1 66 V Remote Set Switch Transition to Open State PTO_STANDBY STANDBY SPEED SET SPEED_1 or SET SPEED 2 gt 1 66 V lt 3 33 V Remote Set Switch Transition to High SET_SPEED 2 STANDBY SPEED SET SPEED_1 or SET SPEED 2 Voltage gt 3 33 V If the PTO factory preset order to satisfy the requirements of See www gmupfitter com for more parameters do not match the the installed PTO system and body information on the installation of settings described above then they equipment wiring and programming for PTO may have already been altered in aftermarket equipment Vehicle Care General Information Accessories and Modifications Vehicle Checks Engine Compartment Overview 005 Engine Oil Engine Oil Life System Aut
20. changing engine oil The engine oil pressure gauge reads in kPa kilopascals or psi pounds per square inch when the engine is running Oil pressure may vary with engine speed outside temperature and oil viscosity If readings are outside the normal operating range the low oil pressure message may display on the Driver Information Center DIC or for vehicles without DIC the oil pressure light comes on If the oil level is outside the normal operating range of 0 548 kPa 0 80 psi check the oil level immediately DO NOT operate the engine with the oil pressure warning light on or a ENGINE OIL LOW ADD OIL message displayed Malfunction Indicator Lamp A computer system called OBD II On Board Diagnostics Second Generation monitors operation of the fuel ignition and emission control systems It makes sure that emissions are at acceptable levels for the life of the vehicle helping to produce a cleaner environment CT This light comes on when the ignition is on but the engine is not running as a check to show it is working If it does not have the vehicle serviced by your dealer If the check engine light comes on and stays on while the engine is running this indicates that there is an OBD II problem and service is required This light also comes on when the Diesel Exhaust Fluid DEF is not working See Diesel Exhaust Fluid on page 9 12 for more information Malfunctions often are indicated by th
21. confirm Litho in U S A Part No 22743552 B Third Printing each of the features found on your vehicle For vehicles first sold in Canada substitute the name General Motors of Canada Limited for GMC and Chevrolet Motor Division wherever it appears in this manual This manual contains information that pertains to the operation of your diesel engine It also contains your Diesel Maintenance Schedule The sections in this manual correspond to the sections in your owner manual This manual along with your owner manual will assist you in the proper use and maintenance of your vehicle Keep this manual in the vehicle for quick reference Canadian Vehicle Owners Propri taires Canadiens A French language copy of this manual can be obtained from your dealer or from On peut obtenir un exemplaire de ce guide en fran ais aupr s du concessionnaire ou a l adresse suivante Helm Incorporated P O Box 07130 Detroit MI 48207 1 800 551 4123 Num ro de poste 6438 de langue frangaise www helminc com 2010 General Motors LLC All Rights Reserved Using this Supplement This supplement contains information specific to the unique components of the vehicle It does not explain everything you need to know about the vehicle Read this supplement along with the owner manual to learn about the vehicle s features and controls Index A good place to look for what you need is the Index in back of this su
22. engine see Battery in the Index of the vehicle owner manual Be sure you have the right oil for the engine and that you have changed the oil at the proper times If you use the wrong oil the engine may be harder to start Be sure you are using the proper fuel for existing weather conditions See Fuel for Diesel Engines on page 9 16 If the engine starts runs a short time then stops the vehicle needs service Z WARNING Do not use gasoline or starting aids such as ether in the air intake They could damage the engine There could also be a fire which could cause serious personal injury Elevated Idle The engine has a cold temperature high idle feature which elevates the engine idle speed from base idle to 1050 rpm for pickup models or 1200 rpm for van models when outside temperatures are below 0 C 32 F and the engine coolant temperature is below 65 C 150 F This feature enhances heater performance by raising the engine coolant temperature faster Driving and Operating 9 3 This feature can be turned on or off using the DIC buttons If the vehicle is not equipped with DIC buttons do the following to turn this feature on or off 1 Turn the ignition to ON RUN with the vehicle off 2 Press the accelerator pedal to the floor and hold while quickly pressing the brake pedal three times in less than eight seconds 3 Release the accelerator pedal and start the engine
23. hot transmission low fuel diesel particulate filter regeneration If PTO operation is continued when critical engine conditions are present a horn chirp warning will occur after 2 to 5 minutes The engine will be shutdown 2 minutes after the horn warning The operator can re start the engine with the ignition key The above horn warning and engine shutdown will again occur if the critical engine condition is still present Prolonged or Extended PTO Operation While operating the vehicle in stationary PTO mode the Diesel Particulate Filter DPF will continue to filter the exhaust and accumulate soot The engine control system depending on the speed and load being applied by the PTO may not be able to generate enough energy or adequate heat needed to clean or regenerate the DPF Continued operation under conditions that do not allow effective regeneration or cleaning will eventually plug the DPF and result in reduced power The ENGINE POWER IS REDUCED Driver Information Center DIC message and Malfunction Indicator Lamp will be displayed and dealer service will be required to return the vehicle to normal full power operation To prevent this from occurring frequently monitor the vehicle during PTO operation If the DIC message is displayed during PTO operation see Diesel Particulate Filter Exhaust Filter on page 9 10 for information on how to clean or regenerate the DPF Also see Remote Engine Shutdown
24. not run the engine or severe engine damage can occur Contact your dealer to have the fuel system flushed Filling a Portable Fuel Container Z WARNING Never fill a portable fuel container while it is in the vehicle Static electricity discharge from the container can ignite the fuel vapor You can be badly burned and the vehicle damaged if this occurs To help avoid injury to you and others e Dispense fuel only into approved containers Do not fill a container while it is inside a vehicle in a vehicle s trunk pickup bed or on any surface other than the ground Continued WARNING Continued e Bring the fill nozzle in contact with the inside of the fill opening before operating the nozzle Contact should be maintained until the filling is complete Do not smoke while pumping fuel Do not use a cellular phone while pumping fuel Towing Trailer Towing When towing at high elevation on steep uphill grades consider the following Engine coolant at higher elevation will boil at a lower temperature than at or near sea level If the engine is turned off immediately after towing at high elevation on steep uphill grades the vehicle may show signs similar to engine overheating Driving and Operating 9 35 To avoid this let the engine run while parked preferably on level ground with the transmission in P Park and the park brake applied for at least five minutes before turn
25. of the gasoline from the tank as possible preferably until the fuel gauge reads near E empty Refuel with Ultra Low Sulfur Diesel fuel Your dealer will be able to perform this procedure Operating your vehicle for a prolonged period of time on gasoline could result in engine or fuel system damage which would not be covered by the vehicle warranty 9 22 What Fuel to Use in Canada and Mexico The emission control system requires the use of diesel fuel with ultra low sulfur content 15 ppm or 0 0015 by weight maximum What Fuel to Use in Canada Notice Use of diesel fuel other than Ultra Low Sulfur Diesel 15 ppm sulfur maximum will cause permanent damage to the exhaust after treatment system This damage would not be covered by the vehicle warranty At a minimum the diesel fuel you use should meet the latest version of specification CAN CGSB 3 517 ULS in Canada If there are questions about the fuel you are using contact your fuel supplier Driving and Operating Diesel Fuel Types Canadian fuels are blended for seasonal changes Diesel Type A fuel is blended for better cold weather starting in extreme conditions however you might notice some power and fuel economy loss If Type A fuel is used in warmer temperatures stalling and hard starting may occur Diesel Type B fuel is blended for higher temperatures experienced during most of the year Premium Diesel Fuel Diesel fu
26. poor quality fuel we recommend that biodiesel users purchase biodiesel blends from a BQ 9000 certified marketer A listing of certified marketers can be found at www bq 9000 org If there are questions about the biodiesel containing fuels you are using contact your fuel supplier Notice Certain driving patterns are not compatible with biodiesel use It is the operator s responsibility to ensure that biodiesel in the vehicle s tank does not lead to engine fuel system or exhaust after treatment system damage We neither encourage nor discourage the use of biodiesel blends for vehicles As a renewable fuel biodiesel provides some environmental benefits 9 20 Driving and Operating However biodiesel has unique properties and needs to be handled differently than diesel fuel Its use presents additional risks and may not be appropriate in all situations Certain vehicle operating modes increase these risks and should be avoided Read further to determine if your driving habits are compatible with the use of biodiesel e Biodiesel fuel quality degrades with time and exposure to high temperature much more quickly than conventional diesel fuel More frequent refueling provides the best opportunity to have a supply of fresh fuel Owners who have very low fuel usage or who have vehicles stored for extended periods of time should avoid the use of biodiesel Storage at hot ambient temperatures will accelerate biodiese
27. the proper coolant mixture With plain water or the wrong mixture the engine could get too hot but you would not get the overheat warning The engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If an improper coolant mixture is used the engine could overheat and be badly damaged The repair cost would not be covered by the vehicle warranty Too much water in the mixture can freeze and crack the engine radiator heater core and other parts If coolant has to be added more than four times a year have the dealer check the vehicle cooling system Notice If you use extra inhibitors and or additives in your vehicle s cooling system you could damage your vehicle Use only the proper mixture of the engine coolant listed in this manual for the cooling system See Recommended Fluids and Lubricants on page 11 8 for more information Never dispose of engine coolant by putting it in the trash pouring it on the ground or into sewers streams or bodies of water Have the coolant changed by an authorized service center familiar with legal requirements regarding used coolant disposal This will help protect the environment and your health Checking Coolant Pickup Models The coolant surge tank is located in the engine compartment on the passenger side of the vehicle See Engine Compartment Overview on page 10 4 for more info
28. the winter cover is warm 9 6 Driving and Operating Installation Chevrolet Pickup Open the hood A Slide the channels of the cover down the back edge of the grille on both sides B Hook J clips to the bottom of the grille C Hook J clips on to the top edge of the grille by the engine compartment D Hook J clips to the side edge of the grille E To remove the winter cover reverse the steps listed previously Installation GMC Pickup Open the hood A Slide the channels of the cover down the back edge of the grille on both sides B Driving and Operating 9 7 Insert pockets between the grille and the bumper C Hook J clips on to the top edge of the grille by the engine compartment 9 8 Driving and Operating D To remove the winter cover reverse the steps listed previously Installation Van Models Open the hood and secure it with the prop rod A Hook the 5 J clips on to the B Hook the top center J clip by bottom edge of the grille the hood latch C Attach the metal hooks one each at the top corners D To remove the winter cover reverse the steps listed previously Engine Heater The engine coolant heater can provide easier starting and better fuel economy during engine warm up in cold weather conditions at or below 18 C 0 F Vehicles with an engine coolant heater should be plugged in at least four h
29. 0 7 Endin Coolant 50 50 mixture of clean drinkable water and use only DEX COOL Coolant 9 See Engine Coolant on page 10 21 TOPE E DOT 3 Hydraulic Brake Fluid GM Part No 12377967 in y y Canada 89021320 Diesel Exhaust Fluid GM Part No 88862659 in Canada 88862660 or diesel exhaust fluid that meets ISO 22241 1 or displays the API Diesel Exhaust Fluid Certification Mark Windshield Washer Optikleen Washer Solvent Van Models Parking Brake Cable Chassis Lubricant GM Part No 12377985 in Canada 88901242 or Guides lubricant meeting requirements of NLGI 2 Category LB or GC LB Power Steering System GM Power Steering Fluid GM Part No 89021184 in Canada 89021186 Diesel Exhaust Aftertreatment System Service and Maintenance 11 9 DEXRON VI Automatic Transmission Fluid Allison Transmission Only For areas where ambient temperatures are Automatic Transmission below 40 C 40 F use Synthetic Transmission Fluid approved to Allison Transmission specification TES 295 GM Part No 12378515 in Canada 88900701 f Multi Purpose Lubricant Superlube GM Part No 12346241 in Key Lock Cylinders Canada 10953474 ees Lubriplate Lubricant Aerosol GM Part No 12346293 in Canada 992723 Pickup Models Floor Shift Linkage or lubricant meeting requirements of NLGI 2 Category LB or GC LB Chassis Lubricant GM Part No 12377985 in Canada 88901242 or lubricant meeting requirements of NLGI 2 Category LB or GC
30. 2 Within five seconds of releasing the remote start arming switch press and hold the engine start switch for about two seconds horn will sound until the engine starts 3 Release the remote engine start switch To enable normal PTO operation after remotely starting the vehicle 1 Press and release the remote start arming switch 2 Within five seconds of releasing the remote start arming switch the PTO remove enable switch must be moved from OFF to ON 3 The PTO system will raise engine rpm to standby speed and engage the PTO load Press the remote PTO SET or RES switch to elevate PTO to the desired engine operating speed Remote Engine Shutdown Control The vehicle s PTO system allows for remote engine shutdown while operating in the stationary PTO mode This feature has the following functions e Engine shutdown using the operator remote switch The vehicle wiring system provides remote engine shutdown switch connections which is accessed through the PTO upfitter connector Timed auto engine shutdown The timed auto engine shutdown feature provides the means to shut down the engine automatically after a predefined time PTO must be operational for this function to be active Engine shutdown based on critical engine conditions The engine will be shutdown when PTO is operating if a critical engine condition is detected by the vehicle system i e low oil low oil pressure hot engine
31. 2011 DURAMAX Diesel Engine LML LGH CA ln Brief eega tus 1 1 Initial Drive Information 1 1 Performance and Maintenance 1 2 Instruments and Controls 5 1 Warning Lights Gauges and MGIC ATOMS ee eck dors eee ees 5 2 Information Displays 5 10 Vehicle Messages 5 10 Vehicle Personalization 5 14 Driving and Operating Starting and Operating Engine Exhaust General Information OA Vehicle Checks Electrical System Service and Maintenance 11 1 General Information 11 1 Scheduled Maintenance 11 2 Recommended Fluids Lubricants and Parts 11 8 Maintenance Records 11 12 Technical Data 12 1 Vehicle Data 12 2 Index 000005 i 1 ii Introduction The names logos emblems slogans vehicle model names and vehicle body designs appearing in this manual including but not limited to GM the GM logo CHEVROLET GMC the CHEVROLET and GMC Truck Emblems SILVERADO SIERRA DENALI EXPRESS SAVANA and Duramax are trademarks and or service marks of General Motors LLC its subsidiaries affiliates or licensors This manual describes features that may or may not be on your specific vehicle either because they are options that you did not purchase or due to changes subsequent to the printing of this owner manual Please refer to the purchase documentation relating to your specific vehicle to
32. 30 minutes If the filter is not cleaned the malfunction indicator lamp will come on and the REDUCED ENGINE POWER message will be displayed Vehicle performance will be limited See Diesel Particulate Filter Exhaust Filter on page 9 10 for more information Service Vehicle Messages SERVICE EXHAUST FLUID SYSTEM SEE OWNERS MANUAL NOW This message displays when the exhaust fluid system needs service This message may be accompanied by other messages that provide more information Starting the Vehicle Messages ELEVATED IDLE OFF If your vehicle does not have DIC buttons this message will appear when the elevated idle exhaust restrictor feature has been turned off This feature can be turned on or off by pressing the pedals For more information on the elevated idle exhaust restrictor feature see Elevated Idle under Starting the Diesel Engine on page 9 1 If your vehicle has DIC buttons this message will not be displayed The Elevated Idle can be turned on or off using the customization menus Press the customization button until ELEVATED IDLE appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following settings OFF ON or NO CHANGE Choose one of the available settings and press the set reset button while it is displayed on the DIC to select it ELEVATED IDLE ON If your vehicle does not have
33. 5 897 kg 13 000 Ibs with ball hitch Trailer rating limited to 7 257 kg 16 000 Ibs with ball hitch Trailer rating limited to 7 484 kg 16 500 Ibs with ball hitch Trailer rating limited to 7 711 kg 17 000 Ibs with ball hitch See Towing a Trailer in the owner Conversions and add on equipment such as salt manual for more information spreaders snow plows winches Add Ons and lift buckets The PTO system controls engine speed to values Power Take Off PTO higher than normal base idle i PTO load relay engagement and The power take off PTO is an shutdown of the engine upfitter integrated system that allows the user to create an auxiliary power source for running 9 40 ae Le Ea ol A S Primary PTO Operating Modes PTO modes of operation include the following e Preset PTO Mode Stationary operation only e Variable PTO Mode Stationary and mobile operation Driving and Operating The PTO stationary mode provides both in cab and remote controls The in cab controls are enabled as the factory preset The remote controls are disabled This factory preset configuration can be programmed to enable the remote controls and or disable the in cab PTO controls See your dealer for more information PTO Sub Modes The primary PTO modes have the following sub modes e Engine speed control e PTO load relay engagement disengagement e Remote engine start and shutd
34. Control earlier in this section Driving and Operating 9 47 Factory Preset Parameters The following table lists the factory preset parameters These may be altered by the service technician to configure the various PTO features 9 48 Driving and Operating Programmable Factory Setting Minimum Value Maximum Value Parameters E In cab Control Eme M O PTO Remote Control Remote Control DISABLED DISABLED ENABLED ee Set Switch MOMENTARY MOMENTARY LATCHING peration Press ON then go to DISABLED DISABLED ENABLED Set 1 Speed Remote Engine Start DISABLED DISABLED ENABLED Remote Engine Shutdown DISABLED DISABLED ENABLED m feedback seme BE E BE a Engage Relay Relay DISABLED DISABLED ENABLED Keep Relay engage during DISABLED DISABLED ENABLED braking Action after brake is RETURN TO BASE RETURN TO BASE RETURN TO released IDLE RPM IDLE RPM STANDBY RPM Auto a Shutdown ENABLED DISABLED ENABLED imer Eng sat eral due to DISABLED DISABLED ENABLED Driving and Operating 9 49 Programmable Factory Setting Minimum Value Maximum Value Parameters Engine Shutdown warning DISABLED DISABLED ENABLED Set Low Fuel level for Engine Run Time While Min PTO Engage Speed 500 RPM 500 RPM 1800 RPM Max PTO Engine Speed 1800 RPM 950 RPM 3100 RPM 500 RPM Normal engine PTO Standby RPM 850 RPM idle will override if higher 3100 RPM than Standby Speed 500 RPM PTO Set Speed 1 PTO Set Speed 1 1250 RPM cannot
35. DIC buttons this message will appear when the elevated idle exhaust restrictor feature has been turned on This feature can be turned on or off by pressing the pedals For more information on the elevated idle exhaust restrictor feature see Elevated Idle under Starting the Diesel Engine on page 9 1 Instruments and Controls If your vehicle has DIC buttons this message will not be displayed The Elevated Idle can be turned on or off using the customization menus Press the customization button until ELEVATED IDLE appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following settings OFF ON or NO CHANGE Choose one of the available settings and press the set reset button while it is displayed on the DIC to select it FAST IDLE ON If your vehicle has this feature this message displays when the fast idle feature is on See Fast Idle Control under Starting the Diesel Engine on page 9 1 5 13 Transmission Messages SHIFT INHIBITED SELECT N TO RESET Pickup Models If the transmission is unable to shift into a selected gear this message will appear on the DIC The electronic shift position indicator on the instrument panel cluster may blink when this occurs To make the vehicle shift to the requested gear you may have to shift back to P Park or N Neutral and re select the desired gear
36. DIC for 10 seconds when a fuel filter change is required See Fuel Filter Replacement on page 9 31 for more information WATER IN FUEL SERVICE REQUIRED This message will come on to warn you if there is water in the diesel fuel system For more information on how this message works see Water in Fuel on page 9 26 Diesel Exhaust Fluid Messages EXHAUST FLUID EMPTY REFILL NOW This message will be displayed when the exhaust fluid is empty This message may be accompanied by other messages that provide more information 5 12 EXHAUST FLUID LOW SPEED LIMITED SOON When the exhaust fluid range is less than 120 km 75 miles this message will be displayed EXHAUST FLUID RANGE XXX When the exhaust fluid is getting low the range will be displayed in either kilometers or miles It is normal for the EXHAUST FLUID RANGE to vary based on vehicle and environmental driving conditions EXHAUST FLUID QUALITY POOR SEE OWNERS MANUAL NOW This message displays when the exhaust fluid is of poor quality This message may be accompanied by other messages that provide more information Instruments and Controls Diesel Particulate Filter Messages CLEANING EXHAUST FILTER KEEP DRIVING UNTIL MESSAGE IS CLEARED This message will appear on the DIC when an exhaust particulate filter cleaning is required To clean the filter drive the vehicle above 50 km h 30 mph until the warning message goes off This will take about
37. ER LIFE REMAINING on the display it means 90 of the current fuel filter life remains The fuel filter Instruments and Controls life system will alert you to change your fuel filter on a schedule consistent with your driving conditions When the remaining fuel filter life is low the CHANGE FUEL FILTER message will appear on the display You should change your fuel filter as soon as you can FUEL FILTER LIFE RESET You must reset the FUEL FILTER LIFE REMAINING display after each fuel filter change It will not reset itself Also be careful not to reset the FUEL FILTER LIFE REMAINING display at any time other than when the fuel filter has just been changed because it cannot be reset accurately until the next fuel filter change The fuel filter life will change to 100 when the system has been reset To reset the system press and hold the set reset button or the trip stem if there are no DIC buttons for two seconds while FUEL FILTER LIFE REMAINING is displayed on the DIC Vehicle Messages The Driver Information Center DIC will display warning messages if a problem is detected Pressing the select button or the set reset button for vehicle with DIC buttons or the trip odometer reset stem for vehicles without DIC buttons will acknowledge some current warning or service messages Other messages are more urgent and cannot be cleared from the display until the issue is corrected The following are some addi
38. Exhaust Fluid DEF Warning Light 5 9 Information Displays Driver Information Center DIC Vehicle Messages Vehicle Messages Engine Cooling System Messages Engine Oil Messages Engine Power Messages Fuel System Messages Diesel Exhaust Fluid Messages Diesel Particulate Filter Messages Instruments and Controls Starting the Vehicle 5 10 Messages Transmission Messages Per Vehicle Speed Messages Vehicle Personalization 5 11 Vehicle Personalization 5 11 5 11 5 11 5 11 5 12 Service Vehicle Messages 5 12 5 12 5 13 5 13 5 14 5 2 Instruments and Controls Warning Lights Gauges and Indicators Instrument Cluster C 50 89 70 JS 40 so 100 English Pickup Shown Metric Similar Instruments and Controls 5 3 gJ 2 12 BDF S gigs 20 aD 20585 o a 40 km h 120 140 _ 90 1605 ULTRA LOW SULFUR DIESEL FUEL ONLY English Van Shown Metric Similar 5 4 Instruments and Controls See the owner manual for telltales and gauges not listed in supplement Fuel Gauge Metric Pickup Models Metric Van Models English Van Models When the ignition is on the fuel gauge shows approximately how much fuel the vehicle has left in the tank The gauge will first indicate E empty before the vehicle is out of f
39. INUTES e NO CHANGE To select a setting press the set reset button while the desired setting is displayed on the DIC Driving and Operating Starting and Operating Starting the Diesel Engine 9 1 Winter Cover 05 9 5 Engine Heater 9 9 Fuel Operated Heater FOH Van Models Only 9 10 Parking Over Things That Burn sac eae cone ees sees 9 10 Engine Exhaust Diesel Particulate Filter Exhaust Filter 9 10 Diesel Exhaust Fluid 9 12 Brakes Exhaust Brake Pickup Models only 9 15 Fuel Fuel for Diesel Engines 9 16 What Fuel to Use in The UiS2aeagiveeeesee Games 9 17 What Fuel to Use in Canada and Mexico 9 22 Cold Weather Operation 9 25 Water in Fuel 9 26 Running Out of Fuel 9 30 Fuel Filter Replacement 9 31 Filling the Tank 9 33 Filling a Portable Fuel Container 9 34 Towing Trailer Towing 9 35 Conversions and Add Ons Power Take Off PTO 9 39 Driving and Operating 9 1 Starting and Operating Starting the Diesel Engine The diesel engine starts differently than a gasoline engine The vehicle will only start in the P Park or the N Neutral position Move the shift lever to P Park or N Neutral To restart the engine when the vehicle is already moving use N Neutral only Notice
40. If there are questions about the biodiesel containing fuels you are using contact your fuel supplier Notice Certain driving patterns are not compatible with biodiesel use It is the operator s responsibility to ensure that biodiesel in the vehicle s tank does not lead to engine fuel system or exhaust after treatment system damage We neither encourage nor discourage the use of biodiesel blends for vehicles As a renewable fuel biodiesel provides some environmental benefits However biodiesel has unique properties and needs to be handled differently than diesel fuel Its use presents additional risks and may not be appropriate in all situations Certain vehicle operating modes increase these risks and should be avoided Read further to determine if your driving habits are compatible with the use of biodiesel e Biodiesel fuel quality degrades with time and exposure to high temperature much more quickly than conventional diesel fuel Driving and Operating 9 23 More frequent refueling provides the best opportunity to have a supply of fresh fuel Owners who have very low fuel usage or who have vehicles stored for extended periods of time should avoid the use of biodiesel Storage at hot ambient temperatures will accelerate biodiesel degradation When vehicles will be stored for extended periods of time greater than one month they should be run out of biodiesel to below 1 4 tank r
41. LB Wheel bearing lubricant meeting requirements of NLGI 2 Category GC or Van Models Front Wheel Bearings GC LB GM Part No 1051344 in Canada 993037 Front and Rear Axle SAE 75W 90 Synthetic Axle Lubricant GM Part No 89021677 in Canada 89021678 DEXRON VI Automatic Transmission Fluid Van Models One Piece Propshaft Slip Yoke Spline Two Piece Spline Lubricant Special Lubricant GM Part No 12345879 in Propshaft Slip in Tube Spline C Nada 10953511 Pickup Models Front Axle Propshaft Spline Lubricant Special Lubricant GM Part No 12345879 in Spline Canada 10953511 Chassis Lubrication 11 10 Service and Maintenance Pickup Models Rear Driveline Center Chassis Lubricant GM Part No 12377985 in Canada 88901242 or Spline lubricant meeting requirements of NLGI 2 Category LB or GC LB Head Hinges Multi Purpose Lubricant Superlube GM Part No 12346241 in 9 Canada 10953474 Pickup Models Body Door Hinge 3 Pins Tailgate Hinge and Linkage deat 7a Superlube GM Part No 12346241 in Folding Seats and Fuel Door Hinge Pickup Models Tailgate Handle Pivot F F Points Hinges Latch Bolt and Multi Purpose Lubricant Superlube GM Part No 12346241 in Canada 10953474 Linkage Weatherstrib Conditionin Weatherstrip Lubricant GM Part No 3634770 in Canada 10953518 or P 9 Dielectric Silicone Grease GM Part No 12345579 in Canada 992887 Weatherstrip Squeaks ara eee Teflon Super
42. O DISENGAGE CRUISE CONTROL Mobile only In addition to these messages the PTO switch LED will indicate when all conditions required to engage PTO have not been met When enabling PTO the LED will turn on then off after one second Under normal operating conditions the PTO LED will remain on throughout the PTO operating cycle PTO Disengage Conditions To disengage the stationary or mobile PTO operation do one of the following e Press the brake PTO will disengage immediately The PTO LED will blink slowly indicating that the PTO set speed is stored in memory Pressing the RES switch position will restore engine speed to the stored PTO set speed PTO can also be programmed to reengage at PTO standby speed upon releasing the brake pedal mobile PTO only Press and release the O on the PTO in cab switch The engine speed will return to normal engine idle The PTO LED light will go off indicating the PTO load relay has been disengaged and PTO set speed has been cleared from memory From the remote PTO controls move the speed enable switch to the off position The engine will return to normal idle The PTO load relay is disengaged PTO memory speed is also cleared Stationary PTO only From the remote PTO controls press the remote engine shutdown switch PTO is disengaged and the engine is shutdown simultaneously Stationary remote PTO only The mobile PTO mode will also disengage if the follo
43. Parking Brake in the owner manual Be ready to apply the regular brake immediately if the vehicle begins to move 3 With the engine off turn the ignition to ON RUN but do not start the engine Without applying the regular brake try to move the shift lever out of P Park with normal effort If the shift lever moves out of P Park contact your dealer for service Ignition Transmission Lock Check While parked and with the parking brake set try to turn the ignition to LOCK OFF in each shift lever position e The ignition should turn to LOCK OFF only when the shift lever is in P Park e The ignition key should come out only in LOCK OFF Contact your dealer if service is required Vehicle Care 10 27 Park Brake and P Park Mechanism Check ZN WARNING When you are doing this check the vehicle could begin to move You or others could be injured and property could be damaged Make sure there is room in front of the vehicle in case it begins to roll Be ready to apply the regular brake at once should the vehicle begin to move Park on a fairly steep hill with the vehicle facing downhill Keeping your foot on the regular brake set the parking brake e To check the parking brake s holding ability With the engine running and the transmission in N Neutral slowly remove foot pressure from the regular brake pedal Do this until the vehicle is held by the parking brake only 10 28
44. Vehicle Care e To check the P Park mechanism s holding ability With the engine running shift to P Park Then release the parking brake followed by the regular brake Contact your dealer if service is required Electrical System Engine Compartment Fuse Block 68 C13 c37 4 s 4 C5Jf C6IC7IJCTC8I C94 a gg mao an i 1g Ed 6 203 cet 293 233 c24 YY 973 283261 Cnc C29 CMPRSR ISTR PMP 303 59 OF Bean 5 82 etl fed c373 m 28 cc i a E Pickup Models The underhood fuse block is located For vans equipped with a Duramax in the engine compartment on the driver side of the vehicle Lift the cover to access the fuse block engine see Engine Compartment Fuse Block in the vehicle owner manual To remove fuses hold the end of the fuse between your thumb and index finger and pull straight out The vehicle may not be equipped with all of the fuses and relays shown Electronic Stability Suspension Control Automatic Level Control Exhaust 2 Left Trailer Stop Turn Lamp Engine Controls 4 Right Trailer Stop Turn Lamp 6 Fuel Heater Transmission Control Module Battery Anti lock Brakes System 2 Trailer Back up Lamps 10 Left Low Beam Headlamp 11 Engine Control Module Battery 12 Diesel Electronic Control Module Transmission 13 pe Ignition 1 Vehicle Back up Lamps 15 Right Low Beam Headlamp 16 Air Conditioning Compressor Electronic
45. ace Keep the engine running e With the parking brake applied place the shift lever in P Park e With foot on the brake pedal move the shift lever through each gear range pausing for about three seconds in each range Then position the shift lever in P Park e Let the engine run at idle for three minutes or more Then without shutting off the engine follow these steps t a The transmission dipstick is located near the center of the engine compartment and will be labeled with the graphic shown See Engine Compartment Overview on page 10 4 for more information on location 1 Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel 2 Push it back in all the way wait 3 seconds and then pull it back out again CIOTA Check both sides of the dipstick and read the lower level The fluid level must be in the COLD area for a cold check or in the HOT or cross hatched area for a hot check Be sure to keep the dipstick pointed down to get an accurate reading 3 Ifthe fluid level is in the acceptable range push the dipstick in all the way then flip the handle down to lock the dipstick in place Vehicle Care 10 15 What Transmission Fluid to Use Allison Transmission Only Cold Operation When temperatures are very cold the transmission will prevent certain operations to protect against damage The Chart below shows shift range availability b
46. ained Close the valve hand tight For van models open the primary fuel filter drain valve by turning it two to three turns Allow the filter to drain until all of the water has been removed Close the valve hand tight Repeat this process for the secondary fuel filter 9 28 5 Remove the fuel resistant container and properly dispose of the contaminated fuel To find out how to properly dispose of contaminated diesel fuel see What to Do With Used Oil under Engine Oil Life System on page 10 10 6 Install the fuel cap For pickup models start the engine and let it run for a few minutes If the engine stalls the fuel system may need to be primed While draining the water from the fuel filter air may enter Driving and Operating the fuel system If air has entered the fuel system the fuel system will need to be primed For van models start the engine and let it run for a few minutes If the WATER IN FUEL message warning light comes on again after driving a short distance or the engine runs rough or stalls a large amount of water has probably been pumped into the fuel tank The fuel tank should be purged Fuel Priming In order for the fuel system to work properly the fuel lines must be full of fuel and contain no air If air gets into the fuel lines it will be necessary to prime the fuel lines to eliminate air before operating the vehicle and the fuel operated heater FOH If air is i
47. ased on transmission oil temperatures e All shift ranges available at 25 C 13 F or above e 2 Second and 3 Third shift ranges only at 35 C 31 F to 25 C 13 F e 2 Second shift range only at 35 C 31 F or lower Torque converter clutch operation will also be prevented when air or transmission oil temperatures are below certain levels 10 16 Vehicle Care Transmission shifting might be firmer with a cold transmission This difference in shift quality is normal A For areas where ambient temperatures stay above 40 C 40 F regular transmission fluid can be used See Recommended Fluids and Lubricants on page 11 8 B For areas where ambient temperatures fall below 40 C 40 F synthetic transmission fluid approved to Allison Transmission Specification should be used See Recommended Fluids and Lubricants on page 11 8 The synthetic transmission fluid can be used for all temperature ranges How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission fluid to use See Recommended Fluids and Lubricants on page 11 8 Using a funnel add fluid down the transmission dipstick tube only after checking the transmission fluid while it is hot A cold check is used only as a reference If the fluid level is low add only enough of the proper fluid to bring the level up to the HOT area for a hot check It does not take much fluid gene
48. ature Settings Menu 1 Turn the ignition on and place the vehicle in P Park To avoid excessive drain on the battery it is recommended that the headlamps are turned off 2 Press the customization button to scroll through the available customizable options Feature Settings Menu Items PTO STANDBY SPEED This feature allows you to select the PTO standby speed Press the customization button until the PTO STANDBY SPEED screen appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following choices e 800RPM e 900RPM e 1000 RPM e 1100 RPM e 1200 RPM e 1300 RPM e 1400 RPM e 1500 RPM e NO CHANGE To select a setting press the set reset button while the desired setting is displayed on the DIC Instruments and Controls PTO SET 1 SPEED This feature allows you to select the PTO 1 set speed Press the customization button until the PTO SET 1 SPEED screen appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following choices e 1000 RPM e 1200 RPM e 1400 RPM e 1600 RPM e 1800 RPM e 2000 RPM e 2200 RPM e 2400 RPM NO CHANGE To select a setting press the set reset button while the desired setting is displayed on the DIC 5 15 PTO SET 2 SPEED This feature allows you to s
49. b 2WD C 3500 Pickup Model Crew Cab Standard Box 2WD C 3500 Pickup Model Crew Cab Long Box 2WD 9 38 Driving and Operating K 3500 Pickup Model Extended Cab 4WD Single Rear Wheels 11113 kg 24 500 Ibs Dual Rear Wheels 13 245 kg 29 200 Ibs K 3500 Pickup Model Crew Cab Standard Box 4WD Single Rear Wheels 11113 kg 24 500 Ibs Single Rear Wheels Sierra Denali 11113 kg 24 500 Ibs K 3500 Pickup Model Crew Cab Long Box 4WD Single Rear Wheels 7 620 kg 16 800 Ibs 11113 kg 24 500 Ibs Dual Rear Wheels 13 245 kg 29 200 Ibs Dual Rear Wheels Sierra Denali 13 245 kg 29 200 Ibs Vans Models 2WD G2500 Cargo Van Short Wheelbase 7711 kg 17 000 Ibs G2500 Cargo Van Long Wheelbase 7711 kg 17 000 Ibs G3500 Cargo Van Short Wheelbase 7711 kg 17 000 Ibs G3500 Cargo Van Long Wheelbase 8 391 kg 18 500 Ibs Driving and Operating 9 39 G3500 Passenger Van Short Wheelbase 4 536 kg 9 900 Ibs 7711 kg 17 000 Ibs G3500 Passenger Van Long Wheelbase 4 536 kg 9 700 Ibs 7 711 kg 17 000 Ibs Fifth wheel or gooseneck kingpin weight should be 15 percent to 25 percent of trailer weight up to 1587 kg 3 500 Ibs maximum The Gross Combination Weight Rating GCWR is the total allowable weight of the completely loaded vehicle and trailer including any passengers cargo equipment and conversions The GCWR for the vehicle should not be exceeded Trailer rating limited to
50. b PTO switch position The current engine speed will become the new stand by speed This adjustment can only be done once at the initial engagement of PTO The initial stand by speed adjustment must be between engine base idle speed and 1800 rpm maximum PTO engage speed O This is the PTO switch Off position Press and release the in cab O switch position or assert the remote enable switch to off to disengage PTO The engine speed will be reduced to the base idle speed and the PTO load relay will be disengaged SET SET TAP DOWN COAST SET Press and hold the accelerator to obtain the desired engine speed then press and release the SET position of the PTO switch The current engine speed will be maintained This action can be repeated as desired to a higher rpm value The PTO set speed cannot exceed 2100 rpm TAP DOWN Press and release the SET switch position on the PTO switch to reduce the engine speed by increments of 100 rpm COAST Press and hold the SET switch position on the PTO switch to reduce the rpm by 200 rpm per second until the desired engine speed is reached or until the initial PTO standby speed is reached RES RESUME TAP UP ACCEL RESUME When a PTO set speed has been achieved press and release the brake pedal Engine speed will reduce to basic idle speed The PTO LED will blink slowly indicating the previous PTO set speed has been retained in memory Press and release the
51. be changed during routine vehicle service Service and Maintenance Additional Required Services At the First 160 km 100 Miles 1 600 km 1 000 Miles and 10 000 km 6 000 Miles e For pickups with dual wheels Check dual wheel nut torque For proper torque see Capacities and Specifications in the owner manual Every 12 000 km 7 500 Miles e Rotate tires Tires should be rotated every 12 000 km 7 500 miles See Tire Rotation in the owner manual At Each Fuel Stop e Engine oil level check See Engine Oil on page 10 7 e Engine coolant level check See Engine Coolant on page 10 21 e Windshield washer fluid level check See Washer Fluid in the owner manual 11 5 Once a Month e Tire inflation pressures check See Tire Pressure in the owner manual e Tire wear inspection See Tire Inspection in the owner manual e Sunroof track and seal inspection if equipped See Sunroof in the owner manual Once a Year e See Starter Switch Check in the owner manual e See Automatic Transmission Shift Lock Control Function Check in the owner manual e See Ignition Transmission Lock Check in the owner manual e See Park Brake and P Park Mechanism Check in the owner manual e Accelerator pedal check for damage high effort or binding Replace if needed e Underbody flushing service 11 6 Hood and liftgate gas strut support service Visua
52. cedure earlier in this section to prime the fuel filter 3 Turn the ignition key to START for 10 to 15 seconds at a time until the engine starts If the engine tries to run but does not run smoothly increase the rpm a little using the accelerator pedal This will help force air through the system 4 Return to Step 2 if the engine stalls and will not restart Van Models If the engine stalls and you think that you may have run out of fuel do this to restart the engine 1 If parked on a level surface add at least one gallon of fuel However if parked on a slope up to five gallons of fuel might need to be added 2 Follow the vehicle fuel system priming procedure earlier in this section to re prime the system and re start the engine The check engine light may come on if the vehicle has run out of fuel This light may stay on for a few drive cycles after the condition is corrected but will eventually clear itself The fuel operated heater stops automatically when the fuel tank volume is less or equal to 10 percent of the total tank volume If the vehicle runs out of fuel the FOH fuel lines will not need to be primed because they will still have fuel remaining Driving and Operating Fuel Filter Replacement Pickup Models If you want to change the fuel filter yourself here s how to do it Z WARNING Diesel fuel is flammable It could start a fire if something ignites it and you could be bu
53. d The costly repairs would not be covered by the vehicle warranty If No Steam Is Coming from the Engine Compartment The ENGINE OVERHEATED STOP ENGINE or ENGINE OVERHEATED IDLE ENGINE Driver Information Center DIC message along with a low coolant condition can indicate a serious problem If there is an engine overheat warning and the vehicle does not have a low coolant condition and no steam is heard or seen the problem may not be too serious Sometimes the engine can get a little too hot when the vehicle e Climbs a long hill on a hot day e Stops after high speed driving e Idles for long periods in traffic 10 26 Vehicle Care e Tows a trailer See Driving on Grades in the Index of the vehicle s owner manual If the ENGINE OVERHEATED STOP ENGINE or ENGINE OVERHEATED IDLE ENGINE Driver Information Center DIC message comes on with no sign of steam try this for a minute or so 1 In heavy traffic let the engine idle in N Neutral while stopped If it is safe to do so pull off the road shift to P Park or N Neutral and let the engine idle 2 Turn on the heater to full hot at the highest fan speed and open the window as necessary If the vehicle no longer has the overheat warning the vehicle can be driven Just to be safe drive slower for about 10 minutes If the warning does not come back on drive normally If the warning continues pull over stop and park the vehicle right away
54. damage the vehicle Do not let the engine run when you are not in the vehicle Cold Weather Starting Diesel Engine The following tips will help with cold weather starting Use the recommended engine oil when the outside temperature drops below freezing See Engine Oil on page 10 7 When the outside temperature drops below 18 C 0 F use of the engine coolant heater is recommended If you experience longer cranking times notice an unusual amount of exhaust smoke or are at higher elevations over 2 135 m or 7 000 ft you may use the engine coolant heater See Engine Heater on page 9 9 See Fuel for Diesel Engines on page 9 16 for information on what fuel to use in cold weather If the Diesel Engine Will Not Start If you have run out of fuel see Running Out of Fuel on page 9 30 If the vehicle is not out of fuel and the engine will not start do this Turn the ignition key to ON RUN Immediately after the wait to start light goes off turn the ignition key to START If the light does not go off wait a few seconds then try starting the engine again See your dealer as soon as you can for a starting system check If the light comes on and then goes off and you know the batteries are charged but the engine still will not start the vehicle needs service If the light does not come on when the engine is cold the vehicle needs service If the batteries don t have enough charge to start the
55. e conditions such as dirty fuel may decrease fuel filter life and a change filter message may come on Driving and Operating If you run out of fuel Running Out of Fuel on page 9 30 tells you how to restart the engine What Fuel to Use in The U S Notice Use of diesel fuel other than Ultra Low Sulfur Diesel 15 ppm sulfur maximum will cause permanent damage to the exhaust after treatment system This damage would not be covered by the vehicle warranty The emission control system requires the use of diesel fuel with ultra low sulfur content 15 ppm or 0 0015 by weight maximum Look for the following label on the dispenser to ensure you are filling with Ultra Low Sulfur Diesel fuel 9 17 DN ULTRA LOW SULFUR HIGHWAY DIESEL FUEL 15 ppm Sulfur Maximum Required for use in all model year 2007 and later highway diesel vehicles and engines Recommended for use in all diesel vehicles and engines At a minimum the diesel fuel you use should meet the latest version of ASTM specification D 975 Grades No 2 D or No 1 D S15 commonly known as Ultra Low Sulfur Diesel in the United States If there are questions about the fuel you are using contact your fuel supplier 9 18 Diesel Fuel Grades For best results use No 2 D diesel fuel year round above and below freezing conditions as oil companies blend No 2 D fuel to address climate differences No 1 D diesel fuel can be us
56. e system before any problem is apparent Heeding the light can prevent more serious damage to the vehicle This system assists the service technician in correctly diagnosing any malfunction Notice lf the vehicle is continually driven with this light on after a while the emission controls might not work as well the vehicle fuel economy might not be as good and the engine might not run as smoothly This could lead to costly repairs that might not be covered by the vehicle warranty Instruments and Controls 5 7 Notice Modifications made to the engine transmission exhaust intake or fuel system of the vehicle or the replacement of the original tires with other than those of the same Tire Performance Criteria TPC can affect the vehicle s emission controls and can cause this light to come on Modifications to these systems could lead to costly repairs not covered by the vehicle warranty This could also result in a failure to pass a required Emission Inspection Maintenance test See Accessories and Modifications on page 10 1 This light comes on during a malfunction in one of two ways Light Flashing A misfire condition has been detected A misfire increases vehicle emissions and could damage the emission control system on the vehicle Diagnosis and service might be required The following can prevent more serious damage to the vehicle e Reduce vehicle speed e Avoid hard accelerations e Avoid st
57. e than five seconds The oil life will change to 100 To reset the Engine Oil Life System on most pickup models 1 Display the OIL LIFE REMAINING on the DIC If the vehicle does not have DIC buttons the vehicle must be in P Park to access this display 2 Press and hold the SET RESET button on the DIC or the trip odometer reset stem if the vehicle does not have DIC buttons for more than five seconds The oil life will change to 100 On all models the Engine Oil Life System can be reset as follows 1 Turn the ignition to ON RUN with the engine off 2 Fully press the accelerator pedal slowly three times within five seconds 3 Display the OIL LIFE REMAINING on the DIC If the display shows 100 the system is reset 4 Turn the key to LOCK OFF See Engine Oil Life System on page 10 10 Diesel Particulate Filter Exhaust Filter The Duramax engine is equipped with a Diesel Particulate Filter DPF that by design will filter or trap particulates The DPF is located under the vehicle in the exhaust system and looks like a catalyst Depending on a number of factors monitored by the engine computer the DPF will need to be cleaned of accumulated solids When a cleaning is needed the engine computer will initiate a cleaning action by warming the exhaust gas In Brief 1 3 temperature This feature has been designed to operate automatically with limited operator involvement or awareness
58. e this operation can be a little difficult the decision may be made to have this done at the dealership service department If the decision is made to perform this operation be sure to follow all the instructions here or a false reading on the dipstick could result Vehicle Care 10 11 Notice Too much or too little fluid can damage the transmission Too much can mean that some of the fluid could come out and fall on hot engine parts or exhaust system parts starting a fire Too little fluid could cause the transmission to overheat Be sure to get an accurate reading if checking the transmission fluid Wait at least 30 minutes before checking the transmission fluid level if the vehicle has been driven e When outside temperatures are above 32 C 90 F e At high speed for quite a while e In heavy traffic especially in hot weather e While pulling a trailer 10 12 Vehicle Care Checking the Fluid Level Prepare the vehicle as follows e Park the vehicle on a level place Keep the engine running e With the parking brake applied place the shift lever in P Park e With foot on the brake pedal run the engine for at least one minute and shift to D Drive Then shift to N Neutral and then R Reverse to fill the hydraulic system Then put the shift lever in P Park e Allow the engine to run at idle 500 800 rpm Slowly release the brake pedal Then without shutting off the eng
59. ed in very cold temperatures when it stays below 18 C or 0 F however it will produce a power and fuel economy loss Avoid the use of No 1 D diesel fuel in warm or hot climates It can result in stalling poor starting when the engine is hot and could damage the fuel injection system Premium Diesel Fuel Diesel fuel corresponding to the Engine Manufacturers Association EMA Recommended Guideline on Premium Diesel Fuel FQP 1A could provide better starting less noise and better vehicle performance but its use is not required Driving and Operating Biodiesel What is biodiesel Biodiesel is a fuel produced from vegetable oils or animal fats that have been chemically modified to reduce the possibility of damage to the fuel system and engine Notice Raw vegetable oil or other unmodified bio oils or fats are not biodiesel and must not be used in your vehicle as they could damage the fuel system and engine What not to use Do not use home made biodiesel in your vehicle since its quality cannot be verified by approved scientific methods Home test kits are not approved scientific methods Notice Any damage caused by raw unmodified or home made biodiesel would not be covered by the vehicle warranty Biodiesel blends It is acceptable to use diesel fuel containing up to 20 biodiesel B20 The diesel fuel portion of the blend must meet the same specification ASTM D975 Grades No 2 D or N
60. ed This can vary based on vehicle speed gear and load The exhaust brake will be more active when in Tow Haul Mode Fuel Fuel for Diesel Engines Some states and provinces have restrictions on the purchase of diesel fuel for light duty vehicles and require you to buy permits or pay special taxes Some of these restrictions apply only to residents and others apply to both residents and visitors These restrictions can change To learn the current restrictions in any state or province contact your auto club the police or other officials Notice Diesel fuel or fuel additives not recommended in this manual could damage the fuel system fuel operated heater FOH Van models only and engine Your warranty would not cover this damage And e Diesel fuel that has been mixed with engine oil or automatic transmission fluid could damage the engine and emission controls e We do not test aftermarket diesel fuel additives Some additives particularly those which contain alcohol or water emulsifiers could damage the fuel system If you believe that unique circumstances call for a fuel additive to be used consult your dealer for advice e If you ever run out of diesel fuel it can be difficult to restart the engine To avoid this never let the tank get empty If gasoline is ever accidentally added to the fuel tank to avoid severe engine damage do not run the engine until the fuel tank can be drained Som
61. eep uphill grades e If towing a trailer reduce the amount of cargo being hauled as soon as it is possible If the light continues to flash when it is safe to do so stop the vehicle Find a safe place to park the vehicle Turn the vehicle off wait at least 10 seconds and restart the engine If the light is still flashing follow the previous steps and see your dealer for service as soon as possible Light On Steady An emission control system malfunction has been detected on the vehicle Diagnosis and service might be required 5 8 Instruments and Controls An emission system malfunction might be corrected by doing the following e If the vehicle has been driven through a deep puddle of water the vehicle s electrical system might be wet The condition is usually corrected when the electrical system dries out A few driving trips should turn the light off e Make sure to fuel the vehicle with quality fuel Poor fuel quality causes the engine not to run as efficiently as designed and may cause stalling after start up stalling when the vehicle is changed into gear misfiring hesitation on acceleration or stumbling on acceleration These conditions might go away once the engine is warmed up If one or more of these conditions occurs change the fuel brand used It will require at least one full tank of the proper fuel to turn the light off See Fuel for Diesel Engines on page 9 16 If none of the abo
62. eezing conditions additional time may be required to remove speed limitations A DIC message EXHAUST FLUID RANGE XXX will be displayed at approximately 1600 km 1000 miles of fluid range remaining This message will appear again at approximately 500 km 300 miles of range remaining before the exhaust fluid tank becomes empty Below 500 km 300 miles of range remaining these messages will appear every time the vehicle is started If these warnings are ignored and the DEF tank becomes empty a DIC message 89 km h 55 mph MAX SPEED UPON RESTART will be displayed There will also be a warning light and chime The vehicle will be speed limited to 89 km h 55 mph at the next restart When adding DEF to an empty or very low tank always add at least 3 78 liters one gallon of fluid to release the vehicle from speed limitation The capacity of the DEF tank is approximately 18 9 L 5 gal If the vehicle continues to be driven without filling the DEF tank it will be limited to 7 km h 4 mph after the second fuel fill See Vehicle Messages on page 5 10 Diesel Exhaust Fluid DEF Warning Light on page 5 9 and Recommended Fluids and Lubricants on page 11 8 for more information Exhaust Fluid Quality Poor Use only exhaust fluid that is GM approved or fluid containing the API certified or ISO 22241 label All DEF has an expiration date If the system detects poor quality contaminated or diluted DEF the
63. efueled with conventional Ultra Low Sulfur Diesel fuel and driven several miles before storage Biodiesel gels sooner than conventional diesel fuel at cold temperature and biodiesel fuel requires proper blending for winter time operation Fuels improperly blended for cold temperature operation may result in restricted fuel filters and degraded vehicle performance 9 24 Driving and Operating Your vehicle is equipped with a fuel heating system to provide a level of protection against filter plugging from gelling waxing of conventional diesel fuel and biodiesel blends However the system will not prevent all cases of plugged filters if the operating temperature is far below the temperature at which gelling or waxing of the fuel occurs cloud point Use of biodiesel blends greater than B5 5 blend should be avoided in cold temperatures e Vehicles operated for extended periods of time on conventional diesel fuel and then switched to biodiesel blends may experience premature fuel filter clogging and require more frequent fuel filter service With long term use of conventional diesel fuel gum and varnish may be deposited within the tank and fuel system These deposits while not problematic with the use of conventional diesel fuel may become loosened with a sudden switch to biodiesel blends and cause fuel filter plugging This vehicle is equipped with a fuel filter restriction monitoring system that will a
64. el for Diesel Engines on page 9 16 for information on what fuel to use in cold weather 9 10 Fuel Operated Heater FOH Van Models Only If the vehicle includes an FOH it will enhance heater performance and will reduce the amount of time it takes to warm the inside of the vehicle in cold conditions below or equal to 4 C 39 F The FOH is installed on the frame rail on the driver side of the vehicle and uses diesel fuel to heat the engine coolant which warms up the passenger cabin air Driving and Operating The FOH will turn on if all of the following conditions exist e Outside air temperature is below or equal to 4 C 39 F e Fuel level is greater or equal to 12 5 percent of the total fuel tank volume e The engine is running e Coolant temperature is less than 75 C 167 F Parking Over Things That Burn Z WARNING Things that can burn could touch hot exhaust parts under the vehicle and ignite Do not park over papers leaves dry grass or other things that can burn Engine Exhaust Diesel Particulate Filter Exhaust Filter The vehicle has a Diesel Particulate Filter DPF as part of the exhaust system to reduce vehicle emissions The DPF requires a unique exhaust tailpipe with an exhaust cooler The exhaust cooler mixes air with the exhaust to lower the temperature before it leaves the tailpipe The DPF the tailpipe or other exhaust system components must
65. el blends and cause fuel filter plugging This vehicle is equipped with a fuel filter restriction monitoring system that will alert you if the fuel filter requires service but it will not prevent damage caused by poor quality biodiesel e Use of biodiesel blends will degrade the performance of your vehicle s water separator Biodiesel reduces the effectiveness of the vehicle s water separator and in the event of water contamination of the fuel increases the risk of damage to the fuel system Refueling Diesel fuel can foam when you fill the tank This can cause the automatic pump nozzle to shut off even though the tank is not full If this happens wait for the foaming to stop and then try filling the tank more slowly See Filling the Tank on page 9 33 Driving and Operating Z WARNING Heat coming from the engine can cause the fuel to expand and force the fuel out of the tank If something ignites the fuel a fire could start and people could be burned To help avoid this try filling the tank more slowly and fill the fuel tank only until the automatic nozzle shuts off Do not try to top it off 9 21 Accidental Refueling with Gasoline If you accidentally refuel with gasoline your vehicle will run very rough will produce smoke and will have significantly reduced power Avoid operating the vehicle and or operate only at low speeds and or low accelerator positions Siphon or pump as much
66. elect the PTO 2 set speed Press the customization button until the PTO SET 2 SPEED screen appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following choices e 1800 RPM e 2000 RPM e 2200 RPM e 2400 RPM e 2600 RPM e 2800 RPM e 3000 RPM e 3200 RPM e NO CHANGE To select a setting press the set reset button while the desired setting is displayed on the DIC 5 16 PTO TAP STEP This feature allows you to select the PTO tap step Press the customization button until the PTO TAP STEP screen appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following choices e 25RPM e 75RPM e 100 RPM e 150 RPM e 200 RPM e 250 RPM e 350 RPM e NO CHANGE To select a setting press the set reset button while the desired setting is displayed on the DIC Instruments and Controls PTO SHUTDOWN TIME This feature allows you to select the PTO shutdown time Press the customization button until the PTO SHUTDOWN TIME screen appears on the DIC display Press the set reset button once to access the settings for this feature Then press the customization button to scroll through the following choices OFF e 20 MINUTES e 35 MINUTES e 50 MINUTES e 65 MINUTES e 80 MINUTES e 95 MINUTES e 110 M
67. els corresponding to the Engine Manufacturers Association EMA Recommended Guideline on Premium Diesel Fuel FQP 1A could provide better starting less noise and better vehicle performance but their use is not required Biodiesel What is biodiesel Biodiesel is a fuel produced from vegetable oils or animal fats that have been chemically modified to reduce the possibility of damage to the fuel system and engine Notice Raw vegetable oil or other unmodified bio oils or fats are not biodiesel and must not be used in your vehicle as they could damage the fuel system and engine What not to use Do not use home made biodiesel in your vehicle since its quality cannot be verified by approved scientific methods Home test kits are not approved scientific methods Notice Any damage caused by raw unmodified or home made biodiesel would not be covered by the vehicle warranty Biodiesel blends It is acceptable to use diesel fuel containing up to 20 biodiesel B20 For low level under 5 biodiesel blends B1 to B5 the fuel you use should meet the latest version of specification CAN CGSB 3 520 ULS At the time of printing of this manual a CGSB standard for B6 B20 is under development and has not been published Until a CGSB B6 B20 specification is available biodiesel blends containing more than 5 and up to 20 biodiesel must meet the latest version of ASTM specification D7467 Biodiesel blend B6 B20
68. er replacement See Engine Air Cleaner Filter on page 10 17 Pickup Models Automatic transmission fluid and filter change normal service See Automatic Transmission Fluid on page 10 11 Van Models Automatic transmission fluid and filter change severe service for vehicles mainly driven in heavy city traffic in hot weather in hilly or mountainous terrain when frequently towing a trailer or used for taxi police or delivery service See Automatic Transmission Fluid on page 10 11 Four wheel drive pickup models only Transfer case fluid change severe service for vehicles mainly driven when frequently towing a trailer or used for taxi police or delivery service Check vent hose at transfer case for kinks and proper installation Check to be sure vent hose is unobstructed clear and free of debris During any maintenance if a power washer is used to clean mud and dirt from the underbody care should be taken to not directly spray the transfer case output seals High pressure water can overcome the seals and contaminate the transfer case fluid Contaminated fluid will decrease the life of the transfer case and should be replaced Service and Maintenance 11 7 First Engine Oil Change After Every 160 000 km 100 000 Miles e Van Models Automatic transmission fluid and filter change normal service See Automatic Transmission Fluid on page 10 11 e Four wheel drive pickup models only Transfer case fluid
69. essories When you go to your GM dealer and ask for GM Accessories you will know that GM trained and supported service technicians will perform the work using genuine GM Accessories See your vehicle s Warranty booklet for more information Aftermarket Engine Performance Enhancement Products and Modifications Some aftermarket engine performance products and modifications promise a way to increase the horsepower and torque levels of the vehicle s powertrain You should be aware that these products could have harmful effects on the performance and life of the engine exhaust emission system transmission and drivetrain The engines transmissions and drivetrains have been designed and built to offer industry leading durability and performance in the most demanding applications Engine power enhancement products may enable the engine to operate at horsepower and torque levels that could damage create failure or reduce the life of the engine engine emission system transmission and drivetrain Vehicle Care 10 3 Damage failure or reduced life of the engine transmission emission system drivetrain or other vehicle components caused by aftermarket engine performance enhancement products or modifications might not be covered under the vehicle warranty 10 4 Vehicle Care Vehicle Checks Engine Compartment Overview United States Pickup models Shown Canada Similar gt moo
70. fall on hot engine parts or exhaust system parts starting a fire Too little fluid could cause the transmission to overheat Be sure to get an accurate reading if checking the transmission fluid Wait at least 30 minutes before checking the transmission fluid level if the vehicle has been driven e When outside temperatures are above 32 C 90 F e At high speed for quite a while e In heavy traffic especially in hot weather e While pulling a trailer To get the right reading the fluid should be at normal operating temperature which is 82 C to 93 C 180 F to 200 F Get the vehicle warmed up by driving about 24 km 15 miles when outside temperatures are above 10 C 50 F If it is colder than 10 C 50 F drive the vehicle until the engine temperature gauge moves and then remains steady for 10 minutes A cold check can be made after the vehicle has been sitting for eight hours or more with the engine off but this is used only as a reference Let the engine run at idle for five minutes if outside temperatures are 10 C 50 F or more If it is colder than 10 C 50 F the engine may have to idle longer Should the fluid level be low during this cold check the fluid must be checked when hot before adding fluid Checking the fluid hot will give you a more accurate reading of the fluid level Checking the Fluid Level Prepare the vehicle as follows e Park the vehicle on a level pl
71. ge 11 8 for more information Cooling System Pickup Models 28 5 qt Cooling System Van Models Front Heat or AC Only 21 2 qt Front Heat or AC Plus Fuel Operated Heater FOH 22 1 qt Front and Rear Heat or AC Only 21 5L 22 7 qt Front and Rear Heat or AC Plus Fuel Operated Heater FOH ai 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 5L 10 0 qt Technical Data 12 3 Transmission Fluid Pan Removal and Filter l Auto 6 Speed Transmission Allison OL 7 4qt 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 this manual Recheck fluid level after filling Engine Specifications 6 6L V8 Turbo Diesel LML Engine 12 4 Technical Data Engine Drive Belt Routing Accessories and Modifications 10 1 Air Cleaner Filter Engine 10 17 Automatic Transmission FGI EE ENE E EN 10 11 Shift Lock Control Function Check 10 27 Brake Exhaust ss vsrescnaeacevrrnds 9 15 C Canadian Vehicle Owners ii Capacities and Specifications 12 2 Check Engine Light 5 6 Ignition Transmission Lock 10 27 Cluster Instrument 5 2 Cold Weather Operation 9 25 Coolant ENnGQINGHsc2cncrctesdenesaeta 10 21 Cooling Sy
72. he air cleaner filter assembly may have an air cleaner filter restriction indicator that shows when the engine air cleaner filter is dirty and needs to be serviced The air cleaner filter restriction indicator is located on the air cleaner resonator When to Inspect See Scheduled Maintenance on page 11 2 for more information How to Inspect When the restriction indicator is in the red orange change zone replace the filter and reset the restriction indicator The air cleaner filter assembly is located at the front of the engine compartment To inspect and replace the filter and reset the restriction indicator A Cover Screws B Restriction Indicator 1 Loosen the screws A on the cover of the housing and lift up the cover 2 Remove the air cleaner filter from the housing Care should be taken to dislodge as little dirt as possible 3 Clean the filter sealing surface and the housing 4 Install the new engine air cleaner filter 5 Reinstall the cover and tighten the screws 6 Reset the air cleaner filter restriction indicator B if equipped by pressing the top button on the indicator See Scheduled Maintenance on page 11 2 to determine when to replace the engine air cleaner filter 10 19 Operating the engine with the air cleaner filter off can cause you or others to be burned The air Vehicle Care cleaner not only cleans the air it helps to stop flames if the engine
73. id while it is hot A cold check is used only as a reference If the fluid level is low add only enough of the proper fluid to bring the level up to the HOT area for a hot check It doesn t take much fluid generally less than 0 5L 1 pint Do not overfill Vehicle Care 10 13 Notice Use of the incorrect automatic transmission fluid may damage the vehicle and the damages may not be covered by the vehicle warranty Always use the automatic transmission fluid listed in Recommended Fluids and Lubricants on page 11 8 e After adding fluid recheck the fluid level as described under How to Check e When the correct fluid level is obtained push the dipstick back in all the way When to Check and Change Van Models Change the fluid and filter at the intervals listed See Scheduled Maintenance on page 11 2 And be sure to use the transmission fluid listed in Recommended Fluids and Lubricants See Recommended Fluids and Lubricants on page 11 8 for more information 10 14 Vehicle Care How to Check Because this operation can be a little difficult the decision may be made to have this done at the dealership service department If the decision is made to perform this operation be sure to follow all the instructions here or a false reading on the dipstick could result Notice Too much or too little fluid can damage the transmission Too much can mean that some of the fluid could come out and
74. in P Park can cause exhaust parts and gases to become very hot Keep the exhaust area clear of material that could ignite or burn See Parking Over Things That Burn on page 9 10 for more information For vehicles with Power Take Off PTO monitor the instrument panel cluster for lights related to the DPF All engines consume some amount of engine oil Ash is the by product of engine oil combustion The ash will become trapped in the DPF over the life of the vehicle Eventually the buildup of ash will restrict the exhaust gases and the DPF will need to be cleaned or replaced Driving and Operating See Accessories and Modifications on page 10 1 for important information if you are considering adding accessories or modifying the vehicle Diesel Exhaust Fluid Z WARNING Diesel Exhaust Fluid DEF is corrosive Do not allow it to come in contact with your skin eyes or the finished surfaces of the vehicle If exposed it may cause skin and eye irritation Wear skin and eye protection when handling Inhalation may cause irritation to the upper respiratory tract Store in a cool well ventilated area For more safety information see the label of the Diesel Exhaust Fluid container Diesel Exhaust Fluid DEF is used with diesel engines to reduce the amount of regulated emissions produced The fluid level in the DEF tank must be maintained for the vehicle to run correctly The capacity of the DEF tank is
75. ine follow these steps Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made The fluid level rises as fluid temperature increases DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures 1 Pull out the dipstick and wipe it with a clean rag or paper towel The transmission dipstick is located near the center of the engine compartment See Engine Compartment Overview on page 10 4 for more information on location 2 Push it back in all the way wait 3 seconds and then pull it back out again 3 Check the fluid level reading Repeat the check procedure to verify the reading 4 lf the fluid level is within the COLD CHECK band the transmission may be operated until the fluid is hot enough to perform a hot check If the fluid level is not within the COLD CHECK band add or drain fluid as necessary to bring the level into the middle of the COLD CHECK band 5 Perform a hot check at the first opportunity after the normal operating temperature of 71 C 160 F to 93 C 200 F is reached 6 If the fluid level is in the acceptable range push the dipstick back in all the way Hot Check Procedure The fluid must be hot to ensure an accurate check The fluid level rises as temperature increases 1 Operate the transmission in D Drive until the normal ope
76. ine for 15 seconds 4 Ifthe engine does not start repeat Steps 2 and 3 until the engine starts 9 30 If the engine does not run after repeating Steps 2 and 3 three times turn the ignition key off for 60 seconds allowing the Electronic Control Module ECM to reset Repeat the above steps until the engine starts If the engine runs but does not run smoothly increase the engine speed slightly by pressing the accelerator pedal This will help to force out air through the system If the engine starts and runs but stalls again turn the ignition key off for 60 seconds to reset the ECM and repeat the steps above When the engine starts let it idle for a few minutes and check the filters for any leaks Driving and Operating To Prime the Fuel Operated Heater FOH Fuel Lines Van Models See your dealer or qualified technician if the FOH fuel lines need to be primed Running Out of Fuel Pickup Models If the engine stalls and you think that you have run out of fuel do this to restart the engine Z WARNING Diesel fuel is flammable It could start a fire if it gets on hot engine parts You could be burned Do not let too much fuel flow from the air bleed valve and wipe up any spilled fuel with a cloth 1 If parked on a level surface add at least two gallons of fuel However if parked on a slope up to five gallons of fuel might need to be added 2 Follow the fuel priming pro
77. ing the engine off If the overheat warning comes on see Engine Overheating on page 10 25 Use the following chart to determine how much the vehicle can weigh based upon your vehicle model and options 9 36 Driving and Operating Vehicle C 2500 Pickup Models 2WD Pickup Model Extended Cab Standard Box Pickup Model Crew Cab Standard Box Pickup Model Sierra Denali Pickup Model Regular Cab Long Box Pickup Model Extended Cab Long Box Pickup Model Crew Cab Long Box K 2500 Pickup Models 4WD Pickup Model Extended Cab Standard Box Pickup Model Crew Cab Standard Box Pickup Model Sierra Denali Pickup Model Regular Cab Long Box Pickup Model Extended Cab Long Box Pickup Model Crew Cab Long Box Axle Ratio Max Trailer Wt GCWR 3 73 3 73 3 73 3 73 3 73 3 73 3 73 3 73 3 73 3 73 3 73 3 73 7 802 kg 17 200 Ibs 8 074 kg 17 800 Ibs 7 893 kg 17 400 Ibs 7 802 kg 17 200 Ibs 7 802 kg 17 200 Ibs 7 575 kg 16 700 Ibs 7 076 kg 15 600 Ibs 7 938 kg 17 500 Ibs 7 484 kg 16 500 Ibs 7 076 kg 15 600 Ibs 11113kg 11113 kg 11113 kg 11113 kg 11113 kg 11113 kg 11113 kg 11113 kg 11113 kg 11113kg 7 938 kg 17 500 Ibs 11113 kg 24 500 Ibs 7 893 kg 17 400 Ibs 11113 kg 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs 24 500 Ibs Driving and Operating 9 37 C 3500 Pickup Model Extended Ca
78. ions or retailers may also have DEF for purchase For vehicles with an active OnStar subscription OnStar can help to locate a DEF retailer For more information on locating DEF see www afdc energy gov afdc vehicles diesels _fluid html See Customer Assistance Offices in the owner manual for phone numbers to assist you in contacting a GM dealer See Recommended Fluids and Lubricants on page 11 8 As the DEF tank becomes low on fluid warnings begin with approximately 1600 km 1000 miles of remaining range These warnings will increase in intensity as the tank becomes empty Once the tank is empty the vehicle will be speed limited to 89 km h 55 mph and eventually to 7km h 4 mph The tank should be refilled to avoid vehicle speed limitation If there is an issue with the quality of the fluid or the exhaust fluid system warnings will be displayed in the Driver Information Center DIC In Brief 1 5 The vehicle will have 322 km 200 miles before being speed limited to 89 km h 55 mph If the vehicle continues to be driven in this condition it will become speed limited to 7km h 4 mph See Diesel Exhaust Fluid on page 9 12 1 6 In Brief NOTES Instruments and Controls Warning Lights Gauges and Indicators Instrument Cluster 5 2 Fuel Gauge 5 4 Engine Oil Pressure Gauge 5 5 Malfunction Indicator Lamp 5 6 Wait to Start Light 5 9 Diesel
79. ire and Loading Information label See Loading the Vehicle in the owner manual e are driven on reasonable road surfaces within legal driving limits 11 2 e are driven off road in the recommended manner pickup models only See Off Road Driving in the owner manual e use the recommended fuel See Fuel for Diesel Engines on page 9 16 ZN WARNING Performing maintenance work on a vehicle can be dangerous In trying to do some jobs you can be seriously injured Do your own maintenance work only if you have the required know how and the proper tools and equipment for the job If you have any doubt see your dealer to have a qualified technician do the work See Doing Your Own Service Work in the owner manual Service and Maintenance At your General Motors dealer you can be certain that you will receive the highest level of service available Your dealer has specially trained service technicians uses genuine GM replacement parts as well as up to date tools and equipment to ensure fast and accurate diagnostics The proper replacement parts fluids and lubricants to use are listed in Recommended Fluids and Lubricants on page 11 8 and Maintenance Replacement Parts on page 11 11 We recommend the use of genuine parts from your dealer Rotation of New Tires To maintain ride handling and performance of the vehicle it is important that the first rotation service for new tires be pe
80. is procedure could cause the engine to overheat and be severely damaged Z WARNING Steam and scalding liquids from a hot cooling system can blow out and burn you badly They are under pressure and if you turn the coolant surge tank pressure cap even a little they can come out at high speed Never turn the cap when the cooling system including the coolant surge tank pressure cap is hot Wait for the cooling system and coolant surge tank pressure cap to cool if you ever have to turn the pressure cap If no coolant is visible in the surge tank add coolant as follows 1 Remove the coolant surge tank pressure cap when the cooling system including the coolant surge tank pressure cap and upper radiator hose is no longer hot Turn the pressure cap slowly counterclockwise about one full turn If a hiss is heard wait for that to stop A hiss means there is still some pressure left Keep turning the pressure cap slowly and remove it Fill the coolant surge tank with the proper mixture as follows To the MAX mark on the pickup To the COLD FILL mark on the van With the coolant surge tank pressure cap off start the engine and let it run until the engine coolant temperature gauge indicates approximately 90 C 195 F By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixture to the coolant surge tank until
81. ke to enhance the vehicle brake system and reduce brake lining wear A switch is used to activate the system and is located below the climate controls in the center of the vehicle instrument panel The switch must be pressed at each vehicle start for the system to be active A light in the switch will come on when the Exhaust Brake is activated 9 16 The Driver Information Center DIC displays the message EXHAUST BRAKE ENABLED for approximately 10 seconds then clears To turn the brake off press the exhaust brake switch a second time The DIC displays the message EXHAUST BRAKE DISABLED for approximately 10 seconds then clears Downshifts may be automatically selected to increase engine speed which increases the effectiveness of the exhaust brake The number of downshifts selected is determined by the length of time the vehicles Driving and Operating brakes are applied and the rate the vehicle is slowing The system delivers the correct amount of braking to assist in vehicle control The heavier the vehicle load the more active the engine exhaust brake will be Use of the exhaust brake will help maintain vehicle speed when used with cruise control See Tow Haul Mode in the vehicle owner manual Automatic downshifts will not occur if the vehicle is in Range Selection Mode See Manual Mode in the vehicle owner manual The exhaust brake only activates when the transmission torque converter is lock
82. l in this section e Change the engine oil at the appropriate time See Engine Oil Life System on page 10 10 e Always dispose of engine oil properly See What to Do with Used Oil in this section Vehicle Care 10 7 Checking Engine Oil It is a good idea to check the engine oil level at each fuel fill In order to get an accurate reading the oil must be warm at normal operating temperature and the vehicle must be on level ground The engine oil dipstick handle is a yellow loop See Engine Compartment Overview on page 10 4 for the location of the engine oil dipstick Obtaining an accurate oil level reading is essential 1 Turn off the engine and allow at least five minutes for the oil to drain back into the oil pan With a cool engine allow 30 minutes Checking the oil level too soon after engine shutoff will not provide an accurate oil level reading 2 Pull out the dipstick and clean it with a paper towel or a cloth then push it back in all the way Remove it again keeping the tip down 10 8 Vehicle Care When to Add Engine Oil If the oil is below the cross hatched area at the tip of the dipstick add 1 L 1 qt of the recommended oil and then recheck the level See Selecting the Right Engine Oil in this section for an explanation of what kind of oil to use For engine oil crankcase capacity see Capacities and Specifications on page 12 2 Notice Do not add too much oil Oil
83. l System bse Tv Pg 3 11 Vehicle friese sorereniiasss 5 14 Maintenance Records 11 12 Service Vehicle ee eT 212 Power Take Off PTO 9 39 Maintenance General SD the VENER sssrin 5 12 Information s 11 1 el ee eee aes R Vehicle Messages 5 12 Vehicle Speed n 5 13 Recommended Fluids and eee Lubricants u ti Sheck Automatic O Records Transmission ET ET 10 27 Maintenance 11 12 Specifications and Oil l Replacement Parts Capacities E T EAT 12 2 ENJIN Erenet aee tersa 10 7 Maintenanten ao etdccdiecats 41 11 Starter Switch Check 10 26 Engine Oil Life System 10 10 Routing Engine Drive Belt 42 4 Starting the Vehicle Engine Oil Pressure Gauge 5 5 Running Out of Fuel 9 30 Messsages TE EEEE 5 12 Messages n n 5 11 Starting Your Diesel Engine 9 1 Overheating Engine 10 25 Supplement USING fitisittdntiaanonbinnnann dees iii i 4 INDEX Towing Trailer 2 0 0 0 cc cece ee eee eee 9 35 Trailer Towing 9 35 Transmission Fluid Automatic 10 11 Messages 2 0055 5 13 U Using this Supplement iii V Vehicle Canadian Owners ii Messages 2 0055 5 10 Personalization 5 14 Speed Messages 5 13 W Wait to Start Light 5 9 Warning Light Diesel Exhaust Fluid DEF 5 9 Water in Fuel
84. l degradation When vehicles will be stored for extended periods of time greater than one month they should be run out of biodiesel to below 1 4 tank refueled with conventional Ultra Low Sulfur Diesel fuel and driven several miles before storage Biodiesel gels sooner than conventional diesel fuel at cold temperature and biodiesel fuel requires proper blending for winter time operation Fuels improperly blended for cold temperature operation may result in restricted fuel filters and degraded vehicle performance Your vehicle is equipped with a fuel heating system to provide a level of protection against filter plugging from gelling waxing of conventional diesel fuel and biodiesel blends However the system will not prevent all cases of plugged filters if the operating temperature is far below the temperature at which gelling or waxing of the fuel occurs cloud point Use of biodiesel blends greater than B5 5 blend should be avoided in cold temperatures Vehicles operated for extended periods of time on conventional diesel fuel and then switched to biodiesel blends may experience premature fuel filter clogging and require more frequent fuel filter service With long term use of conventional diesel fuel gum and varnish may be deposited within the tank and fuel system These deposits while not problematic with the use of conventional diesel fuel may become loosened with a sudden switch to biodies
85. lert you if the fuel filter requires service but it will not prevent damage caused by poor quality biodiesel Use of biodiesel blends will degrade the performance of your vehicle s water separator Biodiesel reduces the effectiveness of the vehicle s water separator and in the event of water contamination of the fuel increases the risk of damage to the fuel system What Fuel to Use in Mexico Notice Use of diesel fuel other than Ultra Low Sulfur Diesel 15 ppm sulfur maximum will cause permanent damage to the exhaust after treatment system This damage would not be covered by the vehicle warranty Ultra Low Sulfur Diesel fuel is not available in all regions of Mexico Refueling Diesel fuel can foam when you fill the tank This can cause the automatic pump nozzle to shut off even though the tank is not full If this happens wait for the foaming to stop and then try filling the tank more slowly See Filling the Tank on page 9 33 Z WARNING Heat coming from the engine can cause the fuel to expand and force the fuel out of the tank If something ignites the fuel a fire could start and people could be burned To help avoid this try filling the tank more slowly and fill the fuel tank only until the automatic nozzle shuts off Do not try to top it off Accidental Refueling with Gasoline If you accidentally refuel with gasoline your vehicle will run very rough will produce smoke and wi
86. levels above or below the acceptable operating range shown on the dipstick are harmful to the engine If you find that you have an oil level above the operating range i e the engine has so much oil that the oil level gets above the cross hatched area that shows the proper operating range the engine could be damaged You should drain out the excess oil or limit driving of the vehicle and seek a service professional to remove the excess amount of oil See Engine Compartment Overview on page 10 4 for the location of the engine oil fill cap Be sure to add enough oil to put the level somewhere in the proper operating range Push the dipstick all the way back in when through Selecting the Right Engine Oil Look for three things e CJ 4 Oils designated as API CJ 4 are required for the vehicle The CJ 4 designation can appear either alone or in combination with other American Petroleum Institute API designations such as API CJ 4 SL These letters show API levels of quality SAE 15W 40 SAE 5W 40 SAE 15W 40 SAE 15W 40 is best for the vehicle When it is very cold below 18 C 0 F use SAE 5W 40 to improve cold starting These numbers on the oil container show its viscosity or thickness Do not use other viscosity oils such as SAE 10W 30 SAE 10W 40 or SAE 20W 50 e American Petroleum Institute API symbol This doughnut shaped logo symbol is used on most oil containers to he
87. lf there is water in the diesel fuel and the weather is warm or humid fungus and bacteria can grow in the fuel They can damage the fuel system and fuel operated heater FOH if equipped A diesel fuel biocide can be used to sterilize the fuel system However the fuel system may still need to be cleaned Your dealer can advise you of the appropriate solution If the fuel tank needs to be purged to remove water see your dealer or a qualified technician Improper purging can damage the fuel system and block the FOH Sometimes water can be pumped into the fuel tank along with the diesel fuel This can happen if a service station does not regularly inspect and clean its fuel tanks or if it gets contaminated fuel from its suppliers If this happens a WATER IN FUEL SERVICE REQUIRED message will appear on the Driver Information Center DIC The water must be drained Water in Fuel Light Chart If the WATER IN FUEL SERVICE REQUIRED message comes on use this chart Message comes on but does not remain on after an ignition cycle Recommended Action Water separator is approximately half full Drain water as soon as possible Water level may continue to increase Message remains on after an ignition cycle At temperatures above freezing Drain fuel filter immediately If no water can be drained and message stays on see your dealer for assistance At temperatures below freezing
88. lines will allow adequate airflow for proper radiator and air cooler performance e Do not use the winter cover if towing a trailer The added power needed to tow a trailer requires the radiator grille to have full airflow under all conditions The vehicle may overheat if the cover is used while towing a trailer e Do not modify the cover The winter cover does not cover some sections of the front of the vehicle because these openings are needed to provide enough airflow to the radiator grille and air cooler in extremely cold temperatures e When the winter cover is used the temperature sensor found on the inside rearview mirror will not function properly The temperature that is shown will be incorrect Driving and Operating 9 5 e Keep the underside of the winter cover as clean as possible at all times Remove monthly or as necessary and clean away dust and debris e Use only a mild soap to clean the winter cover Do not use harsh soap strong detergents or vinyl protectant sealant type products as they may destroy the special finish of the winter cover Allow the winter cover to dry completely before reinstalling on the vehicle Installation Instructions When you first try to fit the cover it may appear to be undersized This is due to the nature of the special vinyl which will stretch during installation to ensure a tight fit For this reason the initial installation of the cover is best performed when
89. ll have significantly reduced power Avoid operating the vehicle and or operate only at low speeds and or low accelerator positions Siphon or pump as much of the gasoline from the tank as possible preferably until the fuel gauge reads near E empty Refuel with Ultra Low Sulfur Diesel fuel Your dealer will be able to perform this procedure Operating your vehicle for a prolonged period of time on gasoline could result in engine or fuel system damage which would not be covered by the vehicle warranty Driving and Operating 9 25 Cold Weather Operation Follow the instructions listed previously under the heading What Fuel to Use Notice Never use home heating oil or gasoline in the vehicle They can cause engine damage not covered by the vehicle warranty In cold weather the fuel filter could become clogged by wax naturally present in the fuel To unclog it move the vehicle to a warm garage area and allow the filter to warm up to between 0 C 32 F and 10 C 50 F You will not need to replace the filter Additional information on the fuel filter follows Use of biodiesel blends greater than B5 5 blend should be avoided in cold temperatures 9 26 Driving and Operating Water in Fuel ZN WARNING Diesel fuel containing water is still flammable You could be burned If you ever try to drain water from the fuel keep sparks flames and smoking materials away from the mixture Notice
90. ll is desired An automatic transfer mechanism will maintain approximately equal fuel levels in both tanks so no switching is required by the operator 9 34 To remove the fuel cap turn it slowly to the left counterclockwise Z WARNING Fuel can spray out on you if you open the fuel cap too quickly If you spill fuel and then something ignites it you could be badly burned This spray can happen if the tank is nearly full and is more likely in hot weather Open the fuel cap slowly and wait for any hiss noise to stop Then unscrew the cap all the way Be careful not to spill diesel fuel Do not top off or overfill your tank and wait a few seconds after you have finished pumping before you remove the nozzle Clean fuel from painted surfaces as soon as possible See Washing Your Vehicle in the Index of the owner manual When you put the fuel cap back on turn it to the right clockwise until you hear a clicking sound Make sure you fully install the cap Driving and Operating ZN WARNING If a fire starts while you are refueling do not remove the nozzle Shut off the flow of fuel by shutting off the pump or by notifying the station attendant Leave the area immediately Notice If you need a new fuel cap be sure to get the right type Your dealer can get one for you If you get the wrong type it may not fit properly Notice If your vehicle has been accidentally filled with gasoline do
91. lly inspect gas strut for signs of wear corrosion cracks loss of lubricant or other damage Check the hold open ability of gas strut Replace as necessary with genuine parts from your dealer First Engine Oil Change After Every 40 000 km 25 000 Miles Pickup Models Automatic transmission fluid and external filter change severe service for vehicles mainly driven in heavy city traffic in hot weather in hilly or mountainous terrain when frequently towing a trailer or used for taxi police or delivery service See Automatic Transmission Fluid on page 10 11 Service and Maintenance Four wheel drive pickup models only Transfer case fluid change extreme duty service for vehicles mainly driven off road in four wheel drive Vehicles used for farming mining forestry Department of Natural Resources DNR and snow plowing occupations meet this definition Check vent hose at transfer case for kinks and proper installation Check to be sure vent hose is unobstructed clear and free of debris During any maintenance if a power washer is used to clean mud and dirt from the underbody care should be taken to not directly spray the transfer case output seals High pressure water can overcome the seals and contaminate the transfer case fluid Contaminated fluid will decrease the life of the transfer case and should be replaced First Engine Oil Change After Every 80 000 km 50 000 Miles Engine air cleaner filt
92. lp you select the correct oil It means that the oil has been certified by the American Petroleum Institute Look for this on the oil container and use only those oils that display this logo Notice Use only engine oils that have the designation CJ 4 for the diesel engine Failure to use the recommended oil can damage the DPF and result in engine damage not covered by the vehicle warranty Engine Oil Additives Engine Oil Flushes Do not add anything to the oil The recommended oils with the API service symbol are all that is needed for good performance and engine protection Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty Vehicle Care 10 9 What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer Do not let used oil stay on your skin for very long Clean your skin and nails with soap and water or a good hand cleaner Wash or properly dispose of clothing or rags containing used engine oil See the manufacturer s warnings about the use and disposal of oil products Used oil can be a threat to the environment If you change your own oil be sure to drain all the oil from the filter before disposal Never dispose of oil by putting it in the trash or pouring it on the ground into sewers or into streams or bodies of water Recycle it by taking it to a place that collects u
93. lube GM Part No 12371287 in Service and Maintenance 11 11 Maintenance Replacement Parts Replacement 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 Pickup Models 12633243 TP3012 Van Models Primary and Secondary Filter Kit 19256348 TP3013 Engine Oil Filter 88917036 PF2232 Use only the specified filters Racor service kit includes primary filter secondary filter and o rings 11 12 Service and Maintenance Maintenance Records After the scheduled services are performed record the date odometer reading who performed the service and the type of services performed in the boxes provided Retain all maintenance receipts Maintenance Record Odometer j Service and Maintenance 11 13 Maintenance Record cont Odometer Serviced By Services Performed Reading 11 14 Service and Maintenance Maintenance Record cont Odometer Serviced By Services Performed Reading Technical Data Vehicle Data Capacities and Specifications 12 2 Engine Drive Belt Routing 12 4 Technical Data 12 1 12 2 Technical Data Vehicle Data Capacities and Specifications The following approximate capacities are given in metric and English conversions See Recommended Fluids and Lubricants on pa
94. n cab or remote switches 9 44 Engine speed selection is variable between base engine idle speed and a maximum of 3100 rpm factory setting 2100 rpm In the mobile PTO mode the vehicle will operate at a vehicle speed resulting from the current PTO engine speed request and current transmission gear range selected Vehicle speed stability is greatly improved by shifting into the transmission manual mode because upshifts are limited This reduces the maximum vehicle speed while allowing high engine speed operation Therefore low vehicle speed operation 16 40 km h 10 25 mph and high PTO engine speed 1 500 2 000 rpm can be achieved in the manual mode 1 and 2 transmission ranges Driving and Operating PTO Switch Operation The In cab PTO Switch has four positions O SET and RES This is the PTO switch On position To engage PTO press and release the in cab switch position or press and release the remote PTO arming switch then within five seconds assert the remote enable switch to on The vehicle will increase engine speed to a factory preset engine speed 800 rpm This PTO stand by speed is not intended to be an operational PTO speed but allows the engagement of the PTO at lower initial start up rom to match with the engagement of the PTO load relay The initial stand by speed can be adjusted by holding the accelerator to the desired engine speed then pressing and releasing the in ca
95. n in the vehicle for 5 years or 240 000 km 150 000 mi whichever occurs first if you add only DEX COOL extended life coolant The following explains the cooling system and how to add coolant when it is low If there is a problem with engine overheating see Engine Overheating on page 10 25 A 50 50 mixture of clean drinkable water and DEX COOL coolant will e Give freezing protection down to 37 C 34 F e Give boiling protection up to 129 C 265 F e Protect against rust and corrosion e Help keep the proper engine temperature e Let the warning lights and gauges work as they should Vehicle Care 10 21 Notice Using coolant other than DEX COOL may cause premature engine heater core radiator and fuel operated heater van models only corrosion In addition the engine coolant may require changing sooner at 50 000 km 30 000 mi or 24 months whichever occurs first Any repairs would not be covered by the vehicle warranty Always use DEX COOL silicate free coolant in the vehicle 10 22 Vehicle Care What to Use Use a 50 50 mixture of clean drinkable water and DEX COOL coolant which will not damage aluminum parts If using this mixture nothing else needs to be added Z WARNING Adding only plain water or some other liquid to the cooling system can be dangerous Plain water and other liquids can boil before the proper coolant mixture will The vehicle s coolant warning system is set for
96. n the fuel lines One of the following may have happened e The vehicle ran out of fuel e The fuel filter was removed for servicing or replacement e The fuel lines were removed or disconnected for servicing e The fuel filter water drain valve was opened while the engine was running e The fuel operated heater FOH pump and FOH fuel lines were removed or disconnected for servicing If one or more of the above occur it is very likely that air has entered the fuel system and priming the fuel system is needed before operating the vehicle Air in the fuel lines does not harm the engine the fuel operated heater FOH or the vehicle However the engine and or the fuel operated heater FOH may not be able to start until the fuel system is primed and the air is removed To Prime the Vehicle Pickup Models The vehicle is equipped with a priming pump which is part of the engine mounted fuel filter The priming pump is hand operated and is designed to bring fuel to the engine to eliminate any air in the fuel lines To prime the engine 1 Correct the condition that caused the loss of prime by making sure there is fuel in the tank 2 Make sure the fuel filter has been installed and properly tightened 3 Make sure the fuel lines are properly connected and the fuel filter is cool enough to touch 4 Remove any dirt from the fuel filter head and vent valve by wiping with a cloth Driving and Opera
97. ng Conditions Mobile PTO To engage mobile PTO operation the following conditions must be met prior to turning on PTO e The engine must be running e The vehicle speed must be less than the PTO top vehicle speed limit The default setting is 80 km h 50 mph This limit can be adjusted by a service technician e The shift lever may be in any position e The brake must be pressed and then released The brake must then remain released e Cruise control cannot be active e Engine speed must be less than the maximum allowed PTO engage speed of 1500 rpm 9 41 e Press and release the position on the PTO switch The PTO LED light will blink fast until the PTO load becomes engaged at which point the LED light will be on steady The SET and RES switch positions can then be used to establish the desired PTO operating speed See Variable PTO Mode PTO Switch operation below DIC WARNING MESSAGES One or more of the following Driver Information Center DIC messages may appear on the instrument panel cluster if the PTO will not engage The operator must take the action indicated then again press and release the position of the PTO switch e PTO SHIFT TO PARK OR NEUTRAL Stationary only e PTO SET PARK BRAKE Stationary only PTO PRESS amp RELEASE BRAKE Mobile only 9 42 Driving and Operating e PTO RELEASE BRAKE e PTO REDUCE VEHICLE SPEED e PTO REDUCE ENGINE SPEED PT
98. not be altered Inspect regularly and clean any mud or dirt from the exhaust cooler especially where the exhaust cooler connects to the tailpipe and the openings where fresh air enters the cooler See Exhaust System Inspection under Scheduled Maintenance on page 11 2 The DPF will clean itself as part of normal operation Several factors including fuel consumed hours of engine operation and miles driven are monitored by the Engine Control Module ECM The self cleaning occurs approximately once per tank of fuel Notice Permanent damage can occur to the DPF or related components if the required Ultra Low Sulfur Diesel 15 ppm sulfur maximum or low ash CJ 4 engine oil is not used This damage would not be covered by the vehicle warranty Under certain driving conditions such as stop and go traffic the filter cannot clean itself The CLEANING EXHAUST FILTER KEEP DRIVING UNTIL MESSAGE IS CLEARED message comes on when the DPF is dirty and needs to perform a self cleaning Driving and Operating For the filter to clean itself the vehicle must be driven above 50 km h 30 mph until the CLEANING EXHAUST FILTER KEEP DRIVING UNTIL MESSAGE IS CLEARED message goes off This will take about 30 minutes Z WARNING During DPF self cleaning or during extended idling in P Park the exhaust system and exhaust gases are very hot Things that burn could touch hot exhaust parts under the vehicle and ignite You or o
99. o 1 D S15 commonly known as Ultra Low Sulfur Diesel as other fuels used in your vehicle and the biodiesel used for making this fuel must meet the latest version of ASTM specification D6751 e Pump labeling Retail pumps dispensing blends containing up to 5 biodiesel B5 are not required to be labeled with the concentration of biodiesel Blends up to B5 must meet ASTM D975 Grades No 2 D or No 1 D S15 commonly known as Ultra Low Sulfur Diesel Notice Do not use blends containing more than 20 biodiesel Any engine fuel system or exhaust after treatment system damage caused by the use of such blends would not be covered by the vehicle warranty Pumps dispensing more than 5 and up to 20 biodiesel are required to be labeled with the concentration of biodiesel When refueling with a biodiesel blend above B5 ensure one of the following two labels appears on the dispenser B 20 Biodiesel Blend contains blomass based diesel or biodiesel In quantttles between 5 percent and 20 percant 20 Biomass Based Diesel Blend contains blomase based diesel or biodiesel In quantitles batwean 5 percent and 20 percent Biodiesel quality Blends containing more than 5 and up to 20 biodiesel must meet the latest version of ASTM Driving and Operating 9 19 specification D7467 Biodiesel blend B6 B20 Biodiesel is an emerging product and its quality can vary widely To reduce the risk of
100. oD Coolant Surge Tank and Pressure Cap Remote Positive Terminal Battery Engine Air Cleaner Filter Diesel Exhaust Fluid DEF Fill Tube r Engine Air Cleaner Filter Restriction Indicator If Equipped Engine Oil Dipstick Engine Oil Fill Cap Engine Fan Out of View Automatic Transmission Dipstick SZz erx U Vehicle Care 10 5 Power Steering Fluid Reservoir Brake Fluid Reservoir Auxiliary Battery Underhood Fuse Block Windshield Washer Fluid Reservoir Remote Negative Terminal 10 6 Vehicle Care i ojii LO Aca WY United States Van models Shown Canada Similar w O romnmmy Battery Coolant Surge Tank and Pressure Cap Automatic Transmission Dipstick Engine Oil Dipstick Engine Fan Out of View Engine Oil Fill Cap Engine Air Cleaner Filter Air Cleaner Filter Restriction Indicator Power Steering Fluid Reservoir Brake Fluid Reservoir Windshield Washer Fluid Reservoir Engine Oil To ensure proper engine performance and long life careful attention must be paid to engine oil Following these simple but important steps will help protect your investment e Always use engine oil approved to the proper specification and of the proper viscosity grade See Selecting the Right Engine Oil in this section e Check the engine oil level regularly and maintain the proper oil level See Checking Engine Oil and When to Add Engine Oi
101. omatic Transmission FWD secsicesien eraieuconenene Engine Air Cleaner Filter Cooling System Engine Coolant Engine Overheating 10 25 Starter Switch Check 10 26 Automatic Transmission Shift Lock Control Function Cheek i sicateaniddeuatendees 10 27 Ignition Transmission Lock CHECK aieru iiaeo 10 27 Park Brake and P Park Mechanism Check 10 27 Electrical System Engine Compartment Fuse BIOCK cerr rer agnis 10 28 Vehicle Care 10 1 General Information Accessories and Modifications Adding non dealer accessories or making modifications to the vehicle can affect vehicle performance and safety including such things as airbags braking stability ride and handling emissions systems aerodynamics durability and electronic systems like antilock brakes traction control and stability control These accessories or modifications could even cause malfunction or damage not covered by the vehicle warranty 10 2 Vehicle Care Damage to vehicle components resulting from modifications or the installation or use of non GM certified parts including control module or software modifications is not covered under the terms of the vehicle warranty and may affect remaining warranty coverage for affected parts GM Accessories are designed to complement and function with other systems on the vehicle Your GM dealer can accessorize the vehicle using genuine GM Acc
102. ontrol arm ball joints on pickup models require lubrication but should not be lubricated unless their temperature is 12 C 10 F or higher or they could be damaged Vehicles used under severe commercial operating conditions require lubrication on a regular basis every 5000 km 3 000 miles Body component lubrication Lubricate all key lock cylinders body door hinges hood latch assembly secondary latch pivots spring anchor release pawl fuel door hinge locks latches and any folding or moving seat hardware Pickup models Lubricate tailgate hinges tailgate linkage tailgate handle pivot points and latch bolt Van models Lubricate hood hinges and rear compartment hinges See Recommended Service and Maintenance Fluids and Lubricants on page 11 8 More frequent lubrication may be required when the vehicle is exposed to a corrosive environment Applying silicone grease on weatherstrips with a clean cloth makes them last longer seal better and not stick or squeak Restraint system component check See Safety System Check in the owner manual Fuel system inspection for damage or leaks Exhaust system including DPF pressure lines and nearby heat shields inspection for loose or damaged components Check to be sure that mud or dirt is not caked on the exhaust system especially in the area of the diesel particulate filter and tailpipe Clean the area as needed See Diesel Particulate Filter Exhaus
103. ours before starting To Use the Engine Heater 1 Turn off the engine 2 Open the hood and unwrap the electrical cord The cord is located in the engine compartment on the passenger s side of the vehicle near the right side auxiliary battery 3 Plug it into a normal grounded 110 volt AC outlet Z WARNING Plugging the cord into an ungrounded outlet could cause an electrical shock Also the wrong kind of extension cord could overheat and cause a fire You could be seriously injured Plug the cord into a properly grounded three prong 110 volt AC outlet If the cord will not reach use a heavy duty three prong extension cord rated for at least 15 amps 4 Before starting the engine be sure to unplug and store the cord as it was before to keep it away from moving engine parts and prevent damage Driving and Operating 9 9 The length of time the heater should remain plugged in depends on the outside temperature You may wish to use the coolant heater to improve ease of starting at temperatures between 18 C 0 F and 29 C 20 F Keep the coolant heater plugged in for a minimum of four hours At temperatures below 29 C 20 F the coolant heater should remain plugged in for at least eight hours It will not harm either the coolant heater or the vehicle to leave the coolant heater plugged in longer than the times stated Be sure to remove and store the cord before starting the engine See Fu
104. own Stationary vehicle operation only PTO Enabling Disabling Conditions Enabling Conditions Stationary PTO To engage stationary PTO operation the following conditions must be met e The engine must be running e The vehicle cannot be moving and the parking brake must be set e The shift lever must be in P Park or N Neutral e The brake pedal must not be pressed e The engine speed must be less than the maximum allowed PTO engage speed of 1500 rpm The PTO engage speed can be adjusted by a service technician For in cab PTO operation Press and release the position on the PTO switch The PTO LED light will blink fast until the PTO load becomes engaged The LED light will then be on steady The SET and RES switch positions can then be used to establish the desired PTO operating speed For remote PTO operation Press and release the remote PTO arming switch then within five seconds move the PTO enable switch from OFF to ON open to closed The remote LED light will come on when the PTO Load is engaged The PTO remote SET switch can then be used to establish the desired PTO operating speed Additional information is available in the service manual for the correct wiring configuration and programming of the remote PTO enable and set switches Driving and Operating These switches are accessed through the PTO upfitter connector located under the passenger side door Enabli
105. pplement It is an alphabetical list of what is in the supplement and the page number where you will find it Introduction iv Introduction NOTES In Brief Initial Drive Information Transmission 1 1 Performance and Maintenance Engine Oil Life System 1 2 Diesel Particulate Filter Exhaust Filter 1 3 Diesel Exhaust Fluid 1 5 Initial Drive Information Transmission Cold Operation Allison Transmission When temperatures are very cold the transmission will prevent certain operations to protect against damage The chart below shows shift range availability based on transmission oil temperature e All shift ranges available at 25 C 13 F or above e 2 Second and 3 Third shift ranges only at 35 C 31 F to 25 C 13 F e 2 Second shift range only at 35 C 31 F or lower In Brief 1 1 Torque converter clutch operation will also be prevented when air or transmission oil temperatures are below certain levels For areas where ambient temperatures are below 40 C 40 F use synthetic transmission fluid approved to Allison Transmission specification TES 295 See Recommended Fluids and Lubricants on page 11 8 and Automatic Transmission Fluid on page 10 11 Adaptive Shift Controls The shift quality of a new vehicle may not be ideal because the Adaptive Shift Control process may not have determined the best settings for
106. rally less than 0 5L 1 pint Do not overfill Notice Use of the incorrect automatic transmission fluid may damage the vehicle and the damages may not be covered by the vehicle warranty Always use the automatic transmission fluid listed in Recommended Fluids and Lubricants on page 11 8 e After adding fluid recheck the fluid level as described under How to Check earlier in this section e When the correct fluid level is obtained push the dipstick back in all the way Then flip the handle down to lock the dipstick in place Engine Air Cleaner Filter Pickup Models The air cleaner filter assembly may have an air cleaner filter restriction indicator that shows when the engine air cleaner filter is dirty and needs to be serviced The air cleaner filter restriction indicator is located on the air cleaner box When to Inspect Inspect the air cleaner filter every 25 000 km 15 000 miles and replace the filter if necessary How to Inspect When the restriction indicator turns black or is in the red orange change zone replace the filter and reset the restriction indicator The air cleaner filter assembly is located on the front corner of the engine compartment on the passenger s side of the vehicle Vehicle Care 10 17 To inspect and replace the filter and reset the restriction indicator Clamp Cover Electrical Connector Restriction Indicator Cover Screws TOM gt Disconnec
107. rating temperature of 71 C 160 F to 93 C 200 F is reached 2 Pull out the dipstick and wipe it with a clean rag or paper towel 3 Push it back in all the way wait three seconds and then pull it back out again Repeat the check procedure to verify the reading 4 Safe operating level is within the HOT RUN band on the dipstick The width of the HOT RUN band represents approximately 1 0 liter 1 06 quart of fluid at normal operating temperature 5 If the fluid level is not within the HOT RUN band add or drain fluid as necessary to bring the fluid level to within the HOT RUN band 6 If the fluid level is in the acceptable range push the dipstick back in all the way Consistency of Readings Always check the fluid level at least twice using the procedures described previously Consistency is important to maintaining proper fluid level If inconsistent readings persist check the transmission breather to be sure it is clean and unclogged If readings are still inconsistent contact the dealer How to Add Fluid In cold operation Allison recommends using Synthetic Transmission Fluid approved to Allison Transmission specification TES 295 in areas where the minimum ambient temperatures are below 40 C 40 F Refer to the Maintenance Schedule to determine what kind of transmission fluid to use See Recommended Fluids and Lubricants on page 11 8 Add fluid only after checking the transmission flu
108. rformed Tires should be rotated every 12 000 km 7 500 miles See Tire Inspection and Rotation in the owner manual Scheduled Maintenance When the Change Engine Oil Soon Message Displays Change engine oil and filter See Engine Oil on page 10 7 An Emission Control Service When the CHANGE ENGINE OIL SOON message displays in the Driver Information Center DIC service is required for the vehicle as soon as possible within the next 1 000 km 600 miles If driving under the best conditions the engine oil life system might not indicate the need for vehicle service for more than a year The engine oil and filter must be changed at least once a year and the oil life system must be reset Your dealer has trained service technicians who will perform this work and reset the system Service and Maintenance 11 3 e Windshield washer fluid level check See Washer Fluid in the owner manual Fluids visual leak check or every 12 months whichever occurs first A leak in any system must be repaired and If the engine oil life system is reset accidentally service the vehicle within 5 000 km 3 000 miles since the last service Reset the oil life e Windshield wiper blade system whenever the oil is changed See Engine Oil Life System on page 10 10 Every Engine Oil Change Change engine oil and filter Reset oil life system See Engine Oil on page 10 7 and Engine Oil Life System on page 10 10 An Emi
109. rmation on its location 10 23 Vehicle Care Turning the surge tank pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be on a level surface When the engine is cold the coolant level should be between the MIN and MAX marks Checking Coolant Van Models The surge tank is located near the center of the engine compartment See Engine Compartment Overview on page 10 4 for more information on its location Turning the surge tank pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be on a level surface When the engine is cold the coolant level should be at the COLD FILL mark 10 24 Vehicle Care Adding Coolant Pickup and Van Models If more coolant is needed add the proper DEX COOL coolant mixture at the surge tank but be careful not to spill it ZN WARNING You can be burned if you spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if the engine parts are hot enough Do not spill coolant on a hot engine Notice This vehicle has a specific coolant fill procedure Failure to follow th
110. rned Do not let it get on hot engine parts and keep matches or other ignition sources away First drain any water from the filter following the procedure for draining water listed previously The vehicle s engine must be off until the end of this procedure 9 31 The fuel filter is located in the engine compartment on the passenger side of the vehicle 1 Apply the parking brake Access the fuel filter through the passenger side wheel house opening It is not necessary to remove all of the wheel liner fasteners 2 Remove only the necessary fasteners to allow the rear of the wheel liner to be lowered enough for fuel filter access 3 Unplug the water sensor wire connected to the fuel filter and unscrew the filter element 4 Remove the filter element If there is any dirt on the filter sealing surface clean it off Remove and reuse the water sensor float switch located on the bottom of the fuel filter 9 32 5 Install the new filter element 6 Reinstall and tighten the filter container and reconnect the water sensor wire to the filter 7 Reposition the wheel liner Install and tighten fasteners 9 Use the fuel filter priming procedure earlier in this section to prime the fuel filter 10 Start the engine and let it idle for five minutes Check the fuel filter and air bleed valve for leaks 11 Reset the fuel filter monitor See Fuel System Messages on page 5 11 for more information
111. s Secondary Filter B 1 Apply the parking brake 2 Unscrew the filter element 3 Remove the filter element If there is any dirt on the filter sealing surface clean it off Remove and reuse the water drain valve located at the bottom of the fuel filter 4 Install and tighten the new filter element 5 Follow the vehicle fuel system priming procedure earlier in this section to re prime the system 6 Start the vehicle and let it idle for 5 minutes Driving and Operating Filling the Tank Z WARNING Fuel vapor burns violently and a fuel fire can cause bad injuries To help avoid injuries to you and others read and follow all the instructions on the fuel pump island Turn off the engine when refueling Do not smoke near fuel or when refueling the vehicle Do not use cellular phones Keep sparks flames and smoking materials away from fuel Do not leave the fuel pump unattended when refueling the vehicle This is against the law in some places Do not re enter the vehicle while pumping fuel Keep children away from the fuel pump never let children pump fuel 9 33 Van Shown Pickup Similar The green fuel cap is located behind a hinged door on the driver side of the vehicle On van models the blue diesel exhaust fluid cap is also behind the fuel door Do not remove both caps at the same time For chassis cab models refuel the front tank first or in instances when only a partial fuel fi
112. sed oil 10 10 Vehicle Care Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter This is based on engine timing engine load and engine temperature and not on mileage Based on driving conditions the mileage at which an engine oil change is indicated can vary considerably For the oil life system to work properly the system must be reset every time the oil is changed When the system has calculated that oil life has been diminished it indicates that an oil change is necessary A CHANGE ENGINE OIL SOON message comes on Change the oil as soon as possible within the next 1000 km 600 mi It is possible that if driving under the best conditions the oil life system might indicate that an oil change is not necessary for up to a year The engine oil and filter must be changed at least once a year and at this time the system must be reset Your dealer has trained service people who will perform this work and reset the system It is also important to check the oil regularly over the course of an oil drain interval and keep it at the proper level If the system is ever reset accidentally the oil must be changed at 5 000 km 3 000 mi since the last oil change Remember to reset the oil life system whenever the oil is changed How to Reset the Engine Oil Life System Reset the system whenever the engine oil is changed
113. shed by an upfitter will vary Check the upfitters manual Driving and Operating 9 13 DEF Fill Pickups For full sized pickups the DEF fill is located under the hood on the passenger side at the back of the engine compartment The DEF cap is blue 9 14 Exhaust Fluid Low Warnings A full DEF tank will last for several thousand kilometers miles depending on vehicle usage As the exhaust fluid level drops warnings will be displayed in the Driver Information Center DIC There will not be any DEF range DIC messages with more than 1600 km 1000 miles of DEF range remaining DIC messages will begin with approximately 1600 km 1000 miles of range and as the tank becomes empty vehicle speed limitation will result To avoid vehicle speed limitations the DEF tank should be refilled at the first opportunity after a low warning indication If DEF is added before the EXHAUST FLUID EMPTY message appears it may take several km miles for the DIC message to update If the vehicle speed has been limited and DEF has been added it may take up to 30 seconds after engine start with the vehicle Driving and Operating stopped for the EXHAUST FLUID EMPTY message to clear If the vehicle is driven prior to the DIC message clearing the vehicle speed will still be limited If the DIC message clears while driving the vehicle must be completely stopped to remove the speed limitation If DEF is added under fr
114. so that the system can calculate the next engine oil change To reset the Engine Oil Life System on van models 1 Display the OIL LIFE REMAINING on the DIC 2 Press and hold the SET RESET button on the DIC for more than five seconds The oil life will change to 100 To reset the Engine Oil Life System on most pickup models 1 Display the OIL LIFE REMAINING on the DIC If the vehicle does not have DIC buttons the vehicle must be in P Park to access this display 2 Press and hold the SET RESET button on the DIC or the trip odometer reset stem if the vehicle does not have DIC buttons for more than five seconds The oil life will change to 100 On all models the Engine Oil Life System can be reset as follows 1 Turn the ignition to ON RUN with the engine off 2 Fully press the accelerator pedal slowly three times within five seconds 3 Display the OIL LIFE REMAINING on the DIC If the display shows 100 the system is reset 4 Turn the key to LOCK OFF If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started the engine oil life system has not reset Repeat the procedure Automatic Transmission Fluid When to Check and Change Pickup Models Change the fluid and filter at the intervals listed See Scheduled Maintenance on page 11 2 And be sure to use the transmission fluid listed in Recommended Fluids and Lubricants on page 11 8 How to Check Becaus
115. ssion Control Service Add diesel exhaust fluid See Diesel Exhaust Fluid on page 9 12 Engine coolant level check See Engine Coolant on page 10 21 Engine cooling system inspection Visual inspection of hoses pipes fittings and clamps and replacement if needed inspection for wear cracking or contamination and windshield and wiper blade cleaning if contaminated See Exterior Care in the owner manual Worn or damaged wiper blade replacement See Wiper Blade Replacement in the owner manual Tire inflation pressures check See Tire Pressure in the owner manual Tire wear inspection See Tire Inspection in the owner manual Rotate tires if necessary See Tire Rotation in the owner manual the fluid level checked Engine air cleaner filter inspection See Engine Air Cleaner Filter on page 10 17 Brake system inspection or every 12 months whichever occurs first Steering and suspension inspection Visually inspect front and rear suspension and steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect power steering lines and hoses for proper hook up binding leaks cracks chafing etc Pickup models Visually check constant velocity joints rubber boots and axle seals for leaks 11 4 Lubricate the front suspension steering linkage rear driveline center splines van models and parking brake cable guides C
116. st Idle Speed 1200 rpm Fast Idle control will be disabled when one or more of the following conditions occur e The cruise control is in the Off position e The cruise control Set switch is pressed and released See Cruise Control in the Index of the vehicle owner manual e The cruise control Cancel switch is pressed e The brake pedal is pressed e The transmission is shifted out of P Park or N Neutral e The park brake is released e The vehicle speed is not O km h 0 mph When Fast Idle is active a FAST IDLE ON message will be displayed in Driver Information Center DIC See Starting the Vehicle Messages on page 5 12 Winter Cover If the vehicle includes a winter cover it can be used to enhance heater performance in extremely cold conditions below 18 C 0 F The winter cover installs over the grille and restricts air flow to the engine compartment For diesel powered vehicles that did not come with a winter cover a GM winter cover can be purchased as an accessory See your dealer for additional information Usage Guidelines The winter cover should only be used while operating the vehicle in extremely cold temperatures or in heavy snow for extended periods of time In these temperatures the vehicle does not need a large amount of air to properly cool the engine When more airflow is required to cool the vehicle the winter cover should not be used The following usage guide
117. stem 10 20 Engine Messages 5 11 Covers WINTER ae dees sesh sawecueyeuu 9 5 Diesel Starting Your Engine 9 1 Diesel Exhaust Fluid 1 5 9 12 Diesel Exhaust Fluid DEF Warning Light 5 9 Diesel Exhaust Fluid Messages 2 2 0 5 11 Diesel Particulate Filter 9 10 Diesel Particulate Filter Messages 0 5 5 12 Driver Information Center DIC 5 10 INDEX E Electrical System Engine Compartment Fuse Block Engine Air Cleaner Filter Check and Service Engine Soon Light Compartment Overview Coolant ca slncccScinennstnaeede Cooling System Cooling System Messages Drive Belt Routing Heater c 5cnskersdeenteseece Oil Pressure Gauge Overheating Power Messages Starting Your Diesel Engine Oil Life System Messages Engines Diesel Fuel Exhaust Brake i 1 i 2 INDEX F Filter Diesel Particulate 9 10 Replacement Fuel 9 31 Filter Engine Air Cleaner 10 17 Fluid Automatic Transmission 10 11 Diesel Exhaust 1 5 9 12 Fuel Cold Weather Operation 9 25 Diesel Engines 9 16 Filling a Portable Fuel Container 9 34 Filling the Tank 9 33 Filter Replacement
118. t Filter on page 9 10 At high mileages the DPF becomes loaded with ash This is normal When the amount of ash loading is high see your dealer for DPF cleaning or replacement For vehicles with Allison Transmission only At the first engine oil change only replace external transmission filter Vans with GVWR above 4 536 kg 10 000 Ibs and all pickups Shields inspection for damage or looseness Adjust or replace as required This is a Noise Emission Control Service Applicable to vehicles sold in the United States and recommended for vehicles sold in Canada Air intake system check Check the air intake system installation to assure that gaskets are properly sealed and that all hose connections fasteners and other components are tight Also check to be sure that the air cleaner housing is properly seated and the cover fits tightly Tighten connections and fasteners or replace damaged parts as necessary This is a Noise Emission Control Service Applicable to vehicles sold in the United States and recommended for vehicles sold in Canada Fuel filter service An Emission Control Service This vehicle has a CHANGE FUEL FILTER message in the Driver Information Center DIC to tell you when to replace the fuel filter See Fuel System Messages on page 5 11 Change the fuel filter a minimum of once every two years The PERCENT FUEL FILTER LIFE REMAINING message may be used to decide if the filter should
119. t the harness connector from the air cleaner cover connector B 2 Loosen the screw on the clamp A holding the air outlet duct in place Do not remove the clamp Move the air duct aside 10 18 Vehicle Care Remove the two air cleaner housing cover screws D Raise the air cleaner housing cover and remove the air cleaner filter from the air cleaner housing Care should be taken to dislodge as little dirt as possible Clean the filter sealing surface and the housing Install the new engine air cleaner filter Lower the air cleaner housing cover and secure with the two screws Install the air duct and tighten the screw on the clamp to secure to the air cleaner housing Install the harness electrical connector 10 Reset the air cleaner filter restriction indicator C if equipped by pressing the top button on the indicator See Scheduled Maintenance on page 11 2 to determine when to replace the engine air cleaner filter Z WARNING Operating the engine with the air cleaner filter off can cause you or others to be burned The air cleaner not only cleans the air it helps to stop flames if the engine backfires Use caution when working on the engine and do not drive with the air cleaner filter off Notice lf the air cleaner filter is off dirt can easily get into the engine which could damage it Always have the air cleaner filter in place when you are driving Van Models T
120. the level reaches the proper level 5 Replace the pressure cap Be sure the pressure cap is hand tight and fully seated 6 Verify coolant level after the engine is shut off and the coolant is cold If necessary repeat coolant fill procedure Steps 1 through 6 If the coolant level is still low after having followed these steps twice have the coolant system checked a certified technician at the dealer for a possible leak Notice If the pressure cap is not tightly installed coolant loss and possible engine damage may occur Be sure the cap is properly and tightly secured Engine Overheating There is an engine coolant temperature gauge on the instrument panel cluster See the owner manual for more information If Steam Is Coming from the Engine Compartment Z WARNING Steam from an overheated engine can burn you badly even if you just open the hood Stay away from the engine if you see or hear steam coming from it Just turn it off and get everyone away from the vehicle until it cools down Wait until there is no sign of steam or coolant before you open the hood If you keep driving when the engine is overheated the liquids in it can catch fire You or others could be badly burned Stop the engine if it overheats and get out of the vehicle until the engine is cool Vehicle Care 10 25 Notice If the engine catches fire because of being driven with no coolant the vehicle can be badly damage
121. thers could be burned Do not park or idle for an extended period of time near or over papers leaves dry grass or other things that can burn Keep the exhaust area clear of material that could ignite or burn See Parking Over Things That Burn on page 9 10 for more information 9 11 Notice Extended idle should be avoided because the DPF system is not capable of self cleaning at idle During extended idle operation monitor the instrument panel telltale lights and Driver Information Center for messages and take appropriate indicated action Continued idling with the warning light message on could cause irreversible damage to the DPF requiring repair and possible replacement that might not be covered by the vehicle warranty You will also notice a change in the exhaust sound and engine idle speed This is normal See Vehicle Messages on page 5 10 If you continue to drive with the DPF warning message on and the exhaust filter is not cleaned as required the Malfunction Indicator Lamp and the ENGINE POWER IS REDUCED message will come on and dealer service is necessary See Malfunction Indicator Lamp on page 5 6 and Engine Power Messages on page 5 11 9 12 Vehicles with DPF have specific fuel and engine oil requirements See What Fuel to Use in The U S on page 9 17 or What Fuel to Use in Canada and Mexico on page 9 22 and Engine Oil on page 10 7 for more information on those requirements Extended idling
122. ting 9 29 Open the fuel filter vent valve by turning the screw counterclockwise several full turns The vent valve is located on top of the fuel filter housing Repeatedly push down on the l fuel filter priming pump with the palm of your hand The pump is located on top of the fuel filter housing Let the pump return upward between pushes Operate the priming pump until a small amount of fuel seeps from the vent valve When fuel is seen the filter is now full of fuel and the system should be primed Close the vent valve Clean any fuel that accumulated on the fuel filter Attempt to start the engine The engine may start and stall If this occurs operate the priming pump several times in between starting attempts Once the engine stays running allow it to idle for a few minutes Check the filter for leaks To Prime the Vehicle Van Models The vehicle has an electric priming pump The priming pump is operated electrically and is designed to bring fuel to the engine to eliminate any air in the fuel lines To prime the engine 1 Correct the condition that caused the loss of prime by making sure there is fuel in the tank 2 Turn the ignition key on for 30 seconds The fuel pump will be operating and starting the priming process Do not start the engine during the first 30 seconds 3 After completing the initial prime in Step 2 turn the ignition off then back to start and crank the eng
123. tional messages that the Duramax Diesel vehicle can display Engine Cooling System Messages COOLANT LEVEL LOW ADD COOLANT Notice Engine damage from running your engine without coolant is not covered by your warranty See Overheated Engine Protection Operating Mode in the Index of your owner s manual for information on driving to a safe place in an emergency If your vehicle has a low coolant level sensor this message will appear on the DIC if the engine coolant level is low Adding coolant to the coolant recovery tank will clear the message See Engine Coolant in the owner manual Instruments and Controls Engine Oil Messages ENGINE OIL LOW ADD OIL If your vehicle has an oil level sensor this message displays if the oil level in the vehicle is low Check the oil level and correct it as necessary You may need to let the vehicle cool or warm up and cycle the ignition to be sure this message clears This message clears itself after 10 seconds until the next ignition cycle See Engine Oil on page 10 7 for additional information Engine Power Messages ENGINE POWER IS REDUCED A computer monitors the operation of the electric accelerator If the ENGINE POWER IS REDUCED message comes on while driving there will be a reduction in performance and acceleration You should take the vehicle in for service 5 11 Fuel System Messages CHANGE FUEL FILTER This message will appear on the
124. tioning y CMPRSR Compressor Stud 1 Trailer Connector Battery STRTR Starter o Power PWRITRN Mid Bussed Electrical FUEL Climate Control Blower Tailgate Open Close Assist Left Bussed Electrical Center 2 10 32 Vehicle Care NOTES Service and Maintenance General Information General Information Scheduled Maintenance Scheduled Maintenance Recommended Fluids Lubricants and Parts Recommended Fluids and Lubricants Maintenance Replacement Pants ivcstetincataatncegete s Maintenance Records Maintenance Records 11 2 Service and Maintenance General Information Notice Maintenance intervals checks inspections recommended fluids and lubricants are necessary to keep this vehicle in good working condition Damage caused by failure to follow scheduled maintenance might not be covered by the vehicle warranty Proper vehicle maintenance helps to keep the vehicle in good working condition improves fuel economy and reduces vehicle emissions for better air quality 11 1 Because of all the different ways people use vehicles maintenance needs vary The vehicle might need more frequent checks and services Please read the information under Scheduled Maintenance To keep the vehicle in good condition see your dealer The maintenance schedule is for vehicles that e carry passengers and cargo within recommended limits on the T
125. uel but the vehicle s fuel tank should be filled soon An arrow on the fuel gauge indicates the side of the vehicle the fuel door is on Instruments and Controls 5 5 Listed are four situations customers Engine Oil Pressure may experience with the fuel gauge Gauge e At the gas station the fuel pump shuts off before the gauge reads F full e t takes a little more or less fuel to fill up than the fuel gauge indicated For example the gauge may have indicated the tank was half full but it actually took a little more or less than half the tank s capacity to fill the tank e The gauge moves a little while turning a corner or speeding up Metric Pickup Models e The gauge does not go back to E empty when the ignition is turned off None of these indicate a problem with the fuel gauge For information on how to fill the fuel tank see Filling the Tank on page 9 33 The vehicle also has a fuel cooler Metric Van Models To clean powerwash the bottom of the vehicle 5 6 English Van Models Z WARNING Do not keep driving if the oil pressure is low The engine can become so hot that it catches fire Someone could be burned Check the oil as soon as possible and have the vehicle serviced Instruments and Controls Notice Lack of proper engine oil maintenance can damage the engine The repairs would not be covered by the vehicle warranty Always follow the maintenance schedule for
126. ve have made the light turn off your dealer can check the vehicle The dealer has the proper test equipment and diagnostic tools to fix any mechanical or electrical problems that might have developed Emissions Inspection and Maintenance Programs Some state provincial and local governments may have programs to inspect the on vehicle emission control equipment For the inspection the emission system test equipment is connected to the vehicle s Data Link Connector DLC The DLC is under the instrument panel to the left of the steering wheel See your dealer if assistance is needed The vehicle may not pass inspection if e the check engine light is on with the engine running or if the light does not come on when the ignition is turned to ON RUN while the engine is off e the critical emission control systems have not been completely diagnosed by the system This can happen if the battery has recently been replaced or if the battery has run down The diagnostic system evaluates critical emission control systems during normal driving This can take several days of routine driving If this has been done and the vehicle still does not pass the inspection your dealer can prepare the vehicle for inspection Wait to Start Light 00 The wait to start light shows that the engine is functioning properly and indicates when the engine can be started Instruments and
127. will display the message REDUCED ENGINE POWER See Diesel Particulate Filter Exhaust Filter on page 9 10 and Engine Power Messages on page 5 11 Fuel Use Ultra Low Sulfur Diesel Fuel ULSD Use Ultra Low Sulfur Diesel Fuel ULSD only The emission control hardware used on the vehicle may be damaged by using fuel with high sulfur levels Use only fuel that is dispensed from pumps bearing the ULSD label Do Not Use Low Sulfur Diesel Fuel LSD Do not use fuel that is dispensed from pumps bearing the LSD label Do Not Use Non Highway Fuel Fuel labeled as off road or non highway is typically very high in sulfur content and will damage the emission control system Non Highway fuel is not intended for use in on highway vehicles and does not have the fuel properties needed by the DPF equipped Duramax Diesel In addition e Use the correct engine oil e Do not add gasoline to diesel fuel e Do not modify the induction or exhaust systems See Fuel for Diesel Engines on page 9 16 and Engine Oil on page 10 7 Diesel Exhaust Fluid Diesel Exhaust Fluid DEF is used with diesel engines to reduce the amount of regulated emissions produced The DEF system must be maintained for the vehicle to run properly Locating Diesel Exhaust Fluid DEF can be purchased at a Chevrolet or GMC dealer It can also be purchased at authorized vehicle and truck dealerships Additionally some diesel truck fuelling stat
128. wing conditions are detected by the vehicle electronics e The PTO load becomes disengaged See service manual e Vehicle speed exceeds 80 km h 50 mph e Engine speed exceeds the maximum allowed PTO operating speed of 3100 rpm factory setting 2100 rpm e The PTO control system will attempt to limit accelerator pedal and PTO switch input as the vehicle approaches the above operational limits There are some vehicle conditions such as down hill acceleration which may cause vehicle speed and or engine speed limits to be exceeded Under these conditions PTO is disengaged The stationary PTO mode will also disengage if any of the following conditions are detected by the vehicle electronics e Movement of the vehicle e The park brake is released e The transmission is shifted from P Park or N Neutral to D Drive or R Reverse e The PTO load becomes disengaged See service manual Preset PTO Mode Preset PTO can only be used when the vehicle is not moving The engine speed is initially set to a stand by engine speed 850 rpm when the PTO in cab switch position is pressed or by pressing and releasing the remote arming switch Then within five seconds assert the remote PTO enable switch to on This provides an initial start up engine speed to match the engagement of the PTO load Driving and Operating The PTO standby engine speed can be reprogrammed to a higher speed by your dealer

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