66l v8 Turbo Diesel Engine PDF

2005 DURAMAX™ Diesel Engine M
Features and Controls ..................................... 2-1 Maintenance Schedule ..................................... 6-1

Starting and Operating Your Vehicle ............. 2-2 Maintenance Schedule ................................ 6-2
Instrument Panel ............................................. 3-1 Index ................................................................ 1
Warning Lights, Gages and Indicators ........... 3-2
Service and Appearance Care .......................... 5-1
Diesel Fuel Requirements and Fuel System ... 5-2
Checking Things Under the Hood ............... 5-14
Capacities and Specifications ..................... 5-36
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General Motors, GM, GMC, CHEVROLET, the GM This manual includes the latest information at the time it
Emblem, the GMC Truck Emblem, the CHEVROLET was printed. We reserve the rights to make changes
Emblem, and the names SIERRA and SILVERADO are in the product after that time without notice.
registered trademarks of General Motors Corporation.
This manual contains information that pertains to Canadian Owners
the operation of your diesel engine. It also contains your
Diesel Maintenance Schedule. The sections in this A French language copy of this manual can be obtained
manual correspond to the sections in your owner from your dealer or from:
manual. This manual, along with your owner manual, Helm, Incorporated
will assist you in the proper use and maintenance P.O. Box 07130
of your vehicle. Detroit, MI 48207
Keep this manual with the owner manual in your
vehicle, so it will be there if you ever need it while you
are on the road. If you sell your vehicle, leave this
manual and the owner manual with the vehicle.
Litho in U.S.A.
©
Part No. 15101364 A First Edition 2004 General Motors Corporation. All Rights Reserved.
ii

Section 2 Features and Controls
Starting and Operating Your Vehicle .................2-2
Starting Your Diesel Engine .............................2-2
Winter Cover .................................................2-5
Engine Coolant Heater ....................................2-7
2-1

Starting and Operating Your Starting Your Engine
Vehicle 1. Turn your ignition key to RUN.
Observe the wait to start light. See Wait to Start
Light on page 3-6. This light may not come on if the
Starting Your Diesel Engine engine is hot.
Your diesel engine starts differently than a gasoline 2. As soon as the wait to start light goes off,
engine. immediately turn the ignition key to START.
When the engine starts, let go of the key.
Automatic Transmission Your engine has a fast warm-up glow plug system.
Move your shift lever to PARK (P) or NEUTRAL (N). The wait to start light will illuminate for a much
Your engine won’t start in any other position — that’s a shorter time than most diesel engines, due to the
safety feature. To restart when you’re already moving, rapid heating of the glow plug system.
use NEUTRAL (N) only. Notice: Holding your key in START for longer than
Notice: Do not try to shift to PARK (P) if your 15 seconds at a time will cause your battery to
vehicle is moving. If you do, you could damage the be drained much sooner. And the excessive heat
transmission. Shift to PARK (P) only when your can damage your starter motor.
vehicle is stopped. Notice: If the wait to start light stays on after
starting your vehicle, your vehicle may not run
Manual Transmission properly. Have your vehicle serviced right away.
Move your shift lever to neutral and hold the clutch pedal 3. If the engine does not start after 15 seconds
to the floor while starting the engine. Your vehicle won’t of cranking, turn the ignition key to OFF. Wait
start if the clutch pedal is not all the way down — that’s a one minute for the starter to cool, then try the
safety feature. same steps again.
If you’re trying to start your engine after you’ve run out
of fuel, follow the steps in Running Out of Fuel on
page 5-9.
2-2

When your engine is cold, let it run for a few minutes If Your Diesel Engine Won’t Start
before you move your vehicle. This lets oil pressure
build up. Your engine will sound louder when it’s cold. If you’ve run out of fuel, look at Running Out of Fuel on
page 5-9. See Diesel Fuel Requirements and Fuel
Notice: If you are not in an idling vehicle and System on page 5-2.
the engine overheats, you would not be there to see
the overheated engine indication. This could If you’re not out of fuel, and your engine won’t start,
damage your vehicle. Do not let your engine run do this:
when you are not in your vehicle. Turn your ignition key to RUN. Immediately after the wait
to start light goes off, turn the ignition key to START.
Cold Weather Starting (Diesel Engine)
If the light doesn’t go off, wait a few seconds, then try
The following tips will help you get good starting in starting your engine again. See your dealer as soon
cold weather. as you can for a starting system check.
Use the recommended engine oil when the outside If the light comes on and then goes off and you know
temperature drops below freezing. See Engine Oil on your batteries are charged, but your engine still
page 5-16. When the outside temperature drops won’t start, your vehicle needs service.
below 0° F (–18°C), use of the engine coolant heater
is recommended. If the light does not come on when the engine is cold,
your vehicle needs service.
If you experience longer cranking times, notice an
unusual amount of exhaust smoke or are at higher If your batteries don’t have enough charge to start your
altitudes (over 7,000 ft. or 2 135 m), you may use your engine, see “Battery” in the owner’s manual Index.
engine coolant heater. See Engine Coolant Heater Be sure you have the right oil for your engine, and that
on page 2-7. you’ve changed the oil at the proper times. If you
See Diesel Fuel Requirements and Fuel System on use the wrong oil, your engine may be harder to start.
page 5-2 for information on what fuel to use in
cold weather.
2-3

Be sure you are using the proper fuel for existing This feature can be turned off and on using the DIC
weather conditions. See Diesel Fuel Requirements and steering wheel control buttons. If your vehicle is
Fuel System on page 5-2. not equipped with the DIC steering wheel control
buttons, doing the following to turn on this feature:
If the engine starts, runs a short time, then stops, your
vehicle needs service. 1. Turn the ignition to RUN, with the vehicle off.
2. Press the accelerator pedal to the floor and hold
while quickly pressing the brake pedal three times
{CAUTION: in less than eight seconds.
3. Release the accelerator pedal and start the engine.
Do not use gasoline or starting aids, such as When the engine is started, it will slowly ramp up to
ether, in the air intake. They could damage the high idle speed after a delay of a few seconds up to
your engine. There could also be a fire, which approximately two minutes. For this method to work
could cause serious personal injury. properly there must be no throttle or brake pedal faults.
The engine idle speed will return to normal once the
following conditions are met:
Elevated Idle/Exhaust Restrictor
• Once engine coolant temperature reaches
The engine has a cold temperature high idle and exhaust 150°F (65°C).
restrictor feature which elevates the engines idle speed
from 680 to 1200 rpms, and restricts the exhaust gas • Air intake temperature reaches 32°F (0°C).
flow, when outside temperatures are below 32°F (0°C),
and the engine coolant temperature is below
150°F (65°C.) This feature enhances heater performance
by raising the engine coolant temperature faster.
2-4

The high idle speed will be temporarily interrupted and Winter Cover
the engine speed will return to normal if any of the
following conditions occur: If your vehicle includes a winter cover, it will enhance
• The brake pedal is applied. heater performance and will reduce the amount of time it
takes to warm the inside of your vehicle in extremely
• The accelerator pedal is pressed. cold conditions (below 0°F (−18°C)). The winter
• The automatic transmission is shifted out cover installs over the front bumper of your vehicle and
of PARK (P) or NEUTRAL (N). restricts the air flowing to the engine compartment
by covering the radiator grille.
• The clutch pedal on the manual transmission
is pressed.
• 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.
2-5

Usage Guidelines • Do not modify the cover. The winter cover does not
cover some sections of the front of the vehicle
The winter cover should only be used while operating because these openings are needed to provide
your vehicle in extremely cold temperatures. In enough airflow to the radiator grille and air cooler in
these temperatures, the vehicle does not need a large extremely cold temperatures.
amount of air to properly cool the engine. During periods
of operation when more airflow is required to cool the • When the winter cover is used, the temperature
vehicle, the winter cover should not be used. The sensor found on the inside rearview mirror will
following usage guidelines will allow adequate airflow for not function properly. The temperature that is shown
proper radiator grille and air cooler performance: will be incorrect.
• Do not use the winter cover when temperatures are
expected to be above 32°F (0°C). Use of the cover
in these conditions could cause your vehicle to
overheat. If this happens while the cover is being
used, remove the cover.
• 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.
Your vehicle may overheat if the cover is used
while towing a trailer.
2-6

Installation Instructions Lower Cover Installation
The following instructions explain how to install and 1. Pre-bend all of the small black tabs into the shape
remove your vehicle’s winter cover. When installing or of a J.
removing the cover please refer to the “Usage 2. Fasten each tab to
Guidelines” mentioned previously. When you first try to edge of the bumper,
fit the cover it may appear to be undersized. This is as illustrated.
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
the winter cover is warm. If you are required to use a
front license plate, simply cut the black stitches on
the back of the patch.
Grille Cover Installation
1. Pre-bend all the small black tabs into the shape of
a J.
2. Remove the four push pins and slide them through
each of the pre-punched tabs. To remove the winter cover, reverse the steps listed
previously.
3. Install the four push pins into the grille.
4. Hook all the tabs to the edge of the grille. Engine Coolant Heater
5. Fasten the snaps. In very cold weather, 0°F (−18°C) or colder, the engine
coolant heater can help. You’ll get easier starting
and better fuel economy during engine warm-up.
Usually, the coolant heater should be plugged in a
minimum of four hours prior to starting your vehicle.
2-7

To Use the Engine Coolant Heater How long should you keep the coolant heater plugged
in? The answer depends on the outside temperature.
1. Turn off the engine. You may wish to use your coolant heater to improve
2. Open the hood and unwrap the electrical cord. The ease of starting at temperatures between 0°F (−18°C)
cord is located in the engine compartment, on the and −20°F (−29°C). Keep the coolant heater plugged in
passenger’s side of the vehicle, near the right for a minimum of four hours. At temperatures below
side engine mount. −20°F (−29°C), the coolant heater should remain
plugged in for at least eight hours. It will not harm either
3. Plug it into a normal, grounded 110-volt AC outlet. 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
{CAUTION: engine. See Diesel Fuel Requirements and Fuel System
on page 5-2 for information on what fuel to use in
Plugging the cord into an ungrounded outlet cold weather.
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. If you don’t, it could
be damaged.
2-8

Section 3 Instrument Panel
Warning Lights, Gages and Indicators ...............3-2 Wait to Start Light ..........................................3-6
Instrument Panel Cluster .................................3-2 Fuel Gage .....................................................3-6
Malfunction Indicator Lamp ..............................3-3 Driver Information Center (DIC) ........................3-7
Oil Pressure Gage ..........................................3-5
3-1

Warning Lights, Gages and Indicators
Instrument Panel Cluster
United States Version shown, Canada similar.
3-2

Your instrument cluster is designed to let you know at a Notice: If you keep driving your vehicle with this
glance how your vehicle is running. You’ll know how light on, after awhile, your emission controls
fast you’re going, about how much fuel you have may not work as well, your fuel economy may not
and many other things you’ll need to know to drive safely be as good, and your engine may not run as
and economically. smoothly. This could lead to costly repairs that may
not be covered by your warranty.
Malfunction Indicator Lamp Notice: Modifications made to the engine,
transmission, exhaust, intake, or fuel system of
Check Engine Light your vehicle or the replacement of the original tires
with other than those of the same Tire Performance
Your vehicle is equipped Criteria (TPC) can affect your vehicle’s emission
with a computer which controls and may cause this light to come on.
monitors operation of the Modifications to these systems could lead to costly
fuel, timing, and emission repairs not covered by your warranty. This may
control systems. also result in a failure to pass a required Emission
Inspection/Maintenance test.
This system is called OBD II (On-Board

Diagnostics-Second Generation) and is intended to
assure that emissions are at acceptable levels for the
life of the vehicle, helping to produce a cleaner
environment. The Check Engine light comes on to
indicate when service is required. Malfunctions often will
be indicated by the system before any problem is
apparent. This may prevent more serious damage to
your vehicle. This system is also designed to assist your
service technician in correctly diagnosing any
malfunction.
3-3

If the Light Comes On Emissions Inspection and Maintenance
This light should come on, as a check to show you it is Programs
working, when the ignition is on and the engine is Some state/provincial and local governments have or
not running. If it does not, have it repaired. This light will may begin programs to inspect the emission control
also come on if an emission control system malfunction equipment on your vehicle. Failure to pass this
has been detected on your vehicle. Diagnosis and inspection could prevent you from getting a vehicle
service may be required. registration.
You also may be able to correct the emission system Here are some things you need to know in order to help
malfunction by considering the following: your vehicle pass an inspection:
Did you just drive through a deep puddle of water? Your vehicle will not pass this inspection if the Check
If so, your electrical system may be wet. The condition Engine light is on or not working properly.
will usually be corrected when the electrical system Your vehicle will not pass this inspection if the OBD
dries out. A few driving trips should turn the light off. (on-board diagnostic) system determines that critical
Are you low on fuel? emission control systems have not been completely
diagnosed by the system. The vehicle would be
As your engine starts to run out of fuel, your engine may
considered not ready for inspection. This can happen if
not run as efficiently as designed since small amounts of
you have recently replaced your battery or if your battery
air are sucked into the fuel line. The system can detect
has run down. The diagnostic system is designed to
this. Adding fuel should correct this condition. It will take a
evaluate critical emission control systems during normal
few driving trips to turn the light off.
driving. This may take several days of routine driving.
If none of the above steps have made the light turn off, If you have done this and your vehicle still does not pass
your dealer can check the vehicle. Your dealer has the the inspection for lack of OBD system readiness, your
proper test equipment and diagnostic tools to fix any GM dealer can prepare the vehicle for inspection.
mechanical or electrical problems that may have
developed.
3-4

Oil Pressure Gage
{CAUTION:
Do not keep driving if the oil pressure is low. If
you do, your engine can become so hot that it
catches fire. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice: Lack of proper engine oil maintenance may

damage the engine. The repairs would not be
United States Canada covered by your warranty. Always follow the
maintenance schedule in this manual for changing
The oil pressure gage shows the engine oil pressure in engine oil.
psi (pounds per square inch) when the engine is
running. Canadian vehicles indicate pressure in
kPa (kilopascals).
Oil pressure may vary under different driving conditions
and oil types. The DURAMAX™ engine may generate
oil pressure in excess of 80 psi (548 kPa) under certain
conditions, especially in cold temperatures. This is a
normal operating range.
3-5

Wait to Start Light Fuel Gage
Your diesel engine has a When the ignition is on,
glow plug system to aid in the fuel gage shows you
starting your vehicle. approximately how
much fuel you have left in
your tank.
An instrument panel wait to start indicator light shows

that the system is functioning properly and tells you
when the engine is ready to be started.
Your vehicle has a fast warm-up glow plug system. The The gage will first indicate E (empty) before you are out
Wait To Start Light will illuminate for a considerably of fuel, but you should get more fuel as soon as
shorter time than most diesel engines due to the rapid possible.
heating of the glow plug system.
For more information, see Starting Your Diesel Engine
on page 2-2.
3-6

Listed are four situations you may experience with your Driver Information Center (DIC)
fuel gage:
• At the gas station, the fuel pump shuts off before The Driver Information Center (DIC) is located on the
the gage reads F (full). instrument panel cluster above the steering wheel. The
DIC comes on when the ignition is on. After a short
• It takes a little more or less fuel to fill up than the delay the DIC will display the current driver and
fuel gage indicated. For example, the gage may the information that was last displayed before the engine
have indicated the tank was half full, but it actually was last turned off.
took a little more or less than half the tank’s
If a problem is detected, a warning message will appear
capacity to fill the tank.
on the display. Pressing the select button on the DIC
• The gage moves a little when you turn a corner or steering wheel buttons, or the trip odometer reset stem
speed up. for vehicles without DIC steering wheel buttons, will
• The gage doesn’t go back to E (empty) when you acknowledge any current warning or service messages.
turn off the ignition. Some messages that your DURAMAX™ diesel may
show are:
None of these indicate a problem with the fuel gage.
For information on how to fill your fuel tank, see Filling ELEVATED IDLE DISABLED
Your Tank on page 5-11. On diesel engines, this message will appear when the
Your vehicle also has a fuel cooler. To clean, elevated idle/exhaust restrictor feature has been
powerwash the bottom of the vehicle. turned off. For more information on the elevated
idle/exhaust restrictor feature, see Starting Your Diesel
Engine on page 2-2.
3-7

ELEVATED IDLE ENABLED WATER IN FUEL
On diesel engines, this message will appear when the This message will come on to warn you if there is water
elevated idle/exhaust restrictor feature has been in the diesel fuel system. For more information on
turned on. For more information on the elevated how this message works, see Diesel Fuel Requirements
idle/exhaust restrictor feature, see Starting Your Diesel and Fuel System on page 5-2.
Engine on page 2-2.
REDUCED ENGINE POWER
A computer monitors the operation of the electric
accelerator. If the REDUCED ENGINE POWER
message comes on while you are driving, the computer
is indicating that your vehicle has a problem. You
should take your vehicle in for service soon.
3-8

Section 5 Service and Appearance Care
Diesel Fuel Requirements and Fuel System .......5-2 Engine Oil Life System ..................................5-19
Diesel Engine Fuel .........................................5-2 Engine Air Cleaner/Filter ................................5-20
What Fuel to Use ...........................................5-2 Automatic Transmission Fluid .........................5-22
Very Cold Weather Operation ...........................5-4 Engine Coolant .............................................5-25
Water in Fuel .................................................5-5 Coolant Surge Tank Pressure Cap ..................5-28
Water in Fuel Light Chart ................................5-6 Engine Overheating .......................................5-28
Running Out of Fuel .......................................5-9 Cooling System ............................................5-30
Fuel Filter Replacement .................................5-10 Capacities and Specifications ..........................5-36
Filling Your Tank ..........................................5-11
Filling a Portable Fuel Container .....................5-13
Checking Things Under the Hood ....................5-14
Engine Compartment Overview .......................5-14
Engine Oil ...................................................5-16
5-1

Diesel Fuel Requirements and • If you ever run out of diesel fuel, it can be
difficult to restart your engine. To avoid all this,
Fuel System never let your tank get empty.
Some states and provinces have restrictions on the If you run out of fuel, Running Out of Fuel on page 5-9
purchase of diesel fuel for light-duty vehicles and require tells you how to restart your engine.
you to buy permits or pay special taxes. Some of
these restrictions apply only to residents, and others What Fuel to Use
apply to both residents and visitors. These restrictions
can change. To learn the current restrictions in any In the United States, for best results use Number 2-D
state or province, contact your auto club, the police or diesel fuel year-round (above and below freezing
other officials. conditions) as oil companies blend Number 2-D fuel to
address climate differences. Number 1-D diesel fuel
Diesel Engine Fuel may be used in very cold temperatures (when it stays
below 0°F or −18°C); however, it will produce a
Notice: Diesel fuel or fuel additives not power and fuel economy loss. Avoid the use of Number
recommended in this manual could damage your 1-D diesel fuel in warm or hot climates. It may result
fuel system and engine. Your warranty would in stalling, poor starting when the engine is hot and may
not cover this damage. And: damage the fuel injection system.
• Diesel fuel that has been mixed with engine oil At a minimum, the diesel fuel you use should meet
or automatic transmission fluid could damage specifications ASTM D975-03 (Grade Low Sulfur) in the
your engine and emission controls. United States. In addition, the Engine Manufacturers
Association (EMA) has identified properties of an
• Aftermarket diesel fuel additives are not tested improved diesel fuel for better engine performance and
by General Motors. Some additives, particularly durability. Diesel fuels corresponding to the EMA
those which contain alcohol or water Recommended Guideline on Premium Diesel Fuel
emulsifiers, may damage your fuel system. (FQP-1A) could provide better starting, less noise and
If you believe that unique circumstances call for better vehicle performance. If there are questions
a fuel additive to be used, consult your dealer about the fuel you are using, contact your fuel supplier.
for advice.
5-2

It is acceptable to use diesel fuel containing up to
5% biodiesel (B5), but the final blended fuel must meet
the same specification, ASTM D975-03 (Grade Low {CAUTION:
Sulfur), as other fuels used in your vehicle, and
the biodiesel used for making this fuel must meet the Heat coming from the engine may cause the
ASTM D6751-03 specification. Biodiesel is produced fuel to expand and force the fuel out of your
from vegetable oils or animal fat that have been
tank. If something ignites the fuel, a fire could
chemically modified to reduce the possibility of damage
to your fuel system and engine. Higher concentration start and people could be burned. To help
(i.e., greater than B5) biodiesel-containing fuels or avoid this, fill your fuel tank only until the
the use of unmodified bio-oils blended into diesel fuel at automatic nozzle shuts off. Do not try to
any concentration is not recommended and could top it off.
damage your fuel system and engine. Such damage
would not be covered by your warranty. If there
are questions about the biodiesel-containing fuels you What Fuel to Use in Canada
are using, contact your fuel supplier.
Canadian fuels are blended for seasonal changes.
Diesel fuel may foam when you fill your tank. This can Diesel Type “A” fuel is blended for better cold weather
cause the automatic pump nozzle to shut off, even starting (below 0°F or −18°C); however, you may
though your tank is not full. If this happens, just wait for notice some power and fuel economy loss. If Type “A”
the foaming to stop and then continue to fill your tank. fuel is used in warmer temperatures, stalling and
hard starting may occur. Diesel Type “B” fuel is blended
for temperatures above 0°F (−18°C). The emission
control system requires the use of diesel fuel with
low-sulfur (0.05% by weight) content. Both low- and
higher-sulfur fuels will be available in Canada.
Only low-sulfur diesel fuels are available in the United
States.
5-3

It is important that diesel-powered trucks are refueled Higher concentration (i.e., greater than B5)
only with low-sulfur fuel. Use of fuels with higher-sulfur biodiesel-containing fuels or the use of unmodified
content will affect the function of the emission bio-oils blended into diesel fuel at any concentration is
components and may cause reduced performance, not recommended and could damage your fuel
excessive smoke and unpleasant odor. system and engine. Such damage would not be covered
by your warranty. If there are questions about the
At a minimum, the diesel fuel you use should meet
biodiesel-containing fuels you are using, contact your
specifications CAN/CGSB-3.517-2000 (Low Sulfur
fuel supplier.
Diesel) in Canada. In addition, the Engine Manufacturers
Association (EMA) has identified properties of an
improved diesel fuel for better engine performance and Very Cold Weather Operation
durability (FQP-1A). Diesel fuels corresponding to
the EMA description could provide better starting, less Follow the instructions listed previously under the
noise and better vehicle performance. If there are heading “What Fuel to Use.”
questions about the fuel you are using, contact your Notice: Never use home heating oil or gasoline in
fuel supplier. your diesel engine. They can cause engine
It is acceptable to use diesel fuel containing up to damage.
5% biodiesel (B5), but the final blended fuel must meet In cold weather, your fuel filter may become
the same specification, CAN/CGSB-3.517-2000 clogged (waxed). To unclog it, move the vehicle to a
(Low Sulfur Diesel) in Canada, as other fuels used in warm garage area and warm the filter to between
your vehicle, and the biodiesel used for making this 32°F and 50°F (0°C to 10°C). You will not need to
fuel must meet the ASTM D6751-03 specification. replace it. Additional information on the fuel filter follows.
Biodiesel is produced from vegetable oils or animal
fat that have been chemically modified to reduce the
possibility of damage to your fuel system and engine.
5-4

Water in Fuel If your fuel tank needs to be purged to remove
water, see your dealer or a qualified technician.
Improper purging can damage your fuel system.
{CAUTION: Sometimes, water can be pumped into your fuel

tank along with your diesel fuel. This can happen if a
service station doesn’t regularly inspect and clean
Diesel fuel containing water is still flammable. its fuel tanks, or if it gets contaminated fuel from its
You could be burned. If you ever try to drain suppliers.
water from your fuel, keep sparks, flames and If this happens, a WATER IN FUEL message will
smoking materials away from the mixture. appear on the Driver Information Center (DIC). If it does,
the water must be drained. Your dealer can show you
how to do this.
Notice: If there is water in your diesel fuel and the
weather is warm or humid, fungus and bacteria
can grow in the fuel. They can damage your
fuel system. A diesel fuel biocide can be used to
sterilize your fuel system. However, your fuel system
may still need to be cleaned. Your dealer can
advise you of the appropriate solution.
5-5

Water in Fuel Light Chart Water In Fuel Light Chart (cont’d)
Problem Recommended Action
If the WATER IN FUEL message comes on, use
this chart. • Immediately after Fuel tank purging
Water In Fuel Light Chart refueling, large required. See your dealer
amount of water for assistance.
Problem Recommended Action
possibly pumped into
Light comes on Drain water from fuel fuel tank.
intermittently. filter.
Light stays on:
Drain fuel filter Notice: If you drive when this warning indicator is
• At temperatures immediately. If no water
above freezing. on, you can damage your fuel injection system
can be drained and light and your engine. If the indicator comes on right after
stays on, see your dealer you refuel, it means water was pumped into your
for assistance. fuel tank. Turn off your engine immediately.
Drain fuel filter Then, have the water drained at once.
immediately. If no water Hard starting, hesitation or flat performance at high
can be drained — water speed or during hard acceleration may be an indication
• At temperatures may be frozen in water of premature fuel filter plugging due to dirty or
below freezing. drain system. Water may contaminated fuel. The filter element may need to be
be frozen in the fuel lines. changed if this happens. See Fuel Filter Replacement
Move the vehicle to a on page 5-10.
warm location to thaw
out, and then drain filter
system.
5-6

To drain water, do the following: 6. Install the fuel cap.
1. Stop and park the vehicle in a safe place. 7. Start the engine and let it run for a few minutes.
Turn off the engine and apply the parking brake. If the engine stalls, the fuel system may need to
2. Remove the fuel cap. be primed. While draining the water from the
fuel filter, air may enter the fuel system. If air has
3. Place a fuel-resistant container under the fuel filter. entered the fuel system the fuel system will need to
The filter drain valve is located in the engine, on the be primed.
passenger’s side of the vehicle, on the bottom of
the fuel filter. If the WATER IN FUEL message comes on again after
driving a short distance or the engine runs rough or
4. Open the drain valve by stalls, a large amount of water has probably been
turning two to three pumped into the fuel tank. The fuel tank should be
turns. When fuel purged.
empties from the valve,
all the water has been
drained. Close the
valve hand tight.
To help remove all the
water, press the priming
pump several times.
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 on
page 5-16.
5-7

Fuel Priming Q: How do I prime the vehicle?
In order for the fuel system to work properly, the fuel A: Your vehicle is equipped with a priming pump
lines must be full of fuel and contain no air. If air which is part of the engine mounted fuel filter.
gets into the fuel lines, it will be necessary to prime the The priming pump is hand operated and is designed
fuel lines, to eliminate air before operating the vehicle. to bring fuel to the engine to eliminate any air
that may be in the fuel lines. To prime the engine,
Q: How does air get into the fuel lines? do the following:
A: One of the following may have happened: 1. You must correct the condition which caused the
loss of prime by making sure there is fuel in the
• The vehicle ran out of fuel tank.
• The fuel filter was removed for servicing or 2. Make sure the fuel filter has been installed and
replacement properly tightened.
• The fuel lines were removed or disconnected for 3. Make sure the fuel lines are properly connected
servicing and the fuel filter is cool enough to touch.
• The fuel filter water drain valve was opened while 4. Remove any dirt from the fuel filter head and vent
the engine was running valve by wiping with a cloth.
If one or more of the above occur, it is very likely that air
has entered your fuel system and that you will need to
prime the fuel system before operating the vehicle. Air in
the fuel lines will not harm the engine or the vehicle.
However, the engine may not be able to start until the
fuel system is primed and the air is removed.
5-8

5. Open the fuel filter vent 7. Operate the priming pump until a small amount of
valve by turning the fuel seeps from the vent valve. When you see the
screw counterclockwise fuel, the filter is now full of fuel and the system
several full turns. should be primed.
The vent valve is 8. Close the vent valve. Clean any fuel which
located on top of the accumulated on the fuel filter. Start the engine and
fuel filter housing. let idle for a few minutes. Check the filter for leaks.
Running Out of Fuel

If the engine stalls and you think that you’ve run out of
fuel, do this to restart your engine:
6. Repeatedly push down {CAUTION:

on the fuel filter priming
pump with the palm
of your hand. The Diesel fuel is flammable. It could start a fire if
pump is located on top it gets on hot engine parts. You could be
of the fuel filter burned. Do not let too much fuel flow from the
housing. Let the pump air bleed valve, and wipe up any spilled fuel
return upward with a cloth.
between pushes.
1. If you’re parked on a level surface, add at least two

gallons of fuel. However, if you’re parked on a slope,
you may need to add up to five gallons of fuel.
2. Follow the fuel priming procedure earlier in this
section to prime the fuel filter.
5-9

3. Close the air bleed valve. The fuel filter is located in the engine compartment on
4. Turn the ignition key to START for 10 to 15 seconds the passenger’s side of the vehicle, or on the driver’s
at a time until your engine starts. If the engine tries side frame rail in front of the fuel tank.
to run, but does not run smoothly, increase the 1. Apply the parking brake.
rpm a little using the accelerator pedal. This will help 2. Unplug the water
force air through the system. sensor wire connected
to the fuel filter and
Fuel Filter Replacement unscrew the filter
element.
If you want to change the fuel filter yourself, here’s how
to do it:
{CAUTION:
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
3. Remove the filter element. If there is any dirt on the
matches or other ignition sources away.
filter sealing surface, clean it off. Remove and
reuse the water sensor float switch located on the
First, drain any water from the filter following the bottom of the fuel filter.
procedure for draining water listed previously. 4. Install the new filter element.
Your vehicle’s engine should be off until the end of this 5. Reinstall and tighten the filter container and
procedure. reconnect the water sensor wire to the filter.
6. Use the fuel filter priming procedure earlier in this
section to prime the fuel filter.
5-10

7. Tighten the air bleed valve by turning it clockwise
until hand tight.
8. Start your engine and let it idle for five minutes.
Check your fuel filter and air bleed valve for leaks.
Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel fire can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your The fuel cap is located behind a hinged door on the
engine when you are refueling. Do not smoke driver’s side of the vehicle.
if you are near fuel or refueling your vehicle. For chassis-cab models, refuel the front tank first,
Keep sparks, flames and smoking materials or in instances when only a partial fuel fill is desired.
away from fuel. Do not leave the fuel pump An automatic transfer mechanism will maintain
unattended when refueling your vehicle — this approximately equal fuel levels in both tanks, so no
is against the law in some places. Keep switching is required by the operator.
children away from the fuel pump; never let
children pump fuel.
5-11

To remove the fuel cap, turn it slowly to the Be careful not to spill diesel fuel. Don’t top off or overfill
left (counterclockwise). your tank, and wait a few seconds after you’ve finished
pumping before you remove the nozzle. Clean fuel from
painted surfaces as soon as possible. See “Cleaning the
{CAUTION: Outside of Your Vehicle” in your owner’s manual. When
you put the fuel cap back on, turn it to the right
(clockwise) until you hear a clicking sound. Make sure
If you spill fuel and then something ignites it, you fully install the cap. The diagnostic system can
you could be badly burned. Fuel can spray out determine if the fuel cap has been left off or improperly
on you if you open the fuel cap too quickly. installed. This would allow fuel to evaporate into the
This spray can happen if your tank is nearly atmosphere. See Malfunction Indicator Lamp on
full, and is more likely in hot weather. Open page 3-3.
the fuel cap slowly and wait for any hiss noise
to stop. Then unscrew the cap all the way.
5-12

Filling a Portable Fuel Container
{CAUTION:
If a fire starts while you are refueling, do not {CAUTION:
remove the nozzle. Shut off the flow of fuel by
shutting off the pump or by notifying the Never fill a portable fuel container while it is in
station attendant. Leave the area immediately. your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
Notice: If you need a new fuel cap, be sure to get damaged if this occurs. To help avoid injury to
the right type. Your dealer can get one for you. you and others:
If you get the wrong type, it may not fit properly.
This may cause your malfunction indicator lamp to • Dispense gasoline only into approved
light and may damage your fuel tank and emissions containers.
system. See Malfunction Indicator Lamp on • Do not fill a container while it is inside a
page 3-3. vehicle, in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
• 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 gasoline.
5-13

Checking Things Under the Hood
Engine Compartment Overview
When you open the hood on the 6.6L DURAMAX™ Diesel Engine, you’ll see:
5-14

A. Engine Air Cleaner/Filter I. Power Steering Fluid Reservoir
B. Coolant Surge Tank J. Remote Negative (−) Terminal
C. Battery K. Remote Positive (+) Terminal
D. Engine Air Cleaner/Filter Restriction Indicator L. Brake Fluid Reservoir
E. Engine Oil Dipstick M. Clutch Fluid Reservoir (If Equipped)
F. Automatic Transmission Dipstick (If Equipped) N. Underhood Fuse Block
G. Engine Oil Fill Cap O. Windshield Washer Fluid Reservoir
H. Engine Fan
5-15

Engine Oil When to Add Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil level every
time you get fuel.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-14 for
the location of the engine oil dipstick.
In order to get an accurate reading, the oil must be If the oil is at or below the cross-hatched area at the tip of
warm (at normal operating temperature) and the vehicle the dipstick, then you will need to add at least two quarts
must be on level ground. of oil. But you must use the right kind. This section
1. Turn off the engine and give the oil at least five explains what kind of oil to use. For engine oil crankcase
minutes to drain back into the oil pan. With a capacity, see Specification Charts on page 5-36.
cool engine, allow 30 minutes. If you do not do this, Notice: Do not add too much oil. If your engine has
the oil dipstick might not show the actual level. so much oil that the oil level gets above the
2. Pull out the dipstick and clean it with a paper towel cross-hatched area that shows the proper operating
or a cloth, then push it back in all the way. Remove range, your engine could be damaged.
it again, keeping the tip down.
5-16

See Engine Compartment What Kind of Engine Oil to Use
Overview on page 5-14 for
the location of the Look for these two things:
engine oil fill cap. • CI-4 or CH-4
Oils designated as API CI-4 or CH-4 are
recommended for your vehicle. The CI-4 or CH-4
designations may appear either alone, together or in
combination with other API designations, such as
API CI-4/SL.
These letters show American Petroleum
Institute (API) levels of quality.
Be sure to add enough oil to put the level somewhere in Notice: Use only engine oils that have one of these
the proper operating range. Push the dipstick all the designations CI-4 or CH-4 for the DURAMAX™ diesel
way back in when you are through. engine. Failure to use the recommended oils can
result in engine damage not covered by your
warranty.
5-17

• SAE 15W-40
As shown in the viscosity chart, SAE 15W-40 is
best for your vehicle. However, you can use
SAE 10W-30 at temperatures above 0°F (−18°C).
When it is very cold, below 0°F (−18°C), you should
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-40 or SAE 20W-50.
This doughnut-shaped
logo (symbol) is used on
most oil containers to
help you select the correct
oil. It means that the oil
has been certified by
the American Petroleum
Institute.
You should look for this on the oil container, and use
only those oils that display this logo.
GM Goodwrench® oil of the recommended viscosity
grades meets all the requirements for your vehicle.
5-18

Engine Oil Additives genuine GM parts and reset the system. It is also
important to check your oil regularly and keep it at the
Do not add anything to your oil. The recommended oils proper level.
with the API service symbol are all you will need for
good performance and engine protection. If the system is ever reset accidentally, you must
change your oil at 3,000 miles (5 000 km) since your
last oil change. Remember to reset the oil life system
Engine Oil Life System whenever the oil is changed.
When to Change Engine Oil How to Reset the Engine Oil Life
Your vehicle has a computer system that lets you know System
when to change the engine oil and filter. This is The Engine Oil Life System calculates when to change
based on engine timing, engine load, and engine your engine oil and filter based on vehicle use.
temperature, and not on mileage. Based on driving Anytime your oil is changed, reset the system so it can
conditions, the mileage at which an engine oil change calculate when the next oil change is required. If a
will be indicated can vary considerably. For the oil situation occurs where you change your oil prior to a
life system to work properly, you must reset the system CHANGE ENGINE OIL message being turned on,
every time the oil is changed. reset the system.
When the system has calculated that oil life has been To reset the Engine Oil Life System, do the following:
diminished, it will indicate that an oil change is
necessary. A CHANGE ENGINE OIL message will 1. Turn the ignition key to RUN with the engine off.
come on. Change your oil as soon as possible within 2. Fully press and release the accelerator pedal three
the next 600 miles (1 000 km). It is possible that, if you times within five seconds.
are driving under the best conditions, the oil life If the OIL LIFE RESET message flashes for
system may not indicate that an oil change is necessary 10 seconds, the system is resetting.
for over a year. However, your engine oil and filter
must be changed at least once a year and at this time 3. Turn the key to LOCK.
the system must be reset. Your dealer has GM-trained
service people who will perform this work using
5-19

If the CHANGE ENGINE OIL message comes back on Engine Air Cleaner/Filter
when you start your vehicle, the engine oil life system
has not reset. Repeat the procedure. If it still does
The air cleaner/filter
not reset, see your dealer for service.
assembly may have an air
What to Do with Used Oil cleaner/filter restriction
indicator that lets you know
Used engine oil contains certain elements that may be when the engine air
unhealthy for your skin and could even cause cancer. cleaner/filter is dirty and
Do not let used oil stay on your skin for very long. Clean needs to be serviced.
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly throw away clothing or
rags containing used engine oil. See the manufacturer’s
warning 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 The air cleaner/filter restriction indicator is
filter before disposal. Never dispose of oil by putting it located on the air cleaner cover.
in the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Instead, recycle it by When to Inspect
taking it to a place that collects used oil. If you have a Inspect the air cleaner/filter every 15,000 miles
problem properly disposing of your used oil, ask (25 000 km) and replace the filter if necessary.
your dealer, a service station or a local recycling center
for help. 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.
5-20

To inspect and replace the filter and reset the
restriction indicator, do the following:
1. Loosen the screws on the cover of the housing and

lift up the cover.
The air cleaner/filter assembly is located on the front 2. Remove the air cleaner/filter from the housing. Care
corner of the engine compartment on the passenger’s should be taken to dislodge as little dirt as possible.
side of the vehicle.
3. Clean the filter sealing surface and the housing.
4. Install the new engine air cleaner/filter.
5. Reinstall the cover and tighten the screws.
6. Reset the air cleaner/filter restriction indicator,
if equipped, by pressing the top button on the
indicator.
5-21

See Scheduled Maintenance on page 6-4 to determine Automatic Transmission Fluid
when to replace the engine air cleaner/filter.
When to Check and Change
{CAUTION: A good time to check your automatic transmission fluid
level is when the engine oil is changed.
Operating the engine with the air cleaner/filter Change both the fluid and filter every 25,000 miles
off can cause you or others to be burned. The (41 500 km) if the vehicle is mainly driven under one or
more of these conditions:
air cleaner not only cleans the air; it helps to
stop flame if the engine backfires. If it is not • In heavy city traffic where the outside temperature
there and the engine backfires, you could be regularly reaches 90°F (32°C) or higher.
burned. Do not drive with it off, and be • In hilly or mountainous terrain.
careful working on the engine with the air
• When doing frequent trailer towing.
cleaner/filter off.
• Uses such as found in taxi, police or delivery
service.
Notice: If the air cleaner/filter is off, a backfire can
If you do not use your vehicle under any of these
cause a damaging engine fire. And, dirt can
conditions, change the fluid and filter every
easily get into your engine, which will damage it.
50,000 miles (83 000 km).
Always have the air cleaner/filter in place when you
are driving. See Scheduled Maintenance on page 6-4.
5-22

How to Check Checking the Fluid Level
Because this operation can be a little difficult, you may Prepare your vehicle as follows:
choose to have this done at the dealership service • Park your vehicle on a level place. Keep the engine
department. running.
If you do it yourself, be sure to follow all the instructions • With the parking brake applied, place the shift lever
here, or you could get a false reading on the dipstick. in PARK (P).
Notice: Too much or too little fluid can damage • With your foot on the brake pedal, run the engine
your transmission. Too much can mean that some for at least one minute and shift to DRIVE (D).
of the fluid could come out and fall on hot engine Then shift to NEUTRAL (N) and then REVERSE (R)
part or exhaust system parts, starting a fire. to fill the hydraulic system. Then, put the shift
Too little fluid could cause the transmission to lever in PARK (P).
overheat. Be sure to get an accurate reading if you
check your transmission fluid. • Allow the engine to run at idle (500 – 800 rpm).
Slowly release the brake pedal.
Wait at least 30 minutes before checking the
transmission fluid level if you have been driving: Then, without shutting off the engine, follow these steps:
• When outside temperatures are above 90°F (32° C). Cold Check Procedure
• At high speed for quite a while. The purpose of the cold check is to determine if the
• In heavy traffic — especially in hot weather. transmission has enough fluid to be operated safely until
a hot check can be made. The fluid level rises as fluid
• While pulling a trailer. 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.
2. Push it back in all the way, wait three seconds and
then pull it back out again.
5-23

3. Check the fluid level reading. Repeat the check 4. Safe operating level is within the HOT RUN band
procedure to verify the reading. on the dipstick. The width of the HOT RUN band
4. If the fluid level is within the COLD CHECK band, represents approximately 1.06 quart (1.0 liter)
the transmission may be operated until the fluid is of fluid at normal operating temperature.
hot enough to perform a hot check. If the fluid 5. If the fluid level is not within the HOT RUN band,
level is not within the COLD CHECK band, add or add or drain fluid as necessary to bring the fluid
drain fluid as necessary to bring the level into level to within the HOT RUN band.
the middle of the COLD CHECK band. 6. If the fluid level is in the acceptable range, push the
5. Perform a hot check at the first opportunity after the dipstick back in all the way.
normal operating temperature of 160°F (71°C) to
200°F (93°C) is reached. Consistency of Readings
6. If the fluid level is in the acceptable range, push the Always check the fluid level at least twice using the
dipstick back in all the way. procedures described previously. Consistency
(repeatable readings) is important to maintaining proper
Hot Check Procedure fluid level. If inconsistent readings persist, check the
The fluid must be hot to ensure an accurate check. The transmission breather to be sure it is clean and
fluid level rises as temperature increases. unclogged. If readings are still inconsistent, contact
your dealer.
1. Operate the transmission in DRIVE (D) until the
normal operating temperature of 160°F (71°C) to
200°F (93°C) 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.
5-24

How to Add Fluid Engine Coolant
Refer to the Maintenance Schedule to determine what The cooling system in your vehicle is filled with
kind of transmission fluid to use. See Recommended DEX-COOL® engine coolant. This coolant is designed
Fluids and Lubricants on page 6-13. to remain in your vehicle for 5 years or 150,000 miles
Add fluid only after checking the transmission fluid while (240 000 km), whichever occurs first, if you add
it is hot. A cold check is used only as a reference. only DEX-COOL® extended life coolant.
If the fluid level is low, add only enough of the proper The following explains your cooling system and how to
fluid to bring the level up to the HOT area for a hot add coolant when it is low. If you have a problem
check. It doesn’t take much fluid, generally less than with engine overheating, see Engine Overheating on
one pint (0.5 L). Don’t overfill. page 5-28.
Notice: We recommend you use only fluid labeled A 50/50 mixture of clean, drinkable water and
DEXRON®-III, Approved for the H-Specification, DEX-COOL® coolant will:
because fluid with that label is made especially for
• Give freezing protection down to −34°F (−37°C)
your automatic transmission. Damage caused
by fluid other than DEXRON®-III, Approved for the • Give boiling protection up to 265°F (129°C)
H-Specification, is not covered by your new vehicle
warranty.
• Protect against rust and corrosion
• After adding fluid, recheck the fluid level as • Help keep the proper engine temperature
described under “How to Check.″ • Let the warning lights and gages work as they should
• When the correct fluid level is obtained, push the Notice: Using coolant other than DEX-COOL® may
dipstick back in all the way. cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs first. Any repairs
would not be covered by your warranty. Always use
DEX-COOL® (silicate-free) coolant in your vehicle.
5-25

What to Use Notice: If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
Use a mixture of one-half clean, drinkable water and The repair cost would not be covered by your
one-half DEX-COOL® coolant which won’t damage warranty. Too much water in the mixture can freeze
aluminum parts. If you use this coolant mixture, and crack the engine, radiator, heater core and
you don’t need to add anything else. other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
{CAUTION:
Notice: If you use the proper coolant, you do not
have to add extra inhibitors or additives which claim
Adding only plain water to your cooling to improve the system. These can be harmful.
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch fire and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL® coolant.
5-26

Checking Coolant The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the FULL
The coolant surge tank is COLD mark.
located in the engine If your vehicle is equipped with a low coolant sensor,
compartment on the and the LOW COOLANT LEVEL message comes
passenger’s side of the on and stays on, it means you’re low on engine coolant.
vehicle. See Engine
Compartment Overview on See “DIC Warnings and Messages” in the Index of
page 5-14 for more your owner’s manual for more information.
information on its location.
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap — even a little — when the engine and
radiator are hot.
5-27

Adding Coolant Coolant Surge Tank Pressure Cap
®
If you need more coolant, add the proper DEX-COOL
coolant mixture at the surge tank, but only when the The surge tank pressure
engine is cool. If the surge tank is empty, see Engine cap must be tightly
Overheating on page 5-28 for the proper fill procedure. installed.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
Notice: If the pressure cap is not tightly installed,
coolant loss and possible engine damage may
When replacing the pressure cap, make sure it is
occur. Be sure the cap is properly and tightly
hand-tight.
secured.
Engine Overheating
You will find a coolant temperature gage on the
instrument cluster. In addition, the Driver Information
Center (DIC) has the following warnings that may
appear: LOW COOLANT LEVEL and ENGINE
OVERHEATED. See your owner’s manual for more
information.
5-28

If Steam Is Coming From Your Engine If No Steam Is Coming From Your
Engine
{CAUTION: An overheat warning, along with a low coolant condition,
or LOW COOLANT LEVEL message, if equipped, can
indicate a serious problem. For more information, see
Steam from an overheated engine can burn “Driver Information Center (DIC)” in your owner’s manual.
you badly, even if you just open the hood. Stay If you get an engine overheat warning and don’t have a
away from the engine if you see or hear steam low coolant condition, or LOW COOLANT LEVEL
coming from it. Just turn it off and get message, if equipped, but see or hear no steam, the
everyone away from the vehicle until it cools problem may not be too serious. Sometimes the engine
down. Wait until there is no sign of steam or can get a little too hot when you:
coolant before you open the hood. • Climb a long hill on a hot day.
If you keep driving when your engine is • Stop after high-speed driving.
overheated, the liquids in it can catch fire. You
or others could be badly burned. Stop your • Idle for long periods in traffic.
engine if it overheats, and get out of the • Tow a trailer. See “Driving on Grades” in the
vehicle until the engine is cool. owner’s manual index.
Notice: If your engine catches fire because you

keep driving with no coolant, your vehicle can
be badly damaged. The costly repairs would not be
covered by your warranty.
5-29

If you get the overheat warning with no sign of steam, Cooling System
try this for a minute or so:
1. In heavy traffic, let the engine idle in NEUTRAL (N) When you decide it’s safe to lift the hood, here’s what
while stopped. If it is safe to do so, pull off the road, you’ll see:
shift to PARK or NEUTRAL (N), and let the
engine idle.
2. If your air conditioner is on, turn it off.
3. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn’t come back on, you can drive
normally.
If the warning continues, pull over, stop, and park your
vehicle right away.
If there’s still no sign of steam and your vehicle is
equipped with an engine driven cooling fan, push down
the accelerator until the engine speed is about twice A. Coolant Surge Tank
as fast as normal idle speed for at least three minutes
B. Coolant Surge Tank Pressure Cap
while you’re parked. If there is no sign of steam and
your vehicle is equipped with an electric cooling fan, idle C. Engine Fan
the engine for three minutes while you’re parked. If If the coolant inside the coolant surge tank is boiling,
you still have the warning, turn off the engine and get don’t do anything else until it cools down. The vehicle
everyone out of the vehicle until it cools down. should be parked on a level surface.
You may decide not to lift the hood but to get service
help right away.
5-30

The coolant level should If there seems to be no leak, start the engine again.
be at or above the FULL If your vehicle is equipped with an engine driven cooling
COLD mark. If it isn’t, fan, the engine cooling fan speed should increase
you may have a leak at the when idle speed is doubled by pushing the accelerator
pressure cap or in the pedal down. If it doesn’t, your vehicle needs service.
radiator hoses, heater Turn off the engine.
hoses, radiator, water
pump or somewhere else Notice: Engine damage from running your engine
in the cooling system. without coolant is not covered by your warranty.
Notice: Using coolant other than DEX-COOL® may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs first. Any repairs
would not be covered by your warranty. Always use
DEX-COOL® (silicate-free) coolant in your vehicle.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine fire, and you could be
burned. Get any leak fixed before you drive the
vehicle.
5-31

How to Add Coolant to the Coolant If no coolant is visible in the surge tank, add coolant as
follows:
Surge Tank
Notice: The diesel engine has a specific coolant fill
procedure. Failure to follow this procedure could {CAUTION:
cause your engine to overheat and be severely
damaged. Steam and scalding liquids from a hot cooling
If you haven’t found a problem yet, check to see if system can blow out and burn you badly. They
coolant is visible in the surge tank. If coolant is visible are under pressure, and if you turn the coolant
but the coolant level isn’t at or above the FULL surge tank pressure cap — even a little — they
COLD mark, add a 50/50 mixture of clean, drinkable can come out at high speed. Never turn the
water and DEX-COOL® coolant at the coolant cap when the cooling system, including the
surge tank, but be sure the cooling system, including
coolant surge tank pressure cap, is hot. Wait
the coolant surge tank pressure cap, is cool before you
do it. See Engine Coolant on page 5-25 for more for the cooling system and coolant surge tank
information. pressure cap to cool if you ever have to turn
the pressure cap.
5-32

{CAUTION: {CAUTION:
Adding only plain water to your cooling You can be burned if you spill coolant on hot
system can be dangerous. Plain water, or engine parts. Coolant contains ethylene glycol
some other liquid such as alcohol, can boil and it will burn if the engine parts are hot
before the proper coolant mixture will. Your enough. Do not spill coolant on a hot engine.
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot Park the vehicle on a level
but you would not get the overheat warning. surface. You can remove
Your engine could catch fire and you or others the coolant surge tank
could be burned. Use a 50/50 mixture of clean, pressure cap when
the cooling system,
drinkable water and DEX-COOL® coolant.
including the coolant surge
tank pressure cap and
Notice: In cold weather, water can freeze and crack upper radiator hose, is no
the engine, radiator, heater core and other parts. longer hot.
Use the recommended coolant and the proper
coolant mixture.
1. Turn the pressure cap slowly counterclockwise (left)

until it first stops. Don’t press down while turning the
pressure cap. If you hear a hiss, wait for that to stop.
A hiss means there is still some pressure left.
2. Then keep turning the cap, but now push down as
you turn it. Remove the pressure cap.
5-33

3. After the engine cools, open the air bleed valve on 6. Then fill the coolant surge tank with the proper
the thermostat housing. mixture, to slightly above the fill mark.
Fill with the proper mixture. Add coolant until you
see a steady stream of coolant coming from
the bleed valve.
4. Close the bleed valve.
5. Rinse or wipe the spilled coolant from the engine
and compartment.
5-34

7. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fan.
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 the level reaches the FULL COLD mark.
8. Then replace the pressure cap.
5-35

Capacities and Specifications
Engine Specification
Engine VIN Code Type
6.6L V8 Turbo Diesel 2 V8
Capacities
Capacities
Application English Metric
Cooling System 24.0 quarts 23.0 L
Automatic Transmission
24.0 quarts 23.0 L
Manual Transmission
Engine Oil With Filter 10.0 quarts 9.5 L
6.6L V8
All quantities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling. See Recommended Fluids and Lubricants on page 6-13 for more
information.
5-36

Section 6 Maintenance Schedule
Maintenance Schedule ......................................6-2 Owner Checks and Services ..........................6-10
Introduction ...................................................6-2 At Each Fuel Fill ..........................................6-10
Maintenance Requirements ..............................6-2 At Least Once a Month .................................6-10
Your Vehicle and the Environment ....................6-2 At Least Once a Year ...................................6-11
Using Your Maintenance Schedule ....................6-2 Recommended Fluids and Lubricants ...............6-13
Scheduled Maintenance ...................................6-4 Normal Maintenance Replacement Parts ..........6-16
Additional Required Services ............................6-6 Maintenance Record .....................................6-17
Maintenance Footnotes ...................................6-8
6-1

Maintenance Schedule Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
Introduction vehicle in good working condition, but also helps the
environment. All recommended maintenance is
Important: Keep engine oil at the proper level and important. Improper vehicle maintenance can even
change as recommended. affect the quality of the air we breathe. Improper fluid
levels or the wrong tire inflation can increase the level of
emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good condition,
be sure to maintain your vehicle properly.
Using Your Maintenance Schedule

We at General Motors want to help you keep your
Have you purchased the GM Protection Plan? The Plan vehicle in good working condition. But we do not know
supplements your new vehicle warranties. See your exactly how you will drive it. You may drive very
Warranty and Owner Assistance booklet or your dealer short distances only a few times a week. Or you may
for details. drive long distances all the time in very hot, dusty
weather. You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in many
Maintenance Requirements other ways.
Notice: Maintenance intervals, checks, inspections, Because of all the different ways people use their
replacement parts and recommended fluids and vehicles, maintenance needs vary. You may need more
lubricants as prescribed in this manual are frequent checks and replacements. So please read
necessary to keep your vehicle in good working the following and note how you drive. If you have any
condition. Any damage caused by failure to follow questions on how to keep your vehicle in good condition,
scheduled maintenance may not be covered by see your GM Goodwrench® dealer.
warranty.
6-2

This schedule is for vehicles that:
• carry passengers and cargo within recommended {CAUTION:
limits. You will find these limits on the tire and
loading information label. See “Loading Your
Vehicle” in your owner manual. Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you
• are driven on reasonable road surfaces within legal
can be seriously injured. Do your own
driving limits.
maintenance work only if you have the
• are driven off-road in the recommended manner. required know-how and the proper tools and
See “Off-Road Driving” or “Off-Road Driving with equipment for the job. If you have any doubt,
Your Four-Wheel-Drive Vehicle” in your owner see your GM Goodwrench® dealer to have a
manual.
qualified technician do the work.
• use the recommended fuel. See Diesel Engine Fuel
on page 5-2.
Some maintenance services can be complex. So,
The services in Scheduled Maintenance on page 6-4 unless you are technically qualified and have the
should be performed when indicated. See Additional necessary equipment, you should have your GM
Required Services on page 6-6 and Maintenance Goodwrench® dealer do these jobs.
Footnotes on page 6-8 for further information.
When you go to your GM Goodwrench® dealer for your
service needs, you will know that GM-trained and
supported service technicians will perform the work
using genuine GM parts.
If you want to purchase service information, see
“Service Publications Ordering Information” in your
owner manual.
6-3

Owner Checks and Services on page 6-10 tells you If the engine oil life system is ever reset accidentally,
what should be checked, when to check it and what you you must service your vehicle within 3,000 miles
can easily do to help keep your vehicle in good (5 000 km) since your last service. Remember to reset
condition. the oil life system whenever the oil is changed. See
Engine Oil Life System on page 5-19 for information on
The proper replacement parts, fluids and lubricants to
the Engine Oil Life System and resetting the system.
use are listed in Recommended Fluids and Lubricants
on page 6-13 and Normal Maintenance Replacement When the CHANGE ENGINE OIL message appears,
Parts on page 6-16. When your vehicle is serviced, certain services, checks and inspections are required.
make sure these are used. All parts should be replaced Required services are described in the following for
and all necessary repairs done before you or anyone “Maintenance I” and “Maintenance II.” Generally,
else drives the vehicle. We recommend the use of it is recommended that your first service be
genuine GM parts. Maintenance I, your second service be Maintenance II
and that you alternate Maintenance I and Maintenance II
thereafter. However, in some cases, Maintenance II
Scheduled Maintenance may be required more often.
When the CHANGE ENGINE OIL message comes on, it Maintenance I — Use Maintenance I if the CHANGE
means that service is required for your vehicle. Have ENGINE OIL message comes on within 10 months since
your vehicle serviced as soon as possible within the next the vehicle was purchased or Maintenance II was
600 miles (1 000 km). It is possible that, if you are performed.
driving under the best conditions, the engine oil
life system may not indicate that vehicle service is Maintenance II — Use Maintenance II if the previous
necessary for over a year. However, your engine oil and service performed was Maintenance I. Always use
filter must be changed at least once a year and at Maintenance II whenever the message comes on
this time the system must be reset. Your GM 10 months or more since the last service or if the
Goodwrench® dealer has GM-trained service technicians message has not come on at all for one year.
who will perform this work using genuine GM parts
and reset the system.
6-4

Scheduled Maintenance
Service Maintenance I Maintenance II
Change engine oil and filter. See Engine Oil on page 5-16. Reset oil life
system. See Engine Oil Life System on page 5-19. An Emission Control
Service. • •
Allison transmission only: Replace external control-main filter only at the first
maintenance service performed on the vehicle.
Lubricate chassis components. See footnote #. • •
Visually check for any leaks or damage. See footnote (j). • •
Inspect engine air cleaner filter change indicator. If necessary, replace filter.
See Engine Air Cleaner/Filter on page 5-20. An Emission Control Service. •
See footnotes † and (n).
Rotate tires and check inflation pressures and wear. See “Tires” in your
• •
owner’s manual.
Inspect brake system. See footnote (a). • •
Check engine coolant and windshield washer fluid levels and add fluid as
• •
needed.
Perform any needed additional services. See “Additional Required Services” in
• •
this section.
Inspect suspension and steering components. See footnote (b). •
Inspect engine cooling system. See footnote (c). •
Inspect wiper blades. See footnote (d). •
Inspect restraint system components. See footnote (e). •
6-5

Scheduled Maintenance (cont’d)
Service Maintenance I Maintenance II
Lubricate body components. See footnote (f). •
Check transmission fluid level and add fluid as needed. •
Replace fuel filter. An Emission Control Service. See footnote †. •
Inspect shields and underhood insulation. See footnote (h). •
Check air intake system. See footnote (k). •
Additional Required Services

The following services should be performed at the first maintenance service (I or II) after the indicated
miles (kilometers) shown for each item.
Additional Required Services
25,000 50,000 75,000 100,000 125,000 150,000
Service and Miles (Kilometers) (41 500) (83 000) (125 000) (166 000) (207 500) (240 000)
Inspect fuel system for damage
• • • • • •
or leaks.
Inspect exhaust system for loose
• • • • • •
or damaged components.
6-speed manual transmission
only: Change clutch fluid. See • • • • • •
footnote (l).
6-6

Additional Required Services (cont’d)
25,000 50,000 75,000 100,000 125,000 150,000
Service and Miles (Kilometers) (41 500) (83 000) (125 000) (166 000) (207 500) (240 000)
Change automatic transmission
fluid and filter (severe service). See • • • • • •
footnote (m).
Change automatic transmission
• • •
fluid and filter (normal service).
Four-wheel drive with automatic
transfer case only: Change transfer • • •
case fluid. See footnote (g).
Engine cooling system service (or
every 5 years, whichever occurs
•
first). An Emission Control Service.
See footnote (i).
Inspect engine accessory drive belt.
•
An Emission Control Service.
5-speed manual transmission only:
•
Change manual transmission fluid.
6-7

Maintenance Footnotes (c) Visually inspect hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
† The U.S. Environmental Protection Agency or the fittings and clamps; replace with genuine GM parts as
California Air Resources Board has determined that the needed. To help ensure proper operation, a pressure test
failure to perform this maintenance item will not nullify of the cooling system and pressure cap and cleaning the
the emission warranty or limit recall liability prior to outside of the radiator and air conditioning condenser is
the completion of the vehicle’s useful life. We, however, recommended at least once a year.
urge that all recommended maintenance services be (d) Visually inspect wiper blades for wear or cracking.
performed at the indicated intervals and the Replace blade inserts that appear worn or damaged
maintenance be recorded. or that streak or miss areas of the windshield.
# Lubricate the front suspension, ball joints, steering (e) Make sure the safety belt reminder light and all your
linkage, transmission shift linkage and parking belts, buckles, latch plates, retractors and anchorages
brake cable guides. Ball joints should not be lubricated are working properly. Look for any other loose or
unless their temperature is 10°F (-12°C) or higher, damaged safety belt system parts. If you see anything
or they could be damaged. Vehicles used under severe that might keep a safety belt system from doing its
commercial operating conditions require lubrication job, have it repaired. Have any torn or frayed safety belts
on a regular basis every 3,000 miles (5 000 km). replaced. Also look for any opened or broken airbag
(a) Visually inspect brake lines and hoses for proper coverings, and have them repaired or replaced.
hook-up, binding, leaks, cracks, chafing, etc. Inspect (The airbag system does not need regular maintenance.)
disc brake pads for wear and rotors for surface (f) Lubricate all key lock cylinders, body door hinges,
condition. Inspect other brake parts, including calipers, hood latch assembly, secondary latch, pivots, spring
parking brake, etc. anchor, release pawl, tailgate hinges, tailgate linkage,
(b) Visually inspect front and rear suspension and tailgate handle pivot points, latch bolt, fuel door
steering system for damaged, loose or missing parts, hinge, locks and folding seat hardware. More frequent
signs of wear or lack of lubrication. Inspect power lubrication may be required when exposed to a corrosive
steering lines and hoses for proper hook-up, binding, environment. Applying silicone grease on weatherstrips
leaks, cracks, chafing, etc. Visually check constant with a clean cloth will make them last longer, seal
velocity joints, rubber boots and axle seals for leaks. better and not stick or squeak.
6-8

(g) Check vent hose at transfer case for kinks and (l) Change clutch fluid (or every 24 months, whichever
proper installation. occurs first).
(h) Inspect shields and underhood insulation for damage (m) Change automatic transmission fluid and filter if the
or looseness. Adjust or replace as required. This is a vehicle is mainly driven under one or more of these
Noise Emission Control Service. Applicable only to conditions:
vehicles sold in the United States. − In heavy city traffic where the outside temperature
(i) Drain, flush and refill cooling system. This service regularly reaches 90°F (32°C) or higher.
can be complex; you should have your dealer perform − In hilly or mountainous terrain.
this service. See Engine Coolant on page 5-25 for − When doing frequent trailer towing.
what to use. Inspect hoses. Clean radiator, condenser,
pressure cap and filler neck. Pressure test the cooling − Uses such as found in taxi, police or delivery
system and pressure cap. service.
(j) A fluid loss in any vehicle system could indicate a (n) If you drive regularly under dusty conditions, inspect
problem. Have the system inspected and repaired and the filter change indicator at each engine oil change.
the fluid level checked. Add fluid if needed.
(k) 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 only to vehicles sold in the United States.
6-9

Owner Checks and Services Engine Coolant Level Check
These owner checks and services should be performed Check the engine coolant level and add
at the intervals specified to help ensure the safety, DEX-COOL® coolant mixture if necessary.
dependability and emission control performance of your See Engine Coolant on page 5-25 for further details.
vehicle. Your GM Goodwrench® dealer can assist Windshield Washer Fluid Level Check
you with these checks and services.
Check the windshield washer fluid level in the windshield
Be sure any necessary repairs are completed at once. washer tank and add the proper fluid if necessary.
Whenever any fluids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Recommended Fluids and Lubricants on page 6-13. At Least Once a Month
Tire Inflation Check
At Each Fuel Fill
Visually inspect your tires and make sure tires are
It is important to perform these underhood checks at inflated to the correct pressures. Do not forget to check
each fuel fill. your spare tire. See “Tires” in your owner manual for
further details. Check to make sure the spare tire
Engine Oil Level Check is stored securely. Push, pull and then try to turn the
Check the engine oil level and add the proper oil if spare tire. If it moves, tighten it. See “Changing a
necessary. See Engine Oil on page 5-16 for further Flat Tire” in your owner manual.
details.
Notice: It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
6-10

At Least Once a Year Automatic Transmission Shift Lock
Control System Check
Starter Switch Check
{CAUTION:
{CAUTION:
When you are doing this inspection, the
When you are doing this inspection, the vehicle could move suddenly. If the vehicle
vehicle could move suddenly. If the vehicle moves, you or others could be injured.
moves, you or others could be injured.
1. Before you start, be sure you have enough room
1. Before you start, be sure you have enough room around the vehicle. It should be parked on a level
around the vehicle. surface.
2. Firmly apply both the parking brake and the regular 2. Firmly apply the parking brake. See “Parking Brake”
brake. See “Parking Brake” in your owner manual, if in your owner manual, if necessary.
necessary. Be ready to apply the regular brake immediately if
Do not use the accelerator pedal, and be ready to the vehicle begins to move.
turn off the engine immediately if it starts. 3. With the engine off, turn the ignition to RUN, but do
3. Try to start the engine in each gear. The starter not start the engine. Without applying the regular
should work only in PARK (P) or NEUTRAL (N). brake, try to move the shift lever out of PARK (P)
If the starter works in any other position, contact with normal effort. If the shift lever moves out
your GM Goodwrench® dealer for service. of PARK (P), contact your GM Goodwrench® dealer
for service.
6-11

Ignition Transmission Lock Check Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake,
While parked, and with the parking brake set, try to set the parking brake.
turn the ignition to LOCK in each shift lever position.
• To check the parking brake’s holding ability:
• The ignition should turn to LOCK only when With the engine running and transmission in
the shift lever is in PARK (P). NEUTRAL (N), slowly remove foot pressure from
• The key should come out only in LOCK. the regular brake pedal. Do this until the vehicle is
held by the parking brake only.
Contact your GM Goodwrench® dealer if service is
required. • To check the PARK (P) mechanism’s holding
ability: With the engine running, shift to PARK (P).
Parking Brake and Automatic Then release the parking brake followed by the
Transmission Park (P) Mechanism Check regular brake.
Contact your GM Goodwrench® dealer if service is
required.
{CAUTION: Underbody Flushing Service
When you are doing this check, your vehicle At least every spring, use plain water to flush any
could begin to move. You or others could be corrosive materials from the underbody. Take care to
injured and property could be damaged. Make clean thoroughly any areas where mud and other debris
can collect.
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.
6-12

Recommended Fluids and Usage Fluid/Lubricant
Lubricants Hydraulic Brake
System
Delco Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Fluids and lubricants identified below by name, part Windshield
Washer Solvent GM Optikleen® Washer Solvent.
number or specification may be obtained from your
dealer. Hydraulic Hydraulic Clutch Fluid
Usage Fluid/Lubricant Clutch System (GM Part No. U.S. 12345347, in
(5-Speed Canada 10953517) or equivalent
Engine oils with the letters CI-4 or Trans.) DOT-3 brake fluid.
CH-4 are best for your vehicle. The
CI-4 or CH-4 designation may Hydraulic Hydraulic Clutch Fluid. Use only
appear either alone, or in Clutch System GM Part No. U.S. 88958860,
combination with other API (6-Speed in Canada 88901244, Super DOT-4
designations, such as API CI-4/SL. Trans.) brake fluid.
Engine Oil
(Diesel Engine) These letters show American Power Steering GM Power Steering Fluid
(GM Part No. U.S. 89021184, in
Petroleum Institute (API) levels of System
quality. GM Goodwrench® oil meets Canada 89021186).
all the requirements for your vehicle. Manual GM Goodwrench® Synthetic Manual
To determine the preferred viscosity Transmission Transmission Fluid
for your vehicle’s diesel engine, see (5-Speed with (GM Part No. U.S. 12346190, in
Engine Oil on page 5-16. Low Gear, Canada 10953477) or equivalent
50/50 mixture of clean, drinkable RPO MW3) SAE 75W-85 GL-4 gear oil.
water and use only
Engine Coolant DEX-COOL® Coolant. See Engine
Coolant on page 5-25.
6-13

Usage Fluid/Lubricant Usage Fluid/Lubricant
Manual Chassis Lubricant
Transmission (GM Part No. U.S. 12377985, in
Synchromesh Transmission Fluid Chassis
(5-Speed (GM Part No. U.S. 12345349, in Lubrication Canada 88901242) or lubricant
without Low meeting requirements of NLGI #2,
Gear, Canada 10953465). Category LB or GC-LB.
RPO MG5) SAE 80W-90 Axle Lubricant
Synthetic Transmission Front Axle (GM Part No. U.S. 1052271, in
Manual Fluid approved to Allison Canada 10950849).
Transmission Transmission® specification TES-295 SAE 75W-90 Synthetic Axle
(6-Speed) (GM Part No. U.S. 12378515, in Lubricant
Canada 88900701). Rear Axle (GM Part No. U.S. 12378261, in
DEXRON®-III Automatic Canada 10953455) meeting GM
Automatic Transmission Fluid. Look for Specification 9986115.
Transmission “Approved for the H-Specification” on DEXRON®-III Automatic
the label. Manual Transmission Fluid. Look for
Key Lock Multi-Purpose Lubricant, Superlube Transfer Case “Approved for the H-Specification”
(GM Part No. U.S. 12346241, in on the label.
Cylinders Canada 10953474).
Automatic AUTO-TRAK II Fluid
Lubriplate Lubricant Aerosol (GM Part No. U.S. 12378508, in
(GM Part No. U.S. 12346293, Transfer Case Canada 10953626).
Floor Shift
Linkage in Canada 992723) or lubricant
meeting requirements of NLGI #2
Category LB or GC-LB.
6-14

Usage Fluid/Lubricant Usage Fluid/Lubricant
Front Axle Body Door
Propshaft Hinge Pins,
Spline or Spline Lubricant, Special Lubricant Tailgate Hinge Multi-Purpose Lubricant, Superlube
One-Piece (GM Part No. U.S. 12345879, in and Linkage, (GM Part No. U.S. 12346241, in
Propshaft Canada 10953511) or lubricant Folding Seats Canada 10953474).
Spline meeting requirements of and Fuel
(Two-Wheel GM 9985830. Door Hinge
Drive with Auto. Tailgate Handle
Trans.) Pivot Points, Multi-Purpose Lubricant, Superlube
Chassis Lubricant Hinges, latch (GM Part No. U.S. 12346241, in
Rear Driveline (GM Part No. U.S. 12377985, in Bolt and Canada 10953474).
Canada 88901242) or lubricant Linkage
Center Spline meeting requirements of NLGI #2, Dielectric Silicone Grease
Category LB or GC-LB. Weatherstrip (GM Part No. U.S. 12345579, in
Conditioning
Multi-Purpose Lubricant, Superlube Canada 992887).
Hood Hinges (GM Part No. U.S. 12346241, in Synthetic Grease with Teflon,
Canada 10953474). Weatherstrip Superlube (GM Part No. U.S.
Squeaks 12371287, in Canada 10953437).
6-15

Normal 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
Oil Filter 88917036 PF2232
Engine Air Cleaner/Filter 25332443 A1618C
Fuel Filter 97382952 —
Use only the specified filters.
6-16

Maintenance Record
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. See Maintenance Requirements on page 6-2 in this section.
Any additional information from Owner Checks and Services on page 6-10 can be added on the following record
pages. Also, you should retain all maintenance receipts.
Maintenance Record
Odometer Maintenance I or
Date Serviced By Services Performed
Reading Maintenance II
6-17

Maintenance Record (cont’d)
6-18

6-19

6-20

A D
Automatic Transmission, Fluid ........................... 5-22 Diesel
Engine Fuel .................................................. 5-2
Filling a Portable Fuel Container .................... 5-13
C Filling Your Tank .......................................... 5-11
Fuel Requirements and Fuel System ................ 5-2
Canadian Owners ................................................ ii
Running Out of Fuel ...................................... 5-9
Capacities and Specifications
Very Cold Weather Operation .......................... 5-4
Specification Charts ..................................... 5-36
Water in Fuel ............................................... 5-5
Coolant
Water in Fuel Light Chart ............................... 5-6
Engine ....................................................... 5-25
What Fuel to Use .......................................... 5-2
Surge Tank Pressure Cap ............................. 5-28
Driver Information Center (DIC) .......................... 3-7
Cooling System .............................................. 5-30

E G
Engine Gage
Air Cleaner/Filter ......................................... 5-20 Fuel ............................................................ 3-6
Compartment Overview ................................ 5-14 Oil Pressure ................................................. 3-5
Coolant ...................................................... 5-25
Oil ............................................................. 5-16
Overheating ................................................ 5-28
Engine Coolant Heater ...................................... 2-7
I
Instrument Panel Cluster ................................... 3-2
F L
Fuel
Lights
At Each Fuel Fill ......................................... 6-10
Malfunction Indicator Lamp ............................. 3-3
Diesel Engine ............................................... 5-2
Wait to Start ................................................. 3-6
Diesel Requirements and Fuel System ............. 5-2
Water in Fuel Light Chart ............................... 5-6
Filling a Portable Fuel Container .................... 5-13
Filling Your Tank .......................................... 5-11
Filter Replacement ....................................... 5-10
Gage ........................................................... 3-6
Running Out of ............................................. 5-9
What to Use ................................................. 5-2

M O
Maintenance Schedule Oil, Engine ..................................................... 5-16
At Each Fuel Fill ......................................... 6-10 Oil Pressure Gage ............................................ 3-5
At Least Once a Month ................................ 6-10 Overheating, Engine ........................................ 5-28
At Least Once a Year .................................. 6-11 Owners, Canadian ............................................... ii
Introduction .................................................. 6-2
Maintenance Requirements ............................. 6-2
Scheduled Maintenance ................................. 6-4
Using Your ................................................... 6-2
R
Running Out of Fuel ......................................... 5-9
Your Vehicle and the Environment ................... 6-2
Malfunction Indicator Lamp ................................ 3-3

S W
Scheduled Maintenance ..................................... 6-4 Wait to Start Light ............................................ 3-6
Specification Charts ......................................... 5-36 Water in Fuel ................................................... 5-5
Starting Your Diesel Engine ................................ 2-2 Water in Fuel Light Chart .................................. 5-6
Surge Tank Pressure Cap, Coolant .................... 5-28 Winter Cover ................................................... 2-5
T
Transmission, Automatic Fluid ........................... 5-22

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2005 DURAMAX™ Diesel Engine M

Features and Controls ..................................... 2-1 Maintenance Schedule ..................................... 6-1

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United States Version shown, Canada similar.

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This system is called OBD II (On-Board

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Notice: Lack of proper engine oil maintenance may

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An instrument panel wait to start indicator light shows

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{CAUTION: Sometimes, water can be pumped into your fuel

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5. Remove the fuel-resistant container and properly

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Running Out of Fuel

6. Repeatedly push down {CAUTION:

1. If you’re parked on a level surface, add at least two

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Filling Your Tank

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

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