2016 Chevrolet Colorado Owners Manual

Equipped).

ii

ii

or (If

8. Windshield Washer Fluid

Reservoir. See Washer Fluid 0 276

ii

9. Battery - North America 0 279

ii

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3.6L V6 Engine

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265

1. Coolant Surge Tank and

Pressure Cap. See Engine Coolant 0 272

ii

2. Engine Air Cleaner/Filter

0 269

ii

3. Engine Cooling Fan (Out of View). See Cooling System 0 271

ii

4. Engine Oil Fill Cap. See

Engine Oil 0 265

ii

5. Engine Oil Dipstick. See

Engine Oil 0 265

ii

6. Engine Compartment Fuse

Block 0 288

ii

7. Brake Fluid Reservoir. See

Brake Fluid 0 278

ii

8. Windshield Washer Fluid

Reservoir. See Washer Fluid 0 276

ii

9. Battery - North America 0 279
If the vehicle has a diesel engine, see the Duramax diesel supplement.

ii

Engine Oil For diesel engine vehicles, see “Engine Oil” in the Duramax diesel supplement. To ensure proper engine performance and long life, careful attention must be paid to engine oil. Following these simple, but important steps will help protect your investment: . Use engine oil approved to the proper specification and of the proper viscosity grade. See “Selecting the Right Engine Oil” in this section.

. Check the engine oil level regularly and maintain the proper oil level. See “Checking Engine Oil” and “When to Add Engine Oil” in this section.

. Change the engine oil at the

appropriate time. See Engine Oil Life System 0 267

ii

. Always dispose of engine oil

properly. See “What to Do with Used Oil” in this section.

Checking Engine Oil It is a good idea to check the engine oil level at each fuel fill. In order to get an accurate reading, the vehicle must be on level ground. The engine oil dipstick handle is a yellow loop. See Engine Compartment Overview 0 262
the engine oil dipstick. Obtaining an accurate oil level reading is essential: 1.

for the location of

ii

If the engine has been running recently, turn off the engine and allow several minutes for the oil to drain back into the oil pan. Checking the oil level too soon after engine shutoff will not provide an accurate oil level reading.

2. Pull out the dipstick and wipe it

with a clean paper towel or cloth, then push it back in all the way. Remove it again, keeping the tip down, and check the level.

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When to Add Engine Oil

2.5L L4 Engine

3.6L V6 Engine

If the oil is below the cross-hatched area at the tip of the dipstick, add 1 L (1 qt) of the recommended oil and then recheck the level. See “Selecting the Right Engine Oil” in this section for an explanation of what kind of oil to use. For engine oil crankcase capacity, see Capacities and Specifications 0 358

ii

Caution

Do not add too much oil. Oil levels above or below the acceptable operating range shown on the dipstick are harmful to the engine. If you find that you have an oil level above the operating range, i.e., the engine has so much oil that the oil level gets above the cross-hatched area that shows the proper operating range, the engine could be damaged. You should drain out the excess oil or limit driving of the vehicle and seek a service professional to remove the excess amount of oil.

ii

See Engine Compartment Overview for the location of the engine 0 262
oil fill cap. Add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when through.

Selecting the Right Engine Oil Selecting the right engine oil depends on both the proper oil specification and viscosity grade. See Recommended Fluids and Lubricants 0 353

ii

Specification Ask for and use engine oils that meet the dexos1™ specification. Engine oils that have been approved by GM as meeting the dexos1 specification are marked with the dexos1 approved logo. See www.gmdexos.com.

Caution

Failure to use the recommended engine oil or equivalent can result in engine damage not covered by the vehicle warranty.

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Viscosity Grade Use SAE 5W-30 viscosity grade engine oil for the 3.6L V6 engine. Use SAE 5W-20 viscosity grade engine oil for the 2.5L L4 engine. Cold Temperature Operation: In an area of extreme cold, where the temperature falls below −29 °C (−20 °F), an SAE 0W-30 oil may be used for the 3.6L V6 engine and SAE 0W-20 viscosity grade engine oil may be used for the 2.5L L4
engine. An oil of this viscosity grade will provide easier cold starting for the engine at extremely low temperatures. When selecting an oil of the appropriate viscosity grade, it is recommended to select an oil of the correct specification. See “Specification” earlier in this section. Engine Oil Additives/Engine Oil Flushes Do not add anything to the oil. The recommended oils meeting the dexos1 specification are all that is needed for good performance and engine protection.

Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash or pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil.

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267

Engine Oil Life System

When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on a combination of factors which include engine revolutions, engine temperature, and miles driven. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. On some vehicles, when the system has calculated that oil life has been diminished, a CHANGE ENGINE OIL SOON message comes on to indicate that an oil change is necessary. See Engine Oil Messages 0 131
soon as possible within the next 1 000 km (600 mi). It is possible that, if driving under the best conditions, the oil life system might indicate that an oil change is not necessary for up to a year. The engine oil and filter must be changed at least once a year and, at this time, the system

. Change the oil as

ii

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Vehicle Care

must be reset. For vehicles without the CHANGE ENGINE OIL SOON message, an oil change is needed when the OIL LIFE REMAINING percentage is near 0%. Your dealer has trained service people who will perform this work and reset the system. It is also important to check the oil regularly over the course of an oil drain interval and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 5 000 km (3,000 mi) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System Reset the system whenever the engine oil is changed so that the system can calculate the next engine oil change. Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the engine oil life system: 1. Display the OIL LIFE

REMAINING on the Driver Information System (DIC).

See Driver Information Center (DIC) (Base Level) 0 123
Driver Information Center (DIC) (Uplevel) 0 126

or

ii

ii

2. Press and hold SET/CLR for several seconds. The oil life will change to 100%.

The oil life system can also be reset as follows: 1. Turn the ignition to ON/RUN

with the engine off.

2. Display the OIL LIFE

REMAINING on the DIC.

3. Fully press the accelerator

pedal slowly three times within five seconds. If the display shows 100%, the system is reset.

If the vehicle has a CHANGE ENGINE OIL SOON message and it comes back on when the vehicle is started and/or the OIL LIFE REMAINING is near 0%, the engine oil life system has not been reset. Repeat the procedure.

Automatic Transmission Fluid

How to Check Automatic Transmission Fluid It is not necessary to check the transmission fluid level. A transmission fluid leak is the only reason for fluid loss. If a leak occurs, take the vehicle to your dealer and have it repaired as soon as possible. There is a special procedure for checking and changing the transmission fluid. Because this procedure is difficult, this should be done at your dealer. Contact your dealer for additional information or the procedure can be found in the service manual. To purchase a service manual, see Service Publications Ordering Information 0 370
Change the fluid and filter at the intervals listed in Maintenance Schedule 0 344
the fluid listed in Recommended Fluids and Lubricants 0 353

, and be sure to use

ii

ii

ii

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Manual Transmission Fluid

When to Check and What to Use

How to Check Manual Transmission Fluid It is not necessary to check the manual transmission fluid level. A transmission fluid leak is the only reason for fluid loss. If a leak occurs, take the vehicle to your dealer and have it repaired as soon as possible. See Recommended Fluids and Lubricants 0 353
proper fluid to use.

for the

ii

Hydraulic Clutch For vehicles with a manual transmission, it is not necessary to regularly check brake/clutch fluid unless there is a leak suspected. Adding fluid will not correct a leak. A fluid loss in this system could indicate a problem. Have the system inspected and repaired.

for reservoir

The brake/hydraulic clutch fluid reservoir cap has this symbol on it. The common brake/clutch fluid reservoir is filled with DOT 3 brake fluid as indicated on the reservoir cap. See Engine Compartment Overview 0 262
location. How to Check and Add Fluid Visually check the brake/clutch fluid reservoir to make sure the fluid level is at the MIN (minimum) line on the front of the reservoir. The brake/ hydraulic clutch fluid system should be closed and sealed.

ii

Vehicle Care

269

Do not remove the cap to check the fluid level or to top-off the fluid level. Remove the cap only when necessary to add the proper fluid until the level reaches the MIN line.

ii

Engine Air Cleaner/Filter The engine air cleaner/filter is in the engine compartment on the passenger side of the vehicle. See Engine Compartment Overview 0 262
When to Inspect the Engine Air Cleaner/Filter For intervals on changing and inspecting the engine air cleaner/ filter, see Maintenance Schedule 0 344
How to Inspect the Engine Air Cleaner/Filter Do not start the engine or have the engine running with the engine air cleaner/filter housing open. Before removing the engine air cleaner/ filter, make sure that the engine air cleaner/filter housing and nearby components are free of dirt and debris. Remove the engine air

ii

Chevrolet Colorado Owner Manual (GMNA-Localizing-U.S/Canada/Mexico- 9159327) - 2016 - crc - 8/28/15

To inspect or replace the engine air cleaner/filter: 1. Remove the screws (1) on top of the engine air cleaner/filter housing.

2. Disconnect the electrical

connector (2).

3. Disconnect the outlet duct by

loosening the air duct clamp (3).

4. Lift the filter cover housing

away from the engine air cleaner/filter housing.

5. Pull out the filter. 6.

Inspect or replace the engine air cleaner/filter.

7. Reverse Steps 2-5 to reinstall

the filter cover housing.

270

Vehicle Care

cleaner/filter. Lightly tap and shake the engine air cleaner/filter (away from the vehicle), to release loose dust and dirt. Inspect the engine air cleaner/filter for damage, and replace if damaged. Do not clean the engine air cleaner/filter or components with water or compressed air. To inspect or replace the air cleaner/ filter:

2.5L L4 Gas Engine Shown, 2.8L

L4 Diesel Engine Similar

1. Screws 2. Electrical Connector 3. Air Duct Clamp

3.6L V6 Engine

1. Screws 2. Electrical Connector 3. Air Duct Clamp

To inspect or replace the engine air cleaner/filter: 1. Remove the screws (1) on top of the engine air cleaner/filter housing.

2. Disconnect the electrical

connector (2).

3. Disconnect the outlet duct by

loosening the air duct clamp (3).

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4. Lift the filter cover housing

away from the engine air cleaner/filter housing.

5. Pull out the filter. 6.

Inspect or replace the engine air cleaner/filter.

7. Reverse Steps 2-5 to reinstall

the filter cover housing.

{ Warning

Operating the engine with the air cleaner/filter off can cause you or others to be burned. The air cleaner not only cleans the air; it helps to stop flames if the engine backfires. Use caution when working on the engine and do not drive with the air cleaner/filter off.

Caution

If the air cleaner/filter is off, dirt can easily get into the engine, which could damage it. Always have the air cleaner/filter in place when you are driving.

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271

Cooling System The cooling system allows the engine to maintain the correct working temperature.

2.5L L4 Gas Engine Shown, 2.8L

L4 Diesel Engine Similar

1. Coolant Surge Tank and

Pressure Cap

2. Engine Cooling Fan (Out

of View)

3.6L V6 Engine

1. Coolant Surge Tank and

Pressure Cap

2. Engine Cooling Fan (Out

of View)

{ Warning

An electric engine cooling fan under the hood can start up even when the engine is not running and can cause injury. Keep hands, clothing, and tools away from any underhood electric fan.

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Vehicle Care

{ Warning

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.

Caution

Using coolant other than DEX-COOL® can cause premature engine, heater core, or radiator corrosion. In addition, the engine coolant could require changing sooner. Any repairs would not be covered by the vehicle warranty. Always use DEX-COOL (silicate-free) coolant in the vehicle.

Engine Coolant The cooling system in the vehicle is filled with DEX-COOL® engine coolant mixture. See Recommended Fluids and Lubricants 0 353
Maintenance Schedule 0 344
The following explains the cooling system and how to check and add coolant when it is low. If there is a problem with engine overheating, see Engine Overheating 0 274
What to Use

and

ii

ii

ii

{ Warning

Adding only plain water or some other liquid to the cooling system can be dangerous. Plain water and other liquids, can boil before the proper coolant mixture will. The coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, the engine could get too hot but you would not get the overheat warning. The engine

(Continued)

Warning (Continued)

could catch fire and you or others could be burned. Use a 50/ 50 mixture of clean, drinkable water and DEX-COOL coolant.

Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: . Gives freezing protection down

to −37 °C (−34 °F) outside temperature.

. Gives boiling protection up to

129 °C (265 °F) engine temperature.

. Protects against rust and

corrosion.

. Will not damage aluminum parts. . Helps keep the proper engine

temperature.

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Caution

If improper coolant mixture, inhibitors, or additives are used in the vehicle cooling system, the engine could overheat and be damaged. Too much water in the mixture can freeze and crack engine cooling parts. The repairs would not be covered by the vehicle warranty. Use only the proper mixture of engine coolant for the cooling system. See Recommended Fluids and Lubricants 0 353

ii

Never dispose of engine coolant by putting it in the trash, or by pouring it on the ground, or into sewers, streams or, bodies of water. Have the coolant changed by an authorized service center, familiar with legal requirements regarding used coolant disposal. This will help protect the environment and your health.

Checking Coolant The vehicle must be on a level surface when checking the coolant level. Check to see if coolant is visible in the coolant surge tank. If the coolant inside the coolant surge tank is boiling, do not do anything else until it cools down. If coolant is visible but the coolant level is not at or above the mark pointed to, add a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Be sure the cooling system is cool before this is done. If no coolant is visible in the coolant surge tank, add coolant as follows: How to Add Coolant to the Coolant Surge Tank

{ Warning

You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol

(Continued)

Vehicle Care

273

Warning (Continued)

and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine.

Caution

This vehicle has a specific coolant fill procedure. Failure to follow this procedure could cause the engine to overheat and be severely damaged.

{ Warning

Steam and scalding liquids from a hot cooling system can blow out and burn you badly. Never turn the cap when the cooling system, including the surge tank pressure cap, is hot. Wait for the cooling system and surge tank pressure cap to cool.

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Vehicle Care

The coolant surge tank pressure cap can be removed when the cooling system, including the surge tank pressure cap and upper radiator hose, is no longer hot. 1. Turn the pressure cap slowly counterclockwise. If a hiss is heard, wait for that to stop. A hiss means there is still some pressure left.

2. Keep turning the cap and

remove it.

3. Fill the coolant surge tank with the proper mixture to the mark pointed to on the front of the coolant surge tank.

4. With the coolant surge tank

cap off, start the engine and let it run until the upper radiator hose starts 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 mark pointed to on the front of the coolant surge tank.

5. Replace the cap tightly.

Caution

If the pressure cap is not tightly installed, coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured.

Engine Overheating The vehicle has an engine coolant temperature gauge on the instrument cluster to warn of engine overheating. See Engine Coolant Temperature Gauge 0 112

ii

Caution

Running the engine without coolant may cause damage or a fire. Vehicle damage would not be covered by the vehicle warranty.

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ii

If the decision is made not to lift the hood when this warning appears, get service help right away. See Roadside Assistance Program 0 365
If the decision is made to lift the hood, make sure the vehicle is parked on a level surface. Then check to see if the engine cooling fan is running. If the engine is overheating, the fan should be running. If it is not, do not continue to run the engine and have the vehicle serviced. If Steam Is Coming from the Engine Compartment { Warning

Steam from an overheated engine can burn you badly, even if you just open the hood. Stay away from the engine if you see or hear steam coming from it. Just turn it off and get everyone away from the vehicle until it cools down.

(Continued)

Warning (Continued)

Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when the engine is overheated, the liquids in it can catch fire. You or others could be badly burned. Stop the engine if it overheats, and get out of the vehicle until the engine is cool.

If No Steam Is Coming from the Engine Compartment If an engine overheat warning is displayed but no steam can be seen or heard, the problem may not be too serious. Sometimes the engine can get a little too hot when the vehicle: . Climbs a long hill on a hot day. . Stops after high-speed driving. Idles for long periods in traffic.

If the overheat warning is displayed with no sign of steam:

Vehicle Care

275

1. Turn the air conditioning off. 2. Turn the heater on to the

highest temperature and to the highest fan speed. Open the windows as necessary.

3. When it is safe to do so, pull off

the road, shift to P (Park) or N (Neutral), and let the engine idle.

If the engine coolant temperature gauge is no longer in the overheat zone, the vehicle can be driven. Continue to drive the vehicle slowly for about 10 minutes. Keep a safe distance from the vehicle in front. If the warning does not come back on, continue to drive normally and have the cooling system checked for proper fill and function. If the warning continues, pull over, stop, and park the vehicle right away. If there is no sign of steam, idle the engine for three minutes while parked. If the warning is still displayed, turn off the engine until it cools down.

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Vehicle Care

Engine Fan If the vehicle has a clutched engine cooling fan, when the clutch is engaged, the fan spins faster to provide more air to cool the engine. In most everyday driving conditions, the fan is spinning slower and the clutch is not fully engaged. This improves fuel economy and reduces fan noise. Under heavy vehicle loading, trailer towing, and/or high outside temperatures, the fan speed increases as the clutch more fully engages, so an increase in fan noise may be heard. This is normal and should not be mistaken as the transmission slipping or making extra shifts. It is merely the cooling system functioning properly. The fan will slow down when additional cooling is not required and the clutch disengages. This fan noise may also be heard when starting the engine. It will go away as the fan clutch partially disengages. If the vehicle has electric cooling fan(s), the fans may be heard spinning at low speed during most

everyday driving. The fans may turn off if no cooling is required. Under heavy vehicle loading, trailer towing, high outside temperatures, or operation of the air conditioning system, the fans may change to high speed and an increase in fan noise may be heard. This is normal and indicates that the cooling system is functioning properly. The fans will change to low speed when additional cooling is no longer required. The electric engine cooling fans may run after the engine has been turned. off. This is normal and no service is required.

Washer Fluid

What to Use When windshield washer fluid needs to be added, be sure to read the manufacturer's instructions before use. Use a fluid that has sufficient protection against freezing in an area where the temperature may fall below freezing.

Adding Washer Fluid

Open the cap with the washer symbol on it. Add washer fluid until the tank is full. See Engine Compartment Overview 0 262
reservoir location.

for

ii

Caution

. Do not use washer fluid that

contains any type of water repellent coating. This can cause the wiper blades to chatter or skip.

. Do not use engine coolant

(antifreeze) in the windshield washer. It can damage the windshield washer system and paint.

(Continued)

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Vehicle Care

277

Caution (Continued)

. Do not mix water with

ready-to-use washer fluid. Water can cause the solution to freeze and damage the washer fluid tank and other parts of the washer system.

. When using concentrated

washer fluid, follow the manufacturer instructions for adding water.

. Fill the washer fluid tank

only three-quarters full when it is very cold. This allows for fluid expansion if freezing occurs, which could damage the tank if it is completely full.

Brakes Disc brake pads have built-in wear indicators that make a high-pitched warning sound when the brake pads are worn and new pads are needed. The sound can come and go or be

heard all the time the vehicle is moving, except when applying the brake pedal firmly.

{ Warning

The brake wear warning sound means that soon the brakes will not work well. That could lead to a crash. When the brake wear warning sound is heard, have the vehicle serviced.

Caution

Continuing to drive with worn-out brake pads could result in costly brake repair.

Some driving conditions or climates can cause a brake squeal when the brakes are first applied or lightly applied. This does not mean something is wrong with the brakes. Properly torqued wheel nuts are necessary to help prevent brake pulsation. When tires are rotated, inspect brake pads for wear and

ii

evenly tighten wheel nuts in the proper sequence to torque specifications in Capacities and Specifications 0 358
Brake linings should always be replaced as complete axle sets. Brake Pedal Travel See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in pedal travel. This could be a sign that brake service may be required. Replacing Brake System Parts Always replace brake system parts with new, approved replacement parts. If this is not done, the brakes may not work properly. The braking performance expected can change in many other ways if the wrong replacement brake parts are installed or parts are improperly installed.

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Vehicle Care

Brake Fluid

The brake/clutch master cylinder reservoir is filled with GM approved DOT 3 brake fluid as indicated on the reservoir cap. See Engine Compartment Overview 0 262
the location of the reservoir.

for

ii

Checking Brake Fluid With the vehicle in P (Park) on a level surface, the brake fluid level should be between the minimum and maximum marks on the brake fluid reservoir. There are only two reasons why the brake fluid level in the reservoir may go down: . Normal brake lining wear. When

new linings are installed, the fluid level goes back up.

. A fluid leak in the brake/clutch

hydraulic system. Have the brake/clutch hydraulic system fixed. With a leak, the brakes will not work well.

Always clean the brake fluid reservoir cap and the area around the cap before removing it. Do not top off the brake/clutch fluid. Adding fluid does not correct a leak. If fluid is added when the linings are worn, there will be too much fluid when new brake linings are installed. Add or remove fluid, as necessary, only when work is done on the brake/clutch hydraulic system.

{ Warning

If too much brake fluid is added, it can spill on the engine and burn, if the engine is hot enough. You or others could be burned, and the vehicle could be damaged. Add brake fluid only when work is done on the brake/clutch hydraulic system.

When the brake/clutch fluid falls to a low level, the brake warning light comes on. See Brake System Warning Light 0 117
Brake fluid absorbs water over time which degrades the effectiveness of the brake fluid. Replace brake fluid at the specified intervals to prevent increased stopping distance. See Maintenance Schedule 0 344

ii

ii

What to Add Use only GM approved DOT 3
brake fluid from a clean, sealed container. See Recommended Fluids and Lubricants 0 353

ii

{ Warning

The wrong or contaminated brake fluid could result in damage to the brake system. This could result in the loss of braking leading to a possible injury. Always use the proper GM approved brake fluid.

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Caution

Warning (Continued)

If brake fluid is spilled on the vehicle's painted surfaces, the paint finish can be damaged. Immediately wash off any painted surface.

Battery - North America For diesel engine vehicles, see “Battery” in the Duramax diesel supplement. The original equipment battery is maintenance free. Do not remove the cap and do not add fluid. Refer to the replacement number shown on the original battery label when a new battery is needed. See Engine Compartment Overview 0 262

for battery location. { Warning WARNING: Battery posts, terminals, and related accessories contain lead and lead (Continued)

ii

compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer. WASH HANDS AFTER HANDLING. See California Proposition 65 Warning 0 259

ii

Vehicle Care

279

Extended Storage: Remove the black, negative (−) cable from the battery or use a battery trickle charger.

Four-Wheel Drive

Transfer Case

When to Check Lubricant Refer to Maintenance Schedule 0 344
the lubricant.

to determine when to check

ii

Vehicle Storage

How to Check Lubricant

{ Warning

Batteries have acid that can burn you and gas that can explode. You can be badly hurt if you are not careful. See Jump Starting - for tips on North America 0 327
working around a battery without getting hurt.

ii

Infrequent Usage: Remove the black, negative (−) cable from the battery to keep the battery from running down.

Electronic Transfer Case

1. Drain Plug

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Vehicle Care

2. Fill Plug

To get an accurate reading, the vehicle should be on a level surface. If the level is below the bottom of the fill plug (2) hole, located on the transfer case, some lubricant will need to be added. Add enough lubricant to raise the level to the bottom of the fill plug (2) hole. Use care not to overtighten the plug.

When to Change Lubricant Refer to Maintenance Schedule to determine how often to 0 344
change the lubricant.

ii

What to Use Refer to Recommended Fluids and to determine what Lubricants 0 353
kind of lubricant to use.

ii

Front Axle

When to Check and Change Lubricant It is not necessary to regularly check front axle fluid unless a leak is suspected, or an unusual noise is

heard. A fluid loss could indicate a problem. Have it inspected and repaired.

to raise the level to the bottom of the fill plug (2) hole. Use care not to overtighten the plug.

How to Check Lubricant

Front Axle for 2.5L Shown, Front

Axle for 3.6L Similar

1. Drain Plug 2. Fill Plug

To get an accurate reading, the vehicle should be on a level surface. If the level is below the bottom of the fill plug (2) hole, located on the front axle, some lubricant will need to be added. Add enough lubricant

What to Use Refer to Recommended Fluids and to determine what Lubricants 0 353
kind of lubricant to use.

ii

Rear Axle

When to Check and Change Lubricant It is not necessary to regularly check rear axle fluid unless a leak is suspected, or an unusual noise is heard. A fluid loss could indicate a problem. Have it inspected and repaired. All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than

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normal because fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. The rear axle assembly must be supported on a flat, level surface to get a true reading.

How to Check Lubricant

Rear Axle for 2.5L Shown, Rear

Axle for 3.6L Similar

1. Drain Plug 2. Fill Plug

To get an accurate reading, the vehicle should be on a level surface. If the level is below the bottom of the fill plug (2) hole, located on the rear axle, some lubricant will need to be added. Add enough lubricant to raise the level to the bottom of the fill plug (2) hole. Use care not to overtighten the plug.

What to Use Refer to Recommended Fluids and to determine what Lubricants 0 353
kind of lubricant to use.

ii

Starter Switch Check

{ Warning When you are doing this inspection, the vehicle could move suddenly. If the vehicle moves, you or others could be injured.

1. Before starting this check, be

sure there is enough room around the vehicle.

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281

2. Apply both the parking brake

and the regular brake. Do not use the accelerator pedal, and be ready to turn off the engine immediately if it starts.

3. For automatic transmission

vehicles, try to start the engine in each gear. The vehicle should start only in P (Park) or N (Neutral). If the vehicle starts in any other position, contact your dealer for service. For manual transmission vehicles, put the shift lever in Neutral, push the clutch pedal down halfway, and try to start the engine. The vehicle should start only when the clutch pedal is pushed down all the way to the floor. If the vehicle starts when the clutch pedal is not pushed all the way down, contact your dealer for service.

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Vehicle Care

Automatic Transmission Shift Lock Control Function Check

{ Warning When you are doing this inspection, the vehicle could move suddenly. If the vehicle moves, you or others could be injured.

1. Before starting this check, be

sure there is enough room around the vehicle. It should be parked on a level surface.

2. Apply the parking brake. Be

ready to apply the regular brake immediately if the vehicle begins to move.

3. With the engine off, turn the

ignition on, but do not start the engine. Without applying the regular brake, try to move the shift lever out of P (Park) with normal effort. If the shift lever moves out of P (Park), contact your dealer for service.

Ignition Transmission Lock Check While parked, and with the parking brake set, try to turn the ignition to LOCK/OFF in each shift lever position. . For automatic transmission

vehicles, the ignition should turn to LOCK/OFF only when the shift lever is in P (Park). . For manual transmission

vehicles, the ignition should turn to LOCK/OFF only when you press the key release button.

On all vehicles, the ignition key should come out only in LOCK/OFF. Contact your dealer if service is required.

Park Brake and P (Park) Mechanism Check { Warning

When you are doing this check, the vehicle could begin to move. You or others could be injured and property could be damaged. Make sure there is room in front of the vehicle in case it begins to roll. Be ready to apply the regular brake at once should the vehicle begin to move.

Park on a fairly steep hill, with the vehicle facing downhill. Keeping your foot on the regular brake, set the parking brake. . To check the parking brake's

holding ability: With the engine running and the transmission in N (Neutral), slowly remove foot pressure from the regular brake pedal. Do this until the vehicle is held by the parking brake only.

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283

2. Press the button (2) in the

middle of the wiper arm connector, and pull the wiper blade away from the arm connector (1).

3. Remove the wiper blade. 4. Reverse Steps 1–3 for wiper

blade replacement.

Caution (Continued)

the vehicle warranty. Do not allow the wiper arm to touch the windshield.

To replace the windshield wiper blade: 1. Pull the windshield wiper assembly away from the windshield.

. To check the P (Park)

mechanism's holding ability: With the engine running, shift to P (Park). Then release the parking brake followed by the regular brake.

Contact your dealer if service is required.

Wiper Blade Replacement Windshield wiper blades should be inspected for wear or cracking. Replacement blades come in different types and are removed in different ways. For proper windshield wiper blade length and type, see Maintenance Replacement Parts 0 355

ii

Caution

Allowing the wiper arm to touch the windshield when no wiper blade is installed could damage the windshield. Any damage that occurs would not be covered by

(Continued)

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Vehicle Care

Headlamp Aiming Headlamp aim has been preset and should need no further adjustment. If the vehicle is damaged in a crash, the headlamp aim may be affected. If adjustment to the headlamps is necessary, see your dealer.

Bulb Replacement For the proper type of replacement bulbs, see Replacement Bulbs 0 286
For any bulb-changing procedure not listed in this section, contact your dealer.

ii

Halogen Bulbs

{ Warning

Halogen bulbs have pressurized gas inside and can burst if you drop or scratch the bulb. You or others could be injured. Be sure to read and follow the instructions on the bulb package.

Headlamps, Front Turn Signal, Sidemarker, and Parking Lamps

Driver Side

1. Low-Beam Headlamp 2. High-Beam Headlamp 3. Front Turn Signal/

Sidemarker/Parking Lamp See your dealer for passenger side replacement.

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Headlamp 1. Open the hood. 2. Remove the headlamp bulb

cover by turning it counterclockwise.

3. Turn the bulb socket

counterclockwise to remove it from the headlamp assembly and pull it straight out.

4. Unplug the electrical connector

from the old bulb by releasing the clip on the bulb socket.

Turn Signal/Sidemarker/ Parking Lamp 1. Open the hood. 2. Turn the bulb socket

counterclockwise to remove it from the headlamp assembly and pull it straight out.

3. Remove the bulb by pulling it straight out of the bulb socket.

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285

Taillamps, Turn Signal, Stoplamps, and Back-Up Lamps 1. Open the tailgate.

4. Pull the rear lamp assembly

straight back to remove it from the vehicle.

5. Turn the bulb socket

counterclockwise.

6. Pull the bulb straight out from

the socket.

7. Replace the bulb, then insert the bulb socket into the rear lamp assembly and turn clockwise.

2. Remove the two rear lamp

assembly screws.

3. Pull the rear lamp assembly outboard away from the box side until the retainers release. There will be a noise when the retainers release.

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Vehicle Care

Center High-Mounted Stoplamp (CHMSL) and Cargo Lamp

9. Verify the retainer ring is in the proper position. If the retainer ring is out of position, it will not engage. Reset the retainer by pulling it forward with a tool.

10. Push the rear lamp assembly

straight in until it is seated against the vehicle.

11. Make sure the rear lamp

assembly is flush with the box side.

12. Reinstall the two rear lamp

assembly screws.

1. Remove the two screws and lift

off the lamp assembly.

2. Turn the bulb socket

counterclockwise and pull it straight out.

3. Pull the bulb straight out from

the socket.

1. Cargo Lamp Bulbs 2. Center High-Mounted

Stoplamp (CHMSL) Bulb

To replace one of these bulbs:

Replacement Bulbs

Exterior Lamp

Back-up Lamp Back-up Lamp* Cargo Lamp

Bulb

Number

921 (W16W)

1156

921 (W16W)

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Bulb

Number 921LL

7444NA-T

W5W LL 9005 LL

H11 LL

7443 W21/ 5W LL-T

1157

Exterior Lamp

Center High-Mounted Stoplamp (CHMSL) Front Turn Signal Lamp and Parking Lamp Sidemarker Lamp High-Beam Headlamp Low-Beam Headlamp Stoplamp/Taillamp/ Turn Signal Lamp Stoplamp/Turn Signal Lamp/ Taillamp* * Chassis Cab Models

For replacement bulbs not listed here, contact your dealer.

Electrical System

Electrical System Overload The vehicle has fuses to protect against an electrical system overload. Fuses also protect power devices in the vehicle. Replace a bad fuse with a new one of the identical size and rating. If there is a problem on the road and a fuse needs to be replaced, there is a fuse puller in the Engine Compartment Fuse Block. Replace the fuse as soon as possible with one of the same amperage rating. Headlamp Wiring An electrical overload may cause the lamps to go on and off, or in some cases to remain off. Have the headlamp wiring checked right away if the lamps go on and off or remain off.

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287

Windshield Wipers If the wiper motor overheats due to heavy snow or ice, the windshield wipers will stop until the motor cools and will then restart. Although the circuit is protected from electrical overload, overload due to heavy snow or ice may cause wiper linkage damage. Always clear ice and heavy snow from the windshield before using the windshield wipers. If the overload is caused by an electrical problem and not snow or ice, be sure to get it fixed.

Fuses The wiring circuits in the vehicle are protected from short circuits by fuses. This greatly reduces the chance of fires caused by electrical problems. Look at the silver-colored band inside the fuse. If the band is broken or melted, replace the fuse. Be sure you replace a bad fuse with a new one of the identical size and rating.

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Vehicle Care

If a fuse goes out, replace the fuse as soon as you can.

Engine Compartment Fuse Block If the vehicle has a diesel engine, see the Duramax diesel supplement. The engine compartment fuse block is in the engine compartment, on the driver side of the vehicle.

Caution

Spilling liquid on any electrical component on the vehicle may damage it. Always keep the covers on any electrical component.

A fuse puller is available inside this fuse block.

Lift the cover to access the fuse block.

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Vehicle Care

The vehicle may not be equipped with all of the fuses, relays, and features shown.

Mini Fuses

(2 pin)

Usage

F01

F02

F03

F04
F05

F07
F08

F09

F10

F11

F13

Traction Control Module Power Engine Control Module Power Air Conditioning Compressor Clutch Not Used Fuel Module Ignition Cargo Lamp Fuel Injectors - Even Fuel Injectors - Odd Engine Control Module Miscellaneous 1
Ignition Traction Control Module

Mini Fuses

(2 pin)

Usage

Mini Fuses

(2 pin)

Usage

F14
F15
F16
F17
F18
F19
F20
F23
F29
F30

F31
F32

F33

F34

F35

Not Used Not Used Not Used Front Axle Actuator Not Used Aeroshutters Not Used Not Used Not Used Heated Seat Power 1
Not Used Heated Seat Power 2
Body Control Module 3
Fuel System Control Module Not Used

F36

F37

F38

F39
F40
F46
F47

F48

F49
F50
F51
F52
F53
F54
F55

Center High Mounted Stop Lamp Right High-Beam Headlamp Left High-Beam Headlamp Not Used Not Used Not Used Miscellaneous 2
Ignition Fog Lamps (If Equipped) Not Used Trailer Park Lamps Horn Not Used Not Used Not Used Not Used

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Mini Fuses

(2 pin)

Usage

F56
F57
F58
F60
F61
F62

F63
F64

F65

F66

F67

F68
F69

F70
F71

Washer Pump Not Used Not Used Mirrors Defogger Not Used Canister Vent Solenoid Not Used Trailer Reverse Lamp Left Trailer Stop/ Turn Lamps Right Trailer Stop/ Turn Lamps Electric Power Steering Not Used Battery Regulated Voltage Control Not Used Not Used

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291

J-Case

Fuses (Low

Profile)

Usage

J-Case

Fuses (Low

Profile)

Usage

F06
F12
F21
F22

F24
F25

F26

F27

F28

F41
F42
F43
F44
F45

Wipers Starter Front Blower Antilock Brake System Valves Trailer Transfer Case Electronic Control Antilock Brake System Pump Trailer Brake Control Module Rear Window Defogger Not Used Not Used Cooling Fan Not Used Brake Vacuum Pump

F59

Not Used

Midi Fuses

Usage

F72
F73
F74
F75

Micro Relays

K01

K02
K03
K04
K05
K06
K08
K09

Not Used Not Used Generator Not Used

Usage

Air Conditioning Compressor Clutch Starter Not Used Wipers Speed Wipers Control Cargo Lamp Not Used Not Used

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Vehicle Care

Micro Relays

Usage

Instrument Panel Fuse Block

K10
K11

K12
K13