2006 Chevrolet Duramax Owners Manual

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Speciﬁcation Charts ......................................5-50 5-1 Diesel Fuel Requirements and Fuel System Some states and provinces have restrictions on the purchase of diesel fuel for light-duty vehicles and require you to buy permits or pay special taxes. Some of these restrictions apply only to residents, and others apply to both residents and visitors. These restrictions can change. To learn the current restrictions in any state or province, contact your auto club, the police or other officials. Diesel Engine Fuel Notice: Diesel fuel or fuel additives not recommended in this manual could damage your fuel system, fuel-operated heater (FOH) (Van models only) and engine. Your warranty would not cover this damage. And: (cid:127) Diesel fuel that has been mixed with engine oil or automatic transmission ﬂuid could damage your engine and emission controls. (cid:127) Aftermarket diesel fuel additives are not tested by General Motors. Some additives, particularly those which contain alcohol or water emulsiﬁers, may damage your fuel system. If you believe that unique circumstances call for a fuel additive to be used, consult your dealer for advice. (cid:127) If you ever run out of diesel fuel, it can be difficult to restart your engine. To avoid all this, never let your tank get empty. If gasoline is ever accidentally added to the fuel tank, to avoid severe engine damage, do not run the engine until the fuel tank can be drained. If you run out of fuel, Running Out of Fuel on page 5-11 tells you how to restart your engine. 5-2 What Fuel to Use In the United States, for best results use No. 2-D diesel fuel year-round (above and below freezing conditions) as oil companies blend No. 2-D fuel to address climate differences. No. 1-D diesel fuel may be used in very cold temperatures (when it stays below 0°F or −18°C); however, it will produce a power and fuel economy loss. Avoid the use of No. 1-D diesel fuel in warm or hot climates. It may result in stalling, poor starting when the engine is hot, and may damage the fuel injection system. At a minimum, the diesel fuel you use should meet the latest version of ASTM speciﬁcation D 975 (Grade Low Sulfur) in the United States. In addition, the Engine Manufacturers Association (EMA) has identiﬁed properties of an improved diesel fuel for better engine performance and durability. Diesel fuels corresponding to the EMA Recommended Guideline on Premium Diesel Fuel (FQP-1A) could provide better starting, less noise, and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the ﬁnal blended fuel must meet the same speciﬁcation, ASTM D 975 (Grade Low Sulfur), as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM speciﬁcation D 6751. 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. Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodiﬁed bio-oils blended into diesel fuel at any concentration is not recommended and could 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 are using, contact your fuel supplier. 5-3 Diesel fuel may foam when you ﬁll your tank. This can cause the automatic pump nozzle to shut off, even though your tank is not full. If this happens, just wait for the foaming to stop and then continue to ﬁll your tank. {CAUTION: Heat coming from the engine may cause the fuel to expand and force the fuel out of your tank. If something ignites the fuel, a ﬁre could start and people could be burned. To help avoid this, ﬁll your fuel tank only until the automatic nozzle shuts off. Do not try to top it off. What Fuel to Use in Canada Canadian fuels are blended for seasonal changes. Diesel Type “A” fuel is blended for better cold weather starting (below 0°F or −18°C); however, you may notice some power and fuel economy loss. If Type “A” fuel is used in warmer temperatures, stalling and hard starting may occur. Diesel Type “B” fuel is blended for temperatures above 0°F (−18°C). The emission control system requires the use of diesel fuel with low-sulfur (.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. It is important that diesel-powered trucks are refueled only with low-sulfur fuel. Use of fuels with higher-sulfur content will affect the function of the emission components and may cause reduced performance, excessive smoke, and unpleasant odor. At a minimum, the diesel fuel you use should meet the latest version of speciﬁcation CAN/CGSB-3.517 (Low Sulfur Diesel) in Canada. In addition, the Engine Manufacturers Association (EMA) has identiﬁed properties of an improved diesel fuel for better engine performance and durability (FQP-1A). Diesel fuels corresponding to the EMA description could provide better starting, less noise, and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. 5-4 It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the ﬁnal blended fuel must meet the same speciﬁcation, CAN/CGSB-3.517 (Low Sulfur Diesel) in Canada, as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM speciﬁcation D 6751. 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. Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodiﬁed bio-oils blended into diesel fuel at any concentration is not recommended and could 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 are using, contact your fuel supplier. Very Cold Weather Operation Follow the instructions listed previously under the heading “What Fuel to Use.” Notice: Never use home heating oil or gasoline in your diesel engine. They can cause engine damage. In cold weather, your fuel ﬁlter may become clogged (waxed). To unclog it, move the vehicle to a warm garage area and warm the ﬁlter to between 32°F and 50°F (0°C to 10°C). You will not need to replace it. Additional information on the fuel ﬁlter follows. Water in Fuel {CAUTION: Diesel fuel containing water is still ﬂammable. You could be burned. If you ever try to drain water from your fuel, keep sparks, ﬂames and smoking materials away from the mixture. 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 and fuel operated heater (FOH) (if equipped). 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. 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 and block your FOH. 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 its fuel tanks, or if it gets contaminated fuel from its suppliers. 5-5 If you have a pickup model and this happens, a WATER IN FUEL message will appear on the Driver Information Center (DIC). The water must be drained. If you have a van model and this happens, this water in fuel warning light will appear on the instrument panel cluster. The water must be drained from both chassis mounted fuel ﬁlters. Your dealer can show you how to do this. Water in Fuel Light Chart If the WATER IN FUEL DIC message or water in fuel warning light comes on, use this chart. Water In Fuel Light/Message Chart Problem Light/Message comes on intermittently. Light/Message stays on: • At temperatures above freezing. • At temperatures below freezing. Recommended Action Drain water from fuel ﬁlter. Drain fuel ﬁlter immediately. If no water can be drained and light stays on, see your dealer for assistance. Drain fuel ﬁlter immediately. If no water can be drained — water may be frozen in water drain system. Water may be frozen in the fuel lines. Move the vehicle to a warm location to thaw out, and then drain ﬁlter system. 5-6 Water In Fuel Light/Message Chart (cont’d) Problem • Immediately after refueling, large amount of water possibly pumped into fuel tank. Recommended Action Fuel tank purging required. See your dealer for assistance. Notice: If you drive when this warning indicator is on, you can damage your fuel injection system and your engine. If the indicator comes on right after you refuel, it means water was pumped into your fuel tank. Turn off your engine immediately. Then, have the water drained at once. Hard starting, hesitation or ﬂat performance at high speed or during hard acceleration may be an indication of premature fuel ﬁlter plugging due to dirty or contaminated fuel. The ﬁlter element may need to be changed if this happens. See Fuel Filter Replacement on page 5-12. To drain water, do the following: 1. Stop and park the vehicle in a safe place. Turn off the engine and apply the parking brake. 2. Remove the fuel cap. 3. Place a fuel-resistant container under the fuel ﬁlter(s). For pickup models, the ﬁlter drain valve is located in the engine compartment, on the passenger’s side of the vehicle, on the bottom of the fuel ﬁlter. For van models, the ﬁlter drain valves for the primary and secondary fuel ﬁlters are located in the chassis (inside frame rail) compartment. They are on the driver’s side of the vehicle, below the fuel ﬁlters. 4. For pickup models, open the drain valve by turning it two to three turns. When fuel 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. 5-7 6. 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 5-21. 7. Install the fuel cap. 8. For pickup models, start the engine and let it run for a few minutes. If the engine stalls, the fuel system may need to be primed. While draining the water from the fuel ﬁlter, air may enter the fuel system. If air has entered the fuel system the fuel system will need to be primed. For van models, start the engine and let it run for a few minutes. If the WATER IN FUEL message/warning light comes on again after driving a short distance or the engine runs rough or stalls, a large amount of water has probably been pumped into the fuel tank. The fuel tank should be purged. 5. For van models, in order to drain the water from the system, you will have to repeat the operation for the primary and secondary fuel ﬁlters. 5-8 Fuel Priming In order for the fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel lines, to eliminate air before operating the vehicle. Q: How does air get into the fuel lines? A: One of the following may have happened: • The vehicle ran out of fuel • The fuel ﬁlter was removed for servicing or replacement • The fuel lines were removed or disconnected for servicing • The fuel ﬁlter water drain valve was opened while the engine was running 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. Q: How do I prime the vehicle? (Pickup Models) A: Your vehicle is equipped with a priming pump which is part of the engine mounted fuel ﬁlter. The priming pump is hand operated (pickup only) and is designed to bring fuel to the engine to eliminate any air that may be in the fuel lines. To prime the engine, do the following: 1. You must correct the condition which caused the loss of prime by making sure there is fuel in the tank. 2. Make sure the fuel ﬁlter has been installed and properly tightened. 3. Make sure the fuel lines are properly connected and the fuel ﬁlter is cool enough to touch. 4. Remove any dirt from the fuel ﬁlter head and vent valve by wiping with a cloth. 5-9 5. Open the fuel ﬁlter vent valve by turning the screw counterclockwise several full turns. The vent valve is located on top of the fuel ﬁlter housing. 7. Operate the priming pump until a small amount of fuel seeps from the vent valve. When you see the fuel, the ﬁlter is now full of fuel and the system should be primed. 8. Close the vent valve. Clean any fuel which accumulated on the fuel ﬁlter. Start the engine and let idle for a few minutes. Check the ﬁlter for leaks. 6. Repeatedly push down on the fuel ﬁlter priming pump with the palm of your hand. The pump is located on top of the fuel ﬁlter housing. Let the pump return upward between pushes. Q: How do I prime the vehicle? (Van Models) A: Your vehicle is equipped with an electric priming pump which is located in front of the fuel tank under your vehicle. The priming pump is operated electrically and is designed to bring fuel to the engine to eliminate any air that may be in the fuel lines. To prime the engine, do the following: 1. Turn the ignition key on for two minutes. The fuel pump will be operating and starting the priming process. Do not start the engine during the ﬁrst two minutes. 2. After completing the initial prime in Step 1, turn the ignition off, then back to start and crank the engine for 15 seconds. 3. If the engine does not start, repeat Steps 1 and 2 until the engine starts. 5-10 4. If the engine does not run after repeating Steps 1 and 2 three times, turn the ignition key off for 60 seconds, allowing the Electronic Control Module (ECM) to reset. 5. Repeat the above steps until the engine starts. 6. If the engine runs, but does not run smoothly, increase the engine speed slightly by pressing the accelerator pedal. This will help to force out air through the system. 7. If the engine starts and runs but stalls again, turn the ignition key off for 60 seconds to reset the ECM and repeat the steps above. 8. When the engine starts, let it idle for a few minutes and check the ﬁlters for any leaks. Running Out of Fuel Pickup Models If the engine stalls and you think that you have run out of fuel, do this to restart your engine: {CAUTION: Diesel fuel is ﬂammable. It could start a ﬁre if it gets on hot engine parts. You could be burned. Do not let too much fuel ﬂow from the air bleed valve, and wipe up any spilled fuel with a cloth. 1. If you are parked on a level surface, add at least two gallons of fuel. However, if you are 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. 3. Close the air bleed valve. 4. Turn the ignition key to START for 10 to 15 seconds at a time until your engine starts. If the engine tries to run, but does not run smoothly, increase the rpm a little using the accelerator pedal. This will help force air through the system. 5-11 Van Models If the engine stalls and you think that you may have run out of fuel, do this to restart your engine: 1. If you are parked on a level surface, add at least one gallon of fuel. However, if you are parked on a slope, you may need to add up to ﬁve gallons of fuel. 2. Follow the vehicle fuel system priming procedure earlier in this section to re-prime the system and re-start the engine. Your check engine light may come on if the vehicle has run out of fuel. This light may stay on for a few drive cycles after the condition is corrected, but will eventually clear itself. Fuel Filter Replacement Pickup Models 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 matches or other ignition sources away. First, drain any water from the ﬁlter following the procedure for draining water listed previously. Your vehicle’s engine should be off until the end of this procedure. The fuel ﬁlter is located in the engine compartment on the passenger’s side of the vehicle, or on the driver’s side frame rail in front of the fuel tank. 1. Apply the parking brake. 5-12 2. Unplug the water sensor wire connected to the fuel ﬁlter and unscrew the ﬁlter element. 3. Remove the ﬁlter element. If there is any dirt on the ﬁlter sealing surface, clean it off. Remove and reuse the water sensor ﬂoat switch located on the bottom of the fuel ﬁlter. 4. Install the new ﬁlter element. 5. Reinstall and tighten the ﬁlter container and reconnect the water sensor wire to the ﬁlter. 6. Use the fuel ﬁlter priming procedure earlier in this section to prime the fuel ﬁlter. 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. 9. Reset the fuel ﬁlter monitor. See Driver Information Center (DIC) (Pickup Models Only) on page 3-9 for more information. Van Models If your fuel operated heater (FOH) is not working, your FOH line requires priming. See your dealer for service. See Fuel Operated Heater (FOH) (Van Models Only) on page 2-8 for more information. 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 matches or other ignition sources away. First, drain any water from the ﬁlter following the procedure for draining water listed previously. Your vehicle’s engine should be off until the end of this procedure. The fuel ﬁlters are located on the driver’s side frame rail in front of the fuel tank. 5-13 4. Install the new ﬁlter element. 5. Reinstall and tighten the ﬁlter’s cap and reconnect the water sensor wire to the ﬁlter. 6. Prime the fuel system. 7. Start your engine and let it idle for ﬁve minutes. Secondary Filter (B) 1. Apply the parking brake. 2. Unscrew the ﬁlter element. 3. Remove the ﬁlter element. If there is any dirt on the ﬁlter sealing surface, clean it off. Remove and reuse the water drain valve located at the bottom of the fuel ﬁlter. 4. Install and tighten the new ﬁlter element. 5. Prime the fuel system. 6. Start your vehicle and let it idle for ﬁve minutes. Primary Filter (A) 1. Apply the parking brake. 2. Unplug the water sensor wire connected to the fuel ﬁlter (lowest wire) and unscrew the ﬁlter’s cap. 3. Remove the ﬁlter element. If there is any dirt on the ﬁlter sealing surface, clean it off. 5-14 Filling the 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 engine when you are refueling. Do not smoke if you are near fuel or refueling your vehicle. Keep sparks, ﬂames, and smoking materials away from fuel. Do not leave the fuel pump unattended when refueling your vehicle — this is against the law in some places. Keep children away from the fuel pump; never let children pump fuel. The fuel cap is located behind a hinged door on the driver’s side of the vehicle. For chassis-cab models, refuel the front tank ﬁrst, or in instances when only a partial fuel ﬁll is desired. An automatic transfer mechanism will maintain approximately equal fuel levels in both tanks, so no switching is required by the operator. 5-15 To remove the fuel cap, turn it slowly to the left (counterclockwise). {CAUTION: If you spill fuel and then something ignites it, you could be badly burned. Fuel can spray out on you if you open the fuel cap too quickly. This spray can happen if your tank is nearly full, and is more likely in hot weather. Open the fuel cap slowly and wait for any hiss noise to stop. Then unscrew the cap all the way. Be careful not to spill diesel fuel. Don’t top off or overﬁll 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 “Washing 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 you fully install the cap. The diagnostic system can determine if the fuel cap has been left off or improperly installed. This would allow fuel to evaporate into the atmosphere. See Malfunction Indicator Lamp on page 3-4. 5-16 {CAUTION: If a ﬁre starts while you are refueling, do not remove the nozzle. Shut off the ﬂow of fuel by shutting off the pump or by notifying the station attendant. Leave the area immediately. If you need a new fuel cap, be sure to get Notice: the right type. Your dealer can get one for you. If you get the wrong type, it may not ﬁt properly. This may cause your malfunction indicator lamp to light and may damage your fuel tank and emissions system. See Malfunction Indicator Lamp on page 3-4. Notice: with gasoline, do not run the engine or severe engine damage can occur. Contact your dealer to have the fuel system ﬂushed. If your vehicle has been accidentally ﬁlled Filling a Portable Fuel Container {CAUTION: Never ﬁll a portable fuel container while it is in your vehicle. Static electricity discharge from the container can ignite the gasoline vapor. You can be badly burned and your vehicle damaged if this occurs. To help avoid injury to you and others: (cid:127) Dispense gasoline only into approved containers. (cid:127) Do not ﬁll a container while it is inside a vehicle, in a vehicle’s trunk, pickup bed, or on any surface other than the ground. (cid:127) 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. (cid:127) Do not smoke while pumping gasoline. 5-17 Checking Things Under the Hood Engine Compartment Overview When you open the hood on the 6.6L DURAMAX® Diesel Engine, you’ll see: United States pickup models shown, Canada similar 5-18 A. Engine Air Cleaner/Filter B. Coolant Surge Tank C. Battery D. Engine Air Cleaner/Filter Restriction Indicator (If Equipped) E. Engine Oil Dipstick F. Automatic Transmission Dipstick (If Equipped) G. Engine Oil Fill Cap H. Engine Fan I. Power Steering Fluid Reservoir J. Remote Negative (−) Terminal K. Remote Positive (+) Terminal L. Brake Fluid Reservoir M. Clutch Fluid Reservoir (If Equipped) N. Underhood Fuse Block O. Windshield Washer Fluid Reservoir 5-19 United States van models shown, Canada similar 5-20 A. Battery B. Coolant Surge Tank C. Automatic Transmission Dipstick D. Engine Fan E. Engine Air Cleaner/Filter F. Engine Oil Fill Cap G. Power Steering Fluid Reservoir H. Brake Fluid Reservoir I. Windshield Washer Fluid Reservoir 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 5-18 for the location of the engine oil dipstick. In order to get an accurate reading, the oil must be warm, at normal operating temperature, and the vehicle must be on level ground. 1. Turn off the engine and give the oil at least ﬁve minutes to drain back into the oil pan. With a cool engine, allow 30 minutes. If you do not do this, the oil dipstick might not show the actual level. 2. Pull out the dipstick and clean it with a paper towel or a cloth, then push it back in all the way. Remove it again, keeping the tip down. When to Add Engine Oil If the oil is below the cross-hatched area at the tip of the dipstick, you will need to add at least two quarts/liters of oil. But you must use the right kind. This section explains what kind of oil to use. For engine oil crankcase capacity, see Speciﬁcation Charts on page 5-50. Notice: Do not add too much oil. If 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. 5-21 See Engine Compartment Overview on page 5-18 for the location of the engine oil ﬁll cap. What Kind of Engine Oil to Use Look for these two things: • CI-4 or CH-4 Be sure to add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when you are through. 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. Notice: Use only engine oils that have one of these designations CI-4 or CH-4 for the DURAMAX® diesel engine. Failure to use the recommended oils can result in engine damage not covered by your warranty. 5-22 • 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. 5W-40 is not recommended for use at high temperatures, above 100°F (38°C). 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. 5-23 Engine Oil Additives Do not add anything to your oil. The recommended oils with the API service symbol are all you will need for good performance and engine protection. Engine Oil Life System When to Change Engine Oil Your vehicle has a computer system that lets you know when to change the engine oil and ﬁlter. This is based on engine timing, engine load, and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an engine oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL message in pickup models or a change engine oil light in van models will come on. Change your oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and ﬁlter must be changed at least once a year and at this time the system must be reset. Your dealer has GM-trained service people who will perform this work using genuine GM parts and reset the system. It is also important to check your oil regularly and keep it at the proper level. 5-24 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 whenever the oil is changed. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change your engine oil and ﬁlter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a CHANGE ENGINE OIL message (pickup models) or a change engine oil light (van models) being turned on, reset the system. To reset the Engine Oil Life System, do the following: 1. Turn the ignition key to RUN with the engine off. 2. Fully press and release the accelerator pedal three times within ﬁve seconds. Pickup Models: If the OIL LIFE RESET message ﬂashes for 10 seconds, the system is resetting. Van Models: If the change engine oil light ﬂashes for ﬁve seconds, the system is reset. 3. Turn the key to LOCK. If the message or light comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does not reset, see your dealer for service. What to Do with Used Oil Used engine oil contains certain elements that may 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 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 ﬁlter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station, or a local recycling center for help. Engine Air Cleaner/Filter Pickup Models The air cleaner/ﬁlter assembly may have an air cleaner/ﬁlter restriction indicator that lets you know when the engine air cleaner/ﬁlter is dirty and needs to be serviced. The air cleaner/ﬁlter restriction indicator is located on the air cleaner cover. When to Inspect Inspect the air cleaner/ﬁlter every 15,000 miles (25 000 km) and replace the ﬁlter if necessary. How to Inspect When the restriction indicator turns black, or is in the red/orange “change” zone, replace the ﬁlter and reset the restriction indicator. 5-25 To inspect and replace the ﬁlter and reset the restriction indicator, do the following: The air cleaner/ﬁlter assembly is located on the front corner of the engine compartment on the passenger’s side of the vehicle. 1. Loosen the screw on the cover of the housing and lift up the cover. 2. Remove the air cleaner/ﬁlter from the housing. Care should be taken to dislodge as little dirt as possible. 3. Clean the ﬁlter sealing surface and the housing. 5-26 4. Install the new engine air cleaner/ﬁlter. 5. Reinstall the cover and tighten the screw. 6. Reset the air cleaner/ﬁlter restriction indicator, if equipped, by pressing the top button on the indicator. See Scheduled Maintenance on page 6-4 to determine when to replace the engine air cleaner/ﬁlter. {CAUTION: 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. If it is not there and the engine backﬁres, you could be burned. Do not drive with it off, and be careful working on the engine with the air cleaner/ ﬁlter off. If the air cleaner/ﬁlter is off, a backﬁre can Notice: cause a damaging engine ﬁre. And, dirt can easily get into your engine, which will damage it. Always have the air cleaner/ﬁlter in place when you are driving. Van Models The air cleaner/ﬁlter assembly may have an air cleaner/ﬁlter restriction indicator that lets you know when the engine air cleaner/ﬁlter is dirty and needs to be serviced. How to Inspect When the restriction indicator is in the red/orange “change” zone, replace the ﬁlter and reset the restriction indicator. To inspect and replace the ﬁlter and reset the restriction indicator, do the following: The air cleaner/ﬁlter restriction indicator is located on the air cleaner resonator. When to Inspect Inspect the air cleaner/ﬁlter every 15,000 miles (25 000 km) and replace the ﬁlter if necessary. The air cleaner/ﬁlter assembly is located at the front of the engine compartment. 5-27 See Scheduled Maintenance on page 6-4 to determine when to replace the engine air cleaner/ﬁlter. {CAUTION: 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. If it is not there and the engine backﬁres, you could be burned. Do not drive with it off, and be careful working on the engine with the air cleaner/ﬁlter off. If the air cleaner/ﬁlter is off, a backﬁre can Notice: cause a damaging engine ﬁre. And, dirt can easily get into your engine, which will damage it. Always have the air cleaner/ﬁlter in place when you are driving. 1. Loosen the screws on the cover of the housing and lift up the cover. 2. Remove the air cleaner/ﬁlter from the housing. Care should be taken to dislodge as little dirt as possible. 3. Clean the ﬁlter sealing surface and the housing. 4. Install the new engine air cleaner/ﬁlter. 5. Reinstall the cover and tighten the screws. 6. Reset the air cleaner/ﬁlter restriction indicator, if equipped, by pressing the top button on the indicator. 5-28 Automatic Transmission Fluid When to Check and Change (Pickup Models) A good time to check your automatic transmission ﬂuid level is when the engine oil is changed. Change both the ﬂuid and ﬁlter every 25,000 miles (41 500 km) if the vehicle is mainly driven under one or more of these conditions: • In heavy city traffic where the outside temperature regularly reaches 90°F (32°C) or higher. • In hilly or mountainous terrain. • When doing frequent trailer towing. • Uses such as found in taxi, police or delivery service. If you do not use your vehicle under any of these conditions, change the ﬂuid and ﬁlter every 50,000 miles (83 000 km). See Scheduled Maintenance on page 6-4. How to Check Because this operation can be a little difficult, you may choose to have this done at the dealership service department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. Notice: Too much or too little ﬂuid can damage your transmission. Too much can mean that some of the ﬂuid could come out and fall on hot engine part or exhaust system parts, starting a ﬁre. Too little ﬂuid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission ﬂuid. Wait at least 30 minutes before checking the transmission ﬂuid level if you have been driving: • When outside temperatures are above 90°F (32°C). • At high speed for quite a while. • In heavy traffic — especially in hot weather. • While pulling a trailer. 5-29 Checking the Fluid Level Prepare your vehicle as follows: • Park your vehicle on a level place. Keep the engine running. • With the parking brake applied, place the shift lever in PARK (P). • With your foot on the brake pedal, run the engine for at least one minute and shift to DRIVE (D). Then shift to NEUTRAL (N) and then REVERSE (R) to ﬁll the hydraulic system. Then, put the shift lever in PARK (P). • Allow the engine to run at idle (500 – 800 rpm). Slowly release the brake pedal. Then, without shutting off the engine, follow these steps: Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough ﬂuid to be operated safely until a hot check can be made. The ﬂuid level rises as ﬂuid temperature increases. DO NOT ﬁll above the COLD CHECK band if the transmission ﬂuid is below normal operating temperatures. 1. Pull out the dipstick and wipe it with a clean rag or paper towel. The transmission dipstick is located near the center of the engine compartment. See Engine Compartment Overview on page 5-18 for more information on location. 2. Push it back in all the way, wait three seconds and then pull it back out again. 3. Check the ﬂuid level reading. Repeat the check procedure to verify the reading. 4. If the ﬂuid level is within the COLD CHECK band, the transmission may be operated until the ﬂuid is hot enough to perform a hot check. If the ﬂuid level is not within the COLD CHECK band, add or drain ﬂuid as necessary to bring the level into the middle of the COLD CHECK band. 5-30 5. Perform a hot check at the ﬁrst opportunity after the normal operating temperature of 160°F (71°C) to 200°F (93°C) is reached. 6. If the ﬂuid level is in the acceptable range, push the dipstick back in all the way. Hot Check Procedure The ﬂuid must be hot to ensure an accurate check. The ﬂuid level rises as temperature increases. 1. Operate the transmission in 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. 4. Safe operating level is within the HOT RUN band on the dipstick. The width of the HOT RUN band represents approximately 1.06 quart (1.0 liter) of ﬂuid at normal operating temperature. 5. If the ﬂuid level is not within the HOT RUN band, add or drain ﬂuid as necessary to bring the ﬂuid level to within the HOT RUN band. 6. If the ﬂuid level is in the acceptable range, push the dipstick back in all the way. Consistency of Readings Always check the ﬂuid level at least twice using the procedures described previously. Consistency (repeatable readings) is important to maintaining proper ﬂuid level. If inconsistent readings persist, check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent, contact your dealer. How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission ﬂuid to use. See Recommended Fluids and Lubricants on page 6-15. Add ﬂuid only after checking the transmission ﬂuid while it is hot. A cold check is used only as a reference. If the ﬂuid level is low, add only enough of the proper ﬂuid to bring the level up to the HOT area for a hot check. It doesn’t take much ﬂuid, generally less than one pint (0.5 L). Don’t overﬁll. Notice: Use of the incorrect automatic transmission ﬂuid may damage your vehicle, and the damages may not be covered by your warranty. Always use the automatic transmission ﬂuid listed in Recommended Fluids and Lubricants on page 6-15. • After adding ﬂuid, recheck the ﬂuid level as described under “How to Check.” • When the correct ﬂuid level is obtained, push the dipstick back in all the way. 5-31 When to Check and Change (Van Models) A good time to check your automatic transmission ﬂuid level is when the engine oil is changed. Change the ﬂuid and ﬁlter at the intervals listed in “Additional Required Services”. See Additional Required Services on page 6-7. And be sure to use the transmission ﬂuid listed in “Recommended Fluids and Lubricants”. See Recommended Fluids and Lubricants on page 6-15 for more information. How to Check Because this operation can be a little difficult, you may choose to have this done at the dealership service department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick. Notice: Too much or too little ﬂuid can damage your transmission. Too much can mean that some of the ﬂuid could come out and fall on hot engine part or exhaust system parts, starting a ﬁre. Too little ﬂuid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission ﬂuid. 5-32 Wait at least 30 minutes before checking the transmission ﬂuid level if you have been driving: • When outside temperatures are above 90°F (32° C). • At high speed for quite a while. • In heavy traffic — especially in hot weather. • While pulling a trailer. To get the right reading, the ﬂuid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it is colder than 50°F (10°C), drive the vehicle until the engine temperature gage moves and then remains steady for 10 minutes. A cold check can be made after the vehicle has been sitting for eight hours or more with the engine off, but this is used only as a reference. Let the engine run at idle for ﬁve minutes if outside temperatures are 50°F (10°C) or more. If it is colder than 50°F (10 C), you may have to idle the engine longer. Should the ﬂuid level be low during this cold check, you must check the ﬂuid hot before adding ﬂuid. Checking the ﬂuid hot will give you a more accurate reading of the ﬂuid level. Checking the Fluid Level Prepare your vehicle as follows: • Park your vehicle on a level place. Keep the engine running. • With the parking brake applied, place the shift lever in PARK (P). • With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then, position the shift lever in PARK (P). • Let the engine run at idle for three minutes or more. Then, without shutting off the engine, follow these steps: The transmission dipstick is located near the center of the engine compartment and will be labeled with the graphic shown. See Engine Compartment Overview on page 5-18 for more information on location. 1. Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel. 2. Push it back in all the way, wait three seconds and then pull it back out again. Check both sides of the dipstick, and read the lower level. The ﬂuid level must be in the COLD area for a cold check or in the HOT or cross-hatched area for a hot check. Be sure to keep the dipstick pointed down to get an accurate reading. 3. If the ﬂuid level is in the acceptable range, push the dipstick in all the way, then ﬂip the handle down to lock the dipstick in place. 5-33 How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission ﬂuid to use. See Recommended Fluids and Lubricants on page 6-15. Using a funnel, add ﬂuid down the transmission dipstick tube only after checking the transmission ﬂuid while it is hot. A cold check is used only as a reference. If the ﬂuid level is low, add only enough of the proper ﬂuid to bring the level up to the HOT area for a hot check. It does not take much ﬂuid, generally less than one pint (0.5L). Do not overﬁll. Notice: Use of the incorrect automatic transmission ﬂuid may damage your vehicle, and the damages may not be covered by your warranty. Always use the automatic transmission ﬂuid listed in Recommended Fluids and Lubricants on page 6-15. • After adding ﬂuid, recheck the ﬂuid level as described under “How to Check” earlier in this section. • When the correct ﬂuid level is obtained, push the dipstick back in all the way. Then ﬂip the handle down to lock the dipstick in place. 5-34 Engine Coolant Pickup Models The cooling system in your vehicle is ﬁlled with DEX-COOL® engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs ﬁrst, if you add only DEX-COOL® extended life coolant. The following explains your cooling system and how to add coolant when it is low. If you have a problem with engine overheating, see Engine Overheating on page 5-39. A 50/50 mixture of clean, drinkable water and DEX-COOL® coolant will: • Give freezing protection down to −34°F (−37°C) • Give boiling protection up to 265°F (129°C) • Protect against rust and corrosion • Help keep the proper engine temperature • Let the warning lights and gages work as they should 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 the ﬁrst maintenance service after each 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. If you use an improper coolant mixture, your Notice: engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core, and other parts. If you have to add coolant more than four times a year, have your dealer check your cooling system. Notice: If you use extra inhibitors and/or additives in your vehicle’s cooling system, you could damage your vehicle. Use only the proper mixture of the engine coolant listed in this manual for the cooling system. See Recommended Fluids and Lubricants on page 6-15 for more information. What to Use Use a mixture of one-half clean, drinkable water and one-half DEX-COOL® coolant which won’t damage aluminum parts. If you use this coolant mixture, you don’t need to add anything else. {CAUTION: Adding only plain water to your cooling 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. 5-35 The vehicle must be on a level surface. When your engine is cold, the coolant level should be at the FULL COLD mark. Adding Coolant If you need more coolant, add the proper DEX-COOL® coolant mixture at the surge tank, but only when the engine is cool. If the surge tank is empty, see Engine Overheating on page 5-39. {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. When replacing the pressure cap, make sure it is hand- tight. Checking Coolant The coolant surge tank is located in the engine compartment on the passenger’s side of the vehicle. See Engine Compartment Overview on page 5-18 for more 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. 5-36 Van Models The cooling system in your vehicle is ﬁlled with DEX-COOL® engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs ﬁrst, if you add only DEX-COOL® extended life coolant. The following explains your cooling system and how to add coolant when it is low. If you have a problem with engine overheating, see Engine Overheating on page 5-39. A 50/50 mixture of clean, drinkable water and DEX-COOL® coolant will: • Give freezing protection down to −34°F (−37°C) • Give boiling protection up to 265°F (129°C) • Protect against rust and corrosion • Help keep the proper engine temperature • Let the warning lights and gages work as they should Notice: Using coolant other than DEX-COOL® may cause premature engine, heater core, radiator and fuel operated heater (FOH) 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. What to Use Use a mixture of one-half clean, drinkable water and one-half DEX-COOL® coolant which won’t damage aluminum parts. If you use this coolant mixture, you don’t need to add anything else. {CAUTION: Adding only plain water to your cooling 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. If you use an improper coolant mixture, Notice: your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core, and other parts. 5-37 If you have to add coolant more than four times a year, have your dealer check your cooling system. Notice: If you use extra inhibitors and/or additives in your vehicle’s cooling system, you could damage your vehicle. Use only the proper mixture of the engine coolant listed in this manual for the cooling system. See Recommended Fluids and Lubricants on page 6-15 for more information. Checking Coolant The coolant recovery tank is located near the center of the engine compartment. See Engine Compartment Overview on page 5-18 for more information on its location. {CAUTION: Turning the radiator pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly. With the coolant recovery tank, you will almost never have to add coolant at the radiator. Never turn the radiator pressure cap — even a little — when the engine and radiator are hot. The vehicle must be on a level surface. When your engine is cold, the coolant level should be at the COLD FILL mark. 5-38 Adding Coolant If you need more coolant, add the proper DEX-COOL® coolant mixture at the coolant recovery tank, but be careful not to spill it. {CAUTION: You can be burned if you spill coolant on hot components in the engine compartment. Coolant contains ethylene glycol, and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine or components in the engine compartment. When replacing the pressure cap, make sure it is hand-tight. Radiator Pressure Cap The radiator pressure cap must be tightly installed. Notice: coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured. If the pressure cap is not tightly installed, Coolant Surge Tank Pressure Cap The surge tank pressure cap must be tightly installed. If the pressure cap is not tightly installed, Notice: coolant loss and possible engine damage may occur. Be sure the cap is properly and tightly secured. Engine Overheating You will ﬁnd an engine coolant temperature gage on the instrument panel cluster. For pickup models, the ENGINE OVERHEATED message may appear in the Driver Information Center (DIC). See your owner’s manual for more information. 5-39 If No Steam Is Coming From Your Engine An overheat warning, along with a low coolant condition, can indicate a serious problem. If you get an engine overheat warning and don’t have a low coolant condition, but see or hear no steam, the problem may not be too serious. Sometimes the engine can get a little too hot when you: • Climb a long hill on a hot day. • Stop after high-speed driving. • Idle for long periods in traffic. • Tow a trailer. See “Driving on Grades” in the owner’s manual Index. If Steam Is Coming From Your Engine {CAUTION: Steam from an overheated engine can burn you badly, even if you just open the hood. Stay away from the engine if you see or hear steam coming from it. Just turn it off and get everyone away from the vehicle until it cools down. Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when your engine is overheated, the liquids in it can catch ﬁre. You or others could be badly burned. Stop your engine if it overheats, and get out of the vehicle until the engine is cool. If your engine catches ﬁre because you keep Notice: driving with no coolant, your vehicle can be badly damaged. The costly repairs would not be covered by your warranty. 5-40 If you get the overheat warning with no sign of steam, try this for a minute or so: 1. In heavy traffic, let the engine idle in NEUTRAL (N) while stopped. If it is safe to do so, pull off the road, shift to PARK (P) or NEUTRAL (N), and let the engine idle. 2. 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 as fast as normal idle speed for at least three minutes while you’re parked. If there is no sign of steam and your vehicle is equipped with an electric cooling fan, idle the engine for three minutes while you’re parked. If you still have the warning, turn off the engine and get everyone out of the vehicle until it cools down. You may decide not to lift the hood but to get service help right away. Cooling System Pickup Models When you decide it’s safe to lift the hood, here’s what you’ll see: A. Coolant Surge Tank Pressure Cap B. Coolant Surge Tank C. Engine Fan If the coolant inside the coolant surge tank is boiling, don’t do anything else until it cools down. The vehicle should be parked on a level surface. 5-41 If there seems to be no leak, start the engine again. If your vehicle is equipped with an engine driven cooling fan, the engine cooling fan speed should increase when idle speed is doubled by pushing the accelerator pedal down. If it doesn’t, your vehicle needs service. Turn off the engine. Notice: Engine damage from running your engine 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. The coolant level should be at or above the FULL COLD mark. If it isn’t, you may have a leak at the pressure cap or in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system. {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. 5-42 How to Add Coolant to the Coolant Surge Tank Notice: The diesel engine has a speciﬁc coolant ﬁll procedure. Failure to follow this procedure could cause your engine to overheat and be severely damaged. If you haven’t found a problem yet, check to see if coolant is visible in the surge tank. If coolant is visible but the coolant level isn’t at or above the FULL COLD mark, add a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant at the coolant surge tank, but be sure the cooling system, including the coolant surge tank pressure cap, is cool before you do it. See Engine Coolant on page 5-34 for more information. If no coolant is visible in the surge tank, add coolant as follows: {CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the coolant surge tank pressure cap — even a little — they can come out at high speed. CAUTION: (Continued) CAUTION: (Continued) Never turn the cap when the cooling system, including the coolant surge tank pressure cap, is hot. Wait for the cooling system and coolant surge tank pressure cap to cool if you ever have to turn the pressure cap. {CAUTION: Adding only plain water to your cooling 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. 5-43 In cold weather, water can freeze and crack Notice: the engine, radiator, heater core and other parts. Use the recommended coolant and the proper coolant mixture. {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. Park the vehicle on a level surface. You can remove the coolant surge tank pressure cap when the cooling system, including the coolant surge tank pressure cap and upper radiator hose, is no longer hot. 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. 5-44 2. Then keep turning the cap, but now push down as you turn it. Remove the pressure cap. 3. After the engine cools, open the air bleed valve on the thermostat housing. 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. 6. Then ﬁll the coolant surge tank with the proper mixture, to slightly above the ﬁll mark. 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. 5-45 Van Models When you decide it is safe to lift the hood, here is what you will see: When the engine is cold, the coolant level should be at or above the COLD FILL mark. If it is not, you may have a leak at the pressure cap or in the radiator hoses, heater hoses, radiator, water pump, fuel operated heater (FOH) or somewhere else in the cooling system. A. Coolant Surge Tank B. Coolant Surge Tank Pressure Cap C. Engine Cooling Fan If the coolant inside the coolant surge tank is boiling, do not do anything else until it cools down. 5-46 {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. If there seems to be no leak, start the engine again. See if the engine cooling fan speed increases when idle speed is doubled by pushing the accelerator pedal down. If it does not, your vehicle needs service. Turn off the engine. Notice: Engine damage from running your engine without coolant is not covered by your warranty. Notice: Using coolant other than DEX-COOL® may cause premature engine, heater core, radiator and fuel operated heater (FOH) 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. How to Add Coolant to the Coolant Surge Tank Notice: The diesel engine has a speciﬁc coolant ﬁll procedure. Failure to follow this procedure could cause your engine to overheat and be severely damaged. If you have not found a problem yet, but the coolant level is not at the COLD FILL mark, add a 50/50 mixture of clean, drinkable water and DEX-COOL® engine coolant at the coolant surge tank. See Engine Coolant on page 5-34 for more information. 5-47 If no coolant is visible in the surge tank, add coolant as follows: {CAUTION: {CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the coolant surge tank pressure cap — even a little — they can come out at high speed. Never turn the cap when the cooling system, including the coolant surge tank pressure cap, is hot. Wait for the cooling system and coolant surge tank pressure cap to cool if you ever have to turn the pressure cap. Adding only plain water to your cooling 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. In cold weather, water can freeze and crack Notice: the engine, radiator, fuel operated heater (FOH), heater core and other parts. Use the recommended coolant and the proper coolant mixture. 5-48 {CAUTION: You can be burned if you spill coolant on hot components in the engine compartment. Coolant contains ethylene glycol, and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine or components in the engine compartment. When the coolant in the coolant surge tank is at the COLD FILL mark, start your vehicle. 1. You can remove the coolant surge tank pressure cap when the cooling system, including the coolant surge tank pressure cap and upper radiator hose, is no longer hot. Turn the pressure cap slowly counterclockwise about one full turn. If you hear a hiss, wait for that to stop. A hiss means there is still some pressure left. 2. Then keep turning the pressure cap slowly, and remove it. 3. Fill the coolant surge tank with the proper mixture, up to the FULL COLD mark. See Engine Coolant on page 5-34 4. 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. 5. Then replace the pressure cap. Be sure the pressure cap is hand-tight and fully seated. 5-49 Capacities and Speciﬁcations Speciﬁcation Charts Engine 6.6L V8 Turbo Diesel VIN Code Capacities Application Cooling System (Pickup Models) Automatic Transmission Manual Transmission Cooling System (Van Models) Front Heat or AC Only Front Heat or AC Plus Fuel Operated Heater (FOH) Front and Rear Heat or AC Only Front and Rear Heat or AC Plus Fuel Operated Heater (FOH) Engine Oil With Filter Capacities English 25.4 quarts 25.0 quarts 21.0 quarts 22.0 quarts 22.5 quarts 23.5 quarts 10.0 quarts Type V8 Metric 24.0 L 23.6 L 20.0 L 20.5 L 21.5 L 22.5 L 9.5 L 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 6-15 for more information. 5-50 Section 6 Maintenance Schedule Maintenance Schedule ......................................6-2 Introduction ...................................................6-2 Maintenance Requirements ..............................6-2 Your Vehicle and the Environment ....................6-2 Using the Maintenance Schedule ......................6-2 Scheduled Maintenance ...................................6-4 Additional Required Services ............................6-7 Maintenance Footnotes ...................................6-9 Owner Checks and Services ..........................6-11 At Each Fuel Fill ..........................................6-11 At Least Once a Month .................................6-12 At Least Once a Year ...................................6-12 Recommended Fluids and Lubricants ...............6-15 Normal Maintenance Replacement Parts ..........6-18 Engine Drive Belt Routing ..............................6-19 Maintenance Record .....................................6-20 6-1 Maintenance Schedule Introduction Important: Keep engine oil at the proper level and change as recommended. Have you purchased the GM Protection Plan? The Plan supplements your new vehicle warranties. See your Warranty and Owner Assistance booklet or your dealer for details. Maintenance Requirements Notice: Maintenance intervals, checks, inspections, replacement parts, and recommended ﬂuids and lubricants as prescribed in this manual are necessary to keep your vehicle in good working condition. Any damage caused by failure to follow scheduled maintenance may not be covered by warranty. 6-2 Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance is important. Improper vehicle maintenance can even 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 the Maintenance Schedule We at General Motors want to help you keep your vehicle in good working condition. But we do not know exactly how you will drive it. You may drive very short distances only a few times a week. Or you may 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 other ways. Because of all the different ways people use their vehicles, maintenance needs vary. You may need more frequent checks and replacements. So please read the following and note how you drive. If you have any questions on how to keep your vehicle in good condition, see your GM Goodwrench® dealer. This schedule is for vehicles that: • carry passengers and cargo within recommended limits. You will ﬁnd these limits on the Tire and Loading Information label. See “Loading Your Vehicle” in your owner manual. • are driven on reasonable road surfaces within legal driving limits. • are driven off-road in the recommended manner, pickup models only. See “Off-Road Driving” in your owner manual. • use the recommended fuel. See Diesel Engine Fuel on page 5-2. The services in Scheduled Maintenance on page 6-4 should be performed when indicated. See Additional Required Services on page 6-7 and Maintenance Footnotes on page 6-9 for further information. {CAUTION: Performing maintenance work on a vehicle can be dangerous. In trying to do some jobs, you can be seriously injured. Do your own maintenance work only if you have the required know-how and the proper tools and equipment for the job. If you have any doubt, see your GM Goodwrench® dealer to have a qualiﬁed technician do the work. See “Doing Your Own Service Work” in your owner manual. Some maintenance services can be complex. So, unless you are technically qualiﬁed and have the necessary equipment, you should have your GM Goodwrench® dealer do these jobs. 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 If the engine oil life system is ever reset accidentally, you must service your vehicle within 3,000 miles (5 000 km) since your last service. Remember to reset the oil life system whenever the oil is changed. See Engine Oil Life System on page 5-24 for information on the Engine Oil Life System and resetting the system. When the message or light appears, certain services, checks, and inspections are required. Required services are described in the following for “Maintenance I” and “Maintenance II.” Generally, it is recommended that your ﬁrst service be Maintenance I, your second service be Maintenance II, and that you alternate Maintenance I and Maintenance II thereafter. However, in some cases, Maintenance II may be required more often. Maintenance I — Use Maintenance I if the message or light comes on within 10 months since the vehicle was purchased or Maintenance II was performed. Maintenance II — Use Maintenance II if the previous service performed was Maintenance I. Always use Maintenance II whenever the message or light comes on 10 months or more since the last service or if the message or light has not come on at all for one year. Owner Checks and Services on page 6-11 tells you what should be checked, when to check it, and what you can easily do to help keep your vehicle in good condition. The proper replacement parts, ﬂuids, and lubricants to use are listed in Recommended Fluids and Lubricants on page 6-15 and Normal Maintenance Replacement Parts on page 6-18. When your vehicle is serviced, make sure these are used. All parts should be replaced and all necessary repairs done before you or anyone else drives the vehicle. We recommend the use of genuine GM parts. Scheduled Maintenance When the CHANGE ENGINE OIL message (pickup models) or the change engine oil light (van models) comes on, it means that service is required for your vehicle. Have your vehicle serviced as soon as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best conditions, the engine oil life system may not indicate that vehicle service is necessary for over a year. However, your engine oil and ﬁlter must be changed at least once a year and at this time the system must be reset. Your GM Goodwrench® dealer has GM-trained service technicians 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 5-21. Reset oil life system. See Engine Oil Life System on page 5-24. An Emission Control Service. Allison Transmission® only: Replace external transmission ﬁlter at the ﬁrst maintenance service performed on the vehicle. Lubricate chassis components. See footnote #. Visually check for any leaks or damage. See footnote (a). Inspect engine air cleaner ﬁlter or change indicator, if equipped. If necessary, replace ﬁlter. See Engine Air Cleaner/Filter on page 5-25. See footnote (b). Rotate tires and check inﬂation pressures and wear. See “Tire Inspection and Rotation” in your owner manual. See “Tire Wear Inspection” in At Least Once a Month on page 6-12. Inspect brake system. See footnote (c). 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 (d). • • • • • • • • • • • • • • • • 6-5 Scheduled Maintenance (cont’d) Service Maintenance I Maintenance II Inspect engine cooling system. See footnote (e). Inspect wiper blades. See footnote (f). Inspect restraint system components. See footnote (g). Lubricate body components. See footnote (h). Check transmission ﬂuid level and add ﬂuid as needed. Van models: Replace both fuel ﬁlters. An Emission Control Service. See footnotes † and (i). Pickup models: Fuel ﬁlter service. An Emission Control Service. See footnotes † and (j). Inspect shields and underhood insulation, vans with GVWR above 10,000 lbs (4 536 kg) and all pickups. See footnote (k). Check air intake system. See footnote (l). Van models: Inspect throttle system. See footnote (m). • • • • • • • • • • 6-6 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. Service and Miles (Kilometers) Inspect fuel system for damage or leaks. Inspect exhaust system for loose or damaged components. Pickup models: 6-speed manual transmission only: Change clutch ﬂuid. See footnote (n). Pickup models: 5-speed manual transmission only: Change manual transmission ﬂuid. Pickup models: Change automatic transmission ﬂuid and external transmission ﬁlter (severe service). See footnote (p). Pickup models: Change automatic transmission ﬂuid and external transmission ﬁlter (normal service). Additional Required Services 75,000 25,000 (40 000) 50,000 (80 000) (120 000) 100,000 (160 000) 125,000 (200 000) 150,000 (240 000) • • • • • • • • • • • • • • • • • • • • • • • • • • • • 6-7 Additional Required Services (cont’d) 25,000 (40 000) 50,000 (80 000) 75,000 (120 000) 100,000 (160 000) 125,000 (200 000) 150,000 (240 000) • • • • • • • • • • Service and Miles (Kilometers) Van models: Change automatic transmission ﬂuid and ﬁlter (severe service). See footnote (p). Van models: Change automatic transmission ﬂuid and ﬁlter (normal service). Pickup models: Four-wheel drive with automatic transfer case only: Change transfer case ﬂuid. See footnote (q). Van models: Replace spark plugs and inspect spark plug wires. An Emission Control Service. Engine cooling system service (or every ﬁve years, whichever occurs ﬁrst). An Emission Control Service. See footnote (r). Inspect engine accessory drive belt. An Emission Control Service. See footnote (s). 6-8 Maintenance Footnotes † The U.S. Environmental Protection Agency or the California Air Resources Board has determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of the vehicle’s useful life. We, however, urge that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded. # Lubricate the front suspension, steering linkage, transmission shift linkage (pickup models), rear driveline center splines (van models), and parking brake cable guides. Pickup models only: Control arm ball joints require lubrication but should not be lubricated unless their temperature is 10°F (-12°C) or higher, or they could be damaged. Vehicles used under severe commercial

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2006 Chevrolet Duramax Owners Manual