2011 Chevrolet Express Owners Manual

Reset the system whenever the engine oil is changed so that the system can calculate the next engine oil change. To reset the system: 1. Turn the ignition key to ON/RUN

with the engine off.

2. Fully press and release the

accelerator pedal slowly three times within five seconds.

3. Turn the key to LOCK/OFF. If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the engine oil life system has not reset. Repeat the procedure.

Vehicle Care

10-11

Automatic Transmission Fluid (4-Speed Transmission) If the vehicle has a diesel engine, see the Duramax diesel supplement for more information. When to Check and Change Automatic Transmission Fluid A good time to check the automatic transmission fluid level is when the engine oil is changed. Change the fluid and filter at the intervals listed in Scheduled Maintenance on page 11‑3 and be sure to use the transmission fluid listed in Recommended Fluids and Lubricants on page 11‑8.

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10-12

Vehicle Care

How to Check Automatic Transmission Fluid Because this operation can be a little difficult, it may be decided to have this done at the dealer service department. If not taken to the dealer, be sure to follow all the instructions here or a false reading on the dipstick could result. Notice: Too much or too little fluid can damage the transmission. Too much can mean that some of the fluid could come out and fall on hot engine parts or exhaust system parts, starting a fire. Too little fluid could cause the transmission to overheat. Be sure to get an accurate reading if checking the transmission fluid.

Wait at least 30 minutes before checking the transmission fluid level if you have been driving: . When outside temperatures are

above 32°C (90°F).

. 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 82°C to 93°C (180°F to 200°F). Get the vehicle warmed up by driving about 24 km (15 mi) when outside temperatures are above 10°C (50°F). If it is colder than 10°C (50°F), drive the vehicle in 3 (Third) until the engine temperature gauge moves and then remains steady for 10 minutes.

A cold fluid check can be made after the vehicle has been sitting for eight hours or more with the engine off, but this is used only as a reference. Let the engine run at idle for five minutes if outside temperatures are 10°C (50°F) or more. If it is colder than 10°C (50°F), the engine may have to idle longer. Should the fluid level be low during this cold check, the fluid must be checked hot before adding fluid. Checking the fluid hot will give a more accurate reading of the fluid level.

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Checking the Fluid Level Prepare the vehicle as follows: 1. Park the vehicle on a level

place. Keep the engine running. 2. With the parking brake applied, place the shift lever in P (Park).

3. 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 P (Park).

4. Let the engine run at idle for

three minutes or more.

Vehicle Care

10-13

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 10‑6 for more information. 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.

3. 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. If the fluid level is in the acceptable range, push the dipstick back in all the way; then flip the handle down to lock the dipstick in place.

4.

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10-14

Vehicle Care

How to Add Automatic Transmission Fluid Refer to Recommended Fluids and Lubricants on page 11‑8 to determine what kind of transmission fluid to use. 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 0.5 L (1 pt). Do not overfill.

Notice: Use of the incorrect automatic transmission fluid may damage the vehicle, and the damages may not be covered by the vehicle warranty. Always use the automatic transmission fluid listed in Recommended Fluids and Lubricants on page 11‑8. . After adding fluid, recheck the fluid level as described under “How to Check Automatic Transmission Fluid,” 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.

Automatic Transmission Fluid (6-Speed Transmission)

When to Check and Change Automatic Transmission Fluid It is usually not necessary to check the transmission fluid level. The only reason for fluid loss is a transmission leak or overheating the transmission. If a small leak is suspected, use the following procedures to check the fluid level. However, if there is a large leak, then it may be necessary to have the vehicle towed to a dealer service department and have it repaired before driving the vehicle further. Change the fluid and filter at the intervals listed in Scheduled Maintenance on page 11‑3, and be sure to use the transmission fluid listed in Recommended Fluids and Lubricants on page 11‑8.

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How to Check Automatic Transmission Fluid Because this operation can be difficult, it is recommended to have this check done at the dealer service department, which can monitor the transmission temperature. The transmission fluid level increases with temperature. To obtain a highly accurate fluid level check, the transmission temperature must be measured. If it is decided to check the fluid level, be sure to follow all the instructions here, or a false reading on the dipstick may occur. Notice: Too much or too little fluid can damage the transmission. Too much can mean that some of the fluid could come out and fall on hot engine parts or exhaust system parts, starting a fire. Too little fluid could cause the transmission to overheat. Be sure to get an accurate reading if checking the transmission fluid.

Wait at least 30 minutes with the engine Off, before checking the transmission fluid level if the vehicle has been driven:

In hot weather, when outside temperatures are above 32°C (90°F). The vehicle is heavily loaded.

. At high speed for quite a while in

hot weather. In heavy traffic and hot weather.

. While pulling a trailer. After driving under these conditions, a hot check can be performed. The fluid should be Hot, which is 71°C to 93°C (160°F to 200°F). A cold fluid level check can be performed 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 is between 15°C to 32°C (60°F to 90°F). Should the fluid level be low during this cold check, the fluid must be checked

Vehicle Care

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Warm or Hot before adding fluid. If the outside temperature is colder than 15°C (60°F) or hotter than 32°C (90°F), a cold check cannot be performed. A warm fluid level check can be performed by driving the vehicle under lightly loaded conditions and outside temperatures between 10°C to 27°C (50°F to 80°F). The vehicle should be driven for at least 24 km (15 mi) before performing a warm check. Checking the fluid Warm or Hot will give a more accurate reading of the fluid level than a cold check. Because the vehicle is equipped with a high-efficiency air-to-oil cooler, the transmission fluid temperature may not reach the required Hot fluid level checking temperature under normal lightly loaded driving vehicle conditions.

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10-16

Vehicle Care

Checking the Fluid Level Prepare the vehicle as follows: 1. Park the vehicle on a level

place. Keep the engine running. 2. With the parking brake applied, place the shift lever in P (Park).

3. With foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. When M is reached, move the selector from M1
through M3. Then, position the shift lever in P (Park).

4. Let the engine run at idle for

two minutes or more.

Then, without shutting off the engine:

The transmission dipstick is located near the center of the engine compartment and will be labeled with the graphic shown. See Engine Compartment Overview on page 10‑6 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.

A. COLD Range B. WARM Range C. HOT Range

3. Check both sides of the dipstick,

and read the lower level. The fluid level must be in the COLD (A) range for a cold check, transmission temperature 27°C to 32°C (80°F to 90°F), between the COLD (A) and HOT (C) range for a WARM (B) check, 50°C to 60°C (122°F to 140°F) or in the HOT (C) cross-hatched range for a hot check, 71°C to 93°C (160°F to 200°F). Be sure to keep the dipstick pointed down to get an accurate reading.

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Using a funnel, add fluid down the transmission dipstick tube only after checking the transmission fluid while it is warm or 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 middle of the WARM (A) or HOT (B) range depending on the ambient temperature and prior driving conditions. Refer to “How to Check Automatic Transmission Fluid”, earlier in this section for instructions on driving to achieve warm or hot transmission fluid. It does not take much fluid, generally less than 0.5 L (1 pt). Do not overfill.

Vehicle Care

10-17

Notice: Use of the incorrect automatic transmission fluid may damage the vehicle, and the damages may not be covered by the vehicle warranty. Always use the automatic transmission fluid listed in Recommended Fluids and Lubricants on page 11‑8. . After adding fluid, recheck the fluid level as described under “How to Check Automatic Transmission Fluid,” 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.

4.

If the fluid level is in the acceptable range, push the dipstick back in all the way; then flip the handle down to lock the dipstick in place.

How to Add Automatic Transmission Fluid Refer to Recommended Fluids and Lubricants on page 11‑8 to determine what kind of transmission fluid to use.

A. WARM Range B. HOT Range

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10-18

Vehicle Care

Engine Air Cleaner/Filter If the vehicle has a diesel engine, see the Duramax diesel supplement for more information.

The engine air cleaner/filter is located near the center of the engine compartment. See Engine Compartment Overview on page 10‑6 for more information on location.

When to Inspect the Engine Air Cleaner/Filter Inspect the air cleaner/filter at the scheduled maintenance intervals and replace it at the first oil change after each 80 000 km (50,000 mi) interval. See Scheduled Maintenance on page 11‑3 for more information. If driving in dusty/dirty conditions, inspect the filter at each engine oil change. How to Inspect the Engine Air Cleaner/Filter To inspect the air cleaner/filter, remove the filter from the vehicle and lightly shake the filter to release loose dust and dirt. If the filter remains covered with dirt, a new filter is required. Never use compressed air to clean the filter.

To inspect or replace the engine air cleaner/filter, do the following: 1. Unhook the retainer clips and

remove the cover.

2. Lift the filter out of the engine air

cleaner/filter housing. Care should be taken to dislodge as little dirt as possible.

3. Clean the engine air cleaner/

4.

filter housing. Inspect or replace the engine air cleaner/filter. Make sure that the filter fits properly into the housing.

5. Reinstall the cover and fasten

the retaining clips.

{ WARNING

Operating the engine with the air cleaner/filter off can cause you or others to be burned.

(Continued)

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WARNING (Continued)

The air cleaner not only cleans the air; it helps to stop flames if the engine backfires. Use caution when working on the engine and do not drive with the air cleaner/ filter off.

Notice: 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.

Cooling System If the vehicle has a diesel engine, see “Van Models” under “Cooling System” in the Duramax diesel supplement. The cooling system allows the engine to maintain the correct working temperature.

A. Radiator Pressure Cap B. Coolant Recovery Tank C. Engine Cooling Fan

(Out of View)

{ WARNING

An electric engine cooling fan can start even when the engine is not running. To avoid injury, always keep hands, clothing, and tools away from any engine cooling fan.

Vehicle Care

10-19

{ 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.

Notice: Using coolant other than DEX-COOL® can cause premature engine, heater core, or radiator corrosion. In addition, the engine coolant could require changing sooner, at 50 000 km (30,000 mi) or 24 months, whichever occurs first. Any repairs would not be covered by the vehicle warranty. Always use DEX-COOL (silicate-free) coolant in the vehicle.

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10-20

Vehicle Care

Engine Coolant The cooling system in the vehicle is filled with DEX-COOL® engine coolant. This coolant is designed to remain in the vehicle for 5 years or 240 000 km (150,000 mi), whichever occurs first. 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 on page 10‑24.

What to Use

{ 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 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.

Notice: If an improper coolant mixture is used, the engine could overheat and be badly damaged. The repair cost would not be covered by the vehicle warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core, and other parts.

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Notice: If extra inhibitors and/or additives are used in the vehicle cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed in this manual for the cooling system. See Recommended Fluids and Lubricants on page 11‑8 for more information. Never dispose of engine coolant by putting it in the trash, pouring it on the ground, or into sewers, streams, or bodies of water. Have the coolant changed by an authorized service center, familiar with legal requirements regarding used coolant disposal. This will help protect the environment and your health.

Checking Coolant The vehicle must be on a level surface when checking the coolant level. Check to see if coolant is visible in the coolant recovery tank. If the coolant inside the coolant recovery 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 COLD FILL mark, add a 50/50 mixture of clean, drinkable water and DEX-COOL coolant at the coolant recovery tank, but be sure the cooling system is cool before this is done.

Vehicle Care

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The coolant recovery tank cap has this symbol on it. When the engine is cold, the coolant level should be at or above the COLD FILL mark. If it is not, there could be a leak in the cooling system. If the coolant is low, add the coolant or take the vehicle to a dealer for service.

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10-22

Vehicle Care

How to Add Coolant to the Recovery Tank for Gasoline Engines If the vehicle has a diesel engine, see “How to Add Coolant to the Coolant Recovery Tank” under “Van Models” in the Cooling System section of the Duramax diesel supplement for the proper coolant fill procedure.

{ WARNING

You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol and it will burn if the engine parts are hot enough. Do not spill coolant on a hot engine.

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

If coolant is needed, add the proper DEX-COOL coolant mixture at the coolant recovery tank. How to Add Coolant to the Radiator If the vehicle has a diesel engine, see “How to Add Coolant to the Radiator” under “Van Models” in the Cooling System section of the Duramax diesel supplement for the proper radiator fill procedure.

{ 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.

{ WARNING

Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the surge tank pressure cap — even a little — they can come out at high speed. 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 if you ever have to turn the pressure cap.

If coolant is needed, add the proper mixture directly to the radiator, but be sure the cooling system is cool before this is done.

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Vehicle Care

10-23

1. Remove the radiator pressure cap when the cooling system, including the radiator pressure cap and upper radiator hose, is no longer hot. Turn the pressure cap slowly counterclockwise until it first stops. Do not press down while turning the pressure cap. If a hiss is heard, wait for that to stop. A hiss means there is still some pressure left.

2. Keep turning the pressure cap, but now push down as you turn it. Remove the pressure cap.

3. Fill the radiator with the proper DEX-COOL coolant mixture, up to the base of the filler neck. See Recommended Fluids and Lubricants on page 11‑8 for more information about the proper coolant mixture.

4. Fill the coolant recovery tank to

the COLD FILL mark.

5. Reinstall the cap back on the

coolant recovery tank, but leave the radiator pressure cap off.

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10-24

Vehicle Care

8. Replace the pressure cap. At

any time during this procedure if coolant begins to flow out of the filler neck, reinstall the pressure cap.

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

Engine Overheating If the vehicle has a diesel engine, see the Duramax diesel supplement for more information. The vehicle has an indicator to warn of engine overheating. There is an engine coolant temperature gauge on the vehicle's instrument panel. See Engine Coolant Temperature Gauge on page 5‑15 for more information. If the decision is made not to lift the hood when this warning appears, but instead get service help right away.

See Roadside Assistance Program (U.S. and Canada) on page 13‑8 or Roadside Assistance Program (Mexico) on page 13‑10. 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 fans are running. If the engine is overheating, both fans should be running. If they are not, do not continue to run the engine and have the vehicle serviced. See if the engine cooling fan speed increases when idle speed is doubled by pushing the accelerator pedal down. If it does not, the vehicle needs service. Turn off the engine. Notice: Engine damage from running the engine without coolant is not covered by the warranty. Notice: If the engine catches fire because of being driven with no coolant, the vehicle can be badly

6. Start the engine and let it run

until the upper radiator hose can be felt getting hot. Watch out for the engine cooling fan.

7. By this time, the coolant level inside the radiator filler neck may be lower. If the level is lower, add more of the proper DEX-COOL coolant mixture through the filler neck until the level reaches the base of the filler neck.

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damaged. The costly repairs would not be covered by the vehicle warranty. 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. 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. Tows a trailer. See “Driving on Grades” under Trailer Towing on page 9‑48.

If the overheat warning is displayed with no sign of steam: 1. Turn the air off. 2. Turn the heater on to the highest

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

Vehicle Care

10-25

3.

In heavy traffic, let the engine idle in N (Neutral) while stopped. If it is safe to do so, pull off the road, shift to P (Park) or N (Neutral) and let the engine idle.

If the temperature overheat gauge is no longer in the overheat zone or an overheat warning no longer displays, the vehicle can be driven. Continue to drive the vehicle slowly for about 10 minutes. Keep a safe vehicle distance from the vehicle in front. If the warning does not come back on, continue to drive normally. If the warning continues, pull over, stop, and park the vehicle right away. If there is still no sign of steam, push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes while you are parked. If the warning is still on, turn off the engine until it cools down. If the decision is made not to lift the hood, get service help right away.

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10-26

Vehicle Care

Engine Fan 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 partially disengages. This fan noise may be heard when starting the engine. It will go away as the fan clutch partially disengages.

Power Steering Fluid

The power steering fluid reservoir is located in the engine compartment on the driver side of the vehicle. See Engine Compartment Overview on page 10‑6 for reservoir location. When to Check Power Steering Fluid It is not necessary to regularly check power steering fluid unless there is a leak suspected in the system or an unusual noise is heard. A fluid loss in this system could indicate a problem. Have the system inspected and repaired.

How to Check Power Steering Fluid To check the power steering fluid, do the following: 1. Turn the key off and let the

engine compartment cool down. 2. Wipe the cap and the top of the

reservoir clean.

3. Unscrew the cap and wipe the

dipstick with a clean rag.

4. Replace the cap and completely

tighten it.

5. Then remove the cap again and

look at the fluid level on the dipstick.

The level should be at the COLD FILL mark. If necessary, add only enough fluid to bring the level up to the mark. To prevent contamination of brake fluid, never check or fill the power steering reservoir with the brake master cylinder cover off.

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What to Use To determine what kind of fluid to use, see Recommended Fluids and Lubricants on page 11‑8. Always use the proper fluid. Failure to use the proper fluid can cause leaks and damage hoses and seals.

Washer Fluid

What to Use When the vehicle needs windshield washer fluid, be sure to read the manufacturer's instructions before use. If operating the vehicle in an area where the temperature may fall below freezing, use a fluid that has sufficient protection against 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 on page 10‑6 for reservoir location. Notice

. When using concentrated

washer fluid, follow the manufacturer's instructions for adding water.

Vehicle Care

10-27

. 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. Also, water does not clean as well as washer fluid.

. 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.

. Do not use engine coolant

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

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10-28

Vehicle Care

Brakes This vehicle has disc 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.

Notice: 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 evenly tighten wheel nuts in the proper sequence to torque specifications in Capacities and Specifications on page 12‑2. 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 might be required.

Brake Adjustment Every time the brakes are applied, with or without the vehicle moving, the brakes adjust for wear. Replacing Brake System Parts The braking system on a vehicle is complex. Its many parts have to be of top quality and work well together if the vehicle is to have really good braking. The vehicle was designed and tested with top-quality brake parts. When parts of the braking system are replaced, be sure to get new, approved replacement parts. If this is not done, the brakes might not work properly. For example, installing disc brake pads that are wrong for the vehicle, can change the balance between the front and rear brakes — for the worse. The braking performance expected can change in many other ways if the wrong replacement brake parts are installed.

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Brake Fluid

The brake master cylinder reservoir is filled with DOT 3 brake fluid. See Engine Compartment Overview on page 10‑6 for the location of the reservoir. There are only two reasons why the brake fluid level in the reservoir might go down:

The brake fluid level goes down because of normal brake lining wear. When new linings are installed, the fluid level goes back up.

. A fluid leak in the brake

hydraulic system can also cause a low fluid level. Have the brake hydraulic system fixed, since a leak means that sooner or later the brakes will not work well.

Vehicle Care

10-29

Do not top off the brake 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 brake fluid, as necessary, only when work is done on the brake hydraulic system.

{ WARNING

Refer to the Maintenance Schedule to determine when to check the brake fluid. See Scheduled Maintenance on page 11‑3. Checking Brake Fluid Check brake fluid by looking at the brake fluid reservoir. See Engine Compartment Overview on page 10‑6.

If too much brake fluid is added, it can spill on the engine and/or fuel operated heater parts, if equipped. If the vehicle has a diesel engine and a fuel operated heater, see “Fuel Operated Heater (FOH)” in the diesel engine supplement. The fluid will 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 hydraulic system. See “Checking Brake Fluid” in this section.

The fluid level should be above MIN. If it is not, have the brake hydraulic system checked to see if there is a leak.

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10-30

Vehicle Care

After work is done on the brake hydraulic system, make sure the level is above the MIN but not over the MAX mark.

What to Add Use only new DOT 3 brake fluid from a sealed container. See Recommended Fluids and Lubricants on page 11‑8. Always clean the brake fluid reservoir cap and the area around the cap before removing it. This helps keep dirt from entering the reservoir.

{ WARNING

With the wrong kind of fluid in the brake hydraulic system, the brakes might not work well. This could cause a crash. Always use the proper brake fluid.

Notice

. Using the wrong fluid can

badly damage brake hydraulic system parts. For example, just a few drops of mineral-based oil, such as engine oil, in the brake hydraulic system can damage brake hydraulic system parts so badly that they will have to be replaced. Do not let someone put in the wrong kind of fluid.

. If brake fluid is spilled on the

vehicle's painted surfaces, the paint finish can be damaged. Be careful not to spill brake fluid on the vehicle. If you do, wash it off immediately.

Battery Refer to the replacement number shown on the original battery label when a new battery is needed. See Engine Compartment Overview on page 10‑6 for battery location.

{ DANGER

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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Vehicle Care

10-31

Vehicle Storage

{ WARNING

All-Wheel Drive

Transfer Case

When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See Scheduled Maintenance on page 11‑3.

How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface.

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 on page 10‑88 for tips on working around a battery without getting hurt.

Infrequent Usage: Remove the black, negative (−) cable from the battery to keep the battery from running down. Extended Storage: Remove the black, negative (−) cable from the battery or use a battery trickle charger.

If the level is below the bottom of the filler plug hole, some lubricant will need to be added. Add enough lubricant to raise the level to the bottom of the filler plug hole. Use care not to overtighten the plug.

What to Use Refer to Recommended Fluids and Lubricants on page 11‑8 to determine what kind of lubricant to use.

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10-32

Vehicle Care

Front Axle

When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See Scheduled Maintenance on page 11‑3.

How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface.

What to Use Refer to Recommended Fluids and Lubricants on page 11‑8 to determine what kind of lubricant to use.

Rear Axle

When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See Scheduled Maintenance on page 11‑3.

If the level is below the bottom of the fill plug hole, some lubricant may need to be added. When the differential is cold, add enough lubricant to raise the level to 10 mm (3/8 in) below the fill plug hole. When the differential is at operating temperature (warm), add enough lubricant to raise the level to the bottom of the fill plug hole.

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Vehicle Care

10-33

These standards apply only to vehicles sold in the United States. Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser or while it is in use; or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

What to Use Refer to Recommended Fluids and Lubricants on page 11‑8 to determine what kind of lubricant to use.

Noise Control System The following information relates to compliance with federal noise emission standards for vehicles with a Gross Vehicle Weight Rating (GVWR) of more than 4 536 kg (10,000 lbs). The Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system during the life of the vehicle. The noise control system warranty is given in the vehicle warranty booklet.

How to Check Lubricant

To get an accurate reading, the vehicle should be on a level surface. If you have the 1500 Series, the proper level is from 15 mm (5/8 in) to 40 mm (1 5/8 in) below the bottom of the fill plug hole. The proper level for the 2500 and 3500 Series is from 0 to 6 mm (1/4 in) below the bottom of the fill plug hole. Add only enough fluid to reach the proper level.

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10-34

Vehicle Care

Among those acts presumed to constitute tampering are the acts listed below.

Insulation: . Removal of the noise shields or

any underhood insulation.

Engine: . Removal or rendering engine speed governor, if the vehicle has one, inoperative so as to allow engine speed to exceed manufacturer specifications.

Fan and Drive: . Removal of fan clutch, if the

vehicle has one, or rendering clutch inoperative.

. Removal of the fan shroud, if

the vehicle has one.

Air Intake: . Removal of the air cleaner

silencer.

. Modification of the air cleaner.

Exhaust: . Removal of the muffler and/or

resonator.

. Removal of the exhaust pipes

and exhaust pipe clamps.

Fuel Operated Heater (FOH) — Diesel Engine: . Removal of the muffler.

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.

2. Firmly apply both the parking brake and the regular brake. See Parking Brake on page 9‑34. Do not use the accelerator pedal, and be ready to turn off the engine immediately if it starts.

3. Try to start the engine in each gear. The vehicle should start only in P (Park) or N (Neutral). If the vehicle starts in any other position, contact your dealer for service.

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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.

Vehicle Care

10-35

2. Firmly apply the parking brake.

See Parking Brake on page 9‑34. 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.

The ignition should turn to LOCK/OFF only when the shift lever is in P (Park). The ignition key should come out only in LOCK/OFF.

Contact your dealer if service is required.

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Vehicle Care

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.

Wiper Blade Replacement Windshield wiper blades should be inspected for wear and cracking. See Scheduled Maintenance on page 11‑3 for more information on wiper blade inspection. Replacement blades come in different types and are removed in different ways. To remove the type with a release clip, do the following: 1. Lift the wiper arm until it locks

into a vertical position.

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. 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.

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4. To install the new wiper insert, slide the notched end last, into the end with two blade claws. Then slide the insert all the way through the blade claws at the opposite end.

5. Make sure that the notches are

locked by the bottom claws. Make sure that all other claws are properly locked on both sides of the insert slot.

6. Put the blade assembly pivot in

the wiper arm hook. Pull it up until the pivot locking tab locks in the hook slot.

7. Carefully lower the wiper arm and blade assembly into the windshield.

Vehicle Care

10-37

Bulb Replacement For the proper type of replacement bulbs, see Replacement Bulbs on page 10‑43. For any bulb‐changing procedure not listed in this section, contact your dealer.

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.

2. Press down on the blade

assembly pivot locking tab. Pull down on the blade assembly to release it from the wiper arm hook.

3. The insert has two notches at

one end that are locked by bottom claws of the blade assembly. At the notched end, pull the insert from the blade assembly.

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Vehicle Care

Headlamps

Composite Headlamp

A. High‐Beam Headlamp B. Low‐Beam Headlamp To remove the headlamp assembly from the vehicle and access the bulbs: 1. Open the hood. See Hood on

page 10‑4 for more information.

2. Remove the two bolts from the

5. Disconnect the electrical

headlamp assembly.

connector.

3. Lift the headlamp assembly to release the lower tabs from the radiator support.

4. Turn the headlamp forward and

upward to remove it from the grille.

6. Turn the bulb counterclockwise

one quarter turn to remove it from the headlamp assembly.

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Sealed‐Beam Headlamp

Vehicle Care

10-39

7.

Install the new bulb into the headlamp assembly and connect the electrical connector.

8. Reverse the steps to reinstall the

headlamp assembly. To prevent headlamp vibration and shortened bulb life, be sure to insert the headlamp assembly tabs in the slots at the lower portion of the housing.

3. Disconnect the electrical

connector (B) and remove the headlamp bulb (A).

4. Reverse Steps 1 through 3 to

reinstall the headlamp.

A. Headlamp retainer screws B. Headlamp retainer C. Sealed‐beam headlamp bulb 1. Remove the four screws (A)

from the headlamp retainer (B). Pull the retainer (B) out and set it aside.

2. Pull the bulb (C) forward to gain

access to the electrical connector.

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Vehicle Care

Front Turn Signal, Sidemarker, and Parking Lamps

To replace the front turn signal, sidemarker, and/or parking lamp bulb(s):

A. Front Parking and Turn

Signal Lamp

B. Front Sidemarker Lamp

1. Use a small tool to unlatch the

outboard clip on the lamp by pushing inboard and prying the lamp assembly forward.

2. Remove the lamp from the grille. 3. Turn the bulb socket

counterclockwise one quarter turn and remove it from the lamp assembly.

4. Remove the bulb from the

socket by pulling it straight out.

5. Replace the bulb.

6. Turn the bulb socket clockwise

to reinstall it in the lamp assembly.

7. Reinstall the lamp assembly into

the grille until the outboard clip snaps into place.

Taillamps To replace a taillamp/turn signal lamp or back‐up lamp bulb:

1. Remove the two inboard nuts from the inside of the taillamp assembly.

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Vehicle Care

10-41

4. Remove the third nut (C) from

7. Remove the bulb by pulling it

the upper outboard side of the lamp.

straight out.

8. Push the new bulb into the

5. Remove the taillamp assembly

socket.

from the vehicle.

9. Reinstall the bulb socket by turning it clockwise into the lamp assembly.

10. Reverse Steps 1 through 5 to reinstall the taillamp assembly and applique.

2. The third nut (C) is under the applique piece (B) above the lamp. Remove the two inboard applique nuts. Pull the applique (B) straight rearward slightly to clear the studs. Then rotate the applique (B) just far enough to gain access to the outer push pins (A).

3. Carefully disconnect the push

pins (A) from the applique bracket

6. Remove the taillamp/turn signal

lamp (A) or back‐up lamp (B) bulb socket by turning it counterclockwise one quarter turn and pulling it out of the lamp assembly.

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Vehicle Care

Center High-Mounted Stoplamp (CHMSL) The Center High-Mounted Stoplamp (CHMSL) is located above the rear doors at the center of the vehicle. To replace a bulb:

1. Remove the two screws from the

CHMSL assembly.

2. Remove the CHMSL assembly. 3. Turn the bulb socket

counterclockwise one quarter turn to remove it from the lamp assembly.

4. Pull the old bulb straight out of

the socket and push the new bulb into the socket.

5. Turn the bulb socket clockwise

one quarter turn to install it in the lamp assembly.

6. Reinstall the CHMSL assembly

and two screws.

Do not block or damage the CHMSL when items are loaded on the roof of the vehicle.

License Plate Lamp To replace one of these bulbs:

A. Bulb Socket B. License Plate Bulb Assembly C. Screws

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1. Remove the screws (C) that secure the license plate bulb assembly (B).

2. Turn the bulb socket (A)

counterclockwise and pull the bulb straight out of the socket. Install the new bulb.

3. 4. Reverse steps 1 and 2 to

reinstall the license plate bulb assembly.

Vehicle Care

10-43

Exterior Lamp

Headlamps

Composite High-Beam Headlamp Composite Low-Beam Headlamp Sealed Beam Headlamp

Bulb

Number

9005LL

9006LL

H6054

For replacement bulbs not listed here, contact your dealer.

Replacement Bulbs

Exterior Lamp

Back-up, Rear Parking, Stoplamp, and Turn Signal Lamp Center High‐Mounted Stop Lamp (CHMSL) Front Parking and Turn Signal Lamp Front Sidemarker Lamp License Plate Lamp

Bulb

Number

3157KX

912LL

3157KX

194LL

194LL

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Vehicle Care

Electrical System

Electrical System Overload The vehicle has fuses and circuit breakers to protect against an electrical system overload. When the current electrical load is too heavy, the circuit breaker opens and closes, protecting the circuit until the current load returns to normal or the problem is fixed. This

greatly reduces the chance of circuit overload and fire caused by electrical problems. Fuses and circuit breakers protect the following in the vehicle: . Headlamp Wiring . Windshield Wiper Motor . Power Windows and Other

Power Accessories

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, the same amperage fuse can be borrowed. Choose some feature of the vehicle that is not needed to use and replace it as soon as possible. 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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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 and Circuit Breakers The wiring circuits in the vehicle are protected from short circuits by a combination of fuses and circuit breakers. 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.

Vehicle Care

10-45

Engine Compartment Fuse Block The fuse block is located in the engine compartment on the driver side of the vehicle. Notice: Spilling liquid on any electrical component on the vehicle may damage it. Always keep the covers on any electrical component.

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Vehicle Care

Mini Fuse

Usage

10

11
12
13
14
16

Right Stop/Turn Trailer Spare Spare Fuel System Control Module Ignition Body Control Module 5
Body Control Module 7
Body Control Module 4
Instrument Panel Cluster Trailer Wiring Spare Brake Switch Windshield Washer Horn

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

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Mini Fuse

17

18

19

20

21

22
23
24

25

26

Usage Transmission Air Conditioning Compressor Engine Control Module Battery Spare Left Stop/Turn Trailer Spare Spare Fuel Pump Auxiliary Power Outlet Body Control Module 3

Vehicle Care

10-47

Mini Fuse

Usage

Mini Fuse

Usage

27

28

29

30

31

32

33
34

Special Equipment Option Airbag Steering Wheel Sensor Engine Control Module Ignition/ Glow Plug Module Transmission Control Module Ignition Transmission Control Module Battery Spare Spare

35

36

51

52

53

54

55

56

Fuel Operated Heater Module Fuel System Control Module Battery Left High‐Beam Headlamp Right High‐Beam Headlamp Left Low‐Beam Headlamp Right Low‐Beam Headlamp Wiper Canister Vent Solenoid

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