2012 Chevrolet Express Owners Manual

Fluid Level” under Automatic Transmission Fluid (4-Speed Transmission) on page 10‑11 or Automatic Transmission Fluid (6-Speed Transmission) on page 10‑13.

E. Engine Oil Fill Cap. See “When

to Add Engine Oil” under Engine Oil on page 10‑7. F. Engine Oil Dipstick. See

“Checking Engine Oil” under Engine Oil on page 10‑7.

G. Engine Air Cleaner/Filter on

page 10‑16.

H. Power Steering Fluid Reservoir.

See Power Steering Fluid on page 10‑24.

I.

Brake Master Cylinder Reservoir. See Brake Fluid on page 10‑27.

J. Windshield Washer Fluid

Reservoir. See “Adding Washer Fluid” under Washer Fluid on page 10‑25.

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

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10-8

Vehicle Care

Checking Engine Oil It is a good idea to check the engine oil level at each fuel fill. In order to get an accurate reading, the vehicle must be on level ground. The engine oil dipstick handle is a yellow loop. See Engine Compartment Overview on page 10‑6 for the location of the engine oil dipstick. Obtaining an accurate oil level reading is essential: 1.

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

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

When to Add Engine Oil

If the oil is below the cross-hatched area at the tip of the dipstick, add 1 L (1 qt) of the recommended oil and then recheck the level. See “Selecting the Right Engine Oil” in this section for an explanation of what kind of oil to use. For engine oil crankcase capacity, see Capacities and Specifications on page 12‑2. Notice: Do not add too much oil. Oil levels above or below the acceptable operating range shown on the dipstick are harmful to the engine. If you find that you have an oil level above the operating range, i.e., the engine has so much oil that the oil level gets above the cross-hatched

area that shows the proper operating range, the engine could be damaged. You should drain out the excess oil or limit driving of the vehicle and seek a service professional to remove the excess amount of oil. See Engine Compartment Overview on page 10‑6 for the location of the engine oil fill cap. Add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when through. Selecting the Right Engine Oil Selecting the right engine oil depends on both the proper oil specification and viscosity grade. See Recommended Fluids and Lubricants on page 11‑12.

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Specification Use and ask for licensed engine oils with the dexos1™ approved certification mark. Engine oils meeting the requirements for the vehicle should have the dexos1
approved certification mark. This certification mark indicates that the oil has been approved to the dexos1
specification.

Notice: Failure to use the recommended engine oil or equivalent can result in engine damage not covered by the vehicle warranty. Check with your dealer or service provider on whether the oil is approved to the dexos1 specification.

Viscosity Grade SAE 5W‐30 is the best viscosity grade for the vehicle. Do not use other viscosity grade oils such as SAE 10W‐30, 10W‐40, or 20W‐50. If in an area of extreme cold, where the temperature falls below −20°F (−29°C), an SAE 0W‐30 oil should be used. An oil of this viscosity grade will provide easier cold starting for the engine at extremely low temperatures. When selecting an oil of the appropriate viscosity grade, always select an oil that meets the dexos1 specification or equivalent. See “Specification” for more information. Engine Oil Additives/Engine Oil Flushes Do not add anything to the oil. The recommended oils with the dexos specification and displaying the dexos certification mark are all that is needed for good performance and engine protection.

Vehicle Care

10-9

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

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10-10

Vehicle Care

Engine Oil Life System

When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on a combination of factors which include engine revolutions, engine temperature, and miles driven. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See Engine Oil Messages on page 5‑37. Change the oil as soon as possible within the next 1 000 km (600 mi).

It is possible that, if driving under the best conditions, the oil life system might indicate that an oil change is not necessary for up to a year. The engine oil and filter must be changed at least once a year and, at this time, the system must be reset. Your dealer has trained service people who will perform this work and reset the system. It is also important to check the oil regularly over the course of an oil drain interval and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 5 000 km (3,000 mi) since the last oil change. Remember to reset the oil life system whenever the oil is changed.

How to Reset the Engine Oil Life System Reset the system whenever the engine oil is changed 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.

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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 Maintenance Schedule on page 11‑3 and be sure to use the transmission fluid listed in Recommended Fluids and Lubricants on page 11‑12.

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. 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.

Vehicle Care

10-11

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.

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10-12

Vehicle Care

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.

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.

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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How to Add Automatic Transmission Fluid Refer to Recommended Fluids and Lubricants on page 11‑12 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 11‑12.

. 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.

Vehicle Care

10-13

However, if there is a large leak, then it may be necessary to have the vehicle towed to a dealer and have it repaired before driving the vehicle further. Change the fluid and filter at the intervals listed in Maintenance Schedule on page 11‑3, and be sure to use the transmission fluid listed in Recommended Fluids and Lubricants on page 11‑12. How to Check Automatic Transmission Fluid Because this operation can be difficult, it is recommended to have this check done at the dealer, 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.

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10-14

Vehicle Care

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 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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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.

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:

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

Vehicle Care

10-15

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. 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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10-16

Vehicle Care

How to Add Automatic Transmission Fluid Refer to Recommended Fluids and Lubricants on page 11‑12 to determine what kind of transmission fluid to use.

A. WARM Range B. HOT Range 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. 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 11‑12. . 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.

Engine Air Cleaner/Filter

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.

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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 Maintenance Schedule 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.

Vehicle Care

10-17

{ WARNING

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

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

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10-18

Vehicle Care

Cooling System 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.

{ 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.

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 10‑22.

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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.

Vehicle Care

10-19

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 11‑12 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.

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10-20

Vehicle Care

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.

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. How to Add Coolant to the Recovery Tank for Gasoline Engines

{ 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.

The coolant recovery tank cap has this symbol on it.

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

{ 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

(Continued)

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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.

WARNING (Continued)

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.

1. Remove the radiator pressure cap when the cooling system, including the radiator pressure cap and upper radiator hose, is

3. Fill the radiator with the proper DEX-COOL coolant mixture, up to the base of the filler neck.

Vehicle Care

10-21

See Recommended Fluids and Lubricants on page 11‑12 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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10-22

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 5‑16 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.

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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Notice: If the engine catches fire because of being driven with no coolant, the vehicle can be badly 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.

(Continued)

WARNING (Continued)

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 9‑50.

Vehicle Care

10-23

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

3.

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

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10-24

Vehicle Care

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.

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 Notice: Extremely small amounts of contamination can cause steering system damage and cause it to not work properly. Do not allow contaminants to contact the fluid side of the reservoir cap/dipstick or from entering the reservoir. 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.

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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. What to Use To determine what kind of fluid to use, see Recommended Fluids and Lubricants on page 11‑12. Always use the proper fluid. Failure to use the proper fluid can cause leaks and damage hoses and seals.

Washer Fluid

Notice

Vehicle Care

10-25

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.

. When using concentrated

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

. 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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10-26

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

10-27

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 Maintenance Schedule 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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10-28

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 11‑12. 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.

{ WARNING

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

10-29

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 Maintenance Schedule 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 10‑86 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.

A. Drain Plug B. Fill Plug If the level is below the bottom of the fill plug hole, located on the transfer case, some lubricant will need to be added. Add enough lubricant to raise the level to the bottom of the fill plug hole. Use care not to overtighten the plug.

What to Use Refer to Recommended Fluids and Lubricants on page 11‑12 to determine what kind of lubricant to use.

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10-30

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 Maintenance Schedule on page 11‑3.

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

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.

What to Use Refer to Recommended Fluids and Lubricants on page 11‑12 to determine what kind of lubricant to use.

If the level is below the bottom of the fill plug hole, some lubricant may need to be added.

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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. What to Use Refer to Recommended Fluids and Lubricants on page 11‑12 to determine what kind of lubricant to use.

Vehicle Care

10-31

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. These standards apply only to vehicles sold in the United States.

Rear Axle

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

To get an accurate reading, the vehicle should be on a level surface.

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10-32

Vehicle Care

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.

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.

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.

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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.

Automatic Transmission Shift Lock Control Function Check

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

1. Before starting this check, be

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

2. 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.

Vehicle Care

10-33

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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10-34

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.

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.

Wiper Blade Replacement Windshield wiper blades should be inspected for wear and cracking. See Maintenance Schedule on page 11‑3 for more information. Replacement blades come in different types and are removed in different ways. For proper type and length, see Maintenance Replacement Parts on page 11‑14. Notice: Allowing the wiper blade arm to touch the windshield when no wiper blade is installed could damage the windshield. Any damage that occurs would not be covered by your warranty. Do not allow the wiper blade arm to touch the windshield.

1. Lift the wiper arm away from

the windshield.

A. Wiper Arm B. Release Lever C. Blade Assembly

2. Push the release lever (B) to disengage the hook and push the wiper arm (A) out of the blade assembly (C).

3. Push the new blade assembly securely on the wiper arm until the release lever clicks into place.

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Bulb Replacement For the proper type of replacement bulbs, see Replacement Bulbs on page 10‑40. 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.

Vehicle Care

10-35

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

headlamp assembly.

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.

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10-36

Vehicle Care

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.

Sealed‐Beam Headlamp

2. Pull the bulb (C) forward to gain

access to the electrical connector.

5. Disconnect the electrical

connector.

6. Turn the bulb counterclockwise

7.

one quarter turn to remove it from the headlamp assembly. Install the new bulb into the headlamp assembly and connect the electrical connector.

8. Reverse the steps to reinstall

the headlamp assembly.

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.

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Vehicle Care

10-37

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.

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.

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10-38

Vehicle Care

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.

5. Remove the taillamp assembly

from the vehicle.

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

4. Remove the third nut (C) from

the upper outboard side of the lamp.

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.

7. Remove the bulb by pulling it

straight out.

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8. Push the new bulb into the

socket.

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.

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:

Vehicle Care

10-39

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.

1. Remove the two screws from the

CHMSL assembly.

2. Remove the CHMSL assembly.

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10-40

Vehicle Care

License Plate Lamp To replace one of these bulbs:

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

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.

Install the new bulb.

3. 4. Reverse steps 1 and 2 to

reinstall the license plate bulb assembly.

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

10-41

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.

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 power devices in the vehicle. Replace a bad fuse with a new one of the identical size and rating. If there is a problem on the road and a fuse needs to be replaced, 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.