1994 GMC Sierra Owners Manual

Gasoline Engines with Heavy Duty Emissions -

MaintenanceScheduleI ................................ MaintenanceScheduleII ................................ Maintenance Schedule I ............................... Maintenance Schedule I1 ............................. Maintenance Schedule I ............................... Maintenance Schedule 11 ............................... Owner Checks and Services .................................. Recommended Fluids & Lubricants ........................... Maintenance Record ....................................... Service Station Checks .... ., ................................

7-14 7-16 Explanation of Scheduled Maintenance Services . . . . . . . . . . . . . . . 7-18 7-22 7-25 7-27 7-28

7-10 7-12

Have you purchased the GM Protection Plan? The Plan supplements the new vehicle warranties . See your GM dealer for details .

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A Word About Maintenance We at General Motors want to help you keep your vehicle in good working condition. But we don’t know exactly how you’ll drive it. You may drive very short distances only a few times a week. Or you may drive long distances all the time in very hot, dusty weather. You may use your vehicle in making deliveries. Or you may drive it to work, to do errands, or in many other ways. Because of all the different ways people use their GM vehicles, maintenance needs vary. You may even need more frequent checks and replacements than you will find in the schedules in this section. So please read this section and note how you drive. If you have any questions on how to keep your vehicle in good condition? see your GM dealer, the place many GM owners choose to have their maintenance work done. Your dealer can be relied upon to use the proper parts and practices. Your Vehicle and the Environment Proper vehicle maintenance not only helps keep your vehicle in good working condition? but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance or the removal of important components can significantly affect the quality of the air we breathe. Improper fluid levels or even the wrong tire inflation can increase the level of emissions from your vehicle. To help protect our environment, and to help keep your vehicle in good condition, please maintain your vehicle properly. Recording Maintenance Services The Maintenance Record near the end of this section provides a place for you to record the maintenance performed on your vehicle. Whenever any maintenance is performed, be sure to write it down in the Maintenance Record. This will help you determine when your next maintenance should be done. In addition, it is a good idea to keep your maintenance receipts. They may be needed to qualify your vehicle warranty repairs.

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Tf you are skilled enough to do some work on your vehicle, you will probably want to get the service information GM publishes. For information on how to obtain various service publications for your vehicle, see “Service Publications” in the Index. You will find a list of publications and an order form in the back of the book. Scheduled Maintenance Services This part tells you the maintenance services that you should have done and the times you should schedule them. Your GM dealer knows your vehicle best and wants you to be happy with it. If you go to your dealer for your service needs, you’ll know that GM-trained and supported service people will perform the work using genuine GM parts. These schedules are for vehicles that:

0 carry passengers and cargo within the recommended limits. You will find these limits on your vehicle’s Certification Label. See “Loading Your Vehicle’’ in the Index. are driven on regular road surfaces, and within legal driving limits, as described in Section 4 “Your Driving and the Road.”

0 are driven off-road in the recommended manner. See “Off Road

Driving With Your Four-wheel Drive Vehicle” in the Index.

0 use the recommended fuel. See “Fuel” in the Index. Selecting the Proper Maintenance Services To find the proper maintenance schedule for your vehicle, you must know two things. What engine your vehicle has, and how you use your vehicle. Your engine type will tell you which chart to use, and your driving conditions will tell you which schedule to use. ’The charts are found later in this section.

Selecting the Proper Maintenance Chart Your engine type (Gasoline or Diesel) and its emissions classification (Light Duty or Heavy Duty Emissions) will tell you which maintenance chart to use. Find your Vehicle Identification Number (VIN), and look at the eighth character to see what your engine code is. Then use the following Engine Emissions Classifications tables to find your emissions classification. Your VIN is on the plate on the top left corner of your instrument panel, the Certification Label and on the Service Parts Identification Label. See “Vehicle Identification Number’’ in the Tndex. If your engine has more than one emissions classification, look at your Certification Label to see what your Gross Vehicle Weight Rating (GVWR) is. See “Loading Your Vehicle” in the Index.

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Engine Emissions Classification - Gas Engines Engine Type VIN Fuel System Emissions

5.0L V8

TBIT LD

*Light Duty Emissions with 8500 GVWR and below or: :%*Heavy Duty Emissions with 8501 GVWR and above +Throttle Body Injection Engine Emissions Classification - Gas Engines (cont.) 7.4L Engine V8 Type VTN Fuel System Emissions

5.7L V8

LD*/HD*'k

TBTT

TBIY

LD*/HD**

*Light Duty Emissions with 8500 GVWR and below or: **Heavy Duty Emissions with 8501 GVWR and above ?Throttle Body Injection

Engine Emissions Classification - Diesel Engines Engine Type VIN Fuel System Emissions

6.5L V8

6.5L V8

Diesel LD

Turbo Diesel

LD

6.5L V8

HD

Turbo Diesel

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Selecting the Proper Maintenance Schedule Here is how to tell which schedule to follow once you find the proper maintenance chart to use. MAINTENANCE SCHEDULE I Is any one of these true for your vehicle?

Most trips are less than 4 miles (6 kilometers.) Most trips are less than 10 miles ( 16 kilometers), and the outside temperatures are below freezing. The engine is at low speed most of the time (as in door-to-door delivery, stop-and-go traffic, or commercial use). You operate in dusty areas or off-road frequently. You tow a trailer.

If any one (or more) of these is true for your driving, follow Schedule I. Schedule I is shown by a plus sign (+) on the chart. MAINTENANCE SCHEDULE I1 Follow Schedule I1 ONLY if none of the above conditions are true. Schedule TI is shown by a dot ( 0 ) on the chart.

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GASOLINE ENGINES WITH LIGHT DUTY EMISSIONS - MAINTENANCE SCHEDULE ft

* An Emission Control Service ** See “Explanation of Scheduled Maintenance Services” in the Index $ The California Air Resources Board has determined that the failure to perform this

maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded. t To determine the emissions classification of your engine, refer to “Selecting the Proper TO40 1 KO90 1

Maintenance Chart” in this section.

GASOLINE ENGINES WITH LIGHT DUTY EMISSIONS - MAINTENANCE SCHEDULE 13. (continued)

If your driving conditions do NOT meet those specified in “Scheduled Maintenance Services” in this section, use Maintenance Schedule II (e).

-HE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE )ONE AFTER 60,000 MILES AT THE SAME INTERVALS. ’0402R0902

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GASOLINE ENGINES WITH LIGHT DUTY EMISSIONS - MAINTENANCE SCHEDULE 113.

* An Emission Control Service ** See “Explanation of Scheduled Maintenance Services” in the Index. $ The California Air Resources Board has determined that the failure

to perform this

maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded. t To determine the emissions classification of your engine, refer to “Selecting the Proper T0403/T0903

Maintenance Chart” in this section.

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GASOLINE ENGINES WITH LIGHT DUTY EMISSIONS - MAINTENANCE SCHEDULE I@ (continued) If your driving conditions do NOT meet those specified in “Scheduled Maintenance Services” in this section, use Maintenance Schedule II (e),

THE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE DONE AFTER 60,000 MILES AT THE SAME INTERVALS. T0403alT0903a

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GA! -/I

;OLINE ENGINES WITH HEAVY DUTY EMISSIONS IAINTENANCE SCHEDULE If your driving conditions meet those specified in “Scheduled Maintenance Services’’ in this section (or see Index), use Maintenance Schedule I (t).

Item No.

10 11 12 13

14 15 16

17

18 19 20 21

23 24 25 n Emission Control Service

* I ** ee “Explanation of Scheduled Maintenance Services” in the Index. < A I Noise Emission Control Service pplicable only to vehicles sold in the United States 2 determine the emissions classification of your engine, refer to “Selecting the Proper t 1 F laintenance Chart” in this section. TO404

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THE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE DONE AFTER 60,000 MILES AT THE SAME INTERVALS. TO405

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GASOLINE ENGINES WITH HEAVY DUTY EMISSIONS - MAINTENANCE SCHEDULE Iff

* An Emission Control Service ** See “Explanation of Scheduled Maintenance Services” in the Index. A A Noise Emission Control Service V Applicable only to vehicles sold in the United States t To determine the emissions classification of your engine, refer to “Selecting the Proper TO406

Maintenance Chart” in this section.

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GASOLINE ENGINES WITH HEAVY DUTY EMISSIONS - MAINTENANCE SCHEDULE lh- (continued)

THE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (1 00 000 km) ARE TO BE DONE AFTER 60,000 MILES AT THE SAME INTERVALS. TO407

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DIESEL ENGINES - MAINTENANCE SCHEDULE yf

System

Intake

Fan

20 Air InspectionAB 21 Thermostatically Controlled Engine

CheckAW-Every

Cooling 12 Months or

22 Exhaust Pressure Regulator Valve

Inspection*

Wheel and

Rotation**

Axle

Drive

Tire

23 24 25 Brake Systems Inspection** A Change filter every 15,000 miles (24 000 km), except when operating in dusty

conditions. Dusty conditions may require more frequent filter replacement. Extreme dust and dirt operating conditions (off-road), may require the air filter often as every 300 miles (483 km) and replaced as necessary.

to be checked as

* An Emission Control Service ** See “Explanation of Scheduled Maintenance Services” in this section. A A Noise Emission Control Service 1 Applicable only to vehicles sold in the United States t This maintenance schedule applies to all diesel engines available. T0408/T0908

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DIESEL ENGINES - MAINTENANCE SCHEDULE (continued) If your driving conditions do NOT meet those specified in “Scheduled Maintenance Services”’ in this section, use Maintenance Schedule II (e).

THE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE DONE AFTER 60,000 MILES AT THE SAME INTERVALS. T0409R0909

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DIESEL ENGINES - MAINTENANCE SCHEDULE I@

* An Emission Control Service ** See “Explanation of Scheduled Maintenance Services” in this section. A A Noise Emission Control Service t This maintenance scheduled applies to all diesel engines available. TO41 OR091 0

Applicable only to vehicles sold in the United States.

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DIESEL ENGINES - MAINTENANCE SCHEDULE lh (continued) If your driving conditions do NOT meet those specified in “Scheduled Maintenance Services” in this section, use Maintenance Schedule II (a).

THE SERVICES SHOWN ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE DONE AFTER 60,000 MILES AT THE SAME INTERVALS. TO41 1Tr0911

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Explanation Of Scheduled Mainienance Services Below are explanations of the services listed in the maintenance charts. The proper fluids and lubricants to use are listed in this section. Make sure whoever services your vehicle uses these. All parts should be replaced and all necessary repairs done before you or anyone else drives the vehicle. 1. ENGINE OIL AND OIL FILTER CHANGE“‘ - ALWAYS USE

SJ3 ENERGY CONSERVING I1 (GASOLINE ENGINE) OR CF-4/SH (DIESEL ENGINE) QUALITY OILS OF THE PROPER VISCOSITY. To determine the preferred viscosity oil for your vehicle’s engine (e.g. SAE 5W-30 or 10W-30), see “Engine Oil” in the Index.

2. CHASSIS LUBRICATION - Lubricate the front suspension, king

pin bushings, steering linkage, transmission, and transfer case shift linkage, parking brake cable guides, rear driveline center splines and front axle propshaft splines, brake pedal springs, and clutch pedal springs at the intervals specified. If you have a 3500 HD, lubricate the king pins and king pin bushings, every 1,500 miles (2500 km) for Maintenance Schedule I, or every 3,000 (5000 km) for Maintenance Schedule 11. Ball joints and king pin bushings should not be lubricated unless their temperature is 10” F (-12”C), or higher. When the weather is cold, let them warm up before lubrication or they could be damaged. Also, be sure to check all the vehicle fluid levels at this time.

3. CLUTCH FORK BALL STUD LUBRICATION (5-SPEED

MANUAL TRANSMISSION WITH DEEP LOW ) - Lubricate the clutch fork ball stud through the fitting on the clutch housing. Lubricant must be added “sparingly” to the fitting, as only .0066 lb. (.003 kg) is required to lubricate the ball stud surface. Do not add lubricant more often than the intervals in the Maintenance Charts. Too much lubricant will damage the clutch assembly.

4. COOLING SYSTEM SERVICE”’? - Drain, flush and refill system

with new coolant. See “Engine Coolant” in the Index for the proper coolant and mixture to use in your vehicle. Also inspect the hoses and replace them if they are cracked, swollen, or deteriorated. Tighten all hose clamps (except constant tension clamps). Remove debris and clean the outside of the radiator and air conditioning condenser. Wash the radiator neck. To ensure proper operation, pressure test. the radiator and cap. * An Emission Control Service ?A fluid loss in these systems may indicate a problem. Have them inspected and repaired at once.

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5. AIR CLEANER FILTER REPLACEMENT* - Replace at every 30,000 miles (50 000 km) or more often under dusty conditions. Ask your dealer for the proper replacement intervals for your driving conditions.

6. FRONT WHEEL BEARING REPACK (2-WHEEL DRIVE

ONLY) - Clean and repack the front wheel bearings at each brake relining, or at the specified interval, whichever comes first.

7. TRANSMISSION SERVICE’/-

Automatic Transmission - Change the transmission fluid and filter every 15,000 miles (25 000 km) for vehicles under 8,600 GVWR or every 12,000 miles (20 000 km) for vehicles over 8,600 GVWR if the vehicle is mainly driven under one or more of these conditions:

In heavy city traffic.

0 Where the outside temperature regularly reaches 90°F (32°C) or

higher.

0 In hilly or mountainous terrain.

Frequent trailer pulling. Uses such as taxi, police, delivery or other commercial service.

If the vehicle is not used mainly under any of these conditions, change the fluid and filter every 30,000 miles (50 000 km) for vehicles under 8,600 GVWR or every 24,000 miles (40 000 km) for vehicles over 8,600 GVWR see “Automatic Transmission Fluid” in the Index for more information. Manual Transmission - Transmission fluid does not require periodic changing.

8. CDRV SYSTEM INSPECTION* - Check the Crankcase

Depression Regulator Valve System for any worn, plugged or collapsed hoses. Have the system checked as described in the Service Manual. 9. FUEL FILTER REPLACEMENT*$ - Replace the fuel filter at the

specified interval or sooner if clogged. ?A fluid loss in these systems may indicate a problem. Have them inspected and repaired at once. :i: An Emission Control Service $The California Air Resources Board bas determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of the vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded.

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10.

11.

12.

13.

14.

15.

16.

17.

SPARK PLUG REPLACEMENT* - Replace spark plugs with the type listed in Section 6. See “Specification Charts” in the Index. SPARK PLUG WIRE INSPECTION - Clean wires and inspect for bums, cracks or other damage. Check the wire boot fit at the distributor and at the spark plugs. Replace wires as needed. -f‘A fluid loss in these systems may indicate a problem. Have them inspected and repaired at once. EGR SYSTEM INSPECTION* - Conduct EGR SYSTEM CHECK as described in the Service Manual. ELECTRONIC VACUUM REGULATOR VALVE (EVRV) INSPECTION* - Inspect filter for excessive contamination or plugging. If required, clean element with a solution of biodegradable soap and water, let dry and reinstall element. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK (SOME MODELS)*$ - Adjust timing to underhood label specifications. Inspect the inside and outside of the distributor cap and rotor for cracks, carbon tracking and corrosion. Clean or replace as needed. FUEL TANK, CAP AND LINES INSPECTION*$ - Inspect the fuel tank, cap and lines for damage or leaks. Remove fuel cap, inspect gasket for an even filler neck imprint, and any damage. Replace parts as needed. THERMOSTATICALLY CONTROLLED AIR CLEANER INSPECTION*A - (If so equipped.) Inspect all hoses and ducts for proper hook-up. Be sure the valve works properly. SINGLE ENGINE ACCESSORY DRIVE (SERPENTINE) BELT INSPECTION* - Inspect belt. Look for cracks, fraying, wear, and proper tension. Adjust or replace as needed.

* An Emission Control Service ANoise Emission Control Service $The California Air Resources Board has determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of the vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded.

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18. EVAPORATIVE CONTROL SYSTEM (ECS) INSPECTION* -

Check all fuel and vapor lines and hoses for proper hookup, routing, and condition. Check that the purge valve works properly, if equipped. Replace as needed.

19. SHIELDS AND UNDERHOOD INSULATION

INSPECTIONAV - Inspect shields and underhood insulation for damage or looseness. Adjust or replace as required.

20. AIR INTAKE SYSTEM INSPECTIONAV - Check the air intake system installation to see that gaskets are sealed properly and all hose connections, fasteners, and other components are tight. Also check to be sure that the air cleaner housing is properly seated, that the cover fits tightly, and the wing nuts are tight. Tighten connections and fasteners or replace damaged parts as required.

2 1. THERMOSTATICALLY CONTROLLED ENGINE COOLING FAN INSPECTIONAV - (If so equipped.) Inspect all hoses and ducts for proper hook-up. Be sure the valve works properly.

22. EXHAUST PRESSURE REGULATOR VALVE INSPECTION” - Check that the valve works properly. Correct any binding. Inspect hoses for cracks, chafing or decay. Replace parts as needed.

23. TIRE AND WHEEL ROTATION AND INSPECTION - For

proper wear and maximum tire life, rotate tires at the first 6,000 miles ( 10 000 kilometers) for Schedule I (+) or 7,500 miles (1 2 500 kilometers) for Schedule IT ( 0 ) and then every 15,000 miles (25 000 kilometers) thereafter. Follow the instructions and patterns shown in Section 6. Check tires for uneven wear or damage. If irregular or premature wear is apparent, check wheel alignment. Also, check or damaged wheels. See “Tires” in the Index for more information. For dual wheels, whenever the vehicle, wheels, or fasteners are new, have the wheel fastener torque set at the first 100, 1,000 and 6,000 miles (1 60, 1600 and 10 000 km). Block the tires opposite those being removed to keep the vehicle from rolling.

‘i: An Emission Control Service ANoise Emission Control Service VApplicable only to vehicles sold in the United States

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24. DRIVE AXLE SERVICE? - Check readfront axle fluid level and

add as needed. Check constant velocity joints and axle seals for leaking.

Locking differential - Drain fluid at first oil change and refill. Check fluid level and add as needed at subsequent oil changes. In dusty areas, or trailer towing applications drain fluid at every 15,000 miles (24 135 kilometers) and refill. Standard differential - Check fluid level and add as needed at every oil change. In dusty areas, or trailer towing applications, drain fluid every 15,000 miles (24 I35 kilometers) and refill. More frequent lubrication may be required on heavy-duty or off-road use. 3500 HD Models - 3500 HD Models with applications requiring extreme overload/trdiler tow conditions and high speed conditions (above 45 mph (72 k d h ) ) for extended periods of time must change drive axle fluid every 3,000 miles (4828 kilometers) or 3 months, whichever comes first, OR must use 75W-140 synthetic fluid meeting GM specifications. See “Recommended Fluids and Lubricants” at the end of this section for the proper fluid to use.

25. BRAKE SYSTEM INSPECTION-f - When the engine oil is

changed, inspect the lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. Check the parking brake adjust, and the fluid level in the master cylinder. A low fluid level can indicate worn disc brake pads which may need to be serviced. When the wheels are removed for rotation, inspect disc brake pads for wear and rotors for surfxe condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc., at the same time. Remove any rust or dirt from the wheel and mounting surfaces before mounting the wheel. Inspect brakes more often if driving habits or conditions result in frequent braking.

?A fluid loss in these systems may indicate a problem. Have them inspected and repaired at once.

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Owner Checks and Services Listed below are owner checks and services which should be made at the time period specified to help ensure proper safety, emission performance, and dependability of your vehicle. Be sure any necessary repairs are completed at once. Whenever any fluids or lubricants are added to your vehicle, make sure they are the proper ones, as shown in this Section.

At Least Once a Month Tire inflation pressure check - Check the tires for proper inflation. If they are low, inflate them to the level specified on the Certification/Tire label. See “Loading Your Vehicle” or “Inflation-Tire Pressure” in the Index.

At Least Once a Year Key lock cylinder lubrication - Lubricate key lock cylinders with engine oil. See the “Recommended Fluid and Lubricants” chart in this section. Transmission neutral or clutch start switch operation -

1. Before you start, be sure you have enough room around the vehicle. 2. Firmly apply both the manual parking brake and the regular brake. See “Brakes” and “Parking Brake” in the Index. Do not use the accelerator pedal.

3. Be ready to turn off the engine immediately if it starts. 4. On automatic transmission vehicles, try to start the engine in each gear.

The starter should work only in “ P ’ (Park) or “N” (Neutral).

On manual transmission vehicles, put the shift lever in “N” (Neutral), push the clutch down halfway, and try to start the engine. The starter should work only when the clutch is pushed down all the way to the floor. Steering column lock operation - While parked, try to turn the key to LOCK in each gear shift position. With an automatic transmission, the key should turn to LOCK only when the gear shift is in “P” (Park).

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On vehicles with a key release lever, try to turn the key to LOCK without pressing the lever. The key should turn to LOCK only with the key lever depressed. On all vehicles, the key should come out only in LOCK. Parking brake and transmission “P” (PARK) mechanism operation -

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

To check the parking brake: 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.

0 To check the “ P ’ (Park) mechanism’s holding ability: Apply the regular

brake and shift to “ P ’ (Park). Release the manual parking brake, then slowly release the regular brake.

Lap and Shoulder Belts Condition and Operation - Inspect belt system, including webbing, buckles, latch plates, retractors, guide loops and anchors. Have a belt assembly replaced if the webbing has been cut or otherwise damaged. Body Lubrication Service - Lubricate all body door hinges with engine oil. Also lubricate the tailgate, tailgate handle pivot points, and tailgate mounted spare tire carrier (if equipped}. Lubricate the body hood, fuel door and rear compartment hinges, latches and locks including interior glove box and console doors, and any folding seat hardware. Lubricate the hood safety lever pivot and prop rod pivot. More frequent lubrication may be required when exposed to a corrosive environment. Periodic Maintenance Inspections - Listed below are inspections and services which should be performed at least twice a year (for instance each spring or fall). You should let your GM dealer’s service department or other qualified service center do these jobs. Make sure any necessary repairs are completed at once.

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Steering and Suspension Inspection? - Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. Lubricate the steering linkage. Accelerator Control System - On gasoline engines, lubricate the pivot at the TBI throttle lever stud with engine oil. Do not oil any accelerator or cruise control cables. Replace any cables that have high effort or excessive wear. Exhaust System Inspection - Inspect the complete system including the three-way catalytic converter. Inspect the body near the exhaust system. Look for broken, damaged, missing or out-of-position parts, as well as, open seams, holes, loose connections or other conditions which could cause a heat buildup in the floor pan or could let exhaust fumes seep into the passenger compartments. Drive Axle Service? - Check readfront axle fluid level and add as needed. Check constant velocity joints and axle seals for leaking. I-- oil change intervals, check front axle and transfer case and add lubricant when necessary. Oil the control lever pivot point and all exposed control linkage. Check vent hose at transfer case for kinks and proper installation. More frequent lubrication may be required on heavy-duty or off-road use.

lsfer Case (Four-wheel Drive) Inspection? - Every 12 months or at

?'A fluid loss in these systems may indicate a problem. Have them inspected and repaired at once.

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Recommended Fluids & Lubricants NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from your GM Dealer.

USAGE

Engine Oil - Gasoline Engines

Engine Oil - Diesel Engines

Engine Coolant

Hydraulic Clutch System

Hydraulic Brake Systems

Parking Brake Cables

Power Steering System

Automatic Transmission

FLUIDLUBRICANT

API service SH or SG Energy Conserving I1 oils of the recommended viscosity. The “SH” designation may be shown alone or in combination with others, such as “SH/CD,” “SH, SG, CD,”“SG/CD,” etc. To determine the preferred viscosity for your vehicle’s engine, see “Engine Oil” in the Index. API service C F 4 S H . The “CF4SH” designation may be shown alone or in combination with others, such as “CF-4/SG,” “CE/SH” or “CE/SG,” etc. The designation may also be listed in reverse order, such as “SH/CF-4.” To determine the preferred viscosity for your vehicle’s engine, see “Engine Oil” in the Index. Mixture of water and a good quality ethylene glycol base antifreeze conforming to “GM Specification 6038-M” (GM Part No. 1052753)’ or approved recycled coolant conforming to “GM Specification 603%”’ with a complete coolant flush and refill. Hydraulic Clutch Fluid (GM Part No. I2345347 or equivalent). Delco Supreme 11 Part No. 1052535 or equivalent DOT-3 brake fluid). Chassis Lubricant (GM Part No. I2346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB. GM Power Steering Fluid (GM Part No. 1050017 or equivalent) conforming to “GM Specification 99850 10.” D E X R O N ~ 111 or D E X R O N ~ IIE Automatic Transmission Fluid.

brake fluid (GM

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USAGE

FLUIDLUBRICANT

Manual Transmission: a. 5-Speed with Low Gear (FWO MT8)

a. Castrol Syntorq or equivalent (GM Part No. 12345871 - 1 gal.) (GM Part NO. 12346074 - 1 st.).

b. $-Speed without Low Gear b. Synchromesh Transmission Fluid (RPO MG5) (GM Differential: a. Standard (Saginaw) Front and Rear Axle

equivalent).

Part No.

12345349

or

Column Shift, Transfer Case, Chassis Lubricant (GM Part No. Shift Lever, and Propeller Shaft

b. Locking

c. 3500 HD Models used under extreme conditions Transfer Case

Gas Line

Clutch Fork Ball Stud (5-Speed with Low Gear)

Hood Latch Assembly a. Pivots and spring anchor

b. Release Pawl

Front Wheel Bearings

a. Axle Lubricant (GM Part No. 1052271) or SAE-8OW-90 Gear Lubricant. b. Axle Lubricant (GM Part No. 1052271) or SAE-8OW-90 Gear Lubricant. c. Axle Lubricant SAE-75W-140 Synthetic Gear Lubricant. DEXRON~ 111 or DEXRON@ IIE Automatic Transmission fluid. Gas Line De-Icer (GM Part No. 105 15 16 or equivalent).

12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB. Chassis Lubricant (GM Part No. 12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB.

a. Engine Oil (GM Part No. 1050109 or equivalent). Chassis Lubricant (GM Part No. 12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB. Wheel Bearing Lubricant (GM Part No. 12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category GC or GC-LB.

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USAGE

Propeller Shaft SplineNniversal Joint

FLUIDLUBRICANT

Chassis Lubricant (GM Part No. 12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB.

No. 1050109 or

Automatic Transmission Shift Engine Oil (GM Part Linkage, Floor Shift Linkage, equivalent). Hood and Door Hinges, Body Door Hinge Pins, Tailgate Hinge and Linkage, Folding Seat, Fuel Door Hinge Key Lock Cylinders

Chassis Lubrication

Windshield Washer Solvent and Anti-Freeze Weatherstrip Squeaks

Weatherstrip Conditioning

Outer Tailgate Handle Pivot Points

Engine Oil (GM Part No. 1050109 or equivalent) or a synthetic light weight engine oil (SAE 5W-30). Chassis Lubricant (GM Part No. 12346003 or equivalent) or lubricant meeting requirements of NLGI Grade 2, Category LB or GC-LB. GM Optikleen washer solvent (GM Part No. 105 15 15 or equivalent). Spray-A-Squeek (GM Part No. 1052277). Dielectric Silicone Grease (GM Part No. 12345579 or equivalent). Multi-Purpose Lubricant (GM Part No. 12345 120 or equivalent).

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Maintenance Record After each of the preceding Scheduled Maintenance Services is performed, record the date, odometer reading, services performed (list item numbers) and who performed the services in the appropriate column. In addition, retain copies of your receipts. It is suggested that receipts be kept with your Owner’s Manual.

TO001

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Service Station Checks It is important for you or a service station attendant under-hood checks at each fuel fill.

to perform these

Check the engine oil level and add if necessary. Check the engine coolant level in the recovery bottle and add if necessary. Check the windshield washer fluid level and add if necessary.

See these items in the Index for information on how to check them.

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Secondary Hood Release See Page 6-15.

, Battery

Your vehicle's Delco Freedom battery never needs to have water added. See Page 6-52.

Cooling System 3 Check and add coolant only at the coolant recovery tank (gasoline engine) or only at the coolant surge tank (diesel engine). The fluid level should be at the COLD mark. See Page 6-38.

Transmission Fluid See Page 6-30.

- Spare Tire Pressure See the Certificatisnflire label on the inside rear edge of the driver's door. See Page 6-71.

Fluid See Page 6-45.

engines, use 87 octane (or higher) unleaded gasoline only.

For diesel engines, use at least 1 D diesel fuel. For fuel tank capacity See Page 6-93.

Cold Tire /

Pressure See the Certificationflire label on the inside rear edge of the driver's door. See Page 6-65,6-71.

7-31

Notes

7-32

Customer Assistance Information

Section

Here you will find out how to contact GMC Truck if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects. Customer Satisfaction Procedure . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . 8-2 Customer Assistance for the Hearing or Speech Impaired (TDD) . . . , . 8-3 GM Participation in BBB AUTO LINE - Alternative Dispute Resolution

Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3 Reporting Safety Defects To the United States Government . . . . . . . . . . 8-4 Reporting Safety Defects To the Canadian Government . . . . . . . . . . . . . 8-5 Reporting Safety Defects To General Motors . . . . . . . . . . . . . . . . . . . . . 8-5 Roadside Assistance . . . . . . . . . , . . . . , . , . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Courtesy Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Service Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-1

Customer Satisfaction Procedure Your satisfaction and goodwill are important to your dealer and GMC Truck. Normally, any concern with the sales transaction or the operation of your vehicle will be resolved by your dealer’s Sales or Service Departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur. If your concern has not been resolved to your satisfaction, the following steps should be taken: STEP ONE - Discuss your concern with a member of dealership management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the Sales, Service, or Parts Manager, contact the owner of the dealership or the General Manager. STEP TWO - If after contacting a member of dealership management, it appears your concern cannot be resolved by the dealership without further help, contact your GMC Truck Consumer Relations Manager by calling I -800-GMC-TRUCK Canada, contact GM of Canada Customer Assistance Center in Oshawa bl calling 1-800-263-3777 In Mexico, call (525) 254-3777. In Puerto Rico or U.S. Virgin Islands, cal 1-809-763-1315. In all American Export Sales in Canada by calling 1-905-644-41 12. For prompt assistance, please have the following information available to give the Customer Assistance Manager:

( 1 -8OO-462-8782, Customer Assistance prompt.) In

other overseas locations, contact GM North

(English) or 1-800-263-7854

(French).

0 Your name, address, home and business telephone number 0 Vehicle Identification Number (This is available from the vehicle

registration or title, or the plate at the left top of the instrument panel and visible through the windshield.) Dealership name and location

0 Vehicle delivery date and present mileage

Nature of concern

We encourage you to call the toll free number listed previously in order to give your inquiry prompt attention. However, if you wish to write GMC Truck, write to:

GMC Truck Customer Assistance 31 E. Judson Street 1607-04 Pontiac, MI 48342-2230

Refer to your Warranty and Owner Information booklet for addresses of Canadian and GM overseas offices. When contacting GMC Truck, please remember that your concern will likely be resolved in the dealership, using the dealership’s facilities,

8-2

equipment and personnel. That is why we suggest you follow Step One first if you have a concern, Customer Assistance for the Hearing or Speech Impaired (TDD) To assist customers who have hearing difficulties, GMC Truck has installed special TDD (Telecommunication Devices for the Deaf) equipment at its Customer Assistance Center. Any hearing or speech impaired customer who has access to a TDD or a conventional teletypewriter (TTY) can communicate with GMC Truck by dialing: In the United States, 1-800-GMC-TKTD 1-800-263-3830.)

(1-800-462-8583). (TDD users in Canada can dial

GM Participation in BBB AUTO LINE - Alternative Dispute Resolution Program * *This program may not be available in all states, depending on state law. Canadian owners refer to your Warranty and Owner Assistance Information booklet. General Motors reserves the right to change eligibility limitations and/or to discontinue its participation in this program. Both GMC Truck and your GMC Truck dealer are committed to making sure you are completely satisfied with your new vehicle. Our experience has shown if a situation arises where you feel your concern has not been adequately addressed, the Customer Satisfaction Procedure described earlier in this section is very successful. There may be instances where an impartial third-party can assist in arriving at a solution to a disagreement regarding vehicle repairs or interpretation of the New Vehicle Limited Warranty. To assist in resolving these disagreements GMC Truck voluntarily participates in BBB AUTO LINE. BBB AUTO LINE is an out-of-court program administered by the Better Business Bureau system to settle disputes between customers and automobile manufacturers. This program is available free of charge to customers who currently own or lease a GM vehicle. If you are not satisfied after following the Customer Satisfaction Procedure, you may contact the BBB using the toll-free telephone number, or write them at the following address:

BBB AUTO LINE Council of Better Business Bureaus 4200 Wilson Boulevard Suite 800 Arlington, VA 22203 Telephone: 1-800-955-5 100

8-3

To file a claim, you will be asked to provide your name and address, your vehicle identification number (VIN), and a statement of the nature of your complaint. Eligibility is limited by vehicle age and mileage, and other factors. We prefer you utilize the Customer Satisfaction Procedure before you resort to AUTO LINE, but you may contact the BBB at any time. The BBB will attempt to resolve the complaint by serving as an intermediary between you and GMC Truck. If this mediation is unsuccessful, an informal hearing will be scheduled where eligible customers may present their case to an impartial third-party arbitrator. The arbitrator will make a decision which you may accept or reject. If you accept the decision, GM will be bound by that decision. The entire dispute resolution procedure should ordinarily take about forty days from the time you file a claim until a decision is made. Some state laws may require you to use this program before filing a claim with a state-run arbitration program or in the courts. For further information, contact the BBB at 1-800-955-5 100 or the GMC Truck Customer Assistance Center at 1-800-GMC-TRUCK REPORTING SAFETY DEFECTS TO THE UNITED STATES GOVERNMENT If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA), in addition to notifying General Motors. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or General Motors. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in the Washington, D.C. area) or write to:

(I -800-442-8782).

NHTSA, U.S. Department of Transportation Washington, D.C. 20590 You can also obtain other information about motor vehicle safety from the Hotline.

8-4

REPORTING SAFETY DEFECTS TO THE CANADIAN GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify Transport Canada, in addition to notifying General Motors of Canada Limited. You may write to:

Transport Canada, Box 8880 Ottawa, Ontario K1 G 352 REPORTING SAFETY DEFECTS TO GENERAL MOTORS In addition to notifying NHTSA (or Transport Canada) in a situation like this, we certainly hope you’ll notify us. Please call us at I-800-GMC-TRUCK (1-800-462-8782)

, or write:

GMC Truck Consumer Relations 3 1 E. Judson Street 1607-04 Pontiac, MI 48342-2230 In Canada, please call us at 1-800-263-3777 (French). Or, write:

General Motors of Canada Limited Customer Assistance Center 1908 Colonel Sam Drive Oshawa, Ontario LlH 8P7

(English) or 1-800-263-7854

8-5

Roadside Assistance GMC Truck’s Roadside Assistance provides stranded owners with over-the-phone roadside repairs or towing service for disabled vehicles. This service combines the efforts of technically trained telephone representatives with a network of GMC Truck’s dealer services. Just dial GMC Truck Roadside Assistance at 1-800-GMC TRUCK (1-800-462-8782, Roadside Assistance prompt) to reach a qualified representative who can assist you in repair or arrange a tow. Other recommended services can also be arranged for situations such as retrieving locked-in keys, changing a tire, or delivering gasoline, at a charge to the owner. We also provide dealer information at no charge such as location of the nearest GMC Truck dealer and their hours of operation. Roadside Assistance is available 24 hours a day, seven days a week, 365 days a year, including weekends and holidays. Should you have any questions about roadside assistance, call the GMC Truck Roadside Assistance Center or contact your dealer. Courtesy Transportation

The GMC Truck Commitment Plus Program offers courtesy transportation for customers when obtaining warranty service. The Courtesy Transportation Program is available to retail purchasers of Commitment Plus eligible 1994 GMC light duty trucks. This program is offered in conjunction with the 36 month/36,000 mile BUMPER TO BUMPER New Vehicle Limited Warranty.

0 In Canada, please consult your GM Dealer for information on

courtesy transportation.

COURTESY TRANSPORTATION INCLUDES

0 One way SHUTTLE RIDE from the dealership (up to 10 miles) for

same-day warranty repairs.

0 A loaner vehicle will be made available for overnight warranty repairs

up to a 5 day maximum, or a $30 allowance for a rental vehicle, cab, bus or other transportation in lieu of a loaner. (Bringing vehicles in late in the day, for service on the next day, does not constitute overnight repairs .)

0 GAS allowance of $10 a day for rides provided by another person (i.e., friend, neighbor, etc.) in lieu of rental for overnight warranty repair up to 5 day maximum.

Note: All Courtesy Transportation arrangements will be administered by your GMC Truck dealership service management. All requests should reflect actual costs up to and not to exceed the maximum allowable dollar limits.

8-6

0 The Commitment Plus Courtesy Transportation Program is not part of the BUMPER TO BUMPER Limited Warranty. GMC Truck reserves the right to make any changes or discontinue the Courtesy Transportation Program at any time without notification. For additional program details contact your GMC Truck dealer.

Note: Because of insurance liability considerations, age restrict.ions exist in some states when loaning dealer owned vehicles or obtaining vehicles from rental establishments. See your dealer for details. Service Publications Information on how to obtain Product Service Publications (PSP’s), Subscriptions, Indexes and Summaries as described below is applicable only in the fifty U.S. States (and the District of Columbia) and only for light trucks with GVWR less than 10,000 pounds (4536 kg). In Canada, information pertaining to Product Service Bulletins and Indexes can be obtained by writing to:

General Motors of Canada Limited Service Publications Department 1908 Colonel Sam Dr. Oshawa, Ontario L1H 8P7 GMC Truck regularly sends its dealers useful service bulletins about GMC Truck products. GMC Truck monitors product performance in the field. We then prepare bulletins for servicing our products better. Now, you can get these bulletins too. Bulletins cover various subjects. Some pertain to the proper use and care of your vehicle. Some describe costly repairs. Others describe inexpensive repairs which, if done on time with the latest parts, may avoid future costly repairs. Some bulletins tell a technician how to repair a new or unexpected condition. Others describe a quicker way to fix your vehicle. They can. help a technician service your vehicle better. Most bulletins apply to conditions affecting a small number of cars or trucks. Your GMC Truck dealer or a qualified technician may have to determine if a specific bulletin applies to your vehicle.

Individual PSP’s If you don’t want to buy all the PSP’s issued by GMC Truck for all models in the model year, you can buy individual PSP’s, such as those which may pertain to a particular model. To do this, you will first need to see our index of PSP’s. It provides a variety of information. Here’s what you’ll find in the index and how you can get one:

8-7

What You’// Find in the Index;

A list of all PSP’s published by GMC Truck in a model year. PSP’s covering all models of GMC light trucks are listed in the same index. Ordering information so you can buy the specific PSP’s you may want. Price information for the PSP’s you may want to buy.

How You Can Get an Index: Indexes are published periodically. Most of the PSP’s which could potentially apply to the most recent GMC Truck models will be listed in the most recent publication for that model year. This means you may want to wait until the end of the model year before ordering an index, if you are interested in buying PSP’s pertaining to a current model year car or truck. Some PSP’s pertaining to a particular model year vehicle may be published in later years, and these would be listed in the later year’s index. When you order an index for a model year that is not over yet, we’ll send you the most recently published issue. Check the ordering form for indexes for earlier model years. Cut out the ordering form, fill it out, and mail it in. We will then see to it that an index is mailed to you. There is no charge for indexes for the 1939-1 994 model years.

Toll-Free Telephone Number If you want an additional ordering form for an index or a subscription, just call toll-free and we’ll be happy to send you one. Automated recording equipment will take your name and mailing address. The number to call is 1-800-551-4123.

Copies at Participating Dealers Copies of Indexes and individual PSP’s are at your participating GMC Truck dealer. You can ask to see them.

A Very lmportant Reminder These PSP’s are meant for technicians. They are not meant for the “do-it-yourselfer”. Technicians have the equipment, tools, safety instructions, and know-how to do a job quickly and safely. GMC Truck reserves the right to change these procedures without notice after November, 1992. GMC Truck Service Publications You can get these Product Service Publications by using the order form. You can also get Service Manuals and Owner Publications.

8-8

Notes

8-9

1994 SERVICE PUBLICATIONS

ORDERING INFORMATION

You can get manuals that tell how to operate and service your vehicle. To order them, fill out the order form on the next page and send it to the address below.

GMC Truck Service Publications

Post Office Box 436006

Pontiac, MI 48343

If you have questions or would

like to order using your credit card,

us TOLL FREE at 1-800-627-5699.

call

From outside the Continental United States, please call 1-31 3-455-8016

GLOVE BOX LITERATURE FOR YOUR

$1

SIERRA Form Number

X-9404 x-01 01

Price 0.00 $ 3.00

the Glove Box Literature

these publications. Ask for form

in a vinyl portfolio which

number 15958964-it

X-941

Manual Owner’s Manual Warranty

Manual

Vehicle Manual Storage

You can also order includes all of costs $1 5.00.

SERVICE MANUALS FOR ALL LIGHT DUTY TRUCKS

$1

NATP-9430K

NATP-9457K

Number

Model 1994 C/K Models 1994 G Van 1994 P3 & P/G Models 1994 Safari 1994 Sm Models Includes: Service Manual, Unit Repair Manual, Driveability, Emissions, and Electrical Diagnosis Manual.

Price* $1 20.00 $1 20.00 20.00 20.00 20.00

Kit NATP-9431 K

NATP-9429K $1

NATP-9432K

$1

Description

Form Number

PRODUm SERVICE PUBLICATIONS

1991 Model Year Index 1992 Model Year Index 1993 Model Year Index

For 1994 Call 1-800-782-4356

1994 Model Year Index 1994 Model Year Product Service Publication Subscription Above Subscription With Binder Binder Only

PSP I 91 PSP I 92 PSP I 93

PSP I 94

PSP 94 PSP 948 PSP B

Prices subject to change without notice.

Price Free Free Free

Free

TBD TBD TBD

I I

e..

v)

..

.. I-

Index

3.5.

3.97, 6.94

Aircleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Air Conditioning ............................................ 6.S0 Aircontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Low Refrigerant Change Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Refrigerant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SystemControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Antenna, FixedMast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Anti-Lock Brakes (See “Brakes”) Appearancecare ................................................ 6-80 Materials Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87 Arbitration Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Audiosystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 AMRadio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 AM-FM Stereo Audio System with Cassette Deck . . . . . . . . . . . . . . . . . . . 3-12 AM-FM Stereo Audio System with Cassette Deck and Equalizer . . . . . . . . 3-16 Cassette Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Cassette Tape Player Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 .......................................... 2-21 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Front Locking Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 RearLocking .................................................. 6-39

Automatic Transmission

Axle

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Belts (See “Safety Belts”) Better Business Bureau Mediation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Blizzard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Brakes

Anti-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Leakcheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 PedalTravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 System Warning Light Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 1 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 In Emergencies ................................................ 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Break-In, New Vehicle 2- IO Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97 Replacement Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97

C

Camper Wiring Harness ........................................... Capacities/Specification Charts ..................................... CarbonMonoxide ............................................... CargoLamp .................................................... Cassette Tape Player (see “Audio Systems” ) Catalyticconverter .............................................. Certificationire Label ........................................... Changing a Flat Tire ......................................... Chemical Paint Spotting ........................................... Child Restraints (See “Safety Belts”) CHMSLFeedWire .............................................. Cigarette LightedAshtrays . . . . . ................................... Circuit Breakers (See “Fuses”) Cleaning

2-83 6-91 2-33 2-52

6-64 6-65

2-82 2-52

5-26, 5-32 6-87

Finishcare .................................................. 6-85 Glass ....................................................... 6-84 Insideofvehicle .............................................. 6-81 Instrumentpanel. Top .......................................... 6-83 Outsideofvehicle ............................................. 6-84 Special Problems .............................................. 6-82 VinylorLeather .............................................. 6-83 Wheels and Tires .............................................. 6-86 Windshield .................................................. 6-84 Clock ......................................................... 3-18 AM-FM Stereo Audio System with Cassette Deck . . . . . . . . . . . . . . . . . . . 3-11 AM-FM Stereo Audio System with Cassette Deck and Equalizer . . . 3-14. 3-18

........................................ Conversion to Chassis Cab Coolant (See “Engine”) Cooling System Capacity .......................................... 5-17 Crankcase Capacity .............................................. 6-93 CruiseControl .................................................. 2-44 EraseSpeedMemory .......................................... 2-48 Increasespeed ............................................... 2-46 OnHills ..................................................... 2-48 Passing ..................................................... 2 4 7 Reducespeed ................................................ 2-47 Resume ..................................................... 2-46 Set ......................................................... 2-45 ToGetOutOf ................................................ 2-48 Customer Assistance for the Hearing or Speech Impaired . . . . . . . . . . . . . . . . . 8-3 Customer Satisfaction Procedure ..................................... 8-2

6-70

Indicator Light

Daytime Running Lights (Canada Only) ......................... ..........................................

2.50, 2.75 2.50. 2.75 Diesel Fuel (See “Fuel”) DomeLights .................................................... Doors .......................................................... Driving

2-51 2-7 Locks ........................................................ 2-5 4-21 Across an Incline 4-22 After Off-Road Driving

............................................. ........................................

Driving (continued)

4-24. 4.38

AtNight ............................................... BackingUp .................................................. Defensive .................................................... Downhill .................................................... Freeway ...................................................... Highway Hypnosis ............................................ Hydroplaning ................................................ InBlizzard ................................................... InCity ...................................................... InRain ...................................................... In Sand, Mud, Ice, Or Snow ........................... InWater ..................................................... Nightvision ................................................. Off-Roading ................................................. OnGrades ................................................... On Hill and Mountain Roads .................................... ............................................ On Off-Road Hills On Snow or Ice ..................................... Skidding .................................................... Stuck in Deep Snow ...................................... Throughwater .......................................... Uphill ...................................................... Winter ...................................................... WithaTrailer ................................................ DrunkenDriving .................................................

4-42 4-2 4-19 4-29 4-30 4-27 4-35 4-28 4-26 2-15,4-22, 5-40 4-23 4-25 4-13 4-43 4-31 4-16 2-15,433, 4-55 4-12 4-40, 5-40 2-15, 4-23 4-17 4-33 4-41 4-2

Electronic Heating/Air Conditioning (See “Heating”) Engine

Adding Coolant ..................................... 5.14.5.17. Aircleaner .................................................. Coolant (Block) Heater ................................ 2.19.3-4. Cold Weather Starting (Diesel) ................................... Coolant ...................................... 5.13.5.20.6-92. 6.98 Coolant Temperature Gage ...................................... Diesel .................................................. 2.16. Crankcase .............................................. 2.96. 6.93 Exhaust ................................................ 2.33. 6.64 FanNoise ................................................... Noise Control System .......................................... Identification ................................................. Oil (See “Oil”) Overheating .................................................. RunningWhileParked ......................................... starting ................................................ ............................................. Equipment. Add-on Exhaustsystem ............................................ 2.33.

2.12. 2.16

6-41 6-29 6.23 2-17

2-79 6-5

5-25 6-16 6-89

5-11 2-33

6-68 6-64

F

Fluid

5-25 6-94

FanNoise ...................................................... Filter Replacement Chart .......................................... Finish Care ........................................................ 6-85 Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Brake ....................................................... 6 4 7 Coolant ..................................................... 5-17 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92, 6-93 FrontAxle ................................................... 6-37 Hydraulicclutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 LeakCheck ............................................. 6-47. 6-51 ManualTransmission .......................................... 6-33 Power Steering ............................................... 6-43 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Rear Axle ................................................... 6-39 Recommended Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Windshield Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Four-WheelDrive ............................................... 2 4 4 Transfer Case ........................................... 2-35, 6-36 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Fuel (Diesel Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Cold Weather Operation ......................................... 6-6 Filter Replacement ............................................ 6-11 Fuel Requirements ............................................. 6-4 Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 RunningOutOf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Tankcapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 WaterinFuel ................................................. 2-71 Fuel (Gasoline Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 FillingYourTank ............................................. 6-13 Foreign Countries ............................................. 6-12 Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Gasolines for Cleaner Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Tankcapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 Fuses and Circuit Breakers ................................... 6-64. 6-96 FuseBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63, 6-95 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62-6-97 Power Windows and Other Power Options ......................... 6-62 Trailer Wiring Harness ......................................... 6-62 Windshield Wipers ....................................... 6-45, 6-96

Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Coolant Temperature Gage ...................................... 2-79 FuelGage ................................................... 2-78 Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Oil Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Gages (continued)

Tachometer .................................................. Trip Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-69 2-68 2-82

HalogenBulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Hazard Warning Flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Head Restraints .................................................. 1-5 Headlights ........................................... 2-49,6-53, 6-62 Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Halogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 High Beam Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Hi~h-LowBeam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 1 SealedBeam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 Heating System (with A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Rear Window Defogger ......................................... 3-8 System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Heating System (without A/C) ....................................... 3-5 FanKnob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 FunctionLever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Rear Window Defogger ......................................... 3-8 Temperature Lever ............................................. 3-5 Highway Hypnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Hood

CheclungUnder .............................................. 6-15 LatchesandHinge ............................................ 6-51 Horn .......................................................... 2-39 Hydraulicclutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Grease Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Hydroplaning ................................................... 4-27

If You’re Stuck in Sand. Mud. Ice. or Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Ignitionswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Inflation-Tire Pressure ............................................ 6-71 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Tachometer Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Jack Storage ............................................... 5.29, Jumpstarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.39 5-3

Key ReleaseLever ............................................... Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12 2-3

L

Labels

2-52.6-53. 6-98

6-65 6-68 2-70 2-70

2-73 2-75 2-82 2-51 6-58 6-55 2-72

2-77 2-73

2.58. 6.60

............................................

Certificatioflire .............................................. Truck-Camper ............................................... Lights ......................................................... BrakeSystemWarning ......................................... Bulb Replacement ................................... Cargo Lamp Charging System Light ......................................... Check Gages Light ............................................ CHMSL ..................................................... DomeLights ................................................. Fender ...................................................... Front Parking/Turn Signal ....................................... GlowPlugsLight ............................................. Headlights (See “Headlights”) Indicator .................................................... Low Coolant Warning .......................................... Malfunction Indicator ..................................... 2.74. 6.66 Operation ................................................... Reading ..................................................... Service Engine Soon ........................................... Service Throttle Soon .......................................... SideMarker .................................................. Rear .................................................... Replacementchart ............................................ RoofMarker ................................................. TailgateMarker ................................................ Underhood Reel Lamp ......................................... WaterInFuel ................................................. LoadingYourVehicle ............................................ Lubrication ..................................................... ..................................... Accelerator Control System Body ....................................................... ........................................ Constant Velocity Joints FrontAxle ................................................... Front Shock Absorbers ......................................... Front Suspension and Steering Linkage ............................ FrontWheelBearings .......................................... TailgateHandle ............................................... Hood Latches and Hinge ........................................ Hydraulic Clutch Grease Fitting .................................. Lockcylinders ............................................... ..................................... Propeller Shaft Slip Splines RearAxle ................................................... ...................................... Recommended Lubricants ................................................ Transfer Case

2 4 9 2-51 2-74 2-72 6-58 6-60. 6-61 6-98 6-59 6-59 2-53 2-71 6-65 6-51 6-51 6-51 6-51 6-37 6-49 6-49 6-49 6-52 6-51 6-35 6-52 6-51 6-35 7-25 6-36

M

Maintenance

OtherItems .................................................. Periodic Inspections ........................................... Record ...................................................... Scheduled Maintenance .................................... 7.3. 7.18 Underbody .................................................. 6-87 When Towing a Trailer ......................................... 4-44

6-49 7-24 7-27

Master Cylinder (See “Brakes”) Mirrors ........................................................ Convexoutside ............................................... Electric Outside ............................................... Inside ....................................................... Outside ..................................................... Vanity ......................................................

ModelReference ..................................................

Odometer ...................................................... Off-Road Driving (See “Driving”) Off-RoadRecovery .............................................. Oil (Except Diesel) ............................................... Additives .................................................... DisposalofUsed .............................................. Pressure Gage ................................................ To(3lheck .................................................... WhatKindtoUse ............................................. WhentoAdd ................................................. Whentochange .............................................. Oil(Diese1) ..................................................... Additives .................................................... DisposalofUsed .............................................. ToCheck .................................................... WhatKindtoUse ............................................. WhentoAdd ................................................. Whentochange .............................................. Owner Checks and Services ........................................

2-54 2-55 2-54 2-54 2-54 2-56 ... 111

2-68

4-10 6-17 6-23 6-28 2-80 6-18 6-19 6-18 6-28 6-24 6-28 6-28 6-25 6-26 6-28 6-28 7-22

Parking

OnHills ..................................................... Over Things That Burn ......................................... Torque Lock (Automatic Transmission) ............................ .............................. Your Vehicle (Manual Transmission) ParkingBrake ................................................... Passing Other Vehicles ....................................... Periodic Maintenance Inspections ...................................

4-43 2-32 2-29 2-32 2-28

7-24

4-10. 4-60

Power

DoorLocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Steering ...................................................... 4-8 Steering Fluid ................................................ 6-43 Winches ..................................................... 4-36 Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Product Service Publications ........................................ 8-6

Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Radio (see “Audio Systems”) Recommended Fluids and Lubricants ................................ 7-25 Recovery Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Replacement Parts ............................................... 6-91 Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Roadside Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 RockingYourVehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Safety Belts

.................................................... 1-10 Adults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Center Passenger Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Checking Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 4 Child Restraints ............................................... 1-32 Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 DriverPosition ............................................... 1-16 Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 Lapshoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Large Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Properwear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Questions and Answers ......................................... 1-14 Rearseatpassengers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 ReminderLight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Replacing After a Crash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 Right Front Passenger Position ................................... 1-23 Small Children and Babies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Use During Pregnancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 WhyTheyWork .............................................. 1-11 SafetyChains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Safety Warnings and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Scheduled Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Seats Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Easy Entry Seat ................................................ 1-6 Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5, 1-9 ManualFront . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PowerDriver’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Reclining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Service

6-94

7-28

2.26, 2.76

2.74. 6-65

6-3 6-90

....... ........................................ Do-It-Yourself ....................................... Parts Identification Label .................................... Publications . . . . . . . . . . 8.6, 8.8 ter Recommendations ..................... Replacement Parts and Fj 1 1 .................................. Service Engine Soon Light Service Station Checks .... ....................................... Shift Indicator Light ......................................... ShiftingIntoPark ................................................ Sliding Rear Window ............................................. SpareTire ...................................................... Pickup Bed Mounting ..................................... 5.31. Removal .................................................... Storage ..................................................... Specification Charts .............................................. Speedometer .................................................... Starting your Diesel Engine ........................................ Starting your Gasoline Engine ...................................... Steering ........................................................ Column Shift Lever ............................................ InEmergencies ................................................ Storage Compartments ............................................ Console ................................................ GarageDoorOpener ........................................... GloveBox ................................................... Other ....................................................... SunVisors ..................................................... Swing-Outwindows .............................................

2-30 2-38 5-29 5-40 5-29 5-39 6-91 2-68 2-16 2-12 4-8 2-30 4-9 2-58 2-59. 2-61 2-61 2-58