2002 GMC Savana Owners Manual

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

D If you spill brake fluid on your vehicle’s painted surfaces, the paint finish can be damaged. Be careful not to spill brake fluid on your vehicle. If you do, wash it off immediately. See “Appearance Care” in the Index.

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Some driving conditions or climates may cause a brake squeal when the brakes are first applied or lightly applied. This does not mean something is wrong with your 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 GM torque specifications. Your rear drum brakes don’t have wear indicators, but if you ever hear a rear brake rubbing noise, have the rear brake linings inspected immediately. Also, the rear brake drums should be removed and inspected each time the tires are removed for rotation or changing. When you have the front brake pads replaced, have the rear brakes inspected, too. Brake linings should always be replaced as complete axle sets. See “Brake System Inspection” in Section 7 of this manual under Part C “Periodic Maintenance Inspections.”

Brake Wear Your vehicle has front disc brakes and rear drum 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 may come and go or be heard all the time your vehicle is moving (except when you are pushing on the brake pedal firmly).

CAUTION:

The brake wear warning sound means that soon your brakes won’t work well. That could lead to an accident. When you hear the brake wear warning sound, have your vehicle serviced.

NOTICE:

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

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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 of brake trouble. Brake Adjustment Every time you make a brake stop, your disc brakes adjust for wear. If your brake pedal goes down farther than normal, your rear drum brakes may need adjustment. Adjust them by backing up and firmly applying the brakes a few times. 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. Your vehicle was designed and tested with top-quality GM brake parts. When you replace parts of your braking system -- for example, when your brake linings wear down and you need new ones put in -- be sure you get new approved GM replacement parts. If you don’t, your brakes may no longer work properly. For example, if someone puts in brake linings that are wrong for your vehicle, the balance between your front and rear brakes can change -- for the worse. The braking performance you’ve come to expect can change in many other ways if someone puts in the wrong replacement brake parts.

Battery Your new vehicle comes with a maintenance free ACDelcoR battery. When it’s time for a new battery, get one that has the replacement number shown on the original battery’s label. We recommend an ACDelco battery. See “Engine Compartment Overview” in the Index 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. If you have a diesel engine, you have two batteries. The primary battery is located on the passenger’s side of the engine compartment. The second battery is located on the driver’s side framerail.

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Vehicle Storage If you’re not going to drive your vehicle for 25 days or more, remove the black, negative (-) cable from the battery. This will help keep your battery from running down.

CAUTION:

Batteries have acid that can burn you and gas that can explode. You can be badly hurt if you aren’t careful. See “Jump Starting” in the Index for tips on working around a battery without getting hurt.

Bulb Replacement For any bulb changing procedure not listed in this section, contact your dealer. For the type of bulbs, see “Replacement Bulbs” in the Index. Halogen Bulbs

CAUTION:

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.

Contact your dealer to learn how to prepare your vehicle for longer storage periods. Also, for your audio system, see “Theft-Deterrent Feature” in the Index.

Headlamps You have either a sealed beam headlamp or a composite system.

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Sealed Beam Headlamp

Composite Headlamps 1. Open the hood. 2. Locate the rear side of each of the headlamps.

1. Remove the four screws from the headlamp retainer.

Pull the retainer out and set it aside.

2. Unplug the lamp assembly from the connector. 3. Remove the old headlamp 4. Install a new headlamp into the assembly. 5. Plug the assembly back into the connector. 6. Reassemble the headlamp assembly with the retainer.

3. Without removing the headlamp assembly itself,

remove the bulb socket from the back of the headlamp on the driver’s side. Turn the bulb counterclockwise one quarter turn to remove it from the socket. On the passenger’s side, turn the bulb clockwise one quarter turn. Do not touch the glass part of the bulb.

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Front Parking/Turn Signal Lamps To replace the front parking/turn signal lamps, do the following:

4. Reinstall the new bulb into the socket and return it to

the headlamp assembly.

1. Remove the outer screws from the parking/turn

signal lamp lens assembly. (There are either two or four screws, depending on your vehicle’s trim level.)

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Sidemarker Lamps

2. Remove the lamp from the grille. 3. Squeeze the tab on the side of the bulb assembly

while turning it counterclockwise.

4. Remove the bulb assembly from the back of the lens

and replace the bulb.

5. Turn the socket clockwise to reinstall it in the lens assembly. Reinstall the screws on the parking/turn signal lamp assembly.

1. Remove the screw from the top of the lens.

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Taillamps 1. Open the rear door.

2. Unclip the bottom of the lamp from the grille. 3. Pull the bulb straight out to remove it. Install the

new bulb.

4. Reverse these steps to reinstall the lamp.

2. Push the socket protector until you can see

the fasteners.

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3. Remove the nuts with a deep socket wrench.

4. Remove the hidden upper nuts.

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5. Lift the lamp as you

turn it toward the rear of the vehicle.

6. To remove, squeeze the tab on the side of the sockets

while turning them counterclockwise.

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7. Turn the old bulb counterclockwise to remove it.

Install the new bulb.

8. Reverse the above steps to reinstall the lamp.

Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear and cracking. See “Wiper Blade Check” in the Index for more information.

Replacement blades come in different types and are removed in different ways. To remove the type with a release clip, do the following: 1. Lift the wiper arm until it locks into a

vertical position.

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2. Press down on the blade assembly pivot locking tab.

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

CAUTION:

3. The insert has two notches at one end that are locked

by bottom claws of the blade assembly. At the notched end, pull the insert from the blade assembly. 4. To install the new wiper insert, slide the notched end

last, into the end with two blade claws. Then slide the insert all the way through the blade claws at the opposite end.

5. Make sure that the notches are locked by the bottom

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

6. Put the blade assembly pivot in the wiper arm

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

7. Carefully lower the wiper arm and blade assembly

into the windshield.

Tires Your new vehicle comes with high-quality tires made by a leading tire manufacturer. If you ever have questions about your tire warranty and where to obtain service, see your GM Warranty booklet for details.

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Poorly maintained and improperly used tires are dangerous. D Overloading your tires can cause

overheating as a result of too much friction. You could have an air-out and a serious accident. See “Loading Your Vehicle” in the Index.

D Underinflated tires pose the same danger as

overloaded tires. The resulting accident could cause serious injury. Check all tires frequently to maintain the recommended pressure. Tire pressure should be checked when your tires are cold.

D Overinflated tires are more likely to be

cut, punctured or broken by a sudden impact -- such as when you hit a pothole. Keep tires at the recommended pressure.

D Worn, old tires can cause accidents. If your

tread is badly worn, or if your tires have been damaged, replace them.

Inflation -- Tire Pressure The Certification/Tire label, which is on the rear edge of the driver’s door, shows the correct inflation pressures for your tires when they’re cold. “Cold” means your vehicle has been sitting for at least three hours or driven no more than 1 mile (1.6 km).

NOTICE:

Don’t let anyone tell you that underinflation or overinflation is all right. It’s not. If your tires don’t have enough air (underinflation), you can get the following: D Too much flexing D Too much heat D Tire overloading D Bad wear D Bad handling D Bad fuel economy

NOTICE: (Continued)

NOTICE: (Continued)

If your tires have too much air (overinflation), you can get the following: D Unusual wear D Bad handling D Rough ride D Needless damage from road hazards

When to Check Check your tires once a month or more. Also, check the tire pressure of the spare tire.

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The purpose of regular rotation is to achieve more uniform wear for all tires on the vehicle. The first rotation is the most important. See “Scheduled Maintenance Services” in the Index for scheduled rotation intervals.

If your vehicle has single rear wheels, always use one of the correct rotation patterns shown here when rotating your tires.

How to Check Use a good quality pocket-type gage to check tire pressure. You can’t tell if your tires are properly inflated simply by looking at them. Radial tires may look properly inflated even when they’re underinflated. Be sure to put the valve caps back on the valve stems. They help prevent leaks by keeping out dirt and moisture. Tire Inspection and Rotation Tires should be rotated every 6,000 to 8,000 miles (10 000 to 13 000 km). Any time you notice unusual wear, rotate your tires as soon as possible and check wheel alignment. Also check for damaged tires or wheels. See “When It’s Time for New Tires” and “Wheel Replacement” later in this section for more information. Make sure the spare tire is stored securely. Push, pull, and then try to rotate or turn the tire. If it moves, use the ratchet to tighten the cable. See “Storing a Flat or Spare Tire and Tools” in the Index. If your vehicle has dual rear wheels, also see “Dual Tire Operation” later in this section.

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If your vehicle has dual rear wheels, always use one of the correct rotation patterns shown here when rotating your tires. When you install dual wheels, be sure the vent holes in the inner and outer wheels on each side are lined up. After the tires have been rotated, adjust the front and rear inflation pressures as shown on the Certification/Tire label. Make certain that all wheel nuts are properly tightened. See “Wheel Nut Torque” in the Index.

CAUTION:

Rust or dirt on a wheel, or on the parts to which it is fastened, can make wheel nuts become loose after a time. The wheel could come off and cause an accident. When you change a wheel, remove any rust or dirt from places where the wheel attaches to the vehicle. In an emergency, you can use a cloth or a paper towel to do this; but be sure to use a scraper or wire brush later, if you need to, to get all the rust or dirt off. See “Changing a Flat Tire” in the Index.

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When It’s Time for New Tires

One way to tell when it’s time for new tires is to check the treadwear indicators, which will appear when your tires have only 1/16 inch (1.6 mm) or less of tread remaining. Some commercial truck tires may not have treadwear indicators.

You need a new tire if any of the following statements are true: D You can see the indicators at three or more places

around the tire.

D You can see cord or fabric showing through the

tire’s rubber.

D The tread or sidewall is cracked, cut or snagged deep

enough to show cord or fabric.

D The tire has a bump, bulge or split. D The tire has a puncture, cut or other damage that

can’t be repaired well because of the size or location of the damage.

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Dual Tire Operation When the vehicle is new, or whenever a wheel, wheel bolt or wheel nut is replaced, check the wheel nut torque after 100, 1,000 and 6,000 miles (160, 1 600 and 10 000 km) of driving. For proper torque, see “Wheel Nut Torque” in the Index. The outer tire on a dual wheel setup generally wears faster than the inner tire. Your tires will wear more evenly and last longer if you rotate the tires periodically. If you’re going to be doing a lot of driving on high-crown roads, you can reduce tire wear by adding 5 psi (35 kPa) to the tire pressure in the outer tires. Be sure to return to the recommended pressures when no longer driving under those conditions. See “Tires” and “Inflation - Tire Pressure” in the Index for more information on proper tire inflation.

CAUTION:

If you operate your vehicle with a tire that is badly underinflated, the tire can overheat. An overheated tire can lose air suddenly or catch fire. You or others could be injured. Be sure all tires (including the spare) are properly inflated.

Buying New Tires To find out what kind and size of tires you need, look at the Certification/Tire label. The tires installed on your vehicle when it was new had a Tire Performance Criteria Specification (TPC Spec) number on each tire’s sidewall. When you get new tires, get ones with that same TPC Spec number. That way your vehicle will continue to have tires that are designed to give proper endurance, handling, speed rating, traction, ride and other things during normal service on your vehicle. If your tires have an all-season tread design, the TPC number will be followed by an “MS” (for mud and snow). If you ever replace your tires with those not having a TPC Spec number, make sure they are the same size, load range, speed rating and construction type (bias, bias-belted or radial) as your original tires.

CAUTION:

Mixing tires could cause you to lose control while driving. If you mix tires of different sizes or types (radial and bias-belted tires), the vehicle may not handle properly, and you could have a crash. Using tires of different sizes may also cause damage to your vehicle. Be sure to use the same size and type tires on all wheels.

CAUTION:

If you use bias-ply tires on your vehicle, the wheel rim flanges could develop cracks after many miles of driving. A tire and/or wheel could fail suddenly, causing a crash. Use only radial-ply tires with the wheels on your vehicle.

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Uniform Tire Quality Grading Quality grades can be found where applicable on the tire sidewall between tread shoulder and maximum section width. For example: Treadwear 200 Traction AA Temperature A The following information relates to the system developed by the United States National Highway Traffic Safety Administration, which grades tires by treadwear, traction and temperature performance. (This applies only to vehicles sold in the United States.) The grades are molded on the sidewalls of most passenger car tires. The Uniform Tire Quality Grading system does not apply to deep tread, winter-type snow tires, space-saver or temporary use spare tires, tires with nominal rim diameters of 10 to 12 inches (25 to 30 cm), or to some limited-production tires. While the tires available on General Motors passenger cars and light trucks may vary with respect to these grades, they must also conform to federal safety requirements and additional General Motors Tire Performance Criteria (TPC) standards.

Treadwear The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire graded 150 would wear one and a half (1 1/2) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate. Traction -- AA, A, B, C The traction grades, from highest to lowest, are AA, A, B, and C. Those grades represent the tire’s ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Warning: The traction grade assigned to this tire is based on straight-ahead braking traction tests, and does not include acceleration, cornering, hydroplaning, or peak traction characteristics.

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Wheel Alignment and Tire Balance The wheels on your vehicle were aligned and balanced carefully at the factory to give you the longest tire life and best overall performance. Scheduled wheel alignment and wheel balancing are not needed. However, if you notice unusual tire wear or your vehicle pulling one way or the other, the alignment may need to be reset. If you notice your vehicle vibrating when driving on a smooth road, your wheels may need to be rebalanced.

Temperature -- A, B, C The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. Warning: The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure.

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Wheel Replacement Replace any wheel that is bent, cracked, or badly rusted or corroded. If wheel nuts keep coming loose, the wheel, wheel bolts and wheel nuts should be replaced. If the wheel leaks air, replace it (except some aluminum wheels, which can sometimes be repaired). See your dealer if any of these conditions exist. Your dealer will know the kind of wheel you need. Each new wheel should have the same load-carrying capacity, diameter, width, offset and be mounted the same way as the one it replaces. If you need to replace any of your wheels, wheel bolts or wheel nuts, replace them only with new GM original equipment parts. This way, you will be sure to have the right wheel, wheel bolts and wheel nuts for your vehicle.

CAUTION:

Using the wrong replacement wheels, wheel bolts or wheel nuts on your vehicle can be dangerous. It could affect the braking and handling of your vehicle, make your tires lose air and make you lose control. You could have a collision in which you or others could be injured. Always use the correct wheel, wheel bolts and wheel nuts for replacement.

NOTICE:

The wrong wheel can also cause problems with bearing life, brake cooling, speedometer or odometer calibration, headlamp aim, bumper height, vehicle ground clearance and tire or tire chain clearance to the body and chassis.

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Whenever a wheel, wheel bolt or wheel nut is replaced on a dual wheel setup, check the wheel nut torque after 100, 1,000 and 6,000 miles (160, 1 600 and 10 000 km) of driving. For proper torque, see “Wheel Nut Torque” in the Index. See “Changing a Flat Tire” in the Index for more information.

Used Replacement Wheels

CAUTION:

Putting a used wheel on your vehicle is dangerous. You can’t know how it’s been used or how far it’s been driven. It could fail suddenly and cause a crash. If you have to replace a wheel, use a new GM original equipment wheel.

Tire Chains

NOTICE:

Use tire chains only where legal and only when you must. Use chains that are the proper size for your tires. Install them on the tires of the rear axle. Tighten them as tightly as possible with the ends securely fastened. Drive slowly and follow the chain manufacturer’s instructions. If you can hear the chains contacting your vehicle, stop and retighten them. If the contact continues, slow down until it stops. Driving too fast or spinning the wheels with chains on will damage your vehicle.

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Appearance Care Remember, cleaning products can be hazardous. Some are toxic. Others can burst into flame if you strike a match or get them on a hot part of the vehicle. Some are dangerous if you breathe their fumes in a closed space. When you use anything from a container to clean your vehicle, be sure to follow the manufacturer’s warnings and instructions. And always open your doors or windows when you’re cleaning the inside. Never use these to clean your vehicle: D Gasoline D Benzene D Naphtha D Carbon Tetrachloride D Acetone D Paint Thinner D Turpentine D Lacquer Thinner D Nail Polish Remover

They can all be hazardous -- some more than others -- and they can all damage your vehicle, too. Don’t use any of these unless this manual says you can. In many uses, these will damage your vehicle: D Alcohol D Laundry Soap D Bleach D Reducing Agents Cleaning the Inside of Your Vehicle Use a vacuum cleaner often to get rid of dust and loose dirt. Wipe vinyl, leather, plastic and painted surfaces with a clean, damp cloth. Cleaning of Fabric/Carpet Your dealer has cleaners for the cleaning of fabric and carpet. They will clean normal spots and stains very well. You can get GM-approved cleaning products from your dealer. See “Appearance Care and Materials” in the Index.

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Here are some cleaning tips: D Always read the instructions on the cleaner label. D Clean up stains as soon as you can -- before they set. D Carefully scrape off any excess stain. D Use a clean cloth or sponge, and change to a clean area often. A soft brush may be used if stains are stubborn.

D If a ring forms on fabric after spot cleaning, clean the

entire area immediately or it will set.

Using Cleaner on Fabric 1. Vacuum and brush the area to remove any loose dirt. 2. Always clean a whole trim panel or section. Mask

surrounding trim along stitch or welt lines. 3. Follow the directions on the container label. 4. Apply cleaner with a clean sponge. Don’t saturate

the material and don’t rub it roughly.

5. As soon as you’ve cleaned the section, use a sponge

to remove any excess cleaner.

6. Wipe cleaned area with a clean, water-dampened

towel or cloth.

7. Wipe with a clean cloth and let dry.

Special Fabric Cleaning Problems Stains caused by such things as catsup, coffee (black), egg, fruit, fruit juice, milk, soft drinks, vomit, urine and blood can be removed as follows: 1. Carefully scrape off excess stain, then sponge the

soiled area with cool water.

2. If a stain remains, follow the cleaner instructions

described earlier.

3. If an odor lingers after cleaning vomit or urine, treat the area with a water/baking soda solution: 1 teaspoon (5 ml) of baking soda to 1 cup (250 ml) of lukewarm water.

4. Let dry. Stains caused by candy, ice cream, mayonnaise, chili sauce and unknown stains can be removed as follows: 1. Carefully scrape off excess stain. 2. First, clean with cool water and allow to

dry completely.

3. If a stain remains, follow the cleaner instructions

described earlier.

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Cleaning Vinyl Use warm water and a clean cloth. D Rub with a clean, damp cloth to remove dirt. You

may have to do it more than once.

D Things like tar, asphalt and shoe polish will stain

if you don’t get them off quickly. Use a clean cloth and a vinyl/leather cleaner. See your dealer for this product.

Cleaning Leather Use a soft cloth with lukewarm water and a mild soap or saddle soap and wipe dry with a soft cloth. Then, let the leather dry naturally. Do not use heat to dry. D For stubborn stains, use a leather cleaner. See your

dealer for this product.

D Never use oils, varnishes, solvent-based or abrasive cleaners, furniture polish or shoe polish on leather.

D Soiled or stained leather should be cleaned

immediately. If dirt is allowed to work into the finish, it can harm the leather.

Cleaning the Top of the Instrument Panel Use only mild soap and water to clean the top surfaces of the instrument panel. Sprays containing silicones or waxes may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. Cleaning Interior Plastic Components Use only a mild soap and water solution on a soft cloth or sponge. Commercial cleaners may affect the surface finish. Care of Safety Belts Keep belts clean and dry.

CAUTION:

Do not bleach or dye safety belts. If you do, it may severely weaken them. In a crash, they might not be able to provide adequate protection. Clean safety belts only with mild soap and lukewarm water.

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Cleaning Glass Surfaces Glass should be cleaned often. GM Glass Cleaner or a liquid household glass cleaner will remove normal tobacco smoke and dust films on interior glass. See “Appearance Care and Materials” in the Index.

NOTICE:

Don’t use abrasive cleaners on glass, because they may cause scratches. Avoid placing decals on the inside rear window, since they may have to be scraped off later. If abrasive cleaners are used on the inside of the rear window, an electric defogger element may be damaged. Any temporary license should not be attached across the defogger grid.

Cleaning the Outside of the Windshield and Wiper Blades If the windshield is not clear after using the windshield washer, or if the wiper blade chatters when running, wax, sap or other material may be on the blade or windshield. Clean the outside of the windshield with a full-strength glass cleaning liquid. The windshield is clean if beads do not form when you rinse it with water. Grime from the windshield will stick to the wiper blades and affect their performance. Clean the blade by wiping vigorously with a cloth soaked in full-strength windshield washer solvent. Then rinse the blade with water. Check the wiper blades and clean them as necessary; replace blades that look worn. Weatherstrips Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth at least every six months. During very cold, damp weather more frequent application may be required. See “Recommended Fluids and Lubricants” in the Index.

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Cleaning the Outside of Your Vehicle The paint finish on your vehicle provides beauty, depth of color, gloss retention and durability. Washing Your Vehicle The best way to preserve your vehicle’s finish is to keep it clean by washing it often with lukewarm or cold water. Don’t wash your vehicle in the direct rays of the sun. Use a car washing soap. Don’t use strong soaps or chemical detergents. Be sure to rinse the vehicle well, removing all soap residue completely. You can get GM-approved cleaning products from your dealer. See “Appearance Care and Materials” in the Index. Don’t use cleaning agents that are petroleum based, or that contain acid or abrasives. All cleaning agents should be flushed promptly and not allowed to dry on the surface, or they could stain. Dry the finish with a soft, clean chamois or an all-cotton towel to avoid surface scratches and water spotting. High pressure car washes may cause water to enter your vehicle.

Cleaning Exterior Lamps/Lenses Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Follow instructions under “Washing Your Vehicle.” Finish Care Occasional waxing or mild polishing of your vehicle by hand may be necessary to remove residue from the paint finish. You can get GM-approved cleaning products from your dealer. See “Appearance Care and Materials” in the Index. Your vehicle may have a “basecoat/clearcoat” paint finish. The clearcoat gives more depth and gloss to the colored basecoat. Always use waxes and polishes that are non-abrasive and made for a basecoat/clearcoat paint finish.

NOTICE:

Machine compounding or aggressive polishing on a basecoat/clearcoat paint finish may dull the finish or leave swirl marks.

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Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird droppings, chemicals from industrial chimneys, etc., can damage your vehicle’s finish if they remain on painted surfaces. Wash the vehicle as soon as possible. If necessary, use non-abrasive cleaners that are marked safe for painted surfaces to remove foreign matter. Exterior painted surfaces are subject to aging, weather and chemical fallout that can take their toll over a period of years. You can help to keep the paint finish looking new by keeping your vehicle garaged or covered whenever possible. Protecting Exterior Bright Metal Parts Bright metal parts should be cleaned regularly to keep their luster. Washing with water is all that is usually needed. However, you may use chrome polish on chrome or stainless steel trim, if necessary. Use special care with aluminum trim. To avoid damaging protective trim, never use auto or chrome polish, steam or caustic soap to clean aluminum. A coating of wax, rubbed to high polish, is recommended for all bright metal parts.

Cleaning Aluminum Wheels (If Equipped) Keep your wheels clean using a soft clean cloth with mild soap and water. Rinse with clean water. After rinsing thoroughly, dry with a soft clean towel. A wax may then be applied. The surface of these wheels is similar to the painted surface of your vehicle. Don’t use strong soaps, chemicals, abrasive polishes, abrasive cleaners, cleaners with acid or abrasive cleaning brushes on them because you could damage the surface. Do not use chrome polish on aluminum wheels. Don’t take your vehicle through an automatic car wash that has silicon carbide tire cleaning brushes. These brushes can also damage the surface of these wheels.

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Cleaning Tires To clean your tires, use a stiff brush with a tire cleaner.

NOTICE:

When applying a tire dressing always take care to wipe off any overspray or splash from all painted surfaces on the body or wheels of the vehicle. Petroleum-based products may damage the paint finish and tires.

Sheet Metal Damage If your vehicle is damaged and requires sheet metal repair or replacement, make sure the body repair shop applies anti-corrosion material to the parts repaired or replaced to restore corrosion protection. Original manufacturer replacement parts will provide the corrosion protection while maintaining the warranty. Finish Damage Any stone chips, fractures or deep scratches in the finish should be repaired right away. Minor chips and scratches can be repaired with touch-up materials available from your dealer or other service outlets. Larger areas of finish damage can be corrected in your dealer’s body and paint shop.

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Underbody Maintenance Chemicals used for ice and snow removal and dust control can collect on the underbody. If these are not removed, accelerated corrosion (rust) can occur on the underbody parts such as fuel lines, frame, floor pan and exhaust system even though they have corrosion protection. At least every spring, flush these materials from the underbody with plain water. Clean any areas where mud and other debris can collect. Dirt packed in closed areas of the frame should be loosened before being flushed. Your dealer or an underbody car washing system can do this for you.

Chemical Paint Spotting Some weather and atmospheric conditions can create a chemical fallout. Airborne pollutants can fall upon and attack painted surfaces on your vehicle. This damage can take two forms: blotchy, ringlet-shaped discolorations, and small irregular dark spots etched into the paint surface. Although no defect in the paint job causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by this fallout condition within 12 months or 12,000 miles (20 000 km) of purchase, whichever occurs first.

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GM Vehicle Care/Appearance Materials

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Vehicle Identification Number (VIN)

This is the legal identifier for your vehicle. It appears on a plate in the front corner of the instrument panel, on the driver’s side. You can see it if you look through the windshield from outside your vehicle. The VIN also appears on the Vehicle Certification and Service Parts labels and the certificates of title and registration.

Engine Identification The 8th character in your VIN is the engine code. This code will help you identify your engine, specifications and replacement parts. Service Parts Identification Label You’ll find this label on the front passenger door frame. It’s very helpful if you ever need to order parts. On this label is: D your VIN, D the model designation, D paint information and D a list of all production options and

special equipment.

Be sure that this label is not removed from the vehicle.

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Electrical System Add-On Electrical Equipment

NOTICE:

Don’t add anything electrical to your vehicle unless you check with your dealer first. Some electrical equipment can damage your vehicle and the damage wouldn’t be covered by your warranty. Some add-on electrical equipment can keep other components from working as they should.

Your vehicle has an air bag system. Before attempting to add anything electrical to your vehicle, see “Servicing Your Air Bag-Equipped Vehicle” in the Index.

Headlamp Wiring The headlamp wiring is protected by a circuit breaker in the lamp switch. An electrical overload will cause the lamps to flicker on and off, or in some cases to remain off. If this happens, have your headlamp wiring checked right away. Windshield Wiper Fuses The windshield wiper motor is protected by a circuit breaker and a fuse. If the motor overheats due to heavy snow, etc., the wiper will stop until the motor cools. Although the circuit is protected from electrical overload, overload due to heavy snow, etc., may cause wiper linkage damage. Always clear ice and heavy snow from the windshield before using the windshield wipers. If the overload is caused by some electrical problem and not snow, etc., be sure to get it fixed.

6-62

Instrument Panel Fuse Block

The fuse block access door is on the instrument panel above the hood release lever on the driver’s side of the vehicle.

Be sure to use the correct fuse. If you ever have a problem on the road and don’t have a spare fuse, you can borrow one of the same fuse rating. Just pick some feature of your vehicle that you can get along without -- like the radio or cigarette lighter -- and use its fuse, if it is of the same fuse rating you need. Replace it as soon as you can.

You can remove the cover by turning the fastener counterclockwise. You can remove fuses with a fuse extractor. The fuse extractor is mounted to the fuse block access door. To remove fuses if you don’t have a fuse extractor, hold the end of the fuse between your thumb and index finger and pull straight out.

6-63

POSITION

1. 2. 3. 4.

5. 6. 7. 8. 9.

10. 11. 12.

13.

NAME STOP HTD MIR CTSY GAUGES

HAZARD CRUISE PWR AUX CRANK PARK LPS

AIR BAGS WIPER HTR-A/C CIG LTR

6-64

CIRCUITS PROTECTED Center High Mounted Stop Lamp, Stoplamps Electric Heated Mirrors Courtesy Lamps, Dome/RDG Lamps, Vanity Mirrors, Power Mirrors Instrument Panel Cluster, Daytime Running Lamp Relay, Daytime Running Lamp Module, Headlamp Switch, Keyless Entry Illumination, Low Coolant Module, CHIME Module, DRAB Module Hazard Lamps/CHIME Module Cruise Control Auxiliary Power Outlet, DLC Not Used License Plate Lamp, Parking Lamps, Taillamps, Front Sidemarkers, Glove Box Ashtray Air Bags Wiper Motor, Washer Pump A/C, A/C Blower, High Blower Relay, Heated Mirror

Cigarette Lighter

POSITION

14.

15. 16.

17.

18. 19.

20. 21. 22. 23. 24. A.

B.

NAME ILLUM

DRL TURN B/U

RADIO-1
BRAKE RADIO-B TRANS SECURITY RR DEFOG NOT USED RR HVAC PWR ACCY

PWR WDO

CIRCUITS PROTECTED Instrument Panel Cluster, HVAC Controls, RR HVAC Controls, Instrument Panel Switches, Radio Illumination, Door Switch Illumination Daytime Running Lamp Relay Front Turn, RR Turn, Back-up Lamps, BTSI Solenoid Radio (Ign, Accy), Upfitter Provision Relay

4WAL PCM, ABS, Cruise Control Radio (Battery), Power Antenna

PRNDL, Automatic Transmission Passlock Rear Window Defog Not Used RR HVAC Controls, HIGH, MED, LOW Relays Power Door Lock, Six-Way Power Seat, Keyless Entry Illumination Module Power Windows

6-65

Engine Compartment Fuse Block The fuse block is in the engine compartment on the driver’s side of the vehicle.

6-66

NAME SPARE A.I.R. BLOWER ABS IGN B IGN A BATT LIGHTING

RH-HDLP

LH-HDLP

RH-HIBM

LH-HIBM

CIRCUITS PROTECTED Spare Fuse Air Pump Front Blower Motor Electronic Brake Control Module Ignition Switch Starter Relay, Ignition Switch Instrument Panel Fuse Block Instrument Panel Fuse Block, Headlamp Switch Right-hand Headlamp (Export only) Left-hand Headlamp (Export only) Right-hand High-beam Headlamp (Export only) Left-hand High-beam Headlamp (Export only)

NAME ETC RR BLOWER

CNG ENG-I

ECM-I

IGN-E SPARE SPARE SPARE

CIRCUITS PROTECTED Electronic Throttle Control Rear Auxiliary Blower Motor Relays Compressed Natural Gas Heated O2 Sensors, Mass Air Flow Sensor, Evap Canister Purge Valve, Crankshaft Position Sensor, Secondary Air Injection Relay (Diesel), Water in Fuel Sensor (Diesel), Fuel Heater (Diesel), Glowplug Relay (Diesel), Wastegate Solenoid (Diesel) Ignition Coil, Camshaft Position Sensor, VCM, Fuel Injectors, Coil Driver Air Conditioning Clutch Relay Spare Fuse Spare Fuse Spare Fuse

NAME A/C HORN ECM-B

SPARE SPARE AUX A AUX B A/C RELAY HORN RELAY A.I.R. RELAY FUEL PUMP RELAY STARTER RELAY ABS EXPORT RELAY

CIRCUITS PROTECTED Air Conditioning Clutch Relay Horn Relay, Underhood Lamp(s) Fuel Pump Relay, VCM, PCM, Fuel Pump and Engine Oil Pressure Switch Spare Fuse Spare Fuse Upfitter Provisions Upfitter Provisions Air Conditioning Horn Air Fuel Pump

Starter

ABS Export

6-67

Replacement Bulbs LAMP OR BULB Sealed Beam Headlamps Composite Low-Beam Headlamps Composite High-Beam Headlamps Front Sidemarker Lamp Front Parking and Turn Lamp Rear Parking Lamp Rear Stop and Turn Lamp Back-up Lamp Back-up Lamp Rear Parking, Stop, and Turn Lamp

For any bulb not listed here, contact your dealer.

QTY

NUMBER H6054
6052

9005

194
2357NA 3057
3057
3156

1156

1157

6-68

Capacities and Specifications All capacities are approximate. When adding, be sure to fill to the appropriate level or as recommended in this manual. See refrigerant charge label under the hood for charge capacity information and requirements. Engine Identification -- Gasoline Engines Engine Type VIN Code Fuel System Spark Plug Gap Firing Order

0.060 inches (1.52 mm) 1-6-5-4-3-2

0.060 inches (1.52 mm)

0.060 inches (1.52 mm)

1-8-4-3-6-5-7-2

1-8-4-3-6-5-7-2

“VORTEC” 4300

“VORTEC” 5700

“VORTEC” 5000

V8

V8

V6

V8

CSFI1

CSFI1

CSFI1

MFI2

0.060 inches (1.52 mm)

1-8-7-2-6-5-4-3

“VORTEC” 8100

1Central Sequential Fuel Injection 2Sequential Fuel Injection

6-69

Wheel Nut Torque MODEL All

TORQUE 140 lb-ft (190 N·m)

Cooling System Capacity ENGINE “VORTEC” 4300 V6
“VORTEC” 5000 V8
“VORTEC” 5700 V8
“VORTEC” 8100 V8

VIN

QTY Without Rear Heater

QTY With Rear Heater

11.0 quarts (10.4 L) 17.0 quarts (16.0 L) 17.0 quarts (16.0 L) 23.0 quarts (21.8 L)

14.0 quarts (13.2 L) 20.0 quarts (18.9 L) 20.0 quarts (18.9 L) 26.0 quarts (24.6 L)

After refill, the level MUST be checked as outlined under “Engine Cooling System” in Section 5. Engine Oil Capacity ENGINE “VORTEC” 4300 V6
“VORTEC” 5000 V8
“VORTEC” 5700 V8
“VORTEC” 8100 V8

Quantity 4.5 quarts (4.3 L) 5.0 quarts (4.8 L) 5.0 quarts (4.8 L) 6.5 quarts (6.15 L)

VIN

6-70

Fuel Tank Capacity TYPE Standard Tank Standard Tank Optional Tank*

QUANTITY 31.0 U.S. gallons (117.3 L) 35.0 U.S. gallons (132.5 L) 55.0 U.S. gallons (208.1 L)

*159 inch wheelbase or 177 inch wheelbase only

MODEL TYPE Passenger and Cargo Cab and Chassis Cab and Chassis

Air Conditioning Refrigerant Capacity If you do your own service work, you’ll need the proper service manual. See “Doing Your Own Service Work” in the Index for additional information. It is recommended that service work on your air conditioning system be performed by a qualified technician.

REFRIGERANT TYPE R–134a

R–134a

CAPACITY 2.0 lbs. (0.91 kg) Front 3.5 lbs. (1.6 kg) Front and Rear

6-71

Normal Maintenance Replacement Parts Replacement Parts Replacement part numbers listed in this section are based on the latest information available at the time of printing, and are subject to change. If a part listed in this manual is not the same as the part used in your vehicle when it was built, or if you have any questions, please contact your GM dealer. These specifications are for information only. If you have any questions, see the service manual for the chassis or refer to the body manufacturer’s publications.

Engine

“VORTEC” 4300

“VORTEC” 5000

“VORTEC” 5700

“VORTEC”8100

VIN Oil Filter Engine Air Cleaner Filter * PCV Valve Spark Plugs

Fuel Filter Radiator Cap

V6

PF47
A917C CV769C 41-932
GF481
RC36

V8

PF1218
A917C CV769C 41-932
GF481
RC36

V8

PF1218
A917C CV769C 41-932
GF481
RC36

V8

PF454
A917C

**

TJ14R-P15

GF481
RC36

* Replace with ACDelcoR Air Filter, Part No. A917C and for severe dusty conditions, use ACDelcoR Air Filter, Part No. 1236C. **8100 V8 has an internal PCV which does not require replacement.

6-72

Section 7 Maintenance Schedule

This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety, dependability and emission control performance.

7-2
7-4
7-9
7-33

Introduction Part A: Scheduled Maintenance Services Short Trip/City Scheduled Maintenance Long Trip/Highway Scheduled Maintenance

7-48
7-53
7-55
7-58

Part B: Owner Checks and Services Part C: Periodic Maintenance Inspections Part D: Recommended Fluids and Lubricants Part E: Maintenance Record

7-

7-1

Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance can even affect the quality of the air we breathe. Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle. To help protect our environment, and to keep your vehicle in good condition, please maintain your vehicle properly. Maintenance Requirements Maintenance intervals, checks, inspections and recommended fluids and lubricants as prescribed in this manual are necessary to keep your vehicle in good working condition. Any damage caused by failure to follow recommended maintenance may not be covered by warranty.

Have you purchased the GM Protection Plan? The Plan supplements your new vehicle warranties. See your Warranty and Owner Assistance booklet or your dealer for details.

7-2

How This Section is Organized This maintenance schedule is divided into five parts: “Part A: Scheduled Maintenance Services” explains what to have done and how often. Some of these services can be complex, so unless you are technically qualified and have the necessary equipment, you should let your dealer’s service department or another qualified service center do these jobs.

CAUTION:

Performing maintenance work on a vehicle can be dangerous. In trying to do some jobs, you can be seriously injured. Do your own maintenance work only if you have the required know-how and the proper tools and equipment for the job. If you have any doubt, have a qualified technician do the work.

If you want to get the service information, see “Service and Owner Publications” in the Index.

“Part B: Owner Checks and Services” tells you what should be checked and when. It also explains what you can easily do to help keep your vehicle in good condition. “Part C: Periodic Maintenance Inspections” explains important inspections that your dealer’s service department or another qualified service center should perform. “Part D: Recommended Fluids and Lubricants” lists some recommended products necessary to help keep your vehicle properly maintained. These products, or their equivalents, should be used whether you do the work yourself or have it done. “Part E: Maintenance Record” is a place for you to record and keep track of the maintenance performed on your vehicle. Keep your maintenance receipts. They may be needed to qualify your vehicle for warranty repairs.

7-3

The proper fluids and lubricants to use are listed in Part D. 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. These schedules are for vehicles that: D carry passengers and cargo within recommended limits. You will find these limits on your vehicle’s Certification/Tire label. See “Loading Your Vehicle” in the Index.

D are driven on reasonable road surfaces within legal

driving limits.

D use the recommended fuel. See “Fuel” in the Index. Selecting the Right Schedule First you’ll need to decide which of the two schedules is right for your vehicle. Here’s how to decide which schedule to follow:

Part A: Scheduled Maintenance Services Using Your Maintenance Schedule 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 vehicles, maintenance needs vary. You may need more frequent checks and replacements. So please read the following and note how you drive. If you have any questions on how to keep your vehicle in good condition, see your dealer. This part tells you the maintenance services you should have done and when you should schedule them. 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.

7-4

Scheduled Maintenance

Short Trip/City Definition

Short Trip/City Intervals

Follow the Short Trip/City Scheduled Maintenance if any one of these conditions is true for your vehicle: D Most trips are less than 5 miles (8 km). This is

particularly important when outside temperatures are below freezing.

D Most trips include extensive idling (such as frequent

driving in stop-and-go traffic).

D You frequently tow a trailer or use a carrier on top

of your vehicle.

D If the vehicle is used for delivery service, police,

taxi or other commercial application.

One of the reasons you should follow this schedule if you operate your vehicle under any of these conditions is that these conditions cause engine oil to break down sooner.

At 3,000 Miles (5 000 km): Drive Axle Service

(2500 and 3500 Series with locking differential only).

Every 3,000 Miles (5 000 km): Engine Oil and Filter

Change (or 3 months, whichever occurs first). Chassis Lubrication (or 3 months, whichever occurs first). Drive Axle Fluid Check.

Every 6,000 Miles (10 000 km): Tire Rotation. Every 15,000 Miles (25 000 km): Diesel Engine Only:

Engine Air Cleaner Filter Inspection, if driving in dusty conditions. Drive Axle Service When Towing (2500 and 3500 Series only). Gasoline Engine Only: Noise Shields Inspection (GVWR above 10,000 lbs. only). Diesel Engine Only: Shields and Underhood Insulation Inspection. Diesel Engine Only: Thermostatically Controlled Engine Cooling Fan Check (or every 12 months, whichever occurs first). Diesel Engine Only: Air Intake System Inspection. Front Wheel Bearing Repack (or at each brake relining, whichever occurs first).

7-5

Scheduled Maintenance

Short Trip/City Intervals

Short Trip/City Intervals

Every 24,000 Miles (40 000 km): Diesel Engine Only: Fuel Cap Replacement, if driving in dusty conditions.

Every 30,000 Miles (50 000 km): Diesel Engine Only: Engine Air Cleaner Filter Replacement. Fuel Filter Replacement.

Every 50,000 Miles (83 000 km): Automatic

Transmission Service (vehicles over 8600 GVWR or driven under severe conditions or equipped with diesel engine).

Every 60,000 Miles (100 000 km): Engine Accessory

Drive Belt Inspection. If Equipped: Exhaust Gas Recirculation System Inspection. Gasoline Engine Only: Evaporative Control System Inspection. Diesel Engine Only: Crankcase Depression Regulator Valve (CDRV) System Check.

Every 100,000 Miles (166 000 km): Gasoline Engine Only: Spark Plug Wire Inspection. Gasoline Engine Only: Spark Plug Replacement. Gasoline Engine Only: Automatic Transmission Service (normal conditions). Gasoline Engine Only (Except 8.1L V8): Positive Crankcase Ventilation (PCV) Valve Inspection.

Every 150,000 Miles (240 000 km): Cooling System

Service (or every 60 months, whichever occurs first).

These intervals only summarize maintenance services. Be sure to follow the complete scheduled maintenance on the following pages.

7-6

Scheduled Maintenance

Long Trip/Highway Definition

Long Trip/Highway Intervals

Follow this scheduled maintenance only if none of the conditions from the Short Trip/City Scheduled Maintenance are true. Do not use this schedule if the vehicle is used for trailer towing, driven in a dusty area or used off paved roads. Use the Short Trip/City schedule for these conditions. Driving a vehicle with a fully warmed engine under highway conditions will cause engine oil to break down slower.

At 7,500 Miles (12 500 km): Drive Axle Service

(2500 and 3500 Series with locking differential only). Every 7,500 Miles (12 500 km): Engine Oil and Filter Change (or every 12 months, whichever occurs first). Chassis Lubrication (or every 12 months, whichever occurs first). Drive Axle Fluid Check. Tire Rotation.

Every 15,000 Miles (25 000 km): Gasoline Engine

Only: Noise Shields Inspection (GVWR above 10,000 lbs. only). Diesel Engine Only: Shields and Underhood Insulation Inspection. Diesel Engine Only: Thermostatically Controlled Engine Cooling Fan Check (or every 12 months, whichever occurs first). Diesel Engine Only: Air Intake System Inspection.

7-7

Scheduled Maintenance

Long Trip/Highway Intervals

Long Trip/Highway Intervals

Every 30,000 Miles (50 000 km): Fuel Filter

Replacement. Diesel Engine Only: Engine Air Cleaner Filter Replacement. Front Wheel Bearing Repack (or at each brake relining, whichever occurs first).

Every 50,000 Miles (83 000 km): Automatic

Transmission Service (vehicles over 8600 GVWR or driven under severe conditions or equipped with diesel engine).

Every 60,000 Miles (100 000 km): Engine Accessory

Drive Belt Inspection. If Equipped: Exhaust Gas Recirculation System Inspection. Gasoline Engine Only: Evaporative Control System Inspection. Diesel Engine Only: Crankcase Depression Regulator Valve (CDRV) System Check.

Every 100,000 Miles (166 000 km): Gasoline Engine Only: Spark Plug Wire Inspection. Gasoline Engine Only: Spark Plug Replacement. Gasoline Engine Only: Automatic Transmission Service (normal conditions). Gasoline Engine Only (Except 8.1L V8): Positive Crankcase Ventilation (PCV) Valve Inspection.

Every 150,000 Miles (240 000 km): Cooling System

Service (or every 60 months, whichever occurs first).

These intervals only summarize maintenance services. Be sure to follow the complete scheduled maintenance on the following pages.

7-8

Short Trip/City Scheduled Maintenance

The services shown in this schedule up to 100,000 miles (166 000 km) should be repeated after 100,000 miles (166 000 km) at the same intervals for the life of this vehicle. The services shown at 150,000 miles (240 000 km) should be repeated at the same interval after 150,000 miles (240 000 km) for the life of this vehicle. See “Owner Checks and Services” and “Periodic Maintenance Inspections” following.

Footnotes [ The U.S. Environmental Protection Agency or the California Air Resources Board has determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of the vehicle’s useful life. We, however, urge that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded. # Lubricate the front suspension, kingpin bushings, steering linkage and rear driveline center splines. + A good time to check your brakes is during tire rotation. See “Brake System Inspection” under “Periodic Maintenance Inspections” in Part C of this schedule.

7-9

Short Trip/City Scheduled Maintenance

3,000 Miles (5 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. 2500 and 3500 Series Only: If your vehicle has a locking differential, drain fluid and refill at first engine oil change.

6,000 Miles (10 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

7-10

Short Trip/City Scheduled Maintenance

9,000 Miles (15 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed.

12,000 Miles (20 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

7-11

DATE

ACTUAL MILEAGE

SERVICED BY:

Short Trip/City Scheduled Maintenance

15,000 Miles (25 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Diesel Engine Only: Inspect engine air cleaner filter if you are driving in

dusty conditions. Replace filter if necessary. An Emission Control Service. (See footnote [.) Gasoline Engine Only: See “Engine Air Cleaner Filter Restriction Indicator Check” in the Index.

j Check axle fluid level and add fluid as needed. 2500 and 3500 Series Only: If driving in dusty areas or when towing a trailer, drain fluid and refill every 15,000 miles (25 000 km).

j Clean and repack the front wheel bearings (or at each brake relining,

whichever occurs first).

j Vehicles With GVWR Above 10,000 lbs. or Equipped with Diesel Engine

Only: Inspect shields for damage or looseness. Adjust or replace as required. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

7-12

Short Trip/City Scheduled Maintenance

j Diesel Engine Only: Check the air intake system installation to assure that

gaskets are properly sealed and that all hose connections, fasteners and other components are tight. Also check to be sure that the air cleaner housing is properly seated and the cover fits tightly. Tighten connections and fasteners or replace damaged parts as necessary. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

j Diesel Engine Only: If your engine has a thermostatically controlled cooling

fan, inspect all hoses and ducts for proper hook-up (or every 12 months, whichever occurs first). Be sure the valve works properly. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

18,000 Miles (30 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

DATE

ACTUAL MILEAGE

SERVICED BY:

7-13

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

Short Trip/City Scheduled Maintenance

21,000 Miles (35 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed.

24,000 Miles (40 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

j Diesel Engine Only: Replace fuel cap if driving in dusty conditions.

An Emission Control Service.

7-14

Short Trip/City Scheduled Maintenance

27,000 Miles (45 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed.

30,000 Miles (50 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. 2500 and 3500 Series Only: If driving in dusty areas or when towing a trailer, drain fluid and refill every 15,000 miles (25 000 km).

j Clean and repack the front wheel bearings (or at each brake relining,

whichever occurs first).

j Replace fuel filter. An Emission Control Service. (See footnote [.)

(Continued)

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

7-15

Short Trip/City Scheduled Maintenance

30,000 Miles (50 000 km) (Continued) j Diesel Engine Only: Replace engine air cleaner filter.

An Emission Control Service. Gasoline Engine Only: See “Engine Air Cleaner Filter Restriction Indicator Check” in the Index.

j Vehicles With GVWR Above 10,000 lbs. or Equipped with Diesel Engine

Only: Inspect shields for damage or looseness. Adjust or replace as required. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

j Diesel Engine Only: Check the air intake system installation to assure that

gaskets are properly sealed and that all hose connections, fasteners and other components are tight. Also check to be sure that the air cleaner housing is properly seated and the cover fits tightly. Tighten connections and fasteners or replace damaged parts as necessary. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

j Diesel Engine Only: If your engine has a thermostatically controlled cooling

fan, inspect all hoses and ducts for proper hook-up (or every 12 months, whichever occurs first). Be sure the valve works properly. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

7-16

Short Trip/City Scheduled Maintenance

33,000 Miles (55 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. 36,000 Miles (60 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

j Check axle fluid level and add fluid as needed. 39,000 Miles (65 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed.

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

7-17

Short Trip/City Scheduled Maintenance

42,000 Miles (70 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

45,000 Miles (75 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. 2500 and 3500 Series Only: If driving in dusty areas or when towing a trailer, drain fluid and refill every 15,000 miles (25 000 km).

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

7-18

Short Trip/City Scheduled Maintenance

j Clean and repack the front wheel bearings (or at each brake relining,

whichever occurs first). Diesel Engine Only:Inspect engine air cleaner filter if you are driving in dusty conditions. Replace filter if necessary. An Emission Control Service. (See footnote [.) Gasoline Engine Only: See “Engine Air Cleaner Filter Restriction Indicator Check” in the Index.

j Vehicles With GVWR Above 10,000 lbs. or Equipped with Diesel Engine

Only: Inspect shields for damage or looseness. Adjust or replace as required. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

j Diesel Engine Only: Check the air intake system installation to assure that

gaskets are properly sealed and that all hose connections, fasteners and other components are tight. Also check to be sure that the air cleaner housing is properly seated and the cover fits tightly. Tighten connections and fasteners or replace damaged parts as necessary. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

j Diesel Engine Only: If your engine has a thermostatically controlled cooling

fan, inspect all hoses and ducts for proper hook-up (or every 12 months, whichever occurs first). Be sure the valve works properly. This is a Noise Emission Control Service. Applicable only to vehicles sold in the United States.

7-19

Short Trip/City Scheduled Maintenance

48,000 Miles (80 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)

j Diesel Engine Only: Replace fuel cap if driving in dusty conditions.

An Emission Control Service.

50,000 Miles (83 000 km) j Change automatic transmission fluid and filter if the vehicle has a diesel

engine, if the vehicle’s GVWR is over 8600 lbs. or if the vehicle is mainly driven under one or more of these conditions: – In heavy city traffic where the outside temperature regularly

reaches 90_F (32_C) or higher. – In hilly or mountainous terrain. – When doing frequent trailer towing. – Uses such as found in taxi, police or delivery service. If you do not use your vehicle under any of these conditions, change the fluid and filter at 100,000 miles (166 000 km).

7-20

DATE

ACTUAL MILEAGE

SERVICED BY:

DATE

ACTUAL MILEAGE

SERVICED BY:

Short Trip/City Scheduled Maintenance

51,000 Miles (85 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. 54,000 Miles (90 000 km) j Change engine oil and filter (or every 3 months, whichever occurs first).

An Emission Control Service.

j Lubricate chassis components (or every 3 months, whichever occurs first).

(See footnote #.)

j Check axle fluid level and add fluid as needed. j Rotate tires. See “Tire Inspection and Rotation” in the Index for proper

rotation pattern and additional information. (See footnote +.)