Page 323 of 436
CAUTION
Turning the radiator pressure cap when the engine and radiator are
hot can allow steam and scalding liquids to blow out and burn you
badly. With the coolant recovery tank, you will almost never h\
ave to
add coolant at the radiator. Never turn the radiator pressure cap-even a little-when the engine and radiator are hot.
Add coolant mix at the recovery tank, but be careful not to \
spill it.
You can be burned
if you spill coolant on hot engine parts. Coolant
mtains ethylene glycol, and
it will burn if the engine parts are hot
enough. Don’t spill coolant on a hot engine. ’
Radiator Pressure Cap
K2515
1
Your radiator pressure cap is a 15 psi (105 kPa) pressure-type cap
must be tightly installed to prevent coolant
loss and possible engine
damage from overheating. Be sure the arrows on the cap line up w
overflow tube on the radiator filler neck.
-
When you replace your radiator pressure cap, an ACa cap is recommended.
-
I
6-45
ProCarManuals.com
Page 326 of 436
Service & Appearance Care
Windshield Washer Fluid
To Add:
Open the cap labeled WASHER FLUID ONLY. Add washer fluid until the
bottle
is full.
K2469
- When using a concentrated washer fluid, follow the manufacturer \
instructions for adding water.
I Don’t mix water with ready-to-use washer fluid. Water can us\
e the
solution to freeze and damage your washer fluid tank and other parts
of the washer system.
Also, water doesn’t clean as well as was
I fluid.
1 Fill your washer fluid tank only 3/4 full when it’s very cold. This
I
allows for expansion, which could damage the tank if it is CnrnDletely
full.
I
Don’t use radiator antifreeze for your windshield washer. It can
. damage your washer system and paint.
6-48
ProCarManuals.com
Page 334 of 436
Service & Appearance Care
Composite Headlights
A
1
I
PO234
1. Remove the two screws at the top of the radiator support.
2. Pull the composite headlight lens out.
3. Unplug the electrical connector.
4. Turn the bulb counterclockwise and remove it. ,
5. Put the new bulb in and turn it clockwise until it is tight.
6. Plug in the electrical connector.
7. Put the headlight back into the vehicle and tighten the two screws.
6-56
ProCarManuals.com
Page 398 of 436

Scheduled Maintenance Services
Explanation Of Scheduled Maintenance 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 ve\
hicle.
1.
ENGINE OIL AND OIL FILTER CHANGE* -ALWAYS USE SG OR
SGKE QUALITY, ENERGY CONSERVING II 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, propshaft splines (2 wheel drive), 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 1, or every 3,000
(5000 km) for Maintenance Schedule 2.
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 -Lubricate the clutch fork
ball stud through the fitting on the clutch housing. Lubricant must be
added “sparingly” to the fitting, as only.
0066 Ib. (.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. ENGINE IDLE SPEED ADJUSTMENT (DIESEL ENGINES)* -Adjust to
the specifications shown on the underhood label. You must use
calibrated test equipment.
5. 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
7-1
8
ProCarManuals.com
Page 427 of 436

1 Add-on Equipment ................... 6-94
I- Electronic Heatinghir Conditioning
(See "Heating")
Adding Coolant
... 5.12, 5.14. 6-44
... Engine I
Air Cleaner ................................ 6-31
Block Heater
.......... 2.19. 3.5. 6-26
Cold Weather Starting (Diesel)
.................... 2-1 7
Coolant
....... 5.12. 5-1 4. 6.42. 6-96
Coolant Temperature Gage
...... 2-88
Diesel
................................ 6.6. 6-1 9
Crankcase
.................................. 6-96
Fan Noise
.................................. 5-1 7
Noise Control System
.............. 6-1 9
.-Identification,
............................ 6-95
Oil .(See "Oil")
Overheating
................................. 5-9
Running While Parked
............. 2-35
Equipment, Add-on
...................... 6-69
Exhaust System
................ 2.34, 6-65
Exhaust
........................... 2.34,
6-65
Starting
............................ 2.12, 2-1 5
F
Fan Noise ...................................... 5-1 7
Filter
. Replacement Chart ............ 6-99
Finish Care
............................................ 6-88
Damage
..................................... 6-90
Automatic Transmission
........... 6-33
Brake
.......................................... 6-49
Coolant
............................ 5-1 2. 6-42
Front Axle
.................................. 6- 40
Hydraulic Clutch
....................... 6-37
Leak Check
................................ 6-52
Manual Transmission
................ 6-36
Power Steering
............ 1 ............ 6-46
Radiator
....................................... 5-1 4
Fluid
9-3
Rear Axle .................................. 6-41
Recommended Fluids
.............. 7-25
. Transfer Case ............................ 6-39
Windshield Washer.
................. 6-48
Fog Lamps
.................................... 2-54 .
Four-wheel Drive ............... 2.36, 6-39
Transfer Case
................ .2-37, 6-39
Front Axle
................................. 6-40
Fuel (Diesel Engines)
..................... 6.6
Cold Weather Operation
............ 6-7
Filter Replacement
........ 6-1 1, 6.13,
6-99
Fuel Requirements
..................... 6-6
Gage
........................ ; ................. 2-87
Running Out Of
........................ 6-10
Tank Capacity
........................... 6-97
Water in Fuel
.............................. 627
Fuel (Gasoline Engines)
................. 6-4
Filling Your Ta'nk
....................... 6-16
Foreign
. Countries ..................... 6-15
Gage
.......................................... 2-87
Gasolines for Cleaner Air
......... 6-5 A-
Fuses and Circuit
Breakers
............................ 6-64, 6-1 01 * .
Fuse Block ................................ 6-65 . . f
Headlights .................... 6.64, 6-100
Power Windows and Other
Trailer Wiring Harness
.. 6.64, 6-1 00
. Windshield Wipers ...... 6-64, 6-100
G
Gages ............................................ 2.87
Coolant Temperature Gage
..... 2-88
Fuel Gage
.................................. 2-87
Odometer
................................... 2-76
Oil Pressure Gage
..................... 2-89
Speedometer.
............................ 2-76
Tachometer
..................... 2.76, 2-78
Trip Odameter 2-77
Voltmeter
................................... 2-90
-
-.
I
Power Options ......... 6.64, 6-100 :
. ...........................
...
ProCarManuals.com