
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap — even a little — when the engine and
radiator are hot.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the
FULL COLD mark.
If your vehicle is equipped with a low coolant sensor
and the LOW COOLANT LEVEL message comes
on and stays on, it means you are low on engine
coolant. See “LOW COOLANT LEVEL” underDIC
Warnings and Messages on page 3-54.
Adding Coolant
If you need more coolant, add the proper DEX-COOL®
coolant mixture at the surge tank, but only when the
engine is cool.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
When replacing the pressure cap, make sure it is
hand-tight and fully seated.
5-37

A. Coolant Surge Tank
B. Coolant Surge Tank Pressure Cap
C. Engine Cooling Fan
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
If the coolant inside the coolant surge tank is boiling,
do not do anything else until it cools down. The vehicle
should be parked on a level surface. Check the
coolant level after the system cools down. Some amount
of coolant may be lost due to overheating.
All Other Engines
5-41

The coolant level should
be at or above the FULL
COLD mark. If it is not, you
may have a leak at the
pressure cap or in
the radiator hoses, heater
hoses, radiator, water
pump or somewhere else
in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.If your vehicle is equipped with an electric engine
cooling fan, check the coolant temperature gage. If the
coolant temperature is approximately 232°F (111°C),
the electric cooling fan should be running. If it is
not, your vehicle needs service. Turn off the engine.
If your vehicle is equipped with an engine-driven cooling
fan, start the engine again and see if the fan speed
increases when idle speed is doubled by pushing the
accelerator pedal down. If it does not, your vehicle
needs service. Turn off the engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
SeeOverheated Engine Protection Operating Mode
(V8 Engines Only) on page 5-40for information
on driving to a safe place in an emergency.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-42

How to Add Coolant to the Coolant
Surge Tank for Gasoline Engines
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level is not at or above the FULL COLD
mark, add a 50/50 mixture of clean, drinkable water
and DEX-COOL
®coolant at the coolant surge tank,
but be sure the cooling system, including the coolant
surge tank pressure cap, is cool before you do it.
SeeEngine Coolant on page 5-35for more information.
If no coolant is visible in the surge tank, add coolant
as follows:
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the coolant
surge tank pressure cap — even a little — they
can come out at high speed. Never turn the
cap when the cooling system, including the
coolant surge tank pressure cap, is hot. Wait
for the cooling system and coolant surge tank
pressure cap to cool if you ever have to turn
the pressure cap.
{CAUTION:
Adding only plain water to your cooling system
can be dangerous. Plain water, or some other
liquid such as alcohol, can boil before the
proper coolant mixture will. Your vehicle’s
coolant warning system is set for the proper
coolant mixture. With plain water or the wrong
mixture, your engine could get too hot but
you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and a proper coolant.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
5-43

4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower, add
more of the proper mixture to the coolant surge tank
until the level reaches the FULL COLD mark.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight and fully seated.
Engine Fan Noise
If your vehicle is equipped with a clutched engine
cooling fan, when the clutch is engaged, the fan spins
faster to provide more air to cool the engine. In
most everyday driving conditions, the fan is spinning
slower and the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing, and/or high outside
temperatures, the fan speed increases as the clutch
more fully engages, so you may hear an increase in fan
noise. This is normal and should not be mistaken as
the transmission slipping or making extra shifts.
It is merely the cooling system functioning properly.
The fan will slow down when additional cooling is not
required and the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
If your vehicle is equipped with electric cooling fans, you
may hear the fans spinning at low speed during most
everyday driving. The fans may turn off if no cooling is
required. Under heavy vehicle loading, trailer towing,
and/or high outside temperatures, or if you are operating
your air conditioning system, the fans change to high
speed and you may hear an increase in fan noise.
This is normal and indicates that the cooling system is
functioning properly. The fans will change to low
speed when additional cooling is no longer required.
5-45

ApplicationCapacities
English Metric
VORTEC™ 8100 V8 HD Automatic* 25.0 qt 23.7 L
VORTEC™ 8100 V8 HD Automatic** — —
VORTEC™ 8100 V8 Automatic* 26.9 qt 25.5 L
VORTEC™ 8100 V8 Automatic** — —
VORTEC™ 8100 V8 Manual* 27.1 qt 25.6 L
VORTEC™ 8100 V8 Manual** — —
* Engine Fan Driven cooling system
** Electric Cooling Fan system
Engine Oil with Filter
4300 V6 4.5 qt 4.3 L
4800 V8; 5300 V8; 6000 V8 6.0 qt 5.7 L
8100 V8 6.5 qt 6.1 L
Fuel Tank
Short Bed and 2500 LD 26.0 gal 98.0 L
Long Bed and Chassis Cab (Pickup Box Delete) 34.0 gal 128.7 L
Chassis Cab 3500 and 3500HD — front 27.0 gal 102.0 L
Chassis Cab 3500 and 3500HD — rear 23.0 gal 87.0 L
Wheel Nut Torque 140 ft lb 190Y
After re ll, the level must be rechecked. Add enough engine coolant so that the uid is within the proper operating
range.
5-134