2006 CHEVROLET DURAMAX engine cooling system service

Diesel Fuel Requirements and Fuel System.......5-2
Diesel Engine Fuel.........................................5-2
What Fuel to Use...........................................5-3
Very Cold Weather Operation...........................5-5
Water in Fuel.................................................5-5
Water in Fuel Light Chart................................5-6
Running Out of Fuel.....................................5-11
Fuel Filter Replacement.................................5-12
Filling the Tank............................................5-15
Filling a Portable Fuel Container.....................5-17Checking Things Under the Hood....................5-18
Engine Compartment Overview.......................5-18
Engine Oil...................................................5-21
Engine Oil Life System..................................5-24
Engine Air Cleaner/Filter................................5-25
Automatic Transmission Fluid.........................5-29
Engine Coolant.............................................5-34
Radiator Pressure Cap..................................5-39
Coolant Surge Tank Pressure Cap..................5-39
Engine Overheating.......................................5-39
Cooling System............................................5-41
Capacities and Specications..........................5-50
Specification Charts......................................5-50
Section 5 Service and Appearance Care
5-1
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How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission fluid to use. SeeRecommended
Fluids and Lubricants on page 6-15.
Using a funnel, add fluid down the transmission dipstick
tube only after checking the transmission fluid while it is
hot. A cold check is used only as a reference. If the fluid
level is low, add only enough of the proper fluid to bring
the level up to the HOT area for a hot check. It does not
take much fluid, generally less than one pint (0.5L). Do
not overfill.
Notice:Use of the incorrect automatic transmission
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transmission uid listed in
Recommended Fluids and Lubricants on page 6-15.
•After adding fluid, recheck the fluid level as
described under “How to Check” earlier in
this section.
•When the correct fluid level is obtained, push the
dipstick back in all the way. Then flip the handle
down to lock the dipstick in place.
Engine Coolant
Pickup Models
The cooling system in your vehicle is filled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add only
DEX-COOL
®extended life coolant.
The following explains your cooling system and how
to add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating
on page 5-39.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
•Give freezing protection down to−34°F (−37°C)
•Give boiling protection up to 265°F (129°C)
•Protect against rust and corrosion
•Help keep the proper engine temperature
•Let the warning lights and gages work as they should
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 the rst maintenance
service after each 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.
5-34
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If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. In heavy traffic, let the engine idle in NEUTRAL (N)
while stopped. If it is safe to do so, pull off the road,
shift to PARK (P) or NEUTRAL (N), and let the
engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn’t come back on, you can drive
normally.
If the warning continues, pull over, stop, and park your
vehicle right away.
If there’s still no sign of steam and your vehicle is
equipped with an engine driven cooling fan, push down
the accelerator until the engine speed is about twice as
fast as normal idle speed for at least three minutes while
you’re parked. If there is no sign of steam and your
vehicle is equipped with an electric cooling fan, idle the
engine for three minutes while you’re parked. If you still
have the warning,turn off the engine and get everyone
out of the vehicleuntil it cools down.
You may decide not to lift the hood but to get service
help right away.Cooling System
Pickup Models
When you decide it’s safe to lift the hood, here’s what
you’ll see:
A. Coolant Surge Tank Pressure Cap
B. Coolant Surge Tank
C. Engine Fan
If the coolant inside the coolant surge tank is boiling,
don’t do anything else until it cools down. The vehicle
should be parked on a level surface.
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The coolant level should
be at or above the FULL
COLD mark. If it isn’t, 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 there seems to be no leak, start the engine again. If
your vehicle is equipped with an engine driven cooling
fan, the engine cooling fan speed should increase when
idle speed is doubled by pushing the accelerator pedal
down. If it doesn’t, your vehicle needs service. Turn off
the engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
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
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Scheduled Maintenance (cont’d)
Service MaintenanceIMaintenanceII
Inspect engine cooling system.See footnote (e).•
Inspect wiper blades.See footnote (f).•
Inspect restraint system components.See footnote (g).•
Lubricate body components.See footnote (h).•
Check transmission fluid level and add fluid as needed.•
Van models: Replace both fuel filters.An Emission Control Service.
See footnotes † and (i).•
Pickup models: Fuel filter service.An Emission Control Service.
See footnotes † and (j).•
Inspect shields and underhood insulation, vans with GVWR above
10,000 lbs (4 536 kg) and all pickups.See footnote (k).•
Check air intake system.See footnote (l).•
Van models: Inspect throttle system.See footnote (m).•
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Additional Required Services (cont’d)
Service and Miles (Kilometers)25,000
(40 000)50,000
(80 000)75,000
(120 000)100,000
(160 000)125,000
(200 000)150,000
(240 000)
Van models: Change automatic
transmission fluid and filter
(severe service).See footnote (p).•••
Van models: Change automatic
transmission fluid and filter
(normal service).•
Pickup models: Four-wheel drive with
automatic transfer case only: Change
transfer case fluid.See footnote (q).•••
Van models: Replace spark plugs and
inspect spark plug wires.An Emission
Control Service.•
Engine cooling system service
(or every five years, whichever occurs
first).An Emission Control Service.
See footnote (r).•
Inspect engine accessory drive belt.
An Emission Control Service. See
footnote (s).•
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Maintenance 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, steering linkage,
transmission shift linkage (pickup models), rear driveline
center splines (van models), and parking brake cable
guides. Pickup models only: Control arm ball joints
require lubrication but should not be lubricated unless
their temperature is 10°F (-12°C) or higher, or they could
be damaged. Vehicles used under severe commercial
operating conditions require lubrication on a regular basis
every 3,000 miles (5 000 km).
(a)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired
and the uid level checked. Add uid if needed.
(b)If you drive regularly under dusty conditions, inspect
the lter or change indicator, if equipped, at each engine
oil change.(c)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chang, etc. Inspect disc
brake pads for wear and rotors for surface condition.
Inspect drum brake linings/shoes for wear or cracks.
Inspect other brake parts, including drums, wheel
cylinders, calipers, parking brake, etc.
(d)Visually 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, chang, etc. Pickup models: Visually
check constant velocity joints, rubber boots, and axle
seals for leaks.
(e)Visually inspect hoses and have them replaced if they
are cracked, swollen, or deteriorated. Inspect all pipes,
ttings, and clamps; replace with genuine GM parts as
needed. To help ensure proper operation, a pressure test
of the cooling system and pressure cap and cleaning the
outside of the radiator and air conditioning condenser is
recommended at least once a year.
(f)Visually inspect wiper blades for wear or cracking.
Replace wiper blades that appear worn or damaged
or that streak or miss areas of the windshield.
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(n)Change clutch uid (or every 24 months, whichever
occurs rst).
(p)Change automatic transmission uid and external
transmission lter 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.
(q)Check vent hose at transfer case for kinks and
proper installation.
(r)Drain, ush, and rell cooling system. This service
can be complex; you should have your dealer perform
this service. See Engine Coolant on page 5-34 for
what to use. Inspect hoses. Clean radiator, condenser,
van model fuel operated heater (if equipped), pressure
cap, and ller neck. Pressure test the cooling system
and pressure cap. For van models, see Fuel Operated
Heater (FOH) (Van Models Only) on page 2-8.
(s)Visually inspect belt for fraying, excessive cracks,
or obvious damage. Replace belt if necessary.Owner Checks and Services
These owner checks and services should be performed
at the intervals specified to help ensure the safety,
dependability, and emission control performance of your
vehicle. Your GM Goodwrench
®dealer can assist you
with these checks and services.
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
inRecommended Fluids and Lubricants on page 6-15.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-21for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
6-11
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