Engine Overheating................................... 288
Cooling System (Gas and
DURAMAX
®/Isuzu Engines).................... 290
Engine Fan Noise..................................... 294
Power Steering Fluid................................. 295
Windshield Washer Fluid........................... 296
Brakes...................................................... 297
Battery...................................................... 304
Jump Starting............................................ 305
Rear Axle.................................................... 311
Rear Axle Shift Motor................................ 312
Four-Wheel Drive........................................ 312
Front Axle................................................... 313
Noise Control System................................. 314
Tampering with Noise Control System
Prohibited.............................................. 314
Bulb Replacement....................................... 315
Windshield Wiper Blade Replacement....... 316Other Service Items.................................... 317
Fuel Filter.................................................. 317
Primary Fuel Filter and Water Separator...... 317
Secondary Fuel Filter and Water
Separator/Heater (Caterpillar
®Diesel)...... 318
Automatic Ether Injection System
(Caterpillar
®Diesel)................................ 318
Front Wheel Bearings with
Oil-Filled Hubs....................................... 319
Air Conditioning System............................ 320
Tires............................................................ 321
Inflation - Tire Pressure............................. 322
Wheel Loading.......................................... 323
Dual Tire Operation................................... 323
When It Is Time for New Tires.................. 324
Wheel Alignment and Tire Balance............ 324
Tightening the Wheel Nuts........................ 325
Wheel Replacement.................................. 328
If a Tire Goes Flat.................................... 330
Section 5 Service and Appearance Care
246
Cooling System (Gas and
DURAMAX
®/Isuzu Engines)
When you decide it is safe to lift the hood, here is
what you will see:
A. Engine Fan
B. Coolant Surge TankIf your vehicle has a Caterpillar
®diesel engine,
see the Caterpillar®Diesel Engine Operation and
Maintenance Manual provided with your vehicle.
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.
The coolant level should
be at the FULL COLD
mark or higher. 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.
290
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 DEX-COOL
®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.
292
Other Service Items
Fuel Filter
Fuel Filter/Pressure Regulator
(Gasoline Engines)
The steel fuel filter/pressure regulator is located
near the engine compartment on the driver’s
side frame rail. If your vehicle has a rear steel fuel
tank, the fuel filter/pressure regulator is located
near the rear fuel tank, on the driver’s side frame
rail. SeeScheduled Maintenance on page 363
for recommended service intervals.
If your vehicle is equipped with the optional Davco
spin-on type filter, it is located on the driver’s
side frame rail.
Fuel Filter (Diesel Engines)
If you have a diesel engine, your fuel filter is
located in the engine compartment on the driver’s
side of the vehicle, or along the driver’s side
frame rail. See “Fuel Filter Replacement” earlier in
this section for further information.
Also seeScheduled Maintenance on page 363for
recommended service intervals.
Primary Fuel Filter and Water
Separator
If you have a diesel
engine, you may have
this spin-on filter. It
is located on the driver’s
side frame rail.
It has a clear plastic drain bowl at the bottom.
Check the drain bowl occasionally for any water or
particles.
To drain the bowl, do the following:
1. Shut off the engine.
2. Partially open the drain valve at the bottom of
the filter.
SeeEngine Oil (Caterpillar
®Diesel Engine) on
page 268orEngine Oil (Gasoline Engine) on
page 268orEngine Oil (DURAMAX
®/Isuzu Diesel
Engine) on page 272for proper disposal
procedures.
317
When cleaning your vehicle’s interior, only use
cleaners specifically designed for the surfaces
being cleaned. Permanent damage may result
from using cleaners on surfaces for which
they were not intended. Use glass cleaner only on
glass. Remove any accidental over-spray from
other surfaces immediately. To prevent over-spray,
apply cleaner directly to the cleaning cloth.
Notice:If you use abrasive cleaners when
cleaning glass surfaces on your vehicle, you
could scratch the glass and/or cause damage
to the rear window defogger. When cleaning
the glass on your vehicle, use only a soft cloth
and glass cleaner.
Many cleaners contain solvents that may become
concentrated in your vehicle’s breathing space.
Before using cleaners, read and adhere to all safety
instructions on the label. While cleaning your
vehicle’s interior, maintain adequate ventilation by
opening your vehicle’s doors and windows.
Dust may be removed from small buttons and
knobs using a small brush with soft bristles.Your dealer has a product for cleaning your
vehicle’s glass. Should it become necessary, you
can also obtain a product from your dealer to
remove odors from your vehicle’s upholstery.
Do not clean your vehicle using the following
cleaners or techniques:
•Never use a knife or any other sharp object to
remove a soil from any interior surface.
•Never use a stiff brush. It can cause damage
to your vehicle’s interior surfaces.
•Never apply heavy pressure or rub
aggressively with a cleaning cloth. Use of
heavy pressure can damage your interior and
does not improve the effectiveness of soil
removal.
•Use only mild, neutral-pH soaps. Avoid
laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave a
residue that leaves streaks and attracts dirt.
For liquid cleaners, about 20 drops per gallon
(3.78 L) of water is a good guide.
•Do not heavily saturate your upholstery while
cleaning.
•Damage to your vehicle’s interior may result
from the use of many organic solvents such as
naptha, alcohol, etc.
332
❑Check air brake relay valve operation and
check for leaks (or every month, or every
300 hours, whichever occurs first).
❑Clean air brake application valve (or every
3 months, or every 300 hours, whichever
occurs first). Lubricate linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
❑Thermostatically controlled engine cooling
fan service.(3) (19)
❑Shields and underhood insulation
service.(3) (4) (20)
❑Gasoline Engine: Air compressor remote
mounted air filter dry element pleated paper
air strainer service (or every 6 months or
every 1800 hours, whichever occurs first).
22,500 Miles (36 000 km)
❑Gasoline Engine Only: Check engine oil life
system. If engine oil and filter are changed,
reset system. See “Engine Oil (Gasoline
Engine)” in the Index.(2) (8)
❑Check fluid levels (or every 3 months,
whichever occurs first).(1) (5)❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Inspect door hinge pins and bushings and
replace as necessary.
❑Cooling system service. Clean the cooling
system filter cap with clean water, clean
the core, pressure test the cap and the
system for proper pressure capability, and
inspect condition of cooling and heater
hoses and clamps. Replace hoses if cracked,
swollen, or damaged.
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(6) (36)
❑Parking brake service (or every 6 months,
whichever occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
❑Air brake automatic slack adjuster service (or
every 500 hours, whichever occurs first).(33)
366
❑Diesel Engine: Inspect engine air cleaner filter
change indicator. If necessary, replace the
filter. If vehicle is driven in dusty/dirty conditions,
inspect filter change indicator at every engine
oil change. SeeEngine Air Cleaner/Filter
on page 280for more information.
❑DURAMAX
®/Isuzu Diesel Only: Replace fuel
filter (or every 750 hours of engine operation,
whichever occurs first).
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Cooling system service. Clean the cooling
system filler cap with clean water, clean
the core, pressure test the cap and the
system for proper pressure capability, and
inspect condition of cooling and heater
hoses and clamps. Replace hoses if cracked,
swollen, or damaged.
❑Inspect door hinge pins and bushings and
replace as necessary.
❑Steering system service.(12)
❑Front and rear suspension service.(13)❑Spring-to-axle U-bolts and shackle bolts
service.(15)
❑Exhaust system service (or every 6 months,
whichever occurs first).(2) (3) (16)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(6) (36)
❑Parking brake service (or every 6 months,
whichever occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
❑Air brake automatic slack adjuster service (or
every 500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check
for leaks (or every month, or every 300 hours,
whichever occurs first).
❑Clean air brake application valve (or every
3 months, or every 300 hours, whichever
occurs first). Lubricate linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
371
❑Air brake service (or every 6 months,
whichever occurs first).(32)
❑Air brake automatic slack adjuster service (or
every 500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check
for leaks (or every month, or every 300 hours,
whichever occurs first).
❑Clean air brake application valve (or every
3 months, or every 300 hours, whichever
occurs first). Lubricate linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
❑C600, C700, and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first).(17)
❑Thermostatically controlled engine cooling
fan service.(3) (19)
❑Shields and underhood insulation
service.(3) (4) (20)
❑Gasoline Engine: Air compressor remote
mounted air filter dry element pleated paper
air strainer service (or every 6 months or
every 1800 hours, whichever occurs first).67,500 Miles (108 000 km)
❑Gasoline Engine Only: Check engine oil life
system. If engine oil and filter are changed,
reset system. See “Engine Oil (Gasoline
Engine)” in the Index.(2) (8)
❑Check fluid levels (or every 3 months,
whichever occurs first).(1) (5)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Cooling system service. Clean the cooling
system filler cap with clean water, clean
the core, pressure test the cap and the
system for proper pressure capability, and
inspect condition of cooling and heater
hoses and clamps. Replace hoses if cracked,
swollen, or damaged.
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(6) (36)
❑Parking brake service (or every 6 months,
whichever occurs first).(21)
❑Air brake service (or every 6 months,
whichever occurs first).(32)
375