Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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318 Service and Maintenance
Recommended Daily
(Pre-operation) Inspections
These checks are in addition to, not
instead of, any legally required daily
inspections. See related topics
under "Maintenance Schedule",
especially if problems are found.
For safe and comfortable driving,
keep record of the distances driven
and the condition of the vehicle
during operation. Perform
inspections at appropriate intervals,
and perform maintenance in
accordance with the findings of the
inspections. If an inspection reveals
an abnormality or there was an
abnormality the previous time the
vehicle was driven, have the vehicle
repaired by the nearest dealer
before it is driven again.1. Components that showed abnormalities during the
previous operation
.Check components that
showed abnormalities
during the previous
operation 2. Checks performed at the
engine
.Fan belt looseness and
damage
. Engine oil level
. Engine coolant level
. Power steering fluid level
3. Checks performed from the driver's seat
.Brake fluid level
. Brake pedal free play
. Operation of meters,
gauges and warning/
indicator lights
. Engine startability,
abnormal noise and color of
exhaust gases
. Parking brake lever stroke
. Windshield washer fluid
spray condition and
windshield wiper
effectiveness
. Windshield washer fluid
level .
Steering wheel position and
free play
. Operation of horn and turn
signal lights
. Door lock operation
4. Checks performed during a walk around the vehicle
.Illumination, flashing,
contamination, damage and
obstruction of lights
. Contamination, damage ad
obstruction of windows,
mirrors and reflectors
. Leaf spring damage
. Oil, engine coolant, fuel,
brake fluid and power
steering fluid leaks
. Water separator
5. Checking wheels and tires .Air pressure
. Cracks and other damage
. Abnormal wear
. Tread depth
. Mounting condition of all
wheel nuts
Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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324 Service and Maintenance
one side, unusual sounds when
braking, increased brake pedal
travel or harder pedal. The front and
rear brakes are attached to an auto
adjuster mechanism. If there are no
defects, as the pedal travel is
properly maintained, adjustments
are not necessary. Check regularly
that the brake fluid reservoir
(left-hand side of the instrument
panel) or HBB reservoir (5500HD,
5500XD models: left side behind the
cab) is properly filled and check for
fluid leaks. Any of these conditions
could indicate the need for brake
system inspection and/or service.
G: Exhaust System :Be alert for
any changes in the sound of the
exhaust system or any smell of
fumes. These are signs the system
may be leaking. Have it checked
and/or repaired at once. (Refer to
"Engine Exhaust Emissions Caution
(Carbon Monoxide)" under Engine
Exhaust 0159).
H: Windshield Wipers and
Washers : Check operation and
condition of the wiper blades. Check
the flow of the washer spray. I: Defroster :
Turn the outlet
selector knob to "Defroster" and the
fan speed control knob to the fully
clockwise position. Then check the
airflow from the ducts at the inside
base of the windshield.
J: Rearview Mirrors and Sun
Visors : Check that friction joints
hold mirrors and sun visors in place.
K: Horn : Sound the horn, now and
then, to be sure it works.
L: Lap-Shoulder Belts : Check the
seat belt system (including webbing,
buckles, latch plates and anchors)
for proper operation, and for
damage.
M: Seat Adjusters : When
adjusting the driver's manual seat,
be sure the seat adjusters latch by
pushing the seat forward and
backward. Do not attempt to adjust
the seat when the vehicle is in
motion.
N: Lamps : Check panel lighting,
warning lamps, indicator lamps and
interior lamps. On the outside,
check: license plate lamps, side
marker lamps, reflectors on outside mirrors, headlamps, parking lamps,
identification and clearance lamps,
taillights, brake lamps, turn signals,
cornering lamps, backup lamps and
hazard warning flashers. Have
headlamp aim checked immediately
if beams seem improperly aimed.
O: Glass, Mirrors, Lights and/or
Reflectors Condition :
Look for
broken, scratched, dirty or damaged
glass, mirrors, lamps or reflectors
that could reduce the view or
visibility, or cause injury. Replace,
clean or repair promptly.
P: Door Latches : Check that doors
close, latch and lock tightly. Check
for broken, damaged or missing
parts that might prevent tight
latching.
Q :Tilt Cab (Driving Position) : Be
sure the tilt lever is down and
locked.
R: Fluid Leaks : Check for fuel,
water, oil or other fluid leaks by
looking at the surface beneath the
vehicle after it has been parked for
a while. If you notice diesel fumes or
fluid at any time, have the cause
found and corrected at once.
Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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334 Technical Data
12: Model CombinationF: 3500HD/4JJ1 Diesel/13,000lbs
K: 4500XD/4HK1 Diesel/16,000lbs
0: 4500HD/4HK1 Diesel/14,500lbs
E: GM Chevrolet 5500HD/5500XD
3: 5500XD/4HK1 Diesel/19,500lbs
8: 3500 & 4500/Gas
9: 5500HD/4HK1 Diesel/17,950lbs
13–17: Sequence Number Positions 13 through 17 represent the number sequentially assigned by the manufacturer in the production
process.
Interpretation of the VIN may differ
depending on the vehicle. For
further details, please ask your
dealer.
Engine NumberThe engine number is located on
the left-side rear part of the engine
block and the right-side front part of
the oil pan.
Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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336 Technical Data
Valve clearance (Between
cam and roller)Both intake and exhaust valves:
0.6 mm (0.024 in) in cold engine
Idling speed 500 - 600 r/min
Fan belt tension New belt: 5 - 7 mm (0.20 - 0.28 in)/184 - 206 Hz
When used: 8 - 9 mm (0.31 - 0.35 in)/158 - 170 Hz
Oil filter Cartridge
Engine oil capacity When changing oil and filter:
11.0 L (11.6 qt)
*1
Engine coolant capacity 19.6 L (20.7 qt)*2
Preheating system Glow plugs
Transmission Specifications
Model A465 Model Six-speed automatic transmission (overdrive gear for 5th and 6th), lock-up clutch for
2nd to 6th
Gear ratio 1st 3.742 to 1 2nd 2.003 to 13rd 1.343 to 1
4th 1.000 to 1
5th 0.773 to 1
6th 0.634 to 1
Reverse 3.539 to 1
Transmission oil capacity 13.1 L (27.7 pt)
Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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Customer Information 349
Reporting Safety
Defects
Reporting Safety Defects
to the United States
Government
If you believe that your vehicle
has a defect which could cause
a crash or could cause injury or
death, you should immediately
inform the National Highway
Traffic Safety Administration
(NHTSA) in addition to notifying
General Motors.
If NHTSA receives similar
complaints, it may open an
investigation, and if it finds that
a safety defect exists in a group
of vehicles, it may order a recall
and remedy campaign.
However, NHTSA cannot
become involved in individual
problems between you, your
dealer, or General Motors.To contact NHTSA, you may call
the Vehicle Safety Hotline
toll-free at 1-888-327-4236
(TTY: 1-800-424-9153); go to
http://www.safercar.gov;
or
write to:
Administrator, NHTSA
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
You can also obtain other
information about motor
vehicle safety from
http://www.safercar.gov
.
Reporting Safety Defects
to General Motors
In addition to notifying NHTSA in a
situation like this, notify General
Motors.
Call 1-800-862-4389, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance
Center
P.O. Box 33170
Detroit, MI 48232-5170
Vehicle Data
Recording and
Privacy
Your vehicle, like other modern
motor vehicles, has a number of
sophisticated computer systems that
monitor and control several aspects
of the vehicle performance. Your
vehicle uses onboard vehicle
computers to monitor emission
control components to optimize fuel
economy and to provide anti-lock
braking and to help the driver
control the vehicle in difficult driving
situations. These computers and
your vehicle's Data Recording
Module (DRM) also store
information about the performance
and status of certain systems in
your vehicle including the engine,
throttle, and braking systems.
General Motors and its affiliates, as
well as service and repair facilities
may access or download and share
this information via a direct
connection to your vehicle in order
to diagnose and repair problems
and properly service the vehicle.
Chevrolet Low Cab Forward Owner Manual (GMNA-Localizing-U.S.-
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Index 351
IndexA
Accessories and Modifica-tions . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Add-On Electrical Equipment . . . 215
Additional Maintenance and Care . . . . . . . . . . . . . . . . . . . . . . 323
Adjustments Seat, Initial Drive . . . . . . . . . . . . . . . 38
Agreements Trademarks and License . . . . . .114
Air Cleaner/Filter, Engine . . . . . . . 231
Air Conditioning . . . . . . . . . . . . . . . . 115
Air Filter, Passenger Com- partment . . . . . . . . . . . . . . . . . . . . . . 119
Air Vents . . . . . . . . . . . . . . . . . . . . . . . 118
AM-FM Radio . . . . . . . . . . . . . . . . . . . . 97
Antenna Fixed Mast . . . . . . . . . . . . . . . . . . . 102
Antilock Brake System (ABS) . . . 196
Warning Light . . . . . . . . . . . . . . . . . . . 77
Appearance Care Exterior . . . . . . . . . . . . . . . . . . . . . . . 293
Interior . . . . . . . . . . . . . . . . . . . . . . . . 299
Ashtrays . . . . . . . . . . . . . . . . . . . . . . . . . 68
Assistance Program,
Roadside . . . . . . . . . . . . . . . . . . . . . . 344
Audio Players CD . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Automatic
Transmission . . . . . . . . . . . . . . . . . 185
Transmission Fluid . . . . . . . . . . . 229
Automatic Transmission Selector Lever . . . . . . . . . . . . . . . . 194
Shift Lock Control FunctionCheck . . . . . . . . . . . . . . . . . . . . . . . 251
Automatic Transmission Fluid Temperature Warning Light . . . . . 78
Automatic Transmission Overdrive Off . . . . . . . . . . . . . . . . . . 195
Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . .113
Axle, Rear . . . . . . . . . . . . . . . . . . . . . . 249
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . 247
Battery - North America . . . . . . . . . 287
Battery Warning Light . . . . . . . . . . . . 73
Biodiesel . . . . . . . . . . . . . . . . . . . . . . . 207
Blade Replacement, Wiper . . . . . 252
Brake Exhaust . . . . . . . . . . . . . . . . . . . . . . 201
System Warning Light . . . . . . . . . . 75
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Antilock . . . . . . . . . . . . . . . . . . . . . . . 196
Exhaust Light . . . . . . . . . . . . . . . . . . . 78
Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Parking . . . . . . . . . . . . . . . . . . . . . . . 200
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Index 353
Diesel Exhaust Fluid (DEF)Warning Light . . . . . . . . . . . . . . . . . . 80
Diesel Particulate Filter . . . . . . . . . 161
Distracted Driving . . . . . . . . . . . . . . . 122
Dome Lamps . . . . . . . . . . . . . . . . . . . . 96
Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Locks . . . . . . . . . . . . . . . . . . . . 33
Drive Belt Routing, Engine . . . . . . 341
Driver Behavior . . . . . . . . . . . . . . . . . 122
Driver Information Cen- ter (DIC) . . . . . . . . . . . . . . . . . . . . . . . 82
Driving Emergencies . . . . . . . . . . . . 137, 146
For Better Fuel Economy . . . . . . . 23
Hill and Mountain Roads . . . . . . 132
If the Vehicle is Stuck . . . . . . . . . 136
Wet Roads . . . . . . . . . . . . . . . . . . . 132
Winter . . . . . . . . . . . . . . . . . . . . . . . . 133
E
Electrical Equipment,Add-On . . . . . . . . . . . . . . . . . . . . . . . 215
Electrical System Overload . . . . . . . . . . . . . . . . . . . . . 264
Emergencies . . . . . . . . . . . . . . 137, 146
Engine
Air Cleaner/Filter . . . . . . . . . . . . . 231 Engine (cont'd)
Alarm and Automatic
Shutdown . . . . . . . . . . . . . . . . . . . 155
Check Light (Malfunction In-
dicator) . . . . . . . . . . . . . . . . . . . . . . . . 74
Checks Before Operating . . . . . 156
Compartment Overview . . . . . . . 222
Coolant . . . . . . . . . . . . . . . . . . . . . . . 231
Coolant Temperature Gauge . . . . 72
Cover . . . . . . . . . . . . . . . . . . . . . . . . . 222
Drive Belt Routing . . . . . . . . . . . . 341
Exhaust . . . . . . . . . . . . . . . . . . . . . . 159
Heater . . . . . . . . . . . . . . . . . . . . . . . . 154
High Idle System . . . . . . . . . . . . . 155
Oil Pressure Light . . . . . . . . . . . . . . 79
Overheating . . . . . . . . . . . . . . . . . . 237
Reduced Power Light . . . . . . . . . . . 81
Running While Parked . . . . . . . . 160
Shutdown Warning Light . . . . . . . . 80
Engine Oil Level Indicator Light . . . . . . . . . . . . 80
Engines Diesel Fuel . . . . . . . . . . . . . . . . . . . 206
Exhaust Brake . . . . . . . . . . . . . . . . . . 201
Exhaust Brake Light . . . . . . . . . . . . . 78
Exhaust Fluid Diesel . . . . . . . . . . . . . . . . . . . . . . . . 170
Extender, Seat Belt . . . . . . . . . . . . . . 49 Exterior Lamp Controls . . . . . . . . . . 92
F
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Filter, Engine Air Cleaner . . . . . . . . . . . 231
Fixed Mast Antenna . . . . . . . . . . . . 102
Flash-to-Pass . . . . . . . . . . . . . . . . . . . . 93
Flashers, Hazard Warning . . . . . . . 94
Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . 287
Fluid Automatic Transmission . . . . . . 229
Brakes . . . . . . . . . . . . . . . . . . . . . . . . 246
Diesel Exhaust . . . . . . . . . . . . . . . . . 24
Power Steering . . . . . . . . . . . . . . . 240
Washer . . . . . . . . . . . . . . . . . . . . . . . 241
Frequency Statement Radio . . . . . . . . . . . . . . . . . . . . . . . . . 348
Front Seat Position Seats Adjustment . . . . . . . . . . . . . . . . . . . . . 38
Fuel Biodiesel . . . . . . . . . . . . . . . . . . . . . 207
Cold Weather Operation . . . . . . 209
Diesel Engines . . . . . . . . . . . . . . . 206
Economy Driving . . . . . . . . . . . . . . . 23
Filling the Tank . . . . . . . . . . . . . . . 213
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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354 Index
Fuel (cont'd)Running out of Fuel . . . . . . . . . . . 212
Water in Fuel . . . . . . . . . . . . . . . . . 209
Fuel for Diesel Engines . . . . . . . . . 206
G
Gauges
Diesel Exhaust Fluid (DEF) . . . . . 73
Engine Coolant Temperature . . . 72
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Odometer . . . . . . . . . . . . . . . . . . . . . . . 71
Speedometer . . . . . . . . . . . . . . . . . . . 71
Tachometer . . . . . . . . . . . . . . . . . . . . . 72
Trip Odometer . . . . . . . . . . . . . . . . . . 71
Warning Lights and Indi-cators . . . . . . . . . . . . . . . . . . . . . . . . . 69
General Information Vehicle Care . . . . . . . . . . . . . . . . . . 218
Getting In and Out of the Ve-
hicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Glove Box . . . . . . . . . . . . . . . . . . . . . . . 55
GM Mobility Reimbursement Program . . . . . . . . . . . . . . . . . . . . . . . 344
H
Hazard Warning Flashers . . . . . . . . 94
HeadlampsAiming . . . . . . . . . . . . . . . . . . . . . . . . 254
Bulb Replacement . . . . . . . 254, 257 Headlamps (cont'd)
Daytime Running Lamps
(DRL) Indicator Light . . . . . . . . . . 82
Flash-to-Pass . . . . . . . . . . . . . . . . . . . 93
High-Beam On Light . . . . . . . . . . . . 81
High/Low Beam Changer . . . . . . . 93
Heated Mirrors . . . . . . . . . . . . . . . . . . . 34
Heater Engine . . . . . . . . . . . . . . . . . . . . . . . . 154
Heating . . . . . . . . . . . . . . . . . . . . . . . . . 115
High Idle System . . . . . . . . . . . . . . . 155
High-Beam On Light . . . . . . . . . . . . . 81
Hill and Mountain Roads . . . . . . . . 132
Hooks Shopping Bag . . . . . . . . . . . . . . . . . . 58
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
I
Idle Shutdown . . . . . . . . . . . . . . . . . . 155
Idle Shutdown Light . . . . . . . . . . . . . 81
Ignition Positions . . . . . . . . . . . . . . . 148
Infants and Young Children, Restraints . . . . . . . . . . . . . . . . . . . . . . 51
Information on Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 58
Instrument Cluster . . . . . . . . . . . . . . . 70
Instrument Panel Storage Area . . . . . . . . . . . . . . . . . . . 55 Introduction . . . . . . . . . . . . . . . . . . . . . . . 2
J
Jump Starting - North
America . . . . . . . . . . . . . . . . . . . . . . . 287
K
Keyless EntryRemote (RKE) System . . . . . . . . . 26
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
L
Lamps Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cornering . . . . . . . . . . . . . . . . . . . . . . . 95
Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Exterior Controls . . . . . . . . . . . . . . . . 92
Interior . . . . . . . . . . . . . . . . . . . . . . . . 264
License Plate . . . . . . . . . . . . . . . . . 263
Malfunction Indicator (Check
Engine) . . . . . . . . . . . . . . . . . . . . . . . 74
Roofmarker . . . . . . . . . . . . . . . . . . . 261
Sidemarker . . . . . . . . . . . . . . . . . . . 261
Lap Belt . . . . . . . . . . . . . . . . . . . . . . . . . 48
Lighter, Cigarette . . . . . . . . . . . . . . . . 67
Lighting Illumination Control . . . . . . . . . . . . . 95
Lights
Antilock Brake System(ABS) Warning . . . . . . . . . . . . . . . . 77