engine CHEVROLET C3500 HD 2001 4.G Owners Manual

6-31
What to Add
When you do need brake fluid, use only DOT
-3 brake
fluid. Refer to ªRecommended Fluids and Lubricantsº
in the Index. Use new brake fluid from a sealed
container only.
Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help keep
dirt from entering the reservoir.
CAUTION:
With the wrong kind of fluid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake fluid.
NOTICE:

Using the wrong fluid can badly damage
brake system parts. For example, just a few
drops of mineral
-based oil, such as engine
oil, in your brake system can damage brake
system parts so badly that they'll have to
be replaced. Don't let someone put in the
wrong kind of fluid.

If you spill brake fluid on your vehicle's
painted surfaces, the paint finish can be
damaged. Be careful not to spill brake fluid
on your vehicle. If you do, wash it off
immediately. See ªAppearance Careº in
the Index.

6-33
Battery
Your new vehicle comes with a maintenance free
ACDelco
battery. When it's time for a new battery,
get one that has the replacement number shown on the
original battery's label. We recommend an ACDelco
battery. See ªEngine Compartment Overviewº in the
Index for battery location.
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
Vehicle Storage
If you're not going to drive your vehicle for 25 days or more,
remove the black, negative (
-) cable from the battery.
This will help keep your battery from running down.
CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
aren't careful. See ªJump Startingº in the Index
for tips on working around a battery without
getting hurt.
Contact your dealer to learn how to prepare your vehicle
for longer storage periods.
Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your GM dealership service department.
Before you replace any bulbs, be sure that all the lamps
are off and the engine isn't running. See ªReplacement
Bulbsº in the Index for the proper types of bulbs to use.
Halogen Bulbs
CAUTION:
Halogen bulbs have pressurized gas inside and
can burst if you drop or scratch the bulb. You or
others could be injured. Be sure to read and
follow the instructions on the bulb package.

6-59
Vehicle Identification Number (VIN)
This is the legal identifier for your vehicle. It appears
on a plate in the front corner of the instrument panel,
on the driver's side. You can see it if you look through
the windshield from outside your vehicle. The VIN also
appears on the Vehicle Certification and Service Parts
labels and the certificates of title and registration.
Engine Identification
The 8th character in your VIN is the engine code. This
code will help you identify your engine, specifications
and replacement parts.
Service Parts Identification Label
You'll find this label on the inside of the glove box.
It's very helpful if you ever need to order parts.
On this label is:

your VIN,

the model designation,

paint information and

a list of all production options and special equipment.
Be sure that this label is not removed from the vehicle.
Electrical System
Add-On Electrical Equipment
NOTICE:
Don't add anything electrical to your vehicle
unless you check with your dealer first. Some
electrical equipment can damage your vehicle
and the damage wouldn't be covered by your
warranty. Some add
-on electrical equipment
can keep other components from working as
they should.

6-62
Fuse/Circuit
BreakerUsage
4 Instrument Cluster, DRL Relay,
Lamp Switch, Keyless Entry, Low
Coolant Module, Illuminated Entry
Module, DRAC (Diesel Engine)
5 Not Used
6 Cruise Control
7 Auxiliary Power Outlet
8 Crank
9 License Lamp, Parking Lamps,
Taillamps, Roof Marker
Lamps, Front Sidemarkers,
Door Switch Illumination,
Headlamp Switch Illumination
10 Not Used
11 Wiper Motor, Washer Pump
12 A/C, A/C Blower,
High Blower Relay
13 Power Amp, Cigarette Lighter,
Door Lock RelayFuse/Circuit
BreakerUsage
14 Cluster, Comfort Controls,
Instrument Switches, Radio
Illumination, Chime Module
15 DRL Relay
16 Front and Rear Turn Signals,
Back
-Up Lamps
17 Radio (Ignition)
18 4WAL/VCM, ABS, Cruise Control
19 Radio (Battery)
20 PRNDL, Automatic Transmission,
Speedometer, Check Gages
Warning Light
21 Security/Steering
22 Not Used
23 Not Used
24 TP2 Relay (Gasoline Engine)
A Power Door Lock, Keyless
Entry Module
B Power Windows

6-63
Underhood Fuse/Relay Center
The underhood fuse/relay center is located in the rear of
the engine compartment near the brake fluid reservoir.
See ªEngine Compartment Overviewº in the Index for
more information on location. Move the retainer clips
for the cover to access the fuse block.
You can remove fuses with a fuse extractor which is
mounted to the interior fuse block. To remove fuses
if you don't have a fuse extractor, hold the end of the
fuse between your thumb and index finger and pull
straight out.Name Usage
Starter Relay Starter
A/C Relay Air Conditioning
Fuel Pump Relay Fuel Pump
Brake
Lamp RelayBrake Lamp
Blank Not Used

6-64
Name Usage
Horn Relay Horn
ECM
-B Fuel Pump, PCM/VCM
RR DEFOG Not Used
IGN
-E A/C Compressor Relay,
Dual Tanks
Blank Not Used
Blank Not Used
Blank Not Used
HORN Horn, Underhood Lamps
AUX FAN Not Used
ECM
-1 Injectors, PCM/VCM, Fuel
Solenoid (Diesel Engine) Fuel
Control Module (Diesel Engine)
HTD ST
-FR Not Used
Blank Not Used
Blank Not Used
A/C Air Conditioning
PTO PTO RelayName Usage
ENG
-1 Ignition Switch, EGR, Canister
Purge, EVRV Idle Coast
Solenoid, MAF, Heated O
2,
Fuel Heater (Diesel Engine),
Water Sensor (Diesel Engine),
Boost Solenoid (Diesel Engine),
EPR (Diesel Engine)
HTD ST
-RR Not Used
Blank Not Used
Diode Not Used
LIGHTING Headlamp and Panel Dimmer
Switch, Fog and Courtesy Fuses
BATT Battery, Fuse Block Busbar
IGN A Ignition Switch
IGN B Ignition Switch
ABS Anti
-Lock Brake Module
BLOWER High Blower Relay
STOP/HAZ Stoplamps
HEATED
SEATSNot Used

6-66
Capacities and Specifications
All capacities are approximate. When adding, be sure
to fill to the appropriate level or as recommended in
this manual.
Please refer to ªRecommended Fluids and Lubricantsº
in the Index for more information.
Engine TypeVIN
CodeSpark Plug
Gap
ªVORTECº 8100 V8 G 0.060 inches
(1.52 mm)
Wheels and Tires
Model Description Torque
Front 5 bolts (5/8 in.)
175 lb
-ft (240 N´m)
Rear 10 bolts (5/8 in.)
175 lb
-ft (240 N´m)
Tire Pressure See the Certification/Tire label on
the rear edge of the driver's door
or the incomplete vehicle document
in the cab.
Cooling System Capacity
After refill, the level must be rechecked. See ªCooling
Systemº in the Index.
Engine VIN Quantity
ªVORTECº 8100 G 28.5 quarts (27.0 L)
Crankcase Capacity
After refill, the level must be rechecked. Add enough
engine oil so that the fluid is within the proper operating
range. See ªEngine Oilº in the Index.
Engine VINQuantity with
Filter

ªVORTECº 8100 G 6.6 quarts (6.3 L)

Oil filter should be changed at every oil change.
Fuel Tank Capacity
Type Quantity
Front Tank 22 U.S. gallons (79 L)
Rear Tank 18 U.S. gallons (68 L)

Scheduled Maintenance
7-5
Short Trip/City Definition
Follow the Short Trip/City Scheduled Maintenance if
any one of these conditions is true for your vehicle:

Most trips are less than 5 to 10 miles (8 to 16 km).
This is particularly important when outside
temperatures are below freezing.

Most trips include extensive idling (such as frequent
driving in stop
-and-go traffic).

You operate your vehicle in dusty areas or
off
-road frequently.

You frequently tow a trailer.

If the vehicle is used for delivery service, police, taxi
or other commercial application.
One of the reasons you should follow this schedule
if you operate your vehicle under any of these conditions
is that these conditions cause engine oil to break
down sooner.
Short Trip/City Intervals
Every 3,000 Miles (5 000 km): Engine Oil and Filter
Change (or 3 months, whichever occurs first). Chassis
Lubrication (or 3 months, whichever occurs first).
Rear Axle Fluid Check.
Every 6,000 Miles (10 000 km): Tire Rotation.
Every 15,000 Miles (25 000 km): Shields and
Underhood Insulation Inspection. Diesel Engine
Only: Thermostatically Controlled Engine Cooling
Fan Check (or every 12 months, whichever occurs
first). Diesel Engine Only: Air Intake System
Inspection. Front Wheel Bearing Repack
(or at each brake relining, whichever occurs first).
Every 24,000 Miles (40 000 km): Diesel Engine Only:
Fuel Cap Replacement, if driving in dusty conditions.
(Continued)

Scheduled Maintenance
7-6
Short Trip/City Intervals
Every 30,000 Miles (50 000 km): Rear Axle Fluid
Change with Extreme Overload, Trailer Towing or
High Speed Use. Fuel Filter Replacement.
Every 50,000 Miles (83 000 km): Automatic
Transmission Service.
Every 60,000 Miles (100 000 km): Engine Accessory
Drive Belt Inspection. If Equipped: Exhaust Gas
Recirculation System Inspection. Gasoline Engine
Only: Evaporative Control System Inspection.
Diesel Engine Only: Crankcase Depression Regulator
Valve (CDRV) System Check.
Short Trip/City Intervals
Every 100,000 Miles (166 000 km): Gasoline Engine
Only: Spark Plug Wire Inspection. Gasoline Engine
Only: Spark Plug Replacement. Gasoline Engine
Only: Automatic Transmission Service (normal
conditions). Gasoline Engine Only: Positive
Crankcase Ventilation (PCV) Valve Inspection.
Every 150,000 Miles (240 000 km): Cooling System
Service (or every 60 months, whichever occurs first).
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.

Scheduled Maintenance
7-7
Long Trip/Highway Definition
Follow this scheduled maintenance only if none of the
conditions from the Short Trip/City Scheduled
Maintenance are true. Do not use this schedule if the
vehicle is used for trailer towing, driven in a dusty area
or used off paved roads. Use the Short Trip/City
schedule for these conditions.
Driving a vehicle with a fully warmed engine under
highway conditions causes engine oil to break
down slower.
Long Trip/Highway Intervals
Every 7,500 Miles (12 500 km): Engine Oil and Filter
Change (or every 12 months, whichever occurs first).
Chassis Lubrication (or every 12 months, whichever
occurs first). Rear Axle Fluid Check. Tire Rotation.
Every 15,000 Miles (25 000 km): Shields and
Underhood Insulation Inspection. Diesel Engine
Only: Thermostatically Controlled Engine Cooling
Fan Check (or every 12 months, whichever
occurs first). Diesel Engine Only: Air Intake
System Inspection.
Every 30,000 Miles (50 000 km): Rear Axle
Fluid Change with High Speed Use. Fuel Filter
Replacement. Front Wheel Bearing Repack
(or at each brake relining, whichever occurs first).
(Continued)