Maintenance Information (c & K Series) GMC Cab & Chassis V3500

MODEL IDENTIFICATION

Note. For the 1988-91 model years General Motors manufactured two (2) different truck models; the "R" & "V" models (similar to the older 1973-1987 model trucks), and the new "C" & "K" models. The new models use the old model designations except for payloads (Was: C10/15, Now: C1500).

Note. The Crew-Cab Bonus Cab (Single Rear Wheel) and Dually are only available (1988-91) in "R" & "V" models; and all Extended Cabs only in the new "C" & "K" design. From 1992 all trucks are new design "C" & "K" models.

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VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

SERVICE PARTS IDENTIFICATION LABEL

Label is located inside glove box door and has the vehicle's VIN, wheelbase, paint information, and a list of all production options and special equipment.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 13

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation, emission classification, and Gross Vehicle Weight Rating (GVWR, VIN Position 4). Emission classification is identified by engine VIN code (except diesel-powered vehicles). Manufacturer's Schedules identify items to be serviced based on type of operation. Service schedules are based on the following primary operating conditions

Severe Service

1. Short Trips (4 Miles Or Less)
2. Freezing Temperatures
3. Towing Or Heavily Loaded
4. Severe Dust Conditions
5. Hot Weather, Stop-And-Go Driving
6. Extensive Idling Conditions (Taxi Or Delivery Type Service)

Normal Service

1. No Severe Service Operating Conditions

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Note. For more information regarding lifting and hoisting refer to the JACKING & HOISTING article in the WHEEL ALIGNMENT section.

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DRAINING, FLUSHING AND REPLACEMENT OF DIESEL COOLANT

1. Open the air bleed valve in the engine coolant outlet (thermostat housing). (Scheme 16)
2. Fill the surge tank bottle until coolant comes out of the air bleed valve.
3. ON VEHICLES WITH REAR HEATER, close the air bleed valve. Start the engine and bring the engine speed to 2000 RPM for 2 to 3 minutes to flush any air for rear heater. Shut off the engine and open the air bleed valve. Fill the surge tank until coolant comes out the air bleed valve.
4. Close the air bleed valve and install pressure cap on the surge tank.
5. Monitor the cold coolant level in the surge tank. Add coolant as needed to bring the coolant level to the "Full Cold" mark.
6. Verify there are no leaks.

Scheme 16

Note. For more information regarding Diesel Idle Speed Adjustments refer to the ADJUSTMENTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

DRAINING FUEL FROM WATER/FUEL SEPARATOR (DIESEL)

1. Turn off engine and block drive wheels.
2. Remove fuel filler cap(s) to release any pressure or vacuum in the vehicle fuel tank(s).
3. Place a suitable container under the filter drain hose.
4. Open the drain valve. (Scheme 17)
5. Start engine and allow to idle for 1 to 2 minutes or until clear fuel is observed.
6. Close the drain valve and stop the engine.
7. Replace fuel filler cap(s).
8. Dispose of drained mixture in a proper manner.

Scheme 17

Note. For more information regarding Diesel Idle Speed Adjustments refer to the ADJUSTMENTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

CHANGING FUEL FILTER (DIESEL)

1. Turn off engine and block drive wheels.
2. Remove fuel filler cap(s) to release any pressure or vacuum in the vehicle fuel tank(s).
3. Place a suitable container under the filter drain hose.
4. Start engine and open the drain valve. (Scheme 17)
5. Once fuel begins to flow from the drain hose open the air bleed valve on the top of fuel filter housing. (Scheme 18)
6. Stop the engine.
7. After all fuel has drained from filter housing, close the fuel drain valve (Scheme 17), and the air bleed valve. (Scheme 18).
8. Dispose of drained mixture in a proper manner.
9. Loosen the element nut on the top of the fuel filter housing (Scheme 18) An oil filter type wrench may be used.
10. Remove housing cap and lift out old fuel filter element.
11. Verify filter housing and all mating surfaces are free of any water or other contamination. Some clean fuel may be left in housing, as it will be absorbed by the new filter element.
12. Install new fuel filter by aligning the widest key slot located under the element assembly cap with the widest key in the housing.
13. Push the element assembly downward until the mating surfaces make contact.
14. Install and tighten element nut by hand.
15. Bleed air from fuel/water separator as follows.
16. Open air bleed valve on top of filter housing (Scheme 18).
17. Connect hose to the air bleed valve on the top of the filter housing (Scheme 18).
18. Disconnect the fuel injection pump shutdown solenoid (pink wire) located on the fuel injection pump. (Scheme 19)
19. Crank the engine in 10 to 15 second intervals until clear fuel is observed at the air bleed hose (Wait 1 minute between cranking intervals to avoid overheating the starter).
20. Close the air bleed valve.
21. Connect the shutdown solenoid wire and reinstall fuel filler cap(s).
22. Start the engine and allow to idle for 5 minutes.
23. Check fuel filter assembly for leaks.
24. Dispose of drained mixture in a proper manner.

Scheme 18

Scheme 19

STARTING OUT OF FUEL DIESEL

1. Add 5 gallons of diesel fuel to fuel tank.
2. Open air bleed valve on top of filter housing (Scheme 18).
3. Connect hose to the air bleed valve on the top of the filter housing (Scheme 18).
4. Place a suitable container under the filter drain hose.
5. Crank the engine in 10 to 15 second intervals until clear fuel is observed at the air bleed hose (Wait 1 minute between cranking intervals to avoid overheating the starter). CAUTION: If engine starts during step #5, stop engine and close air bleed valve before attempting restart.
6. Close the air bleed valve.
7. Crank the engine in 10 to 15 second intervals until the engine starts. (Wait 1 minute between cranking intervals to avoid overheating the starter).

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Scheme 21

Note. For more information regarding Diesel Idle Speed Adjustments refer to the ADJUSTMENTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Scheme 22

Note. For more information regarding CDVR testing and service refer to the SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Scheme 23

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Note. For more information regarding EGR system service refer to the EGR FUNCTION TESTING article in the ENGINE PERFORMANCE section.

BRAKE SERVICE INFORMATION

Note. For more information regarding brake system service refer to the BRAKE SYSTEM article in the BRAKES section.

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AXLE & TRANSMISSION IDENTIFICATION

Note. For more information regarding Axle identification refer to the DRIVE AXLE RATIO IDENTIFICATION article in the DRIVE AXLES section.

Note. For more information regarding Automatic Transmission ID refer to the TRANSMISSION OIL PAN GASKET ID article in the AUTOMATIC TRANS SERVICE section.

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

WHEEL & TIRE SPECIFICATIONS

Wheel and tire information can be found on the decal attached to rear of driver's door.

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WHEEL TORQUE

Tighten the lug nuts firmly to torque specified in the wheel lug nut tightening table using patterns (Scheme 33)

WHEEL LUG NUT TORQUE SPECIFICATIONS

BATTERY SPECIFICATIONS

Scheme 34

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

Note. See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

Modification to the air bag system component or wiring can adversely affect system performance and possibly cause injury.

AIR CONDITIONING SERVICING

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

REPLACING BLOWN FUSES

BATTERY WARNING

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

BRAKE PAD REPLACEMENT

CATALYTIC CONVERTER

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

To avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. Full strength anti-freeze has a freeze point of only -8° F (-22°C).

DIESEL FUEL ANTI-FUNGAL ADDITIVES

DIESEL FUEL CONTAMINATION

DIESEL FUEL REQUIREMENTS

Note. A Diesel Fuel #1 and #2 combination (Blended Fuel) may be used, and is recommended for mild winter driving.

JUMP STARTING (TURBO DIESEL)

STARTING FLUID USE (TURBO DIESEL)

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

FUEL SYSTEM SERVICE

HALOGEN BULBS

RADIATOR FAN

TURBOCHARGED MODELS (TURBO-DIESEL)

WARRANTY INFORMATION

BUMPER-TO-BUMPER PLUS COVERAGE LIMITED WARRANTY

Entire vehicle (except battery) is covered for 3 years or 50,000 miles, whichever occurs first. Covered by this warranty are any repairs to vehicle components which have proven defective in material and workmanship under normal use (tires excluded). Warranty repairs (parts and labor) will be made by the Dealer at no charge using new or remanufactured parts. This warranty is subject to a 100 deductible for each repair visit after the first year or 12,000 miles, whichever occurs first.

Note. 1992-93 Models are covered for 3 years or 36,000 miles, whichever occurs first, with no deductible.

BATTERY COVERAGE

Covers replacement cost of battery for 3 years or 50,000 miles (36,000 miles on 1992 models), whichever occurs first. A prorated charge applies after first 12 months or 12,000 miles, whichever occurs first.

CORROSION COVERAGE

Covers any body sheet metal panel that is perforated due to corrosion. Coverage is for 6 years or 100,000 miles, whichever occurs first.

EMISSIONS "DEFECT" & "PERFORMANCE" WARRANTIES (EXCEPT CALIFORNIA)

Defect Warranty ensures vehicle meets applicable EPA regulations and that emission control system is free from defects in materials and workmanship. Coverage is for 5 years or 50,000 miles, whichever occurs first.

Performance Warranty covers all costs of repairing or adjusting any components or parts as needed in order for the vehicle to pass a federally-required state or local emissions test. Other emission control parts related to these components are covered by the Performance Warranty, where applicable. If another part fails due to the failure of one of these components, both parts are covered. See customer's copy of warranty information for specific items covered.

EMISSION "PERFORMANCE" WARRANTY (CALIFORNIA)

If vehicle fails a Smog Check inspection, all necessary repairs and adjustments will be made by manufacturer to ensure vehicle passes inspection. Coverage is for 3 years or 50,000 miles, whichever occurs first.

LIGHT-DUTY EMISSION "DEFECTS" WARRANTY (CALIFORNIA)

If any emission-related part on the vehicle is defective, the part will be repaired or replaced by manufacturer. Coverage is for 3 years or 50,000 miles, whichever occurs first.

Some emission-related parts are covered for 7 years or 70,000 miles, whichever occurs first, and will be repaired or replaced by manufacturer if found to be defective in material or workmanship. See customer's copy of warranty information for specific items covered.

HEAVY-DUTY EMISSION CONTROL SYSTEMS (GASOLINE ENGINES)

Warranty coverage is 5 years or 50,000 miles, whichever occurs first.

HEAVY-DUTY EMISSION CONTROL SYSTEMS (DIESEL ENGINES)

Warranty coverage is 5 years or 100,000 miles, whichever occurs first.

FUSE PANEL LOCATION

The fuse block is located behind a cover in the dash to the left of the steering column.

Scheme 35

Fuse & Circuit Breaker Identification

1. 1 - Gauges 20 Amp Cruise Control, Rear Window Defogger Timer, 4-Wheel Drive Display Illumination, Auxiliary Battery Relay, Seat Belt Reminder, Cluster Ignition Feed
2. 2 - Turn-B/U 15 Amp Back-Up Lights, Turn Signals
3. 3 - EMC/Ign 10 Amp Torque Converter Clutch, Air Injection Reactor Diverter, Electronic Spark Control, EGR, Electronic Control Module, Anti-Lock Switch
4. 4 - Inj A 10 Amp Throttle Body Injectors
5. 5 - Brake 15 Amp Anti-Lock Brakes, Cluster Speedometer
6. 6 - A/C Htr 25 Amp HVAC, 4-Wheel Drive, Auxiliary Battery
7. 7 - Ctsy 20 Amp Courtesy Lights, Glove Box Light, Radio
8. 8 - Park Lt 20 Amp Horn Relay, Horn Feed, Cigarette Lighter, Parking Lights
9. 9 - P Lps 5 Amp 20 Amp ("C" & "K" Series) C49 Switch Illumination, Headlight ON Warning, Radio Illumination, Heater & A/C Illumination, Rear Window Defogger
10. 10 - Stop/Haz 15 Amp Hazard Flasher, Seat Belt Reminder, Stoplights, Rear Anti-lock Memory
11. 11 - Wiper 25 Amp Windshield Washer/Wiper
12. 12 - Radio 10 Amp Radio Feed
13. 13 - Acc/Ign 30 Amp (Circuit Breaker) Power Windows
14. 14 - Acc/Batt 30 Amp (Circuit Breaker) Door Locks, Rear Window Defogger
15. 15 - Crank 5 Amp Discreet Crank
16. 16 - 4WD 25 Amp 4WD 15 Amp ("C" & "K" Series) Speedometer
17. 17 - 15 Amp DRL (Canada)