Chevrolet B7 2001 User manual

i
The 2001 Chevrolet Medium Duty B7 Chassis
Owner’s Manual
1-1 Features and Controls
This section explains how to start and operate your vehicle.
2-1 Your Driving and the Road
Here you’ll find helpful information and tips about the road and how to drive under different conditions.
3-1 Problems on the Road
This section tells you what to do if you have a problem while driving, such as a flat tire or overheated engine, etc.
4-1 Service
Here the manual tells you how to keep your vehicle running properly.
5-1 Maintenance Schedule
This section tells you when to perform vehicle maintenance and what fluids and lubricants to use.
6-1 Customer Assistance Information
This section tells you how to contact Chevrolet for assistance and how to get service and owner publications.
It also gives you information on “Reporting Safety Defects” on page 6-5.
7-1 Index
Here’s an alphabetical listing of almost every subject in this manual. You can use it to quickly find
something you want to read.

ii
GENERAL MOTORS, GM, the GM Emblem,
CHEVROLET and the CHEVROLET Emblem are
registered trademarks of General Motors Corporation.
This manual includes the latest information at the time
it was printed. We reserve the right to make changes
after that time without further notice. For vehicles first
sold in Canada, substitute the name “General Motors of
Canada Limited” for GM Medium Duty Truck Division
whenever it appears in this manual.
Please keep this manual in your vehicle, so it will be
there if you ever need it when you’re on the road.
If you sell the vehicle, please leave this manual in it so
the new owner can use it.
We support voluntary
technician certification.
Litho in U.S.A.
E
Copyright General Motors Corporation 2000
C2101 A First Edition All Rights Reserved

iii
How to Use this Manual
Many people read their owner’s manual from beginning
to end when they first receive their new vehicle. If you
do this, it will help you learn about the features and
controls for your vehicle. In this manual, you’ll find
that pictures and words work together to explain
things quickly.
Safety Warnings and Symbols
You will find a number of safety cautions in this book.
We use a box and the word CAUTION to tell you
about things that could hurt you if you were to ignore
the warning.
CAUTION:
These mean there is something that could hurt
you or other people.
In the caution area, we tell you what the hazard is.
Then we tell you what to do to help avoid or reduce the
hazard. Please read these cautions. If you don’t, you or
others could be hurt.

iv
You will also find a circle
with a slash through it in
this book. This safety
symbol means “Don’t,”
“Don’t do this” or “Don’t
let this happen.”
Vehicle Damage Warnings
Also, in this book you will find these notices:
NOTICE:
These mean there is something that could
damage your vehicle.
In the notice area, we tell you about something that can
damage your vehicle. Many times, this damage would
not be covered by your warranty, and it could be costly.
But the notice will tell you what to do to help avoid
the damage.
When you read other manuals, you might see
CAUTION and NOTICE warnings in different colors or
in different words.
You’ll also see warning labels on your vehicle. They use
the same words, CAUTION or NOTICE.

v
For example,
these symbols
are used on an
original battery:
CAUTION
POSSIBLE
INJURY
PROTECT
EYES BY
SHIELDING
CAUSTIC
BATTERY
ACID COULD
CAUSE
BURNS
AVOID
SPARKS OR
FLAMES
SPARK OR
FLAME
COULD
EXPLODE
BATTERY
These symbols
are important for
you and your
passengers
whenever your
vehicleisdriven:
CHILD
RESTRAINT
TOP STRAP
ANCHOR
DOOR LOCK
UNLOCK
FASTEN
SEAT
BELTS
POWER
WINDOW
AIR BAG
These symbols
have to do with
your lamps:
MASTER
LIGHTING
SWITCH
TURN
SIGNALS
PARKING
LAMPS
HAZARD
WARNING
FLASHER
DAYTIME
RUNNING
LAMPS
FOG LAMPS
These symbols
are on some of
your controls:
WINDSHIELD
WIPER
WINDSHIELD
WASHER
WINDSHIELD
DEFROSTER
REAR
WINDOW
DEFOGGER
VENTILATING
FAN
These symbols
are used on
warning and
indicator lights:
ENGINE
COOLANT
TEMP
BATTERY
CHARGING
SYSTEM
BRAKE
COOLANT
ENGINE OIL
PRESSURE
ANTI-LOCK
BRAKES
Here are some
other symbols
you may see:
FUSE
LIGHTER
HORN
FUEL
Vehicle Symbols
These are some of the symbols you may find on your vehicle. Also see “Warning Lights and Gages” in the Index.

vi
Model Reference
This manual contains information which covers the
B7 Chassis models as shown. Most models are
unfinished from the factory.
Medium Duty Chassis
Since B7 Chassis models delivered from the factory
are finished in a variety of ways by a number of
companies, you’ll probably find other manuals in your
finished vehicle. These manuals are put there by the
companies that have added components or equipment
to the B7 Chassis model. Read all these materials -- as
well as this manual -- carefully, to get all of the
information on your vehicle.

1- 1-1
Section 1 Features and Controls
Here you can learn about the many standard and optional features on your vehicle, and information on starting,
shifting and braking. Also explained are the instrument panel and the warning systems that tell you if everything is
working properly -- and what to do if you have a problem.
1-2 Keys
1-2 Theft
1-3 New Vehicle “Break-In”
1-4 Ignition Positions
1-4 Engine Starter Over-Crank Protection
(If Equipped)
1-4 Starting Your Gasoline Engine
1-7 Starting Your Diesel Engine
1-12 Engine Checks Before Operating
1-13 Engine Coolant Heater (If Equipped)
1-15 Diesel Engine Exhaust Brake
1-16 Two-Speed Rear Axle Electric Shift Control
(If Equipped)
1-17 Automatic Transmission Operation
1-19 Manual Transmission
1-20 Parking
1-23 Parking Over Things That Burn
1-24 Engine Exhaust
1-24 Running Your Engine While You’re Parked
(Automatic Transmission)
1-26 Horn
1-26 Turn Signal Lever
1-27 Exterior Lamps
1-29 Instrument Panel Cluster
1-31 Warning Lights, Gages and Indicators

1-2
Keys
CAUTION:
Leaving children in a vehicle with the ignition
key is dangerous for many reasons. A child or
others could be badly injured or even killed.
They could operate controls or even make the
vehicle move. Don’t leave the keys in a vehicle
with children.
The square-head key is for
the ignition only.
When a new vehicle is delivered, the dealership removes
the plugs from the keys, and gives them to the first owner.
Each plug has a code on it that tells your dealer or a
qualified locksmith how to make extra keys. Keep the
plugs in a safe place. If you lose your keys, you’ll be
able to have new ones made easily using these plugs.
The body manufacturer may provide additional keys for
locks to entry and access doors, and any other locking
compartments on the vehicle. These additional keys may
not have plugs with key codes.
Theft
Vehicle theft is big business, especially in some cities, and
even commercial vehicles are no exception. Although your
vehicle has a number of theft-deterrent features, we know
that nothing we put on it can make it impossible to steal.
However, there are ways you can help.
Key in the Ignition
If you leave your vehicle with the keys inside, it’s an
easy target for joy riders or professional thieves -- so
don’t do it.
Remember to remove your key and take it with you.
Always do this. When you take your key with you, your
ignition will be locked. Also remember to lock the doors.

1-3
New Vehicle “Break-In”
NOTICE:
Your vehicle doesn’t need an elaborate
“break-in.” But it will perform better in the long
run if you follow these guidelines:
D Let your engine warm up before you
operate your vehicle under load.
D Keep your speed at 55 mph (88 km/h) or
less for the first 500 miles (805 km).
D Don’t drive at any one speed -- fast or
slow -- for the first 500 miles (805 km).
Don’t make full-throttle starts.
NOTICE: (Continued)
NOTICE: (Continued)
D Avoid making hard stops for the first
200 miles (322 km) or so. During this time
your new brake linings aren’t yet broken
in. Hard stops with new linings can mean
premature wear and earlier replacement.
Follow this breaking-in guideline every
time you get new brake linings.
D Don’t tow a trailer during break-in.
D Use the lowest gear you can when you start
a loaded vehicle in motion and when going
up hills to avoid overloading the engine.
D Check and adjust engine and transmission
fluid levels often and be sure tires
are properly inflated for the load
you’re carrying.
D If you have a Caterpillar
R
diesel engine, see
the Caterpillar
R
Diesel Engine Operation
& Maintenance Manual.

1-4
Ignition Positions
Use your ignition key to
start your vehicle. You can
turn the ignition switch to
four different positions.
LOCK: This position lets you insert and remove the
ignition key.
ACC (Accessory): This position lets you use
accessories when the engine is off.
ON: This is the position for driving.
START: This position starts your engine.
Engine Starter Over-Crank
Protection (If Equipped)
Some vehicles have an engine starter over-crank
protection system. This system includes a built-in
temperature limiting switch to prevent internal damage
to the starter. If the starter motor overheats and shuts
off due to over-cranking, the motor must cool down
before the switch will reset and allow you to operate the
starter. It can take up to six minutes before the starter
will work again.
Starting Your Gasoline Engine
Engines start differently. The 8th digit of your Vehicle
Identification Number (VIN) shows the code letter for
your engine. See “Vehicle Identification Number” in the
Index. Follow the proper steps to start the engine.
To start a diesel engine, see “Starting Your Diesel
Engine” in the Index.
Automatic Transmission
Set the parking brake and move your shift lever to
NEUTRAL (N) or PARK (P) if so equipped. Your engine
won’t start in any other position -- that’s a safety feature.

1-5
Manual Transmission
Set the parking brake, shift your gear selector to
NEUTRAL and hold the clutch pedal to the floor while
starting the engine.
Starter Motor Operation
D The starter motor will disengage if you release
the key or the engine reaches a predetermined
engine speed.
D To prevent overheating, the starter motor will
disengage after continuously operating for
15 seconds. You must release the key from the
start position to re-engage the starter.
D The starter motor will not engage if the engine is
already running.
D The starter motor will disengage if, after two
seconds, the starter pinion gear does not engage the
flywheel or there is no engine rpm signal from the
engine speed sensor.
Starting Your Engine
1. Without pushing the accelerator pedal, turn your
ignition key to START. When the engine starts, let
go of the key. The idle speed will go down as your
engine gets warm.
2. If the engine doesn’t start in 10 seconds, push the
accelerator pedal all the way down and crank the
engine for five more seconds, unless it starts sooner.
3. If your engine still won’t start (or starts but then
stops), it could be flooded with too much gasoline.
Wait 15 seconds to let the starter motor cool down.
Do Steps 1 through 3 again.
When the engine starts, let go of the key and the
accelerator pedal.

1-6
NOTICE:
Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way
the engine operates. Before adding electrical
equipment, check with your dealer. If you don’t,
your engine might not perform properly.
If you ever have to have your vehicle towed, see
the part of this manual that tells how to do it
without damaging your vehicle. See “Towing
Your Vehicle” in the Index.
Gasoline Engine Warm-Up
When you’ve started your engine, let it run for 20 or
30 seconds to warm up before you put a load on
the engine.
Drive at moderate speeds for the first few miles,
especially in cold weather. Running a cold engine at
high speed can damage it. See “Engine High Idle
System” in the Index if your vehicle has this feature.
Restarting the Gasoline Engine While
Moving (Automatic Transmission)
If you have to restart the engine while the vehicle is
moving, you’ll first have to shift the automatic
transmission to NEUTRAL (N). This safety feature
prevents starting the engine when the transmission is in
a drive gear.
Stopping the Gasoline Engine
Let your engine idle for a few seconds before turning it
off after you have finished driving your vehicle.
If you shift to NEUTRAL (N) or PARK (P), set the
parking brake.
If your vehicle has a two-speed axle, put the range
selector in LOW. To be sure the axle has shifted into
LOW, engage the clutch and transmission; the vehicle
may move slightly when you do this.
While your engine is idling before you turn it off, you
can make a list of any operational or handling concerns
to give to responsible maintenance personnel so they can
handle them right away.
Moisture will condense in a fuel tank that is almost
empty if the vehicle is not run for a while, even just
overnight under some conditions. So, it’s always best to
refuel your vehicle at the end of each run.

1-7
Starting Your Diesel Engine
If you have a Caterpillar diesel engine, also refer to your
Caterpillar
R
Diesel Engine Operation & Maintenance
Manual for starting procedure.
To make starting easier in cold weather (below 32 _ F
or 0 _ C), the proper viscosity engine oil should be used.
It’s also best to heat the engine oil first. You can do this
by using an engine coolant heater. A GM Automatic
Ether Injection System aids cold weather starting.
NOTICE:
If you ever have to have your vehicle towed, see
the part of this manual that tells how to do it
without damaging your vehicle. See “Towing
Your Vehicle” in the Index.
Restarting the Diesel Engine While Moving
(Automatic Transmission)
If you have to restart the engine while the vehicle is
moving, you’ll first have to shift the automatic
transmission to NEUTRAL (N). This safety feature
prevents starting the engine when the transmission is in
a drive gear.
Stopping the Diesel Engine
If you have a Caterpillar diesel engine, see your
Caterpillar
R
Diesel Engine Operation &
Maintenance Manual.
1. Set the parking brake and shift to NEUTRAL (N)
or PARK (P).
2. Turn the ignition key to OFF.
If your vehicle has a two-speed axle, see “Rear Axle,
Two-Speed Electric Shift Control” or “Rear Axle,
Two-Speed Airshift Control” in the Index.

1-8
Cold Weather Starting
(Caterpillar
R
Diesel)
Because the diesel engine uses compression ignition, it
is harder to start in cold weather than a gasoline engine.
The air intake heater and use of the proper engine oil,
optional engine coolant heaters and optional ether
injection systems help cold weather starting. See the
Caterpillar
R
Diesel Engine Operation & Maintenance
Manual for more information.
NOTICE:
Your diesel engine has an electric air intake
heater system which reduces white smoke and
helps start the engine in cold weather. Do not
spray starting fluid into the air intake where it
can contact the heater elements.
If you don’t have the GM Automatic Ether
Injection System, don’t use starting fluid or you
could damage your engine. If you have the GM
system, use only GM approved starting fluid that
has been tested to establish compatibility with the
air inlet heater system.
If It Won’t Start In Cold Weather:
D Be sure the fuel filter is properly serviced. If water in
the primary or secondary filter has frozen, the engine
will not start.
A good way to help prevent this is to add a pint
(1/2 L) of isopropyl alcohol to each 50 gallons
(190 L) of diesel fuel during freezing weather. This
will also help prevent water from freezing in the fuel
tank and lines.
D Be sure the fuel tank vent is open. A closed vent can
create a partial vacuum in the tank that can make
starting difficult or impossible.
D It helps to fill up the fuel tank at the end of every
run. Moisture will condense in a nearly empty
fuel tank.
D Is the fuel correct? See the Caterpillar
R
Operation &
Maintenance Manual for more information.

1-9
Diesel Engine Warm-Up
Several factors affect how quickly your diesel engine
warms up. These can include outside temperature,
engine load, idle time and your vehicle’s option content.
Your vehicle may be equipped with some features that
can help the engine reach operating temperature sooner.
Some of these features are discussed below.
Also, remember that an automatic transmission adds
heat to the cooling system through the heat exchanger
in the radiator. Because of this, vehicles equipped with
automatic transmissions are often able to retain engine
coolant heat better than manual transmission vehicles.
See your Caterpillar
R
Operation & Maintenance manual
for additional diesel engine warm-up information.
Engine Alarm and Automatic
Shutdown (Option)
Your CHECK GAGES light will come on if the system
senses high engine temperature or low engine oil
pressure. If high engine temperature is detected, you
will also hear a tone alarm at two beats per second.
The alarm and light will remain on until the condition
is fixed. If the engine temperature condition worsens,
the tone alarm will go to five beats per second. When
a low oil pressure condition is detected, the five beat
per second alarm will come on immediately.
If the system senses low engine coolant, the five beat
per second alarm and the LOW COOLANT warning
light will come on.
The five beats per second tone alarm means that your
engine will shut down in 25 seconds. Pull off the road
and shut off the engine. Don’t start it until the reason
for the problem is known, and the problem is fixed. If
the engine shuts down when you are still in traffic, you
can restart the engine and get another 25 seconds of
operation. Do this only if you have to, since there is a
problem that can harm the engine if it isn’t fixed. Engine
automatic shutdown, for gasoline engines, requires
activation by your dealer.

1-10
Fast Idle System (Electronically Controlled
Caterpillar
R
Diesel and Gasoline Engines)
If your vehicle is equipped with an electronically
controlled diesel engine, it has both automatic and
manual fast idle capabilities.
Automatic Fast Idle System (Caterpillar
R
Diesel
Engine Only)
The automatic fast idle feature will engage whenever
you start your vehicle and the engine is below the preset
operating temperature. This will help decrease engine
warm-up time.
Idle speed will then return to normal under any of the
following conditions:
D The engine reaches the preset operating temperature.
D The brake pedal is pressed.
D The trailer brake hand lever (if equipped) is applied.
D The manual transmission clutch pedal is pressed or,
the automatic transmission (if equipped) is shifted
from NEUTRAL (N) or PARK (P).
D The vehicle speed exceeds approximately
10 mph (16 km/h).
D When the fast idle switch is pressed a second time.
Manual Fast Idle System (Caterpillar
R
Diesel and
Gasoline Engines)
The manual fast idle switch
is located on the lower
portion of the instrument
panel just to the left of the
steering wheel.
This system can be used to increase your engine idle
speed whenever the following conditions are met:
D The brake pedal is not pressed.
D The trailer brake hand lever (if equipped) is not applied.
D The vehicle speed is below approximately 10 mph
(16 km/h) for vehicles with diesel engines. The
vehicle must not be moving and the accelerator must
not be pressed for vehicles with gasoline engines.
D The manual transmission (if equipped) clutch
pedal is not pressed or, the automatic transmission
(if equipped) is in NEUTRAL (N).

1-11
The manual fast idle feature is activated by pressing the
switch on the instrument panel. When the switch is
pressed again, or any of the previous conditions are not
met, manual fast idle will be deactivated.
For vehicles with gasoline engines, the manual fast idle
has been preset at the factory. Your dealer may change
the setting to fit your needs.
For vehicles with diesel engines, manual fast idle can be
used to set any desired idle speed. To set a new
temporary engine idle speed:
1. Make sure all of the previously described conditions
are met.
2. Press the accelerator pedal to the desired
engine speed.
3. Momentarily press the manual FAST IDLE switch.
For vehicles with diesel engines, the temporary idle
speed will be set. This new rpm level will be
remembered by the system until either the ignition is
turned to OFF or a new idle speed is set.
Radiator Shutters (If Equipped)
Radiator shutters aid engine warm-up by blocking the
airflow through the radiator and charge air cooler to
conserve heat in cold conditions.
The radiator shutters on your vehicle (if equipped)
operate automatically. When the ignition switch is in
START and the engine temperature is below 195 _ F
(90 _ C) for Caterpillar
R
diesel, the shutters will close,
blocking the flow of air through the radiator and charge
air cooler. When the engine temperature reaches 195 _ F
(90 _ C) for Caterpillar
R
diesel, the shutters will open to
the normal operating position.

1-12
Engine Checks Before Operating
When you’ve started your engine, let it run for 20 to
30 seconds before you put a load on the engine. But
don’t leave the vehicle while the engine is running.
During this warm-up period, check your warning lights
and gages:
D If oil pressure doesn’t begin to rise within
15 seconds of starting, stop the engine and find
the cause.
D If the engine coolant temperature gage needle goes
into the hot area on the gage, stop the engine and
find the cause of the overheating.
D If you have air brakes, the dual-needle air pressure
gage should read at least 105 psi (720 kPa) for both
service systems before you try to move the vehicle.
When air pressure is below 60 psi (420 kPa), the
LOW AIR light will come on and you will hear a
tone alarm. If the pressure doesn’t build up or
drops during warm-up, stop the engine and find
the cause before you try to move the vehicle.
Recommended air pressure before actually driving
away is 120 psi (830 kPa).
D The charging system light should come on when
the ignition key is turned to ON or START and
should go out when the engine is running above idle.
If the light doesn’t go out or comes back on during
normal engine operation, have the charging system
checked right away. (This light tells you if the
generator is not charging; it doesn’t reflect the
condition of the battery.)
D The voltmeter charge indicator gage tells you the
condition of your battery’s charge. The gage should
be in the center area during engine operation. The
red area on the left indicates an undercharge
condition; the red area on the right indicates an
overcharge. If the gage is in either red area, have the
battery and charging system checked right away.

1-13
NOTICE:
Don’t allow the engine to operate at low idle for
more than five minutes. This can cause low
engine operating temperatures which can affect
engine operation and reduce engine life. Engine
idle speed should be increased to 1200 rpm
whenever extended idle is required. Once started,
the engine should be placed under load to allow
the engine coolant temperature to reach 150 _ F
(66 _ C) before shutting off the engine.
Engine Coolant Heater (If Equipped)
If your vehicle is equipped
with this feature, the plug-in
receptacle is located behind
the front bumper as shown,
or in the component box
on the driver’s side of
the vehicle.
In very cold weather, 0 _ F (-18
_ C) or colder, the engine
coolant heater can help. You’ll get easier starting and
better fuel economy during engine warm-up. Usually,
the coolant heater should be plugged in a minimum of
four hours prior to starting your vehicle.