2019 Chevrolet Silverado 4500HD, 5500HD, and 6500HD New Model Features

Subject: 2019 Chevrolet Silverado 4500HD 5500HD and 6500HD New Model Features

Involved Country: United States

Overview

This bulletin introduces the new 2019 Chevrolet Silverado 4500HD, 5500HD, and 6500HD medium-duty trucks. It aims to familiarize Service Department Personnel with the vehicle's new Duramax® 6.6L V8 RPO L5D diesel engine, the Allison® transmission with an available PTO option, brake system, chassis, and other general information.

These trucks are exclusively chassis cab models, ready for up-fitters. They are available in 2WD and 4WD and feature advanced connectivity options like OnStar®, Commercial Link, and an OnStar® 4G LTE™ Wi-Fi® Hotspot. They also support wireless cell phone charging, Bluetooth®, Apple CarPlay™, and Android Auto™. Production is in partnership with Navistar at Springfield, Ohio.

Additional Highlights:

• Clean top-of-rail design with no protruding welds or brackets for smooth integrated upfits.
• Robust, single-piece frame rail for enhanced durability.
• Factory-available rear air suspension.
• Fuel tank capacity up to 65 gallons (246 liters).
• Painted chassis for corrosion protection.
• 40/20/40 split-bench front seat.
• 60/40 rear bench seat (Crew Cab).
• Standard Grille Guard Screen for insect protection mounted behind the grille.

Vehicle Features and Systems

Engine

Duramax® 6.6L V8 - RPO L5D

The Duramax® 6.6L V8 - RPO L5D is a turbocharged diesel engine. It is part of a new generation of Duramax® engines, closely related to the 6.6L V8 - RPO L5P, but with a smaller turbocharger and different engine control module calibrations.

Engine Features and Specifications:

• Bore/Stroke: 4.055 inches (103 mm) / 3.8976 inches (99 mm).
• Compression Ratio: 16.0:1
• Cooling System: Capacity is 270 L/min at 3,172 RPM.
• Connecting Rods: One-piece hot forged steel with a fractured split design for durability and reduced internal friction. Tapered small end for reduced weight.
• Crankshaft: Forged steel design with five main bearings.
• Cylinder Block: Deep skirt design for rigidity, 90-degree V-orientation. Induction hardened for durability.
• Cylinder Head: Aluminum construction for lighter weight and rapid heat dissipation. 4 valves per cylinder with high swirl design. Laminated steel head gaskets.
• Emissions Controls: Cooled Exhaust Gas Recirculation (EGR), Selective Catalytic Reduction (SCR), Diesel Particulate Filter (DPF), intake throttle.
• Engine Covers: Front engine cover and flywheel housing made of aluminum. Flywheel housing supplies a crossover passage for engine coolant.
• Engine Oil Capacity with Filter: 10 qt (9.5L).
• Exhaust Gas Recirculation: Water-cooled for improved NOx reduction.
• Exhaust Manifold: 1-piece cast iron design with an externally mounted heat shield.
• Firing Order: 1-2-7-8-4-5-6-3
• Fuel System: Direct injection with high-pressure common rail.
• Fuel Type: GM recommends TOP TIER™ Diesel Fuel. Use Ultra-Low Sulfur Highway Diesel Fuel and/or B20 biodiesel. Do not use diesel fuel with more than 15 ppm Sulfur. Do not use Non-Highway Diesel Fuel.
• Glow Plugs: Eight ceramic glow plugs for greater efficiency and faster preheating. Considered one-time-use; replace with new if removed.
• Governed Speed: 2900 RPM
• Horsepower: 350 hp (257 kW) @ 2700 RPM.
• Torque: 700 lb-ft (949 Nm) @ 1600 RPM.
• Intake Airflow Valve: Throttle plate actuator for EGR rate control.
• Maximum Braking Speed: 4,800 RPM.
• Maximum Powered Speed: 3,450 RPM.
• Oil Cooler: Cools oil with engine coolant.
• Oil Pump: Gear driven directly from the crankshaft.
• Pistons: Full-floating design with piston cooling oil channels. Two compression rings and one oil control ring.
• Turbocharger: Water-cooled, variable vane style for improved durability.
• Upper Oil Pan: Single-piece cast aluminum for rigidity and weight reduction.
• Valvetrain: Mechanical roller lifter, one rocker arm operates two valves.
• Water Pump: Gear driven for improved reliability.

Elevated Idle: The engine has a cold temperature high idle feature (1050-1100 RPM) when outside temperatures are below 32°F (0°C) and engine coolant temperature is below 150°F (65°C) to enhance heater performance.

Engine Block Heater: If equipped, aids starting and fuel economy in cold weather (below 0°F / -18°C). Requires at least four hours of preheating.

Fuel System

The fuel system includes primary and secondary fuel tanks, fuel transfer pump, electric fuel pump, fuel filter assembly (with water separator, heater, temperature, and water sensors), fuel pressure sensor, fuel injection pump, fuel rails, and fuel injectors. High pressure fuel is controlled by the ECM, Fuel Pressure Regulator 1, and Fuel Pressure Regulator 2.

Exhaust Aftertreatment Uses Post Injection: The engine uses post-combustion injection through fuel injectors to increase exhaust gas temperature for regeneration; it does not use an HC Injector.

L5D Fuel System Diagram: Illustrates the components of the fuel system, including tanks, pumps, filters, regulators, and injectors.

Engine Oil

Specification: Use engine oil with CJ-4 or CK-4 designation (alone or combined with other API designations). These letters indicate API levels of quality.

API Symbol: A doughnut-shaped logo certifying oil meets American Petroleum Institute standards. Use only oils displaying this logo.

Caution: Use only CJ-4 or CK-4 oils. Failure to do so can damage the DPF and void the warranty.

Viscosity Grade: Use SAE 15W-40. For very cold conditions (below 0°F / -18°C), use SAE 5W-40 for improved cold starting.

Exhaust Brake

Operation: Enhances the vehicle brake system and reduces brake lining wear. Downshifts may be automatically selected to increase engine speed and exhaust brake effectiveness. The number of downshifts depends on brake application duration and vehicle slowing rate. Heavier loads result in more active exhaust braking. Automatic downshifts do not occur in Range Selection Mode.

Activation: Press the exhaust brake switch in the control panel. An indicator light turns ON. The DIC displays "EXHAUST BRAKE ON". Press again to turn OFF; the DIC displays "EXHAUST BRAKE OFF". The switch must be pressed at each vehicle start for the system to be active.

Exhaust Aftertreatment System

Overview: Reduces hydrocarbons (HC), carbon monoxide (CO), oxides of nitrogen (NOx), and particulate matter in exhaust gases through a 3-stage process: Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), and Selective Catalyst Reduction (SCR).

Fuel Requirements: Use Ultra Low Sulfur Diesel Fuel (ULSD) only. Do not use diesel blends with more than 20% biodiesel. Do not use Non-Highway Fuel, as it can damage the emission control system.

Component Function:

• DOC: Removes HC and CO via oxidation.
• DPF: Captures diesel exhaust particulates (soot) using a porous filter substrate. Capable of removing over 90% of soot.
• SCR: Converts NOx into nitrogen and water vapor using injected Diesel Exhaust Fluid (DEF).

DPF Overview: Captures soot by forcing exhaust through porous cells, trapping particulates. Half the cells are open at the inlet and capped at the outlet, and vice versa, forcing gases through cell walls.

Differential Pressure Sensor: Measures pressure drop across the DPF to monitor soot buildup. Increasing pressure indicates clogging.

DPF Regeneration: The ECM initiates a regeneration event to burn off trapped soot when pressure drop reaches a specified limit (100%). Normal regenerations occur automatically. Service regeneration may be required if normal regeneration is insufficient, involving higher tailpipe temperatures (over 572°F / 300°C) and specific precautions.

SCR Overview: Converts NOx to N2 and H2O using DEF. Requires optimal SCR temperatures (above 480°F / 250°C).

NOx Sensors: Two sensors monitor NOx levels upstream and downstream of the SCR to control exhaust NOx levels. They incorporate electric heaters for quick temperature attainment.

Diesel Exhaust Fluid (DEF): A 32.5% aqueous urea solution. Reacts with NOx in the SCR to form nitrogen, CO2, and water vapor. Optimum reduction occurs at higher temperatures; lower temperatures can lead to ammonia slip.

Exhaust Gas Temperature Sensors: Monitor EGT to maintain SCR catalyst within the optimum NOx conversion temperature range (390–750°F / 200–400°C).

Particulate Matter (PM) Sensor: Determines soot amount in exhaust gas by monitoring DPF collection efficiency. Operates in standby, regeneration, and measurement modes.

Diesel Exhaust Fluid System: Includes reservoir, pump, level/temperature sensors, control module, quality sensor, heaters, and an external DEF injector. The DEF level must be maintained for proper vehicle operation; low levels trigger warnings and speed limitations.

Cold Weather Operation: DEF solution freezes at 12°F (-11°C). DEF heaters in the reservoir and supply line prevent freezing. DEF pump operation is disabled during thawing.

Recommended DEF: Use DEF meeting ISO 22241 standard or displaying the API Certified Diesel Exhaust Fluid Mark. Store in stainless steel, polypropylene, or HDPE tanks. Avoid prolonged exposure to sunlight or temperatures above 75°F (23.8°C).

Regeneration

Normal Regeneration: Soot buildup in the DPF restricts exhaust flow. When soot reaches a limit, the ECM commands regeneration to burn it off. Occurs automatically during normal driving. Requires steady driving for 20-30 minutes. If normal regeneration is insufficient (e.g., short trips), the DPF warning lamp and a "Clean Exhaust Filter" message appear.

Service Regeneration: Required when soot load is too high for normal regeneration. Involves higher tailpipe temperatures (over 572°F / 300°C). Requires outdoor operation, keeping people and combustible material away. If vehicle operator fails to meet conditions for normal regeneration, a "REDUCED ENGINE POWER" message may display until service regeneration is performed.

Intake Air Valve: Controls combustion temperature during DPF regeneration by closing to create back pressure.

Ash Loading: Non-combustible by-product from oil consumption. Accumulates in DPF and requires removal and replacement if ash-loaded. Use low ash content engine oil (CJ-4 or CK-4).

Manual Regeneration: An optional feature allowing manual DPF cleaning when self-cleaning is not possible (e.g., extended idle, short trips). Initiated via DIC message and steering wheel controls. Requires specific safety conditions to be met. Engine speed and cooling fan increase during the process.

Exhaust Gas Recirculation (EGR)

EGR Purpose: Reduces NOx emissions by introducing exhaust gas into the combustion chamber to lower combustion temperatures.

EGR Operation: Intake air is mixed with cooled exhaust gas to satisfy emissions, performance, and fuel economy requirements. The ECM uses the Mass Air Flow (MAF) sensor to control EGR flow.

Vehicle Features and Operation

Marketplace, GM's In-Vehicle Commerce Platform

Allows drivers to pay for fuel via infotainment touchscreens at participating Shell, Exxon, and Mobil stations. Requires linking an ExxonMobil Speedpass+™ or Shell Fuel Rewards® account. Offers security and convenience.

Power Take-Off (PTO)

Overview: Creates an auxiliary power source for add-on equipment (e.g., salt spreaders, snow plows). Controls engine speed and accessory engagement. PTO wiring and operation recommendations from the service manual and GM Upfitter documentation must be followed.

Primary PTO Operating Modes: Preset, Remote Operation, Variable, Mobile, and Operator Selectable In-Cab Mode (OSIM) are available, requiring specific configurations and tools.

Refrigerant R-1234yf

Air Conditioning Service Fittings: Use SAE J639 fittings. Gray caps designate systems with R-1234yf.

A/C Compressor (Manual): Engages via a magnetic clutch. HVAC control module requests A/C operation from the ECM. Utilizes a variable displacement solenoid valve to regulate compressor displacement based on cooling load.

Sensors and Controls

A/C Evaporator Temperature Sensor: Monitors evaporator temperature to prevent icing.

A/C Refrigerant Pressure Sensor: Measures refrigerant pressure, sending a voltage signal to the ECM. Pressure values outside a specified range prevent A/C compressor engagement.

Actuators: Control airflow within the HVAC case assembly.

Blower Motor: Speed controlled by a low-side PWM signal from the HVAC control module.

Rear Vision Camera (RVC): Optional feature to aid parking. Displays image in the infotainment display when the vehicle is shifted into Reverse.

Refueling the Vehicle: Fuel fill port(s) located on the driver side. Dual tanks have separate fill ports.

Supplemental Inflatable Restraint (SIR) System

SIR System Overview: Supplements seat belts. Includes an inflatable restraint sensing and diagnostic module (SDM), airbags, seat belt pretensioners, and impact sensors. The SDM detects collisions and deploys airbags/pretensioners if impact force is sufficient.

SDM: Microprocessor and control center for the SIR system. Processes sensor inputs to determine impact severity and trigger deployment.

Airbags: Two airbags are present (steering wheel and passenger side). Deploy via inflator modules using gas generation.

Impact Sensor: Detects vehicle acceleration to identify severe collisions warranting airbag deployment.

Seat Belt Pretensioners: Pyrotechnic devices that remove seat belt slack during a collision. May deploy independently of airbags.

Snow Plow: Airbag systems are designed to function properly with snow plows. Do not alter the snow plow's "tripping mechanism".

Suspension

Suspension — Air Ride: Provides a smooth ride with constant frame height. Air springs replace steel springs. Adjusts automatically to load changes.

Air Ride Suspension Dump Switch: Allows temporary lowering of the rear suspension for loading. Controlled by the Air Suspension Dump (ASD) switch.

Suspension — Front:

• Non-Driving Axle: Solid I-Beam type, supports load and provides maneuverability.
• Leaf Springs: Tapered leaf springs used at the front axle for a smoother ride.
• Stabilizer Bar: Reduces body roll, improves traction and reduces tire wear.

Suspension — Rear:

• Multileaf Variable Rate Springs: Offers variable deflection rate, becoming stiffer as load increases, providing stability and control.

Tires and Wheels

Tire/Certification Label: Located on the driver side door frame, indicates original equipment tire size and load rating. Replacement tires must meet or exceed GAWR.

Tires — Lug and Rib Patterns: Lug patterns for drive axles, Rib patterns for steer/trailer axles. Zigzag rib patterns offer better wet traction.

Tires: Available in Continental and Goodyear options (225/70R19.5G Highway, and Rear Traction options). Spare tire matches vehicle equipment.

Tire Rotation: Recommended every 7,500 mi (12,000 km) for uniform wear. First rotation is critical.

Tire Rotation Pattern: Specific patterns for aluminum and steel wheels to ensure proper rotation.

Wheels Overview: Differentiates between Stud Piloted and Hub Piloted wheels. Hub Piloted wheels use the hub bore for centering. Avoid harsh cleaners on wheels.

Wheel Size — Material — Color: Lists available wheel sizes (19.5" x 6.75") and materials (Steel, Aluminum) in various colors. Standard is black painted steel wheels.

Traction Control System

System Operation: Limits wheel spin and assists in maintaining control on slippery surfaces. Activates by applying brakes to spinning wheels and reducing engine power. Cruise control may disengage when TCS is active.

Turning the System OFF and ON: The TCS can be turned OFF by pressing the button on the center stack; the "Traction OFF" light illuminates. Press again to turn ON.

Transmission Allison® 6-Speed

Notice: Allison® Transmission and TCM are warranted by Allison® and require service at an Allison® Authorized Distributor and Dealer.

Transmission Component and System Description: Delivers fuel efficiency, performance, and safety. Offers Power Take-Off (PTO) provision for powering attachments. Available transmissions include Allison® 1700, 1750, and 2700 with double overdrive.

Series types: Emergency Vehicle Series™, Highway Series™, Motorhome Series™, Rugged Duty Series™ are available for specific applications.

Automatic Transmission Shift Lock Control: Safety feature preventing inadvertent shifting out of Park. Requires brake pedal application to move the shift lever.

Transfer Case — Four-Wheel Drive: Sends power to all four wheels for extra traction when equipped.

Manual Locking Hubs

Must be manually turned to LOCK before using four-wheel drive modes. Can remain locked in variable traction conditions. Turn to FREE when four-wheel drive is not needed. Locking hubs in two-wheel drive can cause driveline vibration.

Electronic Transfer Case Switch

Caution: Shifting transmission before the mode indicator light stops flashing can damage the transfer case.

The switch indicates the current state of the transfer case. Rotate the switch to shift into and out of four-wheel drive. The indicator light flashes during shifting.

Turbocharger System Description

Variable Vane Turbocharger Overview: Increases engine power by pumping compressed air into combustion chambers. The turbocharger is a BorgWarner single-stage, water-cooled, variable geometry turbocharger (VGT) producing 220 kPa (31.9 psi) boost pressure.

The ECM controls turbocharger vanes via the CAN bus to vary boost pressure independent of engine speed. The vanes adjust boost based on engine load requirements.

Vane Operation: Actuator arm position controls vane opening/closing. Vanes are normally open but can be closed by the ECM for EGR operation or to accelerate engine coolant heating at extreme cold temperatures. Also used for exhaust brake function.

Regeneration Assistance: ECM varies turbocharger vanes to assist exhaust system warm-up and maintain proper DPF regeneration temperatures.

Learn Procedure: Performed each time ignition is turned OFF to ensure proper vane position and clean off combustion soot.

Vehicle Hoisting/Lifting

Requires a 25,000-pound hoist/lift. Do not use jackstands or floor jacks.

Vehicle Personalization

Features can be customized via the infotainment system's Settings menus (Time, Date, Language, Radio, Vehicle, Bluetooth, Apple CarPlay, Android Auto, etc.).

Bluetooth®

Enables hands-free calling using the vehicle audio system. Requires pairing the phone with the system. Pairing is disabled when the vehicle is moving.

Accessory Power Outlets & USB Ports

Available on the instrument panel and center console, depending on seat configuration (bench or bucket seats).

Vehicle Label - Incomplete

Attached to the driver-side door frame. Upfitters add a completion label above it.

Curb Weight

Weight of the vehicle without driver, passengers, or cargo, but including maximum fuel, oil, and coolant.

Gross Axle Weight Rating (GAWR)

Maximum allowable weight for each axle. GAWR includes vehicle weight, passengers, cargo, and trailer tongue weight. Axles should not be loaded beyond the manufacturer's listed GAWR.

Gross Combined Weight Rating (GCWR)

Maximum combined weight limit for the tow vehicle and trailer. Calculated based on chassis manufacturer parameters and SAE International test protocols. GCWR is the total allowable weight of the loaded vehicle and trailer, including all components. Do not exceed GCWR.

GCWR Ranges: 4500HD/5500HD/6500HD Regular/Crew Cab: 26,000–30,000 lbs.

Calculating GCWR: Sum curb weight, trailer weight, passengers, cargo, hitch hardware, and accessories. Compare to GCWR. Can also be confirmed by weighing truck and trailer.

Gross Vehicle Weight Rating (GVWR)

Maximum weight rating established by the chassis manufacturer for the vehicle, ensuring safe and reliable performance. GVWR can be restricted by durability, dynamic stability, and handling standards.

GVWR Ranges:

• 4500HD Regular/Crew Cab: 15,000–16,500 lbs.
• 5500HD Regular/Crew Cab: 17,500–19,500 lbs.
• 6500HD Regular/Crew Cab: 21,000–22,900 lbs.

Gross Vehicle Weight (GVW)

Total weight of the truck and payload at a given time. Includes curb weight, cargo, equipment, and passengers. Affects maximum allowable tongue and trailer weight.

Gross Combined Weight Rating Table

Provides GCWR based on model and equipment:

*GCWR is total allowable weight of loaded vehicle and trailer, including passengers, cargo, equipment, and conversions. Must not be exceeded.

(1) Maximum Trailer Weight cannot be provided as total vehicle weight is unknown.

(2) Use appropriate hitch and load within GCWR, GVWR, and GAWR limits.

Integrated Trailer Brake Control (ITBC)

Adjusts trailer brake power (Trailer Gain). Control panel located on the left of the instrument panel. ITBC information displayed on the DIC.

GM Upfitter Integration Group

Contact the GM Upfitter Integration Group for assistance when adding non-OE content. Visit their Home Page and submit a request form for technical assistance.

Warranty Coverage at a Glance

• Bumper-to-Bumper: 3 years/36,000 miles (includes tires).
• Powertrain (Engine): 5 years/100,000 miles for 6.6 Duramax® Turbo-Diesel Engine. Excludes Allison® transmission and TCM, which are warranted by Allison®.
• Sheet Metal: Corrosion coverage for 3 years/36,000 miles. Rust-through coverage for 6 years/100,000 miles.

Wireless Charging

Located on the storage tray of the center console (Crew Cab bucket seat models only). Device must be placed face up on the charging pad. Charging symbol appears on the infotainment screen.

Special Tools

New tools released for the 2019 Silverado 4500HD, 5500HD, and 6500HD chassis cab medium-duty trucks are listed with their tool numbers and descriptions. A Special Tool Loan Program is also available.

Training Course

New Model Features: Course #90319.50W covers 2019 Medium Duty Silverado 4500HD, 5500HD, & 6500HD New Model Features.

Version Information

Version: 1

Modified: Released December 18, 2018

Trademark Footnotes

Lists registered trademarks for various brands and technologies including ACDelco®, Allison®, Duramax®, Goodyear®, Hydro-Max™, OnStar®, Speedpass+™, Bluetooth®, Bosch®, CarPlay™, and Wi-Fi®.