CHEVROLET KODIAK 2005 Owners Manual

Trailer Connections
Heavy-Duty Trailer Wiring Package
Your vehicle may be equipped with an eight-wire trailer
towing harness. This harness, with a seven-pin
universal heavy-duty trailer connector, is attached to a
bracket on the platform hitch.
The Center High-Mounted Stoplamp (CHMSL) wire
is tied next to the trailer wiring harness for use with
a trailer.The eight-wire harness contains the following trailer
circuits:
•Yellow: Left Stop/Turn Signal
•Dark Green: Right Stop/Turn Signal
•Brown: Taillamps
•White: Ground
•Light Green: Back-up Lamps
•Light Blue: CHMSL
•Red: Battery Feed
•Dark Blue: Trailer Brake
4-37

Trailer Connections
(C7/C8 Models Only)
If your vehicle has these trailer connections, they are
located at the rear of the cab for a tractor and at the rear
of the chassis when towing a trailer. There will be an
air connection and an electrical connection.
Be sure that the couplings to the trailer are
made correctly.
Air Connections
If you are not connecting the trailer air line connections
to another piece of equipment, be sure to replace
their protective caps.
Electrical Connections
This system is a seven-wire cable that will connect to
the trailer, supplying power to the trailer’s lighting
system. When not in use, it is stored in the trailer
air-hose storage bracket.
Power Take-Off (PTO)
If your vehicle is equipped
for the addition of a PTO,
this factory installed
switch will be located in
the instrument panel.
Before using a PTO, refer to the manufacturer’s or
installer’s instructions.
4-38

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Two Safety Cautions about Engine Fan
Breakage...................................................5-5
Fuel................................................................5-6
Gasoline Octane............................................5-6
Gasoline Specifications....................................5-6
Additives.......................................................5-6
Diesel Engine Fuel.........................................5-7
What Fuel to Use...........................................5-8
Very Cold Weather Operation.........................5-10
Water in Fuel...............................................5-10
Running Out of Fuel.....................................5-15
Fuel Filter Replacement.................................5-16
Fuels in Foreign Countries.............................5-17
Filling the Tank............................................5-18
Filling a Portable Fuel Container.....................5-19
Checking Things Under the Hood....................5-20
Hood Latches...............................................5-20
Engine Oil (Caterpillar
®Diesel Engine).............5-22
Engine Oil (DURAMAX®Diesel)......................5-22
Engine Oil (Gasoline Engine)..........................5-26
Engine Oil Life System (Gasoline Engine)........5-29
Engine Oil Life System (DURAMAX
®Diesel).....5-31
Engine Oil Life System (Caterpillar®
Diesel Engine)..........................................5-32Engine Air Cleaner/Filter................................5-33
Automatic Transmission Fluid.........................5-34
Manual Transmission Fluid.............................5-35
Engine Coolant (Gas and
DURAMAX
®Engines).................................5-36
Engine Coolant (Caterpillar®Diesel Engines).....5-38
Coolant Surge Tank Pressure Cap..................5-38
Engine Overheating.......................................5-38
Cooling System (Gas and
DURAMAX
®Engines).................................5-40
Engine Fan Noise.........................................5-45
Power Steering Fluid.....................................5-45
Windshield Washer Fluid................................5-46
Brakes........................................................5-47
Battery........................................................5-55
Jump Starting...............................................5-56
Rear Axle.......................................................5-60
Rear Axle Shift Motor....................................5-62
Four-Wheel Drive............................................5-62
Front Axle......................................................5-63
Noise Control System.....................................5-64
Tampering with Noise Control System
Prohibited.................................................5-64
Bulb Replacement..........................................5-65
Windshield Wiper Blade Replacement..............5-65
Section 5 Service and Appearance Care
5-1

Other Service Items........................................5-66
Fuel Filter....................................................5-66
Primary Fuel Filter and Water Separator..........5-67
Secondary Fuel Filter and Water Separator/
Heater (Caterpillar
®Diesel)..........................5-68
Automatic Ether Injection System
(Caterpillar
®Diesel)....................................5-68
Front Wheel Bearings with Oil-Filled Hubs........5-69
Air Conditioning System.................................5-70
Tires..............................................................5-70
Inflation - Tire Pressure.................................5-71
Wheel Loading.............................................5-71
Dual Tire Operation.......................................5-72
When It Is Time for New Tires.......................5-72
Wheel Alignment and Tire Balance..................5-73
Tightening the Wheel Nuts.............................5-73
Wheel Replacement......................................5-77
If a Tire Goes Flat........................................5-78
Appearance Care............................................5-79
Cleaning the Inside of Your Vehicle.................5-80
Fabric/Carpet...............................................5-81
Instrument Panel, Vinyl, and Other
Plastic Surfaces........................................5-82
Care of Safety Belts......................................5-82
Weatherstrips...............................................5-82Washing Your Vehicle...................................5-83
Cleaning Exterior Lamps/Lenses.....................5-83
Finish Care..................................................5-83
Windshield and Wiper Blades.........................5-84
Aluminum or Chrome-Plated Wheels................5-84
Tires...........................................................5-85
Sheet Metal Damage.....................................5-85
Finish Damage.............................................5-85
Underbody Maintenance................................5-85
Chemical Paint Spotting.................................5-85
Vehicle Identication......................................5-87
Vehicle Identification Number (VIN).................5-87
Service Statement.........................................5-87
Service Parts Identification Label.....................5-88
Electrical System............................................5-88
Add-On Electrical Equipment..........................5-88
Headlamp Wiring..........................................5-88
Windshield Wiper Fuses................................5-88
Fusible Links................................................5-89
Power Windows and Other Power Options.......5-89
Fuses and Circuit Breakers............................5-89
Instrument Panel Fuse Block..........................5-89
Underhood Fuse Block..................................5-92
Capacities and Specications..........................5-95
Normal Maintenance Replacement Parts.........5-100
Section 5 Service and Appearance Care
5-2

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many fluids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-8.
Your vehicle has an airbag system. Before attempting
to do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-59.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeePart D: Maintenance Record on page 6-34.{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts,
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts, and
other fasteners. English and metric
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
5-4

Two Safety Cautions about
Engine Fan Breakage
{CAUTION:
Changing the Fan Drive Ratio or Engine
Governed Speed:
If you change the fan drive ratio or increase
the governed speed of the engine, you may
increase stress and the fan could eventually fail.
If the fan breaks apart while it is rotating, pieces
can cause severe injury to anyone — such as
a service technician — who is nearby. And, of
course, the pieces can severely damage the
vehicle. Do not change the fan drive ratio or
increase the governed speed of the vehicle
without getting the necessary information from
your dealer.
CAUTION: (Continued)
CAUTION: (Continued)
Winter Fronts, Grille Covers or Obstructions:
Winter Fronts, grille covers or other add-on
equipment causing obstructions in front or
behind the fan should not be used on this
vehicle. If this causes the fan to eventually
break apart while it is rotating, the pieces can
cause severe injury to anyone nearby, such as
a service technician working on the engine,
and of course the pieces can severely damage
the vehicle.
5-5

Fuel
If your vehicle has a diesel engine, seeDiesel Engine
Fuel on page 5-7.
For vehicles with gasoline engines, please read this.
Gasoline Octane
Use regular unleaded gasoline with a posted octane of
87 or higher. If the octane is less than 87, you may get a
heavy knocking noise when you drive. If this occurs,
use a gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine.
A little pinging noise when you accelerate or drive uphill is
considered normal. This does not indicate a problem
exists or that a higher-octane fuel is necessary. If you are
using 87 octane or higher-octane fuel and hear heavy
knocking, your engine needs service.
Gasoline Specications
It is recommended that gasoline meet specifications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of Automobile
Manufacturers at www.autoalliance.org/fuel_charter.htm.
Gasoline meeting these specifications could provide
improved driveability and emission control system
performance compared to other gasoline.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work properly.
In most cases, you should not have to add anything to
your fuel. However, some gasolines contain only the
minimum amount of additive required to meet
U.S. Environmental Protection Agency regulations.
General Motors recommends that you buy gasolines that
are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems due to
dirty injectors or valves, try a different brand of gasoline.
Also, your GM dealer has additives that will help correct
and prevent most deposit-related problems.
5-6

Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specifications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors
does not recommend the use of such gasolines.
Fuels containing MMT can reduce the life of spark plugs
and the performance of the emission control system
may be affected. The malfunction indicator lamp
may turn on. If this occurs, return to your authorized
GM dealer for service.Diesel Engine Fuel
For the Caterpillar®diesel, see the Caterpillar®
Operation & Maintenance Manual for information
concerning fuel usage.
Notice:Diesel fuel or fuel additives not
recommended in this manual could damage your
fuel system and engine. Your warranty would
not cover this damage. And:
Diesel fuel that has been mixed with engine oil
or automatic transmission uid could damage
your engine and emission controls.
Aftermarket diesel fuel additives are not tested
by General Motors. Some additives, particularly
those which contain alcohol or water emulsiers,
may damage your fuel system. If you believe that
unique circumstances call for a fuel additive to
be used, consult your dealer for advice.
If you ever run out of diesel fuel, it can be difficult
to restart your engine. To avoid all this, never let
your tank get empty.
If gasoline is ever accidentally added to the fuel
tank, to avoid severe engine damage, do not run the
engine until the fuel tank can be drained.
If you run out of fuel,Running Out of Fuel on page 5-15
tells you how to restart your engine.
5-7

What Fuel to Use
In the United States, for best results use Number 2-D
diesel fuel year-round (above and below freezing
conditions) as oil companies blend Number 2-D fuel to
address climate differences. Number 1-D diesel fuel
may be used in very cold temperatures (when it stays
below 0°F or−18°C); however, it will produce a
power and fuel economy loss. Avoid the use of
Number 1-D diesel fuel in warm or hot climates.
It may result in stalling, poor starting when the engine
is hot and may damage the fuel injection system.
At a minimum, the diesel fuel you use should meet
specifications ASTM D975-03 (Grade Low Sulfur) in the
United States. In addition, the Engine Manufacturers
Association (EMA) has identified properties of an
improved diesel fuel for better engine performance and
durability. Diesel fuels corresponding to the EMA
Recommended Guideline on Premium Diesel Fuel
(FQP-1A) could provide better starting, less noise and
better vehicle performance. If there are questions
about the fuel you are using, contact your fuel supplier.
If your vehicle has the 6.6L engine, it is acceptable
to use diesel fuel containing up to 5% biodiesel (B5), but
the final blended fuel must meet the same specification,
ASTM D975-03 (Grade Low Sulfur), as other fuels
used in your vehicle, and the biodiesel used for making
this fuel must meet the ASTM D6751-03 specification.Biodiesel is produced from vegetable oils or animal fat
that have been chemically modified to reduce the
possibility of damage to your fuel system and engine.
Higher concentration (i.e., greater than B5)
biodiesel-containing fuels or the use of unmodified
bio-oils blended into diesel fuel at any concentration is
not recommended and could damage your fuel
system and engine. Such damage would not be covered
by your warranty. If there are questions about the
biodiesel-containing fuels you are using, contact your
fuel supplier.
Diesel fuel may foam when you fill your tank. This can
cause the automatic pump nozzle to shut off, even
though your tank is not full. If this happens, just wait for
the foaming to stop and then continue to fill your tank.
{CAUTION:
Heat coming from the engine may cause the fuel
to expand and force the fuel out of your tank.
If something ignites the fuel, a re could start
and people could be burned. To help avoid this,
ll your fuel tank only until the automatic nozzle
shuts off. Do not try to top it off.
5-8