CHEVROLET KODIAK 2004 Manual Online

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.
Manual Transmission
Set the parking brake, shift to neutral and hold the
clutch pedal to the floor while starting the engine.
Starter Motor Operation
•The starter motor will disengage if you release the
key or the engine reaches a predetermined engine
speed.
•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.
•The starter motor will not engage if the engine is
already running.
•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.
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 do not, your engine
might not perform properly.
If you ever need to have your vehicle towed, see
Towing Your Vehicle on page 4-31.
2-13

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. SeeHigh Idle Systemunder
Starting Your Diesel Engine on page 2-14
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 engine has 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.
Starting Your Diesel Engine
If you have a Caterpillar®diesel engine, also refer to
your Caterpillar®Diesel Engine Operation &
Maintenance Manual for starting procedure.
For vehicles with the DURAMAX™ diesel engine, also
seeStarting Your DURAMAX™ Diesel Engine on
page 2-19.
To make starting easier in cold weather (below 32°F or
0°C), the proper viscosity engine oil should be used.
SeeEngine Oil (Caterpillar
®Diesel Engine) on
page 5-20orEngine Oil (Gasoline Engine) on page 5-20
orEngine Oil (DURAMAX™ Diesel) on page 5-25. It’s
also best to heat the engine oil first. You can do this by
using an engine coolant heater.
If you ever need to have your vehicle towed, see
Towing Your Vehicle on page 4-31.
2-14

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®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
Two-Speed Rear Axle Electric Shift Control on
page 2-26.
Cold Weather Starting
(Caterpillar®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
®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 uid into the air intake where it
can contact the heater elements.
If you do not have the GM Automatic Ether Injection
System, do not use starting uid or you could
damage your engine. If you have the GM system,
use only GM approved starting uid that has
been tested to establish compatibility with the air
inlet heater system.
2-15

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
®Operation & Maintenance manual
for additional diesel engine warm-up information.
Engine Alarm and Automatic Shutdown
Your check gages light will come on if the system
senses high engine temperature or low engine oil
pressure. If high engine temperature or low engine oil
pressure is detected, you will also hear a tone alarm at
two beats per second. The alarm and the light will
remain on until the condition is fixed. If the engine
temperature or oil pressure condition worsens, the tone
alarm will go to five beats per second.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 about 25–30 seconds.
There is also an engine shutdown light to indicate that
the engine will shut down. SeeEngine Shutdown
Warning Light on page 3-39.
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 25–30 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.
High Idle System (Caterpillar®
Diesel and Gasoline Engines)
Your vehicle has both automatic and manual high idle
capabilities.
2-16

Automatic High Idle System
(Diesel Engines)
The automatic high 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:
•The engine reaches the preset operating
temperature or has been operating for at least
ten minutes.
•The brake pedal is pressed.
•The manual transmission clutch pedal is pressed
or, the automatic transmission (if equipped) is
shifted from NEUTRAL (N) or PARK (P).
•The vehicle speed exceeds about 5 mph (8 km/h).
•The throttle is pressed.
Manual High Idle System
If your vehicle has this
feature, the manual high
idle switch is located in the
instrument panel
switchbank.
This system can be used to increase your engine idle
speed whenever the following conditions are met:
•The brake pedal is not pressed.
•The vehicle speed is below about 5 mph (8 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.
•The manual transmission (if equipped) clutch pedal
is not pressed or, the automatic transmission (if
equipped) is in NEUTRAL (N) or PARK (P).
2-17

The manual high 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 high idle will be deactivated.
The manual high idle has been preset at the factory.
Your dealer may change the setting to fit your needs.
For vehicles with Caterpillar
®diesel engines, manual
high idle can be used to set any desired high 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 high idle switch.
The temporary high idle speed will be set. This new high
idle rpm level will be remembered by the system until
either the ignition is turned to OFF or a new high
idle speed is set.
Exhaust Restrictor (Diesel Engines)
If your vehicle is equipped with this feature, there is an
exhaust restrictor valve located in the exhaust stream.
The valve closes to provide back pressure to the engine
for the purpose of warming the engine quickly.The exhaust restrictor operates:
•while the engine is running.
•while the vehicle is not moving.
•while the accelerator, brake and clutch pedals are
not pressed.
•while idling or driving in cold temperatures.
•when the shift lever is in NEUTRAL (N) or
PARK (P).
On vehicles equipped with a diesel engine exhaust
brake, the exhaust brake switch must be on. The
indicator in the exhaust brake switch will be lit when the
exhaust restrictor is active. The exhaust brake
indicator light in the center of the instrument panel will
also be lit whenever the exhaust restrictor is active.
When the engine coolant temperature is below 149°F
(65°C) and the outside temperature is below 50°F
(10°C), the exhaust restrictor will come on within
45 seconds of starting the engine. After running the
engine for an additional 45 seconds, the engine idle will
increase.
The exhaust restrictor will shut off and engine idle will
return to normal once the engine is warmed up, or
the transmission is shifted into range.
2-18

Starting Your DURAMAX™ Diesel
Engine
Your diesel engine starts differently than a gasoline
engine.
Automatic Transmission
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won’t start in any other position – that’s a
safety feature. To restart when you’re already moving,
use NEUTRAL (N) only.
Notice:Do not try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
Manual Transmission
Move your shift lever to neutral and hold the clutch
pedal to the floor while starting the engine. Your
vehicle won’t start if the clutch pedal is not all the way
down –that’s a safety feature.
Starting Your Engine
1. Turn your ignition key to RUN.
Observe the wait to start light. SeeWait to Start
Indicator on page 3-36. (This light may not come on
if the engine is hot.)
2. As soon as the wait to start light goes off,
IMMEDIATELY turn the ignition key to START.
When the engine starts, let go of the key.
If your vehicle is equipped with the RPO LLY
engine, it has a fast warm-up glow plug system.
The wait to start light will illuminate for a much
shorter time than most diesel engines, due to the
rapid heating of the glow plug system.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor.
Notice:If the WAIT TO START light stays on, it
means that your vehicle could have one of several
problems, so you should have it serviced right away.
3. If the engine does not start after 15 seconds of
cranking, turn the ignition key to OFF. Wait one
minute for the starter to cool, then try the same
steps again.
2-19

If you’re trying to start your engine after you’ve run out
of fuel, seeRunning Out of Fuel on page 5-15.
When your engine is cold, let it run for a few minutes
before you move your vehicle. This lets oil pressure
build up. Your engine will sound louder when it’s cold.
Notice:If you are not in an idling vehicle and
the engine overheats, you would not be there to see
the overheated engine indication. This could
damage your vehicle. Do not let your engine run
when you are not in your vehicle.
Cold Weather Starting (Diesel Engine)
The following tips will help you get good starting in
cold weather.
Use the recommended engine oil when the outside
temperature drops below freezing. SeeEngine Oil
(Caterpillar
®Diesel Engine) on page 5-20orEngine Oil
(Gasoline Engine) on page 5-20orEngine Oil
(DURAMAX™ Diesel) on page 5-25. When the outside
temperature drops below 0°F (−18°C), use of the
engine coolant heater is recommended.If you experience longer cranking times, notice an
unusual amount of exhaust smoke or are at higher
altitudes (over 7,000 ft. or 2 135 m), you may use your
engine coolant heater. SeeEngine Coolant Heater
on page 2-23.
SeeWhat Fuel to Use on page 5-8for information on
what fuel to use in cold weather.
If Your Diesel Engine Won’t Start
If you’ve run out of fuel, seeRunning Out of Fuel on
page 5-15.
If you’re not out of fuel, and your engine won’t start,
do this:
Turn your ignition key to RUN. IMMEDIATELY after
the wait to start light goes off, turn the ignition key
to START.
If the light doesn’t go off, wait a few seconds, then try
starting your engine again. And, see your dealer as soon
as you can for a starting system check.
If the light comes on and then goes off and you know
your batteries are charged, but your engine still
won’t start, your vehicle needs service.
If the light does not come on when the engine is cold,
your vehicle needs service.
2-20

If your batteries don’t have enough charge to start your
engine, seeBattery on page 5-55.
Be sure you have the right oil for your engine, and that
you’ve changed the oil at the proper times. If you
use the wrong oil, your engine may be harder to start.
Be sure you are using the proper fuel for existing
weather conditions. SeeWhat Fuel to Use on page 5-8.
If the engine starts, runs a short time, then stops,
your vehicle needs service.
{CAUTION:
Do not use gasoline or starting “aids” such as
ether, in the air intake. They could damage
your engine. There could also be a re, which
could cause serious personal injury.
Elevated Idle/Exhaust Restrictor
If your vehicle is equipped with the RPO LLY engine, it
has a cold temperature high idle and exhaust restrictor
feature which elevates the engines idle speed from
680 to 1200 rpms, and restricts the exhaust gas flow,
when outside temperatures are below 41°F (5°C),
and the engine coolant temperature is below
150°F (65°C.)
This feature enhances heater performance by raising
the engine coolant temperature faster. When the vehicle
is started in outside temperatures below 41°F (5°C),
and the engine coolant temperature is below 150°F
(65°C), the engine will idle at 1200 rpms and the
variable nozzle turbocharger will restrict the
exhaust flow.
To turn on this feature:
1. Turn the ignition to the run position, with the
vehicle off.
2. Press the accelerator pedal to the floor and hold
while quickly pressing the brake pedal three times
in less than eight seconds.
3. Release the accelerator pedal and start the engine.
2-21

When the engine is started, it will slowly ramp up to the
high idle speed after a delay of a few seconds up to
about two minutes. For this method to work properly
there must be no throttle or brake pedal faults, and the
throttle pedal must not fall below 75 percent of wide
open throttle while pressing the brake pedal.
The engine idle speed will return to normal once the
following conditions are met:
•Once engine coolant temperature reaches
150°F (65°C).
•Air intake temperature reaches 41°F (5°C).
The high idle speed will be temporarily interrupted and
the engine speed will return to normal if any of the
following conditions occur:
•The brake pedal is applied.
•The accelerator pedal is pressed.
•The automatic transmission is shifted out of
PARK (P) or NEUTRAL (N).
•The clutch pedal on the manual transmission is
pressed.
•Vehicle speed is detected.
Once these inputs are removed, the engine idle speed
will slowly ramp back up to high idle after the normal
delay, if the conditions for engine coolant temperature
and air intake temperature are still met.
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.
Butdon’tleave the vehicle while the engine is running.
Avoid unnecessary idling of diesel engine equipped
vehicles.
If the engine idles too long, the temperature of the
engine coolant will fall below the normal operating
range. Low engine operating temperature causes
several conditions which affect engine operation and
reduce engine life.
The engine should be permitted to go through a
warm-up period. Operate the vehicle at a minimum of
600 rpm during the warm-up period. During this
period and during operation, the following observations
should be made.
During this warm-up period, check your warning lights
and gages:
•If oil pressure doesn’t begin to rise within
15 seconds of starting, stop the engine and find the
cause.
•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.
2-22