engine CHEVROLET KODIAK 2009 Owners Manual

{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol and
it will burn if the engine parts are hot enough. Do
not spill coolant on a hot engine.
1. You can remove the
coolant surge tank
pressure cap when
the cooling system,
including the coolant
surge tank pressure
cap and upper radiator
hose, is no longer hot.
Turn the pressure cap slowly counterclockwise
about one full turn. If you hear a hiss, wait for that to
stop. A hiss means there is still some pressure left.
2. Then keep turning the pressure cap slowly, and
remove it.3. Fill the coolant surge tank with the proper mixture,
to the FULL COLD mark.
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4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower, add
more of the proper mixture to the coolant surge tank
until the level reaches slightly above the FULL
COLD mark.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight and fully seated.
Engine Coolant (Caterpillar Diesel
Engines)
If your vehicle has a Caterpillar®diesel engine, see the
Caterpillar®Diesel Engine Operation & Maintenance
Manual provided with your vehicle to find out what to add,
as well as when and how to service your cooling system.
Coolant Surge Tank Pressure Cap
The coolant surge tank pressure cap is located in
the engine compartment, on the driver’s side of the
vehicle.
Notice:Your vehicle’s surge tank pressure cap is
designed for use with medium-duty cooling systems
only. If the surge tank pressure cap is not tightly
installed, coolant loss and possible engine damage
may occur. Be sure the cap is properly and tightly
secured.
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Engine Overheating
You will find an engine coolant temperature gage, as
well as a low coolant warning light, on your vehicle’s
instrument panel. SeeEngine Coolant Temperature
Gage on page 3-34andLow Coolant Warning Light on
page 3-35for more information.
Your vehicle also has a check gages warning light on
the instrument panel. SeeCheck Gages Warning
Light on page 3-43for more information.
If Steam Is Coming From Your Engine
{CAUTION:
Steam from an overheated engine can burn you
badly, even if you just open the hood. Stay away
from the engine if you see or hear steam coming
from it. Just turn it off and get everyone away
from the vehicle until it cools down. Wait until
there is no sign of steam or coolant before you
open the hood.
CAUTION: (Continued)
CAUTION: (Continued)
If you keep driving when your engine is overheated,
the liquids in it can catch fire. You or others could
be badly burned. Stop your engine if it overheats,
and get out of the vehicle until the engine is cool.
Notice:If the engine catches fire because of being
driven with no coolant, your vehicle can be badly
damaged. The costly repairs would not be covered
by the vehicle warranty.
If No Steam Is Coming From Your
Engine
An overheat warning, along with a low coolant light, can
indicate a serious problem. SeeLow Coolant Warning
Light on page 3-35for more information.
If you get an engine overheat warning with no low
coolant light, but see or hear no steam, the problem may
not be too serious. Sometimes the engine can get a
little too hot when you:
•Climb a long hill on a hot day.
•Stop after high-speed driving.
•Idle for long periods in traffic.
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If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. In heavy traffic, let the engine idle in N (Neutral)
while stopped. If it is safe to do so, pull off the
road, shift to P (Park) or N (Neutral) and let
the engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the windows as necessary.
3. If climbing a hill, downshift to raise engine and fan
speeds.
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning does not come back on, you can drive
normally.
If the warning continues and you have not stopped, pull
over, stop, and park your vehicle right away.
If there is still no sign of steam, you can push down the
accelerator until the engine speed is about twice as
fast as normal idle speed for at least three minutes while
you are parked. If you still have the warning, turn off
the engine and get everyone out of the vehicle until it
cools down.
You may decide not to lift the hood but to get service
help right away.Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing and/or high outside
temperatures, the fan speed increases when the clutch
engages. So you may hear an increase in fan noise.
This is normal and should not be mistaken as the
transmission slipping or making extra shifts. It is merely
the cooling system functioning properly. The fan will
slow down when additional cooling is not required and
the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch disengages.
Power Steering Fluid
SeeScheduled Maintenance on page 6-5to determine
when to check your power steering fluid.
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How To Check Power Steering Fluid
Check your power steering fluid only when the engine is
warm. If the engine is not warm, you probably will not
get an accurate reading.
If the fluid level is between the MIN (Minimum) and
MAX (Maximum) marks, you have enough. If you need
fluid, add only enough of the proper fluid to bring it
in between the MIN and MAX marks.
If your power steering fluid level is low, this can cause
the brake or service brakes soon warning lights to come
on. In addition, the steering effort and emergency
brake distance could increase.
If either light remains on after you have added power
steering fluid to the proper level, then shut off the engine
for 10 seconds. This should reset the brake warning
lights. If one or both lights stay on, see “Hydraulic Brake
System Warning Lights” underBrake System Warning
Light on page 3-31for more information.
What to Use
To determine what kind of fluid to use, seePart C:
Recommended Fluids and Lubricants on page 6-31.
Notice:When adding power steering fluid or
making a complete fluid change, always use the
proper fluid. Failure to use the proper fluid can
cause leaks and damage hoses and seals.
Windshield Washer Fluid
What to Use
When you need windshield washer fluid, be sure to read
the manufacturer’s instructions before use. If you will
be operating your vehicle in an area where the
temperature may fall below freezing, use a fluid that has
sufficient protection against freezing.
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Adding Washer Fluid
Open the cap with the
washer symbol on it.
Add washer fluid until
the tank is full.
The windshield washer fluid reservoir is located in the
engine compartment on the driver’s side of the vehicle.Notice:•When using concentrated washer fluid, follow
the manufacturer’s instructions for adding
water.
•Do not mix water with ready-to-use washer fluid.
Water can cause the solution to freeze and
damage your washer fluid tank and other parts
of the washer system. Also, water does not
clean as well as washer fluid.
•Fill the washer fluid tank only three-quarters full
when it is very cold. This allows for fluid
expansion if freezing occurs, which could
damage the tank if it is completely full.
•Do not use engine coolant (antifreeze) in your
windshield washer. It can damage the vehicle’s
windshield washer system and paint.
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Brakes
Brake Fluid
If the vehicle has hydraulic
brakes, there is a brake
master cylinder in the
engine compartment on the
driver side of the vehicle.
Refer to the Maintenance Schedule to determine when
to check the brake fluid.
{CAUTION:
Do not add brake fluid before checking the level or
there could be too much brake fluid. Brake fluid
could spill on the hot engine and it can catch fire.
You could be burned and the vehicle could be
damaged. See “Checking Brake Fluid” in this
section.
Checking Brake Fluid
Apply the brake pedal several times with the ignition off.
The brake fluid reservoir is in the engine compartment on
the driver side of the vehicle. Clean one of the reservoir
caps and the area around the cap, and remove it.
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The fluid level should be
even with the bottom ring of
the filler opening. If it is low,
add enough fluid to fill the
reservoir to the proper
level.
What to Add
Use the proper fluid listed in the Maintenance Schedule.
Use new brake fluid from a sealed container only.
Always clean the brake fluid reservoir cap/cover and the
area around the cap/cover before removing it. This
helps keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of fluid in the brake hydraulic
system, the brakes might not work well. This could
cause a crash. Always use the proper brake fluid.
Notice:
•Using the wrong fluid can badly damage brake
hydraulic system parts. For example, just a
few drops of mineral-based oil, such as engine
oil, in the brake hydraulic system can damage
brake hydraulic system parts so badly that they
will have to be replaced. Do not let someone
put in the wrong kind of fluid, and do not
use DOT-5 silicone brake fluid.
•If brake fluid is spilled on the vehicle’s painted
surfaces, the paint finish can be damaged. Be
careful not to spill brake fluid on the vehicle.
If you do, wash it off immediately. SeeWashing
Your Vehicle on page 5-90.
5-53

Electric Air Compressor
The vehicle might have an electric air compressor.
This compressor is used to run options that require
pressurized air, such as an air horn or air seat.
The air compressor is used when vehicles do not have
an air brake system.
The air supply for this
system must be
maintained by releasing
the drain valve to eject any
moisture that could have
built up in the system.
It is recommended that this system be drained on a
weekly basis.
Clutch Pedal Free Travel
If the vehicle has a V8 engine and a manual
transmission, the clutch needs adjustment when pedal
free travel gets down to about 1/4 inch (6 mm), as
measured at the clutch pedal pad. There should be
1 1/2 to 2 inches (38 to 51 mm) of clutch pedal
free travel.
If the clutch ever needs service, be sure to use only
approved clutch replacement parts.
Chassis Lubrication
The Maintenance Schedule provides all of the required
chassis lubrication intervals and identifies proper
lubricants to use. Be sure to see the Maintenance
Schedule before performing any chassis lubrication
service. To determine location of chassis lubrication
items, use the following charts.
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Item Number Item Remarks
4 Pivot Points and Hinges Apply chassis lubricant.
5 Pivot Points and Hinges Apply chassis lubricant.
6 Slack Adjuster** One fitting.
7Brake Cam Roller Pins at interface of pin
and shoe**Apply engine oil.
8 Front Steering KnucklesOne fitting each side, lower bushing.
(Hand-operated grease gun only.) Hand-pack upper
bearing.
9 Front Wheel Bearings Hand-pack or lubricate.
10 Steering Tie Rod Ends One fitting each end.
11 Spring Slip Pads* (Multi-Leaf Only) Apply chassis lubricant.
12 Clutch Release Bearing* Cup or fitting.
13 Battery Terminal (except “ST” type) Keep coated with petroleum jelly.
14 Transmission Fill to level of filler plug.
15 Propshaft U-JointsLubricate with GM Part No. 1051344 Wheel Bearing
Lubricant.
16 Parking Brake Clevis Pin$ Apply chassis lubricant.
17 Parking Brake Lever Pivot*, $ Apply chassis lubricant.
18Clutch Release Cross Shaft, Master
Cylinder$Apply chassis lubricant, fill to 1/4 inch (6 mm) below
opening.
19 Release Bearing, Clutch Cross Shaft Two fittings, apply chassis lubricant.
20 Clutch Release Fork Two fittings.
* Applies to some vehicles.
** Applies to air brakes only.
$ Applies to hydraulic brakes only.
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