fuel CHEVROLET KODIAK 2009 Workshop Manual

Sheet Metal Damage
If the vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti-corrosion material to parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide the
corrosion protection while maintaining the vehicle
warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the
finish should be repaired right away. Bare metal
will corrode quickly and may develop into major repair
expense.
Minor chips and scratches can be repaired with touch-up
materials available from your dealer/retailer. Larger
areas of finish damage can be corrected in your
dealer’s/retailer’s body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are not
removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, floor pan,
and exhaust system even though they have corrosion
protection.
At least every spring, flush these materials from the
underbody with plain water. Clean any areas where mud
and debris can collect. Dirt packed in close areas of
the frame should be loosened before being flushed.
Your dealer/retailer or an underbody car washing system
can do this.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on the vehicle. This damage can
take two forms: blotchy, ring-shaped discolorations, and
small, irregular dark spots etched into the paint surface.
Although no defect in the paint job causes this, we will
repair, at no charge to the owner, the surfaces of
new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs first.
5-93

Fuse Usage
16 Airbag System
17 Exterior/Interior Lamps
18 Parking Brake
19 Accessory Power
20 Ignition 4
21 Sidemarker Lamps
22 Turn Signal/Backup Lamps
23 Transmission
24 Hydraulics/Air Brake
A Spare
B Spare
Fuse Usage
Blank Not Used
BRK Brake Warning Lamp
RT PRK Passenger Side Parking Lamps
Blank Not Used
Blank Not Used
LT PARK Driver Side Parking Lamps
RT REAR
TRN/STOPPassenger Side Rear Turn
Signal/Stoplamp
LT REAR
TRN/STOPDriver Side Rear Turn
Signal/Stoplamp
Fuse Usage
RADIO Radio
Blank Not Used
Blank Not Used
PWR WNDW Power Windows
Relay Usage
ECU/PTO*Engine Control Unit/Power Take-Off
*Diesel 7.8 Duramax
BRK LAMPC4/C5 Brake Lamps,
C6/C7/C8 Tractor/Trailer Wiring
DRL Daytime Running Lamps
IGN-4 Ignition
CHMSL Center High Mounted Stoplamp
MRK LTS Sidemarker and Clearance Lamps
HTD/MIRR Heated Mirrors
HTR Diesel Heated Fuel
RT TRN TRLR Passenger Side Trailer Turn Signal
Blank Not Used
LT TRN TRLR Driver Side Trailer Turn Signal
Blank Not Used
Blank Not Used
Blank Not Used
5-98

Fuse Usage
PCM-B Powertrain Control Module
TCM Transmissions (LF8)
ENG 4 Engine 4 (LMM/LF6/LF8)
ENG 2 Engine 2 (L18/LMM)
HTD FUEL Heated Fuel (LMM)
BLANK Not Used
BLANK Not Used
NOTE 3 Fan Relay (LMM), Emissions (L18)
A/C COMP Air Conditioning Compressor
ABS 1 Antilock Brake System 1
ABS 2 Antilock Brake System 2
ABS 3 Antilock Brake System 3
ENGINE Engine
E/A PUMP Electronic/Automatic Pump
HORN Horn
NOTE 2Fuel (L18/LMM), Electronic Control
Module (LF6)Fuse Usage
NOTE 4 Electronic Control Module (LF6)
STUD A Spare
STUD B Spare
Relay Usage
NOTE 1 LMM/L18 Fuel Pump Relay
IGN B RELAY Ignition Relay
STARTER
RELAYStarter Relay
HORN RELAY Horn Relay
IGN A RELAY Ignition Relay
PTO/ECU*
RELAYPower Take-Off/Engine Control Unit
(*Diesel 7.8L LF8)
REVERSE
RELAYReverse Relay
FAN RELAY Fan Relay (LMM)
5-100

ApplicationCapacities
English Metric
Fuel Capacity – C4/C5 Models
Standard (Mid-Mounted) 25 gal 94.6 L
Optional
1(Dual-Tank) (Mid-Mounted) 40 gal 151.4 L
Optional (Mid-Mounted) 32 gal 121.1 L
Optional (Side-Mounted) 35 gal 132.5 L
Optional (Mid-Mounted) 40 gal 151.4 L
Optional (Mid-Mounted) 60 gal 227.1 L
Optional (Mid-Mounted) 80 gal 302.8 L
1One 25-gallon (94.6 L) tank and one 15-gallon (56.8 L) tank
Fuel Capacity – C6/C7/C8 Models
Optional 35 gal 132.4 L
Standard 50 gal 189.2 L
Optional 50 gal 189.2 L
Optional
1(Dual Tanks) 70 gal 264.8 L
Optional
2(Dual Tanks) 75 gal 283.8 L
Optional
3(Dual Tanks) 100 gal 378.5 L
1Two 35-gallon (132.4 L) tanks2One 25-gallon (94.6 L) tank and one 50-gallon (189.2 L) tank3Two 50-gallon (189.2 L) tanks
5-104

ApplicationCapacities
English Metric
Transmission Fluid, Manual
ES052-7, ES066-7 22.0 pt 10.4 L
FS5205A 12.5 pt 5.9 L
FSO8406, FS6305A, FS6305B, FS6406, FS5406A 19.5 pt 9.2 L
FS4205A, FS4205B 11.5 pt 5.4 L
RT6609 12.0 pt 5.7 L
RT8709 26.0 pt 12.3 L
RT8908LL 28.0 pt 13.2 L
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this
manual. Recheck the fluid level after filling.
Engine Specifications
Engine RPO Type
6.6L V8 DURAMAX®LMM Common Rail Fuel System
7.2L L6 Caterpillar
®C7 LF6Hydraulic/Electronic Unit Injector
Fuel System
7.8L L6 Isuzu 6H LF8 Common Rail Fuel System
8.1L V8 VORTEC™ L18Single Port Fuel Injector Fuel
System
5-107

Part GM Part Number ACDelco Part Number
Fuel Filter
6.6L V8 98017645 TP1298B
7.2L L6 — 1R-0751
2
Isuzu 6H 98026037 —
8.1L V8 (C4/C5 with NG6/NK1 or U-Haul) 15807649 —
8.1L V8 (C4/C5 with all other fuel tanks) 10376257 —
8.1L V8 (All C6/C7/C8) 10370247 —
Power Steering Fluid Filter 88892858 —
Secondary Fuel Filter
6.6L V8 — —
7.2L L6 (NWB/KUR) 25982639 S3229
3
Isuzu 6H (NWB) 15618921 S32023
Isuzu 6H (KUK) 88983117 TP1519
8.1L V8 (K28 and standard U-Haul) 25014476 TP1247
Spark Plugs
6.6L V8 — —
7.2L L6 — —
Isuzu 6H — —
8.1L V8 12578277 41-983
1Optional air filter (GM Part No. 88937548 AC Delco No. A2035C) for C6/C7/C8 Models. Fits inside standard size
filter (GM Part No. 88937525 AC Delco No. A2031C) listed previously.
2Caterpillar®part number.3Racor part number.
See the Allison Transmission Operator’s Manual in your vehicle for external filter part numbers and information.
5-109

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using the Maintenance Schedule......................6-4
Scheduled Maintenance Supplements................6-4Scheduled Maintenance...................................6-5
Part B: Owner Checks and Services................6-26
At Each Fuel Fill..........................................6-26
At Least Twice a Year...................................6-27
At Least Once a Year...................................6-30
Part C: Recommended Fluids and
Lubricants................................................6-31
Part D: Maintenance Record..........................6-33
Section 6 Maintenance Schedule
6-1

Part A: Scheduled Maintenance
Services
In this part are scheduled maintenance services which
are to be performed at the mileage intervals specified.
Using the Maintenance Schedule
We want to help keep this vehicle in good working
condition. But we do not know exactly how you will drive
it. You might drive very short distances only a few
times a week. Or you might drive long distances all the
time in very hot, dusty weather. You might use the
vehicle in making deliveries or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You might need
more frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep the vehicle in good condition,
see your dealer/retailer.
This part tells you the maintenance services that should
be done and when to schedule them.
When you go to your dealer/retailer for service, trained
and supported service people will perform the work
using genuine parts.The proper fluids and lubricants to use are listed in
Part C. Make sure whoever services the vehicle uses
these. All parts should be replaced and all necessary
repairs done before you or anyone else drives the
vehicle.
This schedule is for vehicles that:
•carry passengers and cargo within recommended
limits on the vehicle’s Certification or Tire
Information label. SeeLoading the Vehicle on
page 4-20.
•are driven on reasonable road surfaces within legal
driving limits.
•use the recommended fuel. SeeGasoline Octane
on page 5-6for gasoline engine vehicles orWhat
Fuel to Use on page 5-8for diesel engine vehicles.
Scheduled Maintenance
Supplements
If the vehicle has a Caterpillar®diesel engine, the owner
manual is supplemented by the Caterpillar®Diesel
Engine Operation & Maintenance Manual. If the vehicle
has an Allison Transmission
®, the owner manual is
supplemented by an Allison Transmission®Operator’s
Manual. Always refer to these manuals for related
maintenance services.
6-4

❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
15,000 Miles (24 000 km)
❑Gasoline Engine Only: Check engine oil life system.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(2) (8)
❑DURAMAX/Isuzu Diesel Without Engine Oil Life
System Only: Change engine oil and filter (or every
12 months, or every 750 hours of engine operation,
whichever occurs first).(2) (39)
❑DURAMAX/Isuzu Diesel With Engine Oil Life System
Only: Check oil life system. If engine oil and filter are
changed, reset system. See “Engine Oil (DURAMAX/
Isuzu Diesel)” in the Index.(2) (9)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)❑Gasoline Engine: Inspect engine air cleaner filter.
If necessary, replace the filter. If vehicle is driven in
dusty/dirty conditions, inspect filter at every engine oil
change. SeeEngine Air Cleaner/Filter on page 5-38
for more information.
❑Diesel Engine: Inspect engine air cleaner filter change
indicator. If necessary, replace the filter. If vehicle is
driven in dusty/dirty conditions, inspect filter change
indicator at every engine oil change. SeeEngine Air
Cleaner/Filter on page 5-38for more information.
❑Diesel Only: Replace fuel filter (or every 750 hours of
engine operation, whichever occurs first).
❑Steering system service.(12)
❑Front and rear suspension service.(13)
❑Spring-to-axle U-bolts and shackle bolts service.(15)
❑Exhaust system service (or every 6 months, whichever
occurs first).(2) (3) (16)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)
6-6

❑Diesel Engine: Inspect engine air cleaner filter change
indicator. If necessary, replace the filter. If vehicle is
driven in dusty/dirty conditions, inspect filter change
indicator at every engine oil change. SeeEngine Air
Cleaner/Filter on page 5-38for more information.
❑Diesel Only: Replace fuel filter (or every 750 hours of
engine operation, whichever occurs first).
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Gasoline Engine Only: Replace fuel filter(s) (or every
12 months, whichever occurs first).(2)
❑Check restraint system.(40)
❑Steering system service.(12)
❑Front and rear suspension service.(13)
❑Spring-to-axle U-bolts and shackle bolts service.(15)
❑Exhaust system service (or every 6 months, whichever
occurs first).(2) (3) (16)
❑Wheel bearing (grease type) service (and whenever
hubs are removed).(22) (36)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)❑Air brake service (or every 6 months, whichever
occurs first).(32)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
❑Air compressor dry element pleated paper air strainer
service (or every 2 months, or every 800 hours,
whichever occurs first).
❑C600, C700, and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first.)(17)
❑Thermostatically controlled engine cooling fan
service.(3) (19)
❑Shields and underhood insulation service.(3) (4) (20)
❑Gasoline Engine: Air compressor remote mounted air
filter dry element pleated paper air strainer service (or
every 6 months or every 1800 hours, whichever
occurs first).
6-9