maintenance CHEVROLET KODIAK 2009 Workshop Manual

150,000 Miles (240 000 km)
❑Cooling system service (or every 60 months since
last service, whichever occurs first).(2) (29)
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
❑Isuzu Diesel Only: Diesel Particulate Filter (DPF)
service (or every 4,500 hours, whichever occurs
first). Then every 150,000 miles (240 000 km),
or every 4,500 hours, whichever occurs first.(7)
200,000 Miles (320 000 km)
❑Rear axle service — Eaton®, Rockwell®, Spicer®
axles (or every 12 months, whichever occurs
first).(30)
❑Remove, disassemble, clean, and inspect the air
brake trailer supply valve (or every 2 years, or
every 7,200 hours, whichever occurs first).
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
250,000 Miles (400 000 km)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case service.(30)
❑Manual transmission (except ZF 6-speed) fluid
replacement (or every 60 months, whichever occurs
first).
300,000 Miles (480 000 km)
❑Rear axle service — Eaton®, Rockwell®, Spicer®
axles (or every 12 months, whichever occurs
first).(30)
❑Remove, disassemble, clean, and inspect the air
brake air dryer (or every 3 years, or 10,800 hours,
whichever occurs first). Replace desiccant.
❑Isuzu Diesel Only: Diesel Particulate Filter (DPF)
service (or every 4,500 hours, whichever occurs
first). Then every 150,000 miles (240 000 km),
or every 4,500 hours, whichever occurs first.(7)
Footnotes
† = The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(1)= If your vehicle has an Allison Transmission
®,
your owner manual is supplemented by an Allison
Transmission
®Operator’s Manual. Always refer to
these manuals for related maintenance services.
(2)= An Emission Control Service.
(3)= A Noise Emission Control Device.
6-20

(24)= Evaporative Control System Service, if equipped:
Check all fuel and vapor lines and hoses for proper
connections and correct routing (or every 24 months,
whichever occurs first). Replace parts as needed.
(25)= Replace spark plugs. Inspect wires for damage.
Check the wire boot and boot heat shield fit at spark
plugs and coil. Replace parts as needed.
(26)= Check the fuel tank, fuel cap and fuel lines for
damage which could cause leakage. Inspect fuel cap for
correct sealing ability and any indications of damage.
Check fuel cap gasket for even filler neck imprint.
Replace parts as needed.
(27)= Check Exhaust Gas Recirculation (EGR) system
as described in the service manual. SeeService
Publications Ordering Information on page 7-10.
(28)= Inspect Electronic Vacuum Regulator Valve
(EVRV) filter for excessive contamination or plugging.
If needed, clean filter with solution of soap and water, let
dry and install.
(29)= Drain, flush, and refill cooling system. This service
can be complex; you should have your dealer/retailer
perform this service. SeePart C: Recommended Fluids
and Lubricants on page 6-31for what to use. Inspect
hoses. Clean radiator, condenser, pressure cap, and
neck. Pressure test cooling system and pressure cap.
For Caterpillar
®diesel engines, always refer to the
Caterpillar®Diesel Engine Operation & Maintenance
Manual for coolant recommendations and change
intervals.(30)= Change the lubricant. SeePart C: Recommended
Fluids and Lubricants on page 6-31.
(31)= Front axle service: Re-pack upper kingpin roller
bearing.
(32)= Air brake service:
•Inspect brake lines and hoses for proper hook-up,
binding, leaks, cracks, chafing, etc. Inspect drum
brake linings for wear or cracks. Inspect other brake
parts at each wheel, including drums and wheel
speed sensor wiring. Check brake pedal for
excessive free play or travel (or every 6 months,
whichever occurs first) and have serviced if needed.
Check brakes more often if driving habits and
conditions result in frequent braking. Replace air
dryer cartridge only if excessive oil or moisture is
present. A small amount of oil in the system is normal
and should not be considered as a reason to replace
the cartridge.
•Test air lines for leaks; tighten as needed. Replace
compressor filter.
•Inspect air parking brake chamber for leaks and
damage. Inspect lines and hoses for leaks, cracks,
chafing, etc. Also check all attachments for tightness,
wear, or damage. Note: The spring brake section of
the rear brake diaphragms are non-serviceable.
6-24

Part C: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number, or specification can be obtained from your
dealer/retailer.
Usage Fluid/Lubricant
Engine Oil
(Gasoline
Engine)Engine oil which meets GM Standard
GM6094M and displays the
American Petroleum Institute (API)
Certified for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, see “Engine Oil” in the Index.
Engine Oil
(DURAMAX
®/
Isuzu Diesel
Engines)Engine oils with the letters CJ-4 are
required for your vehicle. The CJ-4
designation can appear either alone
or in combination with other
American Petroleum Institute (API)
designations, such as API CJ-4/SL.
These letters show API levels of
quality. To determine the preferred
viscosity for your vehicle’s diesel
engine, see “Engine Oil” in the Index.
Engine Oil
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine oil
recommendations.
Usage Fluid/Lubricant
Engine Coolant
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine
coolant recommendations.
Engine Coolant
(Gasoline
Engine &
DURAMAX
®/
Isuzu Diesel
Engines)50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant
(Caterpillar Diesel Engines) on
page 5-47.
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventOptikleen
®Washer Solvent.
Clutch Bearing
LubricantClutch Bearing Lubricant (GM Part
No. 12378484 or equivalent NLGI
#3 consistency).
Exhaust Brake
Ball Joint Cap
LubricantHigh-Temperature Grease
(GM Part No. U.S. 1051344,
in Canada 903037) or NLGI #3
consistency.
Power Steering
SystemDEXRON
®-VI Automatic
Transmission Fluid.
Manual
TransmissionSynthetic Manual Transmission Fluid
(GM Part No. U.S. 88861952,
in Canada 88861953).
Automatic
TransmissionSee the Allison Transmission
®
Operator’s Manual for correct
transmission fluid.
6-31

Part D: Maintenance Record
After the scheduled services are performed, record the date, odometer reading and who performed the service, and
any additional information from “Owner Checks and Services” on the following record pages. Also, you should
retain all maintenance receipts.
DateMiles/km Or
HoursServiced ByMaintenance Record
6-33

DateMiles/km Or
HoursServiced ByMaintenance Record
6-34

DateMiles/km Or
HoursServiced ByMaintenance Record
6-35

DateMiles/km Or
HoursServiced ByMaintenance Record
6-36

Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle suspension,
brakes, electrical, steering, body, etc.
Service Bulletins
Service Bulletins give additional technical service
information needed to knowledgeably service General
Motors cars and trucks. Each bulletin contains
instructions to assist in the diagnosis and service of
your vehicle.
Owner Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner manual includes the
Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00 (U.S.) plus processing fee
Without Portfolio: Owner Manual only.
RETAIL SELL PRICE: $25.00 (U.S.) plus processing fee
Current and Past Model Order Forms
Technical Service Bulletins and Manuals are available
for current and past model GM vehicles. To request
an order form, specify year and model name of
the vehicle.
7-10

A
Accessories and Modifications............................ 5-3
Accessory Power Outlets.................................3-19
Adding a Snow Plow or Similar Equipment.........4-22
Adding Equipment to Your Airbag-Equipped
Vehicle.......................................................1-58
Additives, Fuel................................................. 5-7
Add-On Electrical Equipment............................5-95
Air Cleaner/Filter, Engine.................................5-38
Air Conditioning..............................................3-20
Air Pressure Gage..........................................3-47
Air Suspension...............................................2-44
Air Suspension Seats........................................ 1-6
Airbag
Off Light.....................................................3-28
Readiness Light..........................................3-27
Airbag System................................................1-48
Adding Equipment to Your Airbag-Equipped
Vehicle...................................................1-58
Airbag Off Switch........................................1-55
How Does an Airbag Restrain?......................1-53
Servicing Your Airbag-Equipped Vehicle..........1-58
What Makes an Airbag Inflate?......................1-53
What Will You See After an Airbag
Inflates?..................................................1-54
When Should an Airbag Inflate?....................1-52
Where Are the Airbags?...............................1-50Antenna, Fixed Mast.......................................3-58
Antilock Brake System (ABS)............................. 4-5
Antilock Brake, System Warning Light................3-33
Antilock Brakes, Trailer System
Warning Light.............................................3-34
Appearance Care
Aluminum or Chrome-Plated Wheels..............5-92
Care of Safety Belts....................................5-89
Chemical Paint Spotting...............................5-93
Cleaning Exterior Lamps/Lenses....................5-90
Fabric/Carpet..............................................5-88
Finish Care.................................................5-90
Finish Damage............................................5-93
Instrument Panel, Vinyl, and Other
Plastic Surfaces.......................................5-89
Interior Cleaning..........................................5-87
Sheet Metal Damage...................................5-93
Tires..........................................................5-92
Underbody Maintenance...............................5-93
Washing Your Vehicle...................................5-90
Weatherstrips..............................................5-89
Windshield and Wiper Blades........................5-91
Ashtray.........................................................3-19
Audio System.................................................3-48
Chime Level Adjustment...............................3-58
Fixed Mast Antenna.....................................3-58
Radio Reception..........................................3-58
Setting the Clock.........................................3-48
Theft-Deterrent Feature................................3-57
1

Child Restraints (cont.)
Securing a Child Restraint in the Center
Rear Seat Position...................................1-42
Securing a Child Restraint in the Right
Front Seat Position...................................1-44
Where to Put the Restraint...........................1-38
Chime Level Adjustment..................................3-58
Cigarette Lighter.............................................3-19
Cleaning
Aluminum or Chrome-Plated Wheels..............5-92
Exterior Lamps/Lenses.................................5-90
Fabric/Carpet..............................................5-88
Finish Care.................................................5-90
Instrument Panel, Vinyl, and Other
Plastic Surfaces.......................................5-89
Interior.......................................................5-87
Tires..........................................................5-92
Underbody Maintenance...............................5-93
Washing Your Vehicle...................................5-90
Weatherstrips..............................................5-89
Windshield and Wiper Blades........................5-91
Climate Control System...................................3-20
Outlet Adjustment........................................3-22
Rear Heating System...................................3-23
Clock, Setting.................................................3-48
Collision Damage Repair................................... 7-6
Control of a Vehicle.......................................... 4-3Coolant
Engine.......................................................5-47
Engine Temperature Gage............................3-34
Low Warning Light.......................................3-35
Surge Tank Pressure Cap.............................5-47
Cooling System..............................................5-43
Cruise Control................................................3-10
Customer Assistance Information
Customer Assistance for Text Telephone
(TTY) Users.............................................. 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Reimbursement Program............... 7-5
Reporting Safety Defects to General Motors........ 7-9
Reporting Safety Defects to the Canadian
Government.............................................. 7-9
Reporting Safety Defects to the
United States Government.......................... 7-9
Roadside Assistance Program......................... 7-5
Service Publications Ordering Information........7-10
D
Daytime Running Lamp...................................3-15
Daytime Running Lamps Indicator Light.............3-42
Defensive Driving............................................. 4-2
3