brake CHEVROLET KODIAK 2009 Repair Manual

Service
For service and parts needs, visit your dealer/retailer.
You will receive genuine GM parts and GM-trained and
supported service people.
Genuine GM parts have one of these marks:
Accessories and Modifications
Adding non-dealer accessories to the vehicle can affect
its performance and safety. Such things as airbags,
braking, stability, ride and handling, emissions systems,
aerodynamics, durability, and electronic systems like
anti-lock brakes, traction control, and stability control
could be affected. Some non-dealer accessories could
even cause malfunction or damage to parts and systems
and would not be covered by the vehicle warranty.
Damage to vehicle components resulting from the
installation or use of non-GM certified parts, including
control module modifications, are not covered under the
terms of the vehicle warranty and may affect remaining
warranty coverage for affected parts.
GM Accessories are designed to complement and
function with other systems on the vehicle. Your GM
dealer can accessorize the vehicle using genuine
GM Accessories. When you go to your GM dealer and
ask for GM Accessories, you will know that GM-trained
and supported service technicians will perform the
work using genuine GM Accessories.
Also, seeAdding Equipment to Your Airbag-Equipped
Vehicle on page 1-58.
5-3

Water In Fuel Light
Problem Recommended Action
Light comes on
intermittently.Drain water from the fuel
filter.
Light stays on at
temperatures above
freezing.Drain the fuel filter
immediately. If no water
can be drained and the
light stays on, see your
dealer/retailer for
assistance.
Light stays on at
temperatures below
freezing.Drain the fuel filter
immediately. If no water
can be drained, water
may be frozen in the
water drain system, or in
the fuel lines. Move the
vehicle to a warm location
to thaw out, and then
drain the filter system.
Light stays on
immediately after
refueling, and a large
amount of water was
possibly pumped into the
fuel tank.Fuel tank purging is
required. See your
dealer/retailer for
assistance.Notice:Driving when this warning indicator is on,
can damage the fuel injection system and the engine.
If the indicator comes on right after a refuel, it means
water was pumped into the fuel tank. Turn off the
engine immediately. Then, have the water drained
at once.
To drain water, do the following:
1. Stop and park the vehicle in a safe place. Turn off
the engine and apply the parking brake.
2. Remove the fuel cap.
3. Place a fuel-resistant container under the fuel filter.
The filter drain valve is located on the bottom of the
fuel filter.
If the vehicle has the 6.6L engine, the fuel filter is
located in the engine compartment on the driver side
of the vehicle. If the vehicle has either the 7.2L or
7.8L engine, the fuel filters are located in the engine
compartment on the driver side of the vehicle, and on
the driver side frame rail in front of the fuel tank.
5-12

Fuel Filter Replacement
If you want to change the diesel engine fuel filter
yourself, here is how to do it:
{CAUTION:
Diesel fuel is flammable. It could start a fire if
something ignites it, and you could be burned.
Do not let it get on hot engine parts, and keep
matches or other ignition sources away.
First, drain any water from the filter by following the
water draining procedure earlier in this section.
The vehicle’s engine should be off until the end of this
procedure.If the vehicle has the 6.6L engine, the fuel filter is located
in the engine compartment on the driver side of the
vehicle. If the vehicle has either the 7.2L or 7.8L engine,
the fuel filters are located in the engine compartment
on the driver side of the vehicle, and on the driver side
frame rail in front of the fuel tank.
1. Apply the parking brake.
2. Unplug the water
sensor wire connected
to the fuel filter and
unscrew the filter
element.
3. Remove the filter element. If there is any dirt on the
filter sealing surface, clean it off. Remove and reuse
the water sensor float switch located on the bottom of
the fuel filter.
5-18

4. Install the new filter element.
5. Reinstall and tighten the filter container and
reconnect the water sensor wire to the filter.
6. Use the fuel filter priming procedure earlier in this
section to prime the fuel filter.
7. Tighten the air bleed valve by turning it clockwise
until hand-tight.
8. Start the engine and let it idle for five minutes.
Check the fuel filter and air bleed valve for leaks.
How to Reset Fuel Filter Change
Light - DURAMAX 6.6L (LMM) Engine
The engine controller calculates when to change the fuel
filter based on vehicle and fuel use. Whenever the
fuel filter is changed, reset the fuel filter light so
the engine controller can calculate when the next fuel
filter change is required. If the fuel filter is ever changed
prior to a change fuel filter light being turned on,
reset the fuel filter change light.To reset the Fuel Filter Change light:
1. Turn the ignition key to ON/RUN with the engine off
2. Fully press the accelerator and brake pedals at the
same time for 10 seconds. If the Fuel Filter Change
light flashes for 5 seconds, the system is resetting.
3. Turn the key to OFF.
If the Fuel Filter Change light comes back on when you
start the vehicle, the light has not been reset. Repeat
the procedure. SeeChange Fuel Filter Warning Light on
page 3-45for more information.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel might be hard
to find. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by the vehicle warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-19

Filling a Portable Fuel Container
{CAUTION:
Never fill a portable fuel container while it is in the
vehicle. Static electricity discharge from the
container can ignite the fuel vapor. You can be
badly burned and the vehicle damaged if this
occurs. To help avoid injury to you and others:
•Dispense fuel only into approved containers.
•Do not fill a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or on
any surface other than the ground.
•Bring the fill nozzle in contact with the inside
of the fill opening before operating the nozzle.
Contact should be maintained until the filling
is complete.
•Do not smoke while pumping fuel.
•Do not use a cellular phone while
pumping fuel.
Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine parts and
start a fire. These include liquids like fuel, oil,
coolant, brake fluid, windshield washer and other
fluids, and plastic or rubber. You or others could
be burned. Be careful not to drop or spill things
that will burn onto a hot engine.
5-22

Engine Oil Life System (Caterpillar
Diesel Engine)
How to Reset the Engine Oil Life
System
The Engine Oil Life System calculates when to change
the engine oil and filter based on vehicle use. Whenever
the oil is changed, reset the system so it can calculate
when the next oil change is required. If a situation occurs
where the oil is changed prior to a change engine oil light
being turned on, reset the system.
To reset the Engine Oil Life System:
1. Turn the ignition key to ON/RUN with the
engine off.
2. Fully apply and hold the brake pedal while fully
pressing and releasing the accelerator pedal,
pausing slightly at each press and each release,
three times within five seconds.
3. Turn the key to OFF.
If the change engine oil light comes back on when the
vehicle is started, the Engine Oil Life System has
not reset. Repeat the procedure.
Engine Air Cleaner/Filter
Duramax Diesel 6.6L
EngineV8 Gas, Caterpillar and
Isuzu 6H Diesel
Engines
5-38

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.
5-50

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.
5-52

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

Four-Wheel Disc Brakes
(Hydraulic Only)
The vehicle has four-wheel disc brakes.
Some driving conditions or climates can cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
the brakes.
Brake linings should always be replaced as complete
axle sets.
Four-Wheel and Six-Wheel Drum
Brakes (Air Only)
The brake drums should be removed and inspected
each time the tires are removed for rotation or changing.
When the front brakes are replaced, have the rear
brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
Brake Pedal Travel
See your dealer/retailer if the brake pedal does not
return to normal height, or if there is a rapid increase in
pedal travel. This could be a sign that brake service
might be required.
Brake Adjustment
Every brake stop, the brakes adjust for wear.
Brake Adjustment on Air Braked Vehicles
The vehicle has automatic slack adjusters. Every
brake stop, the brakes automatically adjust for wear.
Slack adjusters should never be manually adjusted
to correct excessive brake chamber pushrod stroke.
Excessive brake chamber pushrod stroke means
that the brake system needs to be serviced by a
qualified service technician.
Notice:Do not manually adjust automatic slack
adjusters. Manual adjustment of the automatic slack
adjusters can result in a degradation of the slack
adjuster performance over time. If the brake
chamber pushrod stroke is out of adjustment, the
brake system needs to be serviced by a qualified
service technician.
5-54