fuel CHEVROLET KODIAK 2009 Repair Manual

37,500 Miles (60 000 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)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑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)
45,000 Miles (72 000 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)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Gasoline Engine: Replace engine air cleaner filter.
SeeEngine Air Cleaner/Filter on page 5-38for 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).
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
6-10

❑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).
❑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)
❑Inspect door hinge pins and bushings and replace as
necessary.
❑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)
❑Isuzu Diesel Engine Only: Adjust valve lash (or every
2,625 hours of engine operation, whichever occurs
first).(18)
❑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)
6-13

72,000 Miles (115 000 km)
❑Lubricate U-joints (or every 6 months, whichever
occurs first).
75,000 Miles (120 000 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)
❑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).
6-15

❑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).
❑Fuel tank, fuel cap and fuel lines service (or every
72 months, whichever occurs first).(2) (26) †
❑Exhaust Gas Recirculation (EGR) system inspection
(if equipped) (or every 72 months, whichever occurs
first).(2) (27)
❑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).82,500 Miles (132 000 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)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑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)
6-16

90,000 Miles (144 000 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)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Gasoline Engine: Replace engine air cleaner filter.
SeeEngine Air Cleaner/Filter on page 5-38for 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).
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)❑Cooling system service. Clean the cooling system filler
cap with clean water, clean the core, pressure test the
cap and the system for proper pressure capability, and
inspect condition of cooling and heater hoses and
clamps. Replace hoses if cracked, swollen, or
damaged.
❑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)
❑Inspect door hinge pins and bushings and replace as
necessary.
❑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)
6-17

(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

•Replace the air compressor filter element, mounted
on the air compressor. For remote air compressor
intake service, refer to engine air cleaner filter
replacement.
•Remove, disassemble, clean, and inspect the safety
valve, service brake chambers, quick release valves,
quick release/double check valve combinations,
parking brake control valve, double check valves,
pressure protection valves, and ether injector
(if equipped).
•Remove, disassemble, and clean the application
valve; replace parts showing wear.
•Remove, disassemble, clean, and inspect the spring
brake control valve; replace rubber parts.
(33)= Clean and lubricate air brake automatic slack
adjuster. Check pushrod travel and auto adjustment
operation. Have serviced if needed.
(34)= Air brake chamber service: Check operation,
mounting clamps, and air lines and check for leaks.
(35)= Trailer brake hand control valve service: Check
operation; lubricate cam and follower.(36)= Tighten the wheel stud nuts to the specified torque
values at 100 miles (160 km). Thereafter, tighten them
1,000 miles (1 600 km) after each time the wheel is
removed. SeeTightening the Wheel Nuts on page 5-80.
(37)= Inspect and clean any accumulated dirt, gravel,
or other foreign objects from the valves and valve boots
as needed. Using light oil, lubricate brake pedal to
brake application valve linkage components. Check any
rubber boots for cracks, holes, or deterioration and
replace if necessary.
(38)= Estimated minimum. Actual mileage depends on
fuel and oil consumed.
(39)= If the vehicle has the Isuzu diesel engine and is
used primarily for long trip, highway service, change
the engine oil and filter every 18,000 miles (28 800 km),
or every 12 months, or every 750 hours of engine
operation, whichever occurs first.
(40)= Make sure any safety belt reminder light and
safety belt assemblies are working properly. Look
for any other loose or damaged safety belt system parts.
If you see anything that might keep a safety belt
system from doing its job, have it repaired. Have any
torn or frayed safety belts replaced.
6-25

Part B: Owner Checks and Services
These owner checks and services should be performed
at the intervals specified to help ensure vehicle
safety, dependability, and emission control performance.
For your safety and that of others, any of the
safety-related components that may have been
damaged in an accident should be checked and any
needed repairs made before operating the vehicle.
At the minimum, these routine checks should be made
every 6 months or 6,000 miles (10 000 km), whichever
occurs first. Whenever repairs are needed, have
them completed before operating the vehicle.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel fill.
Engine Oil Level Check
Notice:It is important to check the engine oil
regularly and keep it at the proper level. Failure to
keep the engine oil at the proper level can cause
damage to the engine not covered by the vehicle
warranty.Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil (DURAMAX Diesel Engine)
on page 5-24orEngine Oil (Caterpillar Diesel Engine)
on page 5-27orEngine Oil (Isuzu Diesel Engine) on
page 5-28orEngine Oil (Gasoline Engine) on page 5-32.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
(Caterpillar Diesel Engines) on page 5-47.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer fluid reservoir and add the proper fluid if
necessary. SeeWindshield Washer Fluid on page 5-50.
Tire Inflation Check
Check tire inflation cold. Make sure the tires are inflated
to the correct pressures. SeeLoading the Vehicle on
page 4-20andInflation - Tire Pressure on page 5-77.
6-26

Fluid Leaks Check
Check for fuel, coolant, oil, or other fluid leaks by
looking at the surface beneath the vehicle after it has
been parked for awhile.
Underbody Inspection
Corrosive materials used for ice, snow removal, and dust
control can collect on the underbody. If these materials
are not removed, accelerated corrosion (rust) can occur
on underbody parts such as fuel lines, frame, floor pan,
and exhaust system. At least every spring, flush these
materials from the underbody with plain water. Take care
to clean well any areas where mud and other debris can
collect. Sediment packed in closed areas of the frame
should be loosened before being flushed.
Engine Cover Check
Check that the cab’s engine cover and seal, if the
vehicle has one, are not torn or damaged. Be sure that
the cover is clamped down firmly to the floor.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part C.
Underbody Flushing Service
At least every spring, use plain water to flush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
Tractor Protection (Breakaway) Valve
Check
On air brake models, remove, disassemble, clean, and
inspect the tractor protection (breakaway) valve.
6-30

ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc.
on the World Wide Web at: helminc.com
Or you can write to:
Helm, Incorporated
P.O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
Vehicle Data Recording and
Privacy
Vehicle Data Recording and Privacy
(Isuzu 7.8L L6 Engine)
Your GM vehicle has a number of sophisticated
computers that record information about the vehicle’s
performance and how it is driven. For example,
your vehicle uses computer modules to monitor and
control engine and transmission performance, to monitor
the conditions for airbag deployment and deploy
airbags in a crash and, if so equipped, to provide
antilock braking to help the driver control the vehicle.
These modules may store data to help your
dealer/retailer technician service your vehicle. Some
modules may also store data about how you operate the
vehicle, such as rate of fuel consumption or average
speed. These modules may also retain the owner’s
personal preferences, such as radio pre-sets, seat
positions, and temperature settings.
7-11