wheel CHEVROLET KODIAK 2009 Manual PDF

(11)= Chassis Lubrication Service: Lubricate all grease
fittings in front suspension, front axle, and steering
linkage. Do not lubricate kingpin bushings with air
pressure equipment; instead, use a hand grease gun to
ensure complete purge and eliminate sealer cap
distortion. Front axle tie rod ends, both upper and lower
kingpin fittings, and both steering linkage relay rod ends
should be greased with the vehicle loaded on the ground
and wheels turned straight ahead, not with the vehicle on
a hoist. Apply kingpin bushing lubricant to both upper and
lower kingpin grease fittings until new lubricant purges
from between the upper shim pack and thrust bearing.
Lubricate transmission and shift linkage, hood latches
and hood hinges, parking brake lever pivot, clevis pins
and linkage, disc brake caliper rails, clutch linkage and
release bearing (if equipped), bearing pads, propshaft
universal joints, brake camshaft bracket, slack adjusters,
pedal shaft, clutch cross shaft, clutch pedal springs, and
clutch cable bushing at transmission. Lubricate
suspension, axle, and steering linkage more often when
operating under dusty or muddy conditions and in
excessive off-road use. Frequently power-washed
vehicles will require more frequent lubrication.(12)= Check steering system:
•Look for damaged, loose, or missing parts. Inspect
the steering linkage relay rod and tie rod ends for
looseness or lack of lubricant. Also look for
parts showing signs of wear or lack of lubrication.
Replace parts as needed. Also check steering gear
mounting bolts, pitman arm nut, gear housing
upper cover and side cover attaching bolts, steering
column mounting bolts and cardan joint clamp
bolts; tighten if necessary. See the service manual.
•Inspect power steering hoses, tubes, and fittings for
leaks. Hoses and lines must not be twisted, kinked,
or tightly bent. Make sure clips, clamps, supporting
tubes, and hoses are in place and properly secured.
•Check steering gear for leakage around pitman shaft
and housing. If leakage is evident (lubricant oozing
out, not just oily film), leak should be corrected
immediately.
(13)= Check front and rear suspension. Look for
damaged, loose, or missing parts or parts showing signs
of wear or lack of lubrication. Replace parts as
needed.
6-22

(14)= Adjust tire pressures as indicated on the
Certification or Tire Information label for optimum tire
life. SeeTires on page 5-76for further details.
Check tires for excessive or abnormal wear or damage.
Also check for damaged wheels. Replace wheels
and/or tires as needed.
(15)= Check spring-to-axle U-bolts and shackle bolts
for proper torque. See the service manual for torque
sequence and specifications. When parts are replaced,
the torque must be checked and adjusted more often
during the first 6,000 miles (10 000 km). Check torque at
500 miles (800 km) and 2,000 miles (3 000 km) after
first use of parts.
(16)= Check complete exhaust system, including DPF
pressure lines, and cab areas near the exhaust system
for broken, damaged, missing, or out-of-position parts.
Also inspect for open seams, holes, loose connections, or
other conditions which could let exhaust fumes seep into
the driver compartment. Needed repairs should be made
at once. To help maintain system integrity, replace
exhaust pipes whenever a new muffler is put on.
(17)= Check all gasoline engine drive belts for cracks,
fraying, and wear. Replace as needed.
(18)= Adjust valve lash. Incorrect valve clearance will
result in increased engine noise and reduced engine
output.(19)= With the engine off and below normal operating
temperature, check to see that the thermostatically
controlled engine cooling fan can be rotated by hand on
viscous-operated drives. Replace as needed.
(20)= Check shields and underhood insulation for
damage or looseness. Adjust or replace as needed.
(21)= Inspect parking brake drum and linings for wear
or cracks and check linkage and adjustment.
(22)= Wheel bearing service:
•Grease type — Clean, inspect, and lubricate with
the proper wheel bearing grease at designated
intervals or when hubs are removed. SeePart C:
Recommended Fluids and Lubricants on page 6-31.
•Oil-filled type — Some wheel bearings are
lubricated by axle lubricant. When you have oil-filled
hubs, use lubricant identical to that used in the
axle. Lubricant change intervals are the same for
front and rear axles. However, you must maintain
the proper oil level between change intervals.
SeeFront Wheel Bearings with Oil-Filled Hubs on
page 5-75andPart C: Recommended Fluids
and Lubricants on page 6-31.
(23)= Check the air intake system installation to
see that gaskets are seated properly and all hose
connections, fasteners, and other components are tight.
Tighten connections and fasteners or replace parts
as required.
6-23

(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

Automatic Transmission Shift Indicator
Check
Check that the indicator points to the gear chosen.
Steering Check
Be alert for any changes in steering action, abnormal
front tire wear or steering wheel position. An inspection
or service is needed when the steering wheel is
harder to turn or has too much free play, or if there are
strange sounds when turning or parking.
Brake System Check
Be alert to the low air warning light or tone alarm, or
changes in braking action, such as repeated pulling to
one side, unusual sounds when braking or increased
brake pedal travel. Make sure air brake system reservoirs
are drained daily with full system air pressure, and check
system for leaks. Any of these conditions could indicate
the need for brake system inspection and/or service.
Engine Cooling System Service
Inspect the hoses and have them replaced if they are
cracked, swollen, or deteriorated. Inspect all pipes,
fittings, and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser. To
help ensure proper operation, a pressure test of the
cooling system and pressure cap is recommended at
least once a year.
Exhaust System Inspection
Be alert for any changes in the sound of the exhaust
system or any smell of fumes. These are signs the
system may be leaking. Have it checked and/or repaired
at once. SeeEngine Exhaust on page 2-45and
Running the Vehicle While Parked on page 2-50.
Check to be sure that mud or dirt is not caked on the
exhaust system, especially in the area of the diesel
particulate filter and tailpipe. Clean the area as needed.
SeeDiesel Particulate Filter on page 2-46.
At high mileages, the DPF becomes loaded with ash.
This is normal. When the amount of ash loading is high,
see your dealer/retailer for DPF cleaning or replacement.
Windshield Wipers and Washers
Check
Check operation and condition of the wiper blades.
Check the flow of the washer spray.
Defroster Check
Move the control to the defrost symbol and the fan to HI
or the high symbol. Then check the airflow from the
ducts at the inside base of the windshield.
6-28

Usage Fluid/Lubricant
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
Chassis
LubricationChassis Lubricant
(GM Part No. U.S. 12377985,
in Canada 88901242) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Front Wheel
Bearings
(Except Oil
Filled Hubs)Wheel bearing lubricant meeting
requirements of NLGI #2,
Category GC or GC-LB
(GM Part No. U.S. 1051344,
in Canada 993037).
Front Wheel
Bearings with
Oil Filled HubsSAE 75W-90 Synthetic Axle
Lubricant for Medium Duty Trucks
(GM Part No. U.S. 89021675,
in Canada 10953512).
Transfer Case
(Four-Wheel
Drive)Manual Transmission Fluid
(GM Part No. U.S. 88861800,
in Canada 88861801).
Front Axle
(Four-Wheel
Drive)SAE 75W-90 Synthetic Axle
Lubricant for Medium Duty Trucks
(GM Part No. U.S. 89021675,
in Canada 10953512).Usage Fluid/Lubricant
Rear Axle and
Rear HubsSAE 75W-90 Synthetic Axle
Lubricant for Medium Duty Trucks
(GM Part No. U.S. 89021675,
in Canada 10953512).
Rear Axle Shift
Motor LubricantRefrigerant Oil
(GM Part No. U.S. 5416939,
in Canada 10953496).
Propshafts and
SplinesWheel bearing lubricant meeting
requirements of NLGI #2,
Category GC or GC-LB
(GM Part No. U.S. 1051344,
in Canada 993037).
Cab — Door
Hinges and
LatchesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
Weatherstrip
ConditioningWeatherstrip Lubricant
(GM Part No. U.S. 3634770,
in Canada 10953518) or
Dielectric Silicone Grease
(GM Part No. U.S. 12345579,
in Canada 992887).
Weatherstrip
SqueaksSynthetic Grease
with Teflon, Superlube
(GM Part No. U.S. 12371287,
in Canada 10953437).
6-32

GM Mobility Reimbursement
Program
This program, available to qualified applicants, can
reimburse you up to $1,000 of the cost of eligible
aftermarket adaptive equipment required for your vehicle,
such as hand controls or a wheelchair/scooter lift.
The offer is available for a very limited period of time
from the date of vehicle purchase/lease. For more
details, or to determine your vehicle’s eligibility, visit
gmmobility.com or call the GM Mobility Assistance
Center at 1-800-323-9935. Text telephone (TTY) users,
call 1-800-833-9935.
General Motors of Canada also has a Mobility Program.
Call 1-800-GM-DRIVE (463-7483) for details. TTY
users call 1-800-263-3830.
Roadside Assistance Program
GM Medium Duty truck’s Roadside Assistance provides
stranded owner/operators with towing service for
disabled GM Medium Duty trucks, during the base
and/or engine warranty period, to the nearest authorized
GM Medium Duty dealer. This service combines the
efforts of trained telephone representatives with a
network of GM Medium Duty truck services.
Call GM Medium Duty truck’s Roadside Assistance at
1-800-862-4389 to reach a qualified representative who
can assist you in arranging a tow to the nearest GM
Medium Duty truck dealer when your vehicle is disabled.
We also provide dealer information at no charge,
such as location of the nearest authorized GM Medium
Duty truck dealer and their hours of operation.
Our Roadside Assistance is available 24 hours a day,
7 days a week, 365 days a year which includes
weekends and holidays. Should you have questions
about GM Medium Duty truck Roadside Assistance, call
the GM Medium Duty Roadside Assistance Center or
contact your dealer.
Canadian Roadside Assistance
Whenever a Medium Duty truck owned and operated in
Canada becomes disabled, the owner/operator should
contact the Canadian Roadside Assistance Center
at 1-800-268-6800 for assistance.
7-5

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

Engine (cont.)
Overheating................................................5-48
Overspeed Warning Light..............................3-40
Reduced Power Light...................................3-42
Shutdown Warning Light...............................3-40
Speed Limiter.............................................3-25
Starter Over-Crank Protection........................2-12
Starting Diesel............................................2-14
Starting the Gasoline...................................2-12
Entry Lighting.................................................3-17
Event Data Recorders.....................................7-12
Exhaust Brake Indicator Light...........................3-41
Exhaust Restrictor...........................................2-22
Extender, Safety Belt.......................................1-28
Exterior Lamps...............................................3-14
F
Filter
Engine Air Cleaner......................................5-38
Filter Minder Gage..........................................3-46
Finish Damage...............................................5-93
Fixed Mast Antenna........................................3-58
Flashers, Hazard Warning.................................. 3-6
Flat Tire........................................................5-85
Fluid
Automatic Transmission................................5-42
Power Steering...........................................5-49
Windshield Washer......................................5-50
Four-Wheel Drive....................................2-30, 5-68Front Axle......................................................5-69
Front Wheel Bearings with
Oil-Filled Hubs............................................5-75
Fuel............................................................... 5-6
Additives...................................................... 5-7
Change Filter Warning Light..........................3-45
Diesel Engine Fuel........................................ 5-8
Driving for Better Economy............................. 4-2
Filling a Portable Fuel Container....................5-22
Filling the Tank...........................................5-20
Filter..........................................................5-72
Filter Replacement.......................................5-18
Fuels in Foreign Countries............................5-19
Gage .........................................................3-44
Gasoline Octane........................................... 5-6
Gasoline Specifications.................................. 5-7
Primary Filter and Water Separator................5-73
Running Out of Fuel....................................5-17
Secondary Filter and Water
Separator/Heater......................................5-74
Very Cold Weather Operation........................5-11
Water in Fuel..............................................5-11
Water in Warning Light.................................3-45
What Fuel to Use.......................................... 5-8
Fuses
Fuses and Circuit Breakers...........................5-96
Instrument Panel Fuse Block.........................5-96
Underhood Fuse Block.................................5-99
Windshield Wiper.........................................5-95
5