clutch CHEVROLET KODIAK 2009 Owners Manual

Engine Starter Over-Crank
Protection
The vehicle may have an engine starter over-crank
protection system. If the starter motor overheats and
shuts off due to over-cranking, the motor must cool down
before it will reset and allow starter operation. It can take
up to six minutes before the starter will work again.
Starting the Gasoline Engine
The 8th digit of the Vehicle Identification Number (VIN)
shows the code letter for the engine. Use this number
to verify the type of engine in the vehicle. SeeVehicle
Identification Number (VIN) on page 5-94. Follow
the proper steps to start the engine.
To start a diesel engine, seeStarting the Diesel Engine
on page 2-14.
Automatic Transmission
Set the parking brake and move the shifter to N (Neutral)
or P (Park), if so equipped. The engine will not start in
any other position.
Manual Transmission
Set the parking brake, shift to N (Neutral) and hold the
clutch pedal to the floor while starting the engine.
Starter Motor Operation
•The starter motor will disengage if you release the
key or the engine reaches a predetermined engine
speed.
•To prevent overheating, the starter motor will
disengage after continuously operating for
15 seconds. You must release the key from the
start position to re-engage the starter.
•The starter motor will not engage if the engine is
already running.
•The starter motor will disengage if, after
two seconds, the starter pinion gear does not
engage the flywheel or there is no engine rpm
signal from the engine speed sensor.
2-12

Starting the Engine
1. Without pushing the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as the
engine gets warm.
2. If the engine does not start in 10 seconds, push the
accelerator pedal all the way down and crank the
engine for five more seconds, unless it starts sooner.
3. If the engine still will not start, or starts but then
stops, it could be flooded with too much gasoline.
Wait 15 seconds to let the starter motor cool down.
Do Steps 1 through 3 again.
When the engine starts, let go of the key and the
accelerator pedal.
Notice:The engine is designed to work with the
electronics in the vehicle. If you add electrical parts
or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer/retailer. If you do not, the
engine might not perform properly. Any resulting
damage would not be covered by the vehicle
warranty.
If you ever need to have the vehicle towed, seeTowing
Your Vehicle on page 4-23.
Gasoline Engine Warm-Up
When the engine starts, let it run for 20 or 30 seconds
to warm up before putting a load on it.
Drive at moderate speeds for the first 2 to 3 miles
(3.2 to 4.8 km), especially in cold weather. SeeHigh
Idle System on page 2-20.
Restarting the Gasoline Engine While
Moving (Automatic Transmission)
If you have to restart the engine while the vehicle is
moving, shift to N (Neutral).
Stopping the Gasoline Engine
Let the engine idle for a few seconds before turning it
off after you have finished driving the vehicle.
If you shift to N (Neutral) or P (Park), set the parking
brake.
If the vehicle has a two-speed axle, put the range
selector in low. To be sure the axle has shifted into low,
engage the clutch and transmission; the vehicle may
move slightly when you do this.
While the engine is idling and before you turn it off, you
can make a list of any operational or handling concerns to
give to responsible maintenance personnel so they can
handle them right away.
2-13

Moisture will condense in a fuel tank that is almost
empty if the engine has not run for a while, even just
overnight under some conditions. So, it is always best to
refuel the vehicle at the end of each run.
Starting the Diesel Engine
The vehicle’s diesel engine starts differently than a
gasoline engine. Read the following pages to learn how
to start, restart, warm-up, and stop the diesel engine.
The information applies to Caterpillar
®Diesel Engine,
6.6L DURAMAX®Diesel Engine, Isuzu 6H Diesel
Engine, unless otherwise noted.
If you have a Caterpillar
®Diesel Engine, also refer to
the Caterpillar®Diesel Engine Operation & Maintenance
Manual for the starting procedure.
Automatic Transmission
Move the shifter to P (Park) or N (Neutral). The engine
will not start in any other position. To restart the
engine when the vehicle is already moving, use
N (Neutral) only.
Notice:Do not try to shift to P (Park) if the
vehicle is moving. If you do, you could damage
the transmission. Shift to P (Park) only when
the vehicle is stopped.
Manual Transmission
Move the shift lever to N (Neutral) and hold the clutch
pedal to the floor while starting the engine. The vehicle
will not start if the clutch pedal is not all the way down.
Starting the Engine
1. Turn your ignition key to ON/RUN.
Observe the wait to start light. SeeWait to Start
Light on page 3-35. This light may not come
on if the engine is hot.
If you have a Caterpillar
®diesel engine, see your
Caterpillar®Diesel Engine Operation & Maintenance
Manual for proper wait to start light operation.
2. As soon as the wait to start light goes off,
immediately turn the ignition key to START.
When the engine starts, let go of the key.
If the vehicle is equipped with a DURAMAX
®
6600 Diesel Engine, it has a fast warm-up glow
plug system. The wait to start light will illuminate for
a much shorter time than most diesel engines,
due to the rapid heating of the glow plugs.
Notice:Holding the key in START for longer than
15 seconds at a time will cause the battery to
be drained much sooner. And the excessive heat
can damage the starter motor.
2-14

Idle Shutdown
If the vehicle has a diesel engine it could have an
engine idle shutdown feature.
This feature automatically shuts down the engine after it
idles continuously for five minutes and if the following
conditions are met:
•The parking brake is set.
•The vehicle is at a complete stop.
•The automatic transmission is in N (Neutral) or
P (Park).
If the parking brake is not engaged, then the engine
shuts down after 15 minutes of continuous idling
operation.
The driver can reset the engine shutdown timer by
momentarily changing the position of the accelerator,
brake, or clutch pedal or by shifting the transmission out
of P (Park) or N (Neutral). Once reset, the engine idle
shutdown will restart the shutdown sequence described
above, and will continue to do so until the engine
shuts down or the vehicle is driven.The engine will not go into idle shutdown mode if:
•The Power Take-Off (PTO) equipment is operating.
SeePower Take-Off (PTO) on page 2-30for more
information.
•The engine coolant temperature is below 60°F.
The engine idle shutdown will be activated once
the vehicle coolant reaches 60°F or above.
•The Diesel Particulate Filter (DPF) is in regeneration
mode and the green DPF lamp is illuminated to
notify the driver that DPF is regenerating. The
engine idle shutdown mode will be overridden for
the time necessary to complete the regeneration
process, up to a maximum of 30 minutes.
•Service or maintenance is being performed on the
engine. The engine idle shutdown mode may be
deactivated, by using a diagnostic scan tool,
for a period of up to a maximum of 60 minutes.
2-19

This system can be used to increase the engine idle
speed whenever the following conditions are met:
•The brake pedal is not pressed.
•The vehicle is at a complete stop for vehicles with
diesel engines. The vehicle must not be moving
and the accelerator must not be pressed for vehicles
with gasoline engines.
•If the vehicle has manual transmission the clutch
pedal is not pressed or, if the vehicle has the
automatic transmission it is in N (Neutral) or
P (Park).
The manual high idle feature is activated by pressing
the switch on the instrument panel. When the switch is
pressed again, or any of the previous conditions are
not met, manual high idle will be deactivated.
The manual high idle has been preset at the factory.
Your dealer/retailer may change the setting to fit
your needs.
For vehicles with Caterpillar
®diesel engines, the high
idle switch can be used to set any desired high idle
speed.To set a new temporary engine idle speed do the
following:
1. Make sure all of the previously described conditions
are met.
2. Press the accelerator pedal to the desired engine
speed.
3. Momentarily press the manual high idle switch.
The temporary high idle speed will be set. This new high
idle rpm level will be remembered by the system until
either the ignition is turned to OFF or a new high
idle speed is set.
Automatic High Idle System
The automatic high idle feature will engage whenever
you start the vehicle and the engine is below the preset
operating temperature. This will help decrease engine
warm-up time.
On vehicles that have the Caterpillar
®diesel engine you
may have an exhaust restrictor that will operate in
High Idle mode. The exhaust brake switch must be on
for this feature to operate. SeeDiesel Engine Exhaust
Brake on page 2-26for more information.
Idle speed will then return to normal when the engine
reaches the preset operating temperature or has
been operating for at least 10 minutes.
2-21

The engine idle speed will return to normal once the
following conditions are met:
•Once engine coolant temperature reaches about
150°F (65°C).
•The intake temperature reaches a certain level.
The high idle speed will be temporarily interrupted and
the engine speed will return to normal if any of the
following conditions occur:
•The brake pedal is applied.
•The accelerator pedal is pressed.
•The automatic transmission is shifted out of
P (Park) or N (Neutral).
•The clutch pedal on the manual transmission is
pressed.
•Vehicle speed is detected.
Once these conditions no longer exist, the engine idle
speed will slowly increase to high idle after the
normal delay, if the conditions for engine coolant
temperature and air intake temperature are still met.
Engine Checks Before Operating
When you have started the engine, let it run for
20 to 30 seconds before you put a load on the engine.
But do not leave the vehicle while the engine is running.
Avoid unnecessary idling of diesel engine equipped
vehicles.
If the engine idles too long, the temperature of the
engine coolant will fall below the normal operating
range. Low engine operating temperature causes
several conditions which affect engine operation and
reduce engine life.
The engine should be permitted to go through a
warm-up period. Operate the vehicle at a minimum of
600 rpm during the warm-up period. During this
period and during operation, the following observations
should be made.
2-23

Diesel Engine Exhaust Brake
If the vehicle has a Isuzu 6H Diesel Engine, it may have
an exhaust brake, which is located in the exhaust
system.
If the vehicle has a 6.6L DURAMAX
®6600 or
Caterpillar®Diesel Engine, it may have an exhaust
brake, which is controlled through the turbocharger.
The exhaust brake for both engines operates the same.
The exhaust brake switch
is located in the instrument
panel switchbank.
Push the bottom of the switch to turn the exhaust brake
on. When you push the top of the switch, the exhaust
brake will turn off.
There is an indicator light on the instrument panel
similar to the symbol on the switch, that comes on when
the exhaust brake is active. SeeExhaust Brake
Indicator Light on page 3-41for more information.While using the exhaust brake, the proper gear range
selection is important. The exhaust brake is most
effective if the gear range selected is the lowest possible
range that does not allow the engine rpm to go more
than 200 rpm above rated (full load) rpm. If you have
a Caterpillar
®Diesel Engine, do not exceed 2900 rpm.
If you have an Isuzu 6H Diesel engine, do not
exceed 2550 rpm. If the vehicle has a DURAMAX
®
6600 Diesel Engine, do not exceed 3600 rpm.
If the vehicle has an Allison
®1000/2200/2300/2350/2500/
2550 series automatic transmission and this button is
pressed, the transmission downshifts to a factory default
setting of third gear. To change the default setting, or for
more information on factory default settings, contact your
dealer/retailer for assistance.
The accelerator and clutch pedals must be released in
order for the exhaust brake to engage. The exhaust
brake will automatically shut off when the antilock brake
system is active.
If the vehicle has a Caterpillar
®Diesel Engine or a
DURAMAX®6600 Diesel Engine, the exhaust brake will
become active in cruise control when you exceed the
set speed by 3 to 5 mph.
2-26

Overdrive Defeat
If your vehicle has this feature, you can select not to
shift up to fifth gear. This is useful when towing or under
a heavy load.
The overdrive defeat
switch is located in the
instrument panel to
the right of the steering
column.
Press the switch to limit the transmission to fourth gear.
This will allow for fewer downshifts while pulling a
trailer or under a heavy load. The indicator light in the
switch comes on whenever overdrive defeat is active.
If the vehicle is equipped with a push button shift
selector, refer to the Allison
®Transmission Operator’s
Manual for shift selector operating instructions.
Manual Transmission Operation
Using the Clutch
When you are starting to move the vehicle, it is
important to begin with the engine speed at idle. Then
start to engage the clutch and listen for an engine speed
drop of about 100 rpm. At this point, the clutch is
engaging, so you should increase the engine speed and
fully engage the clutch. It is important not to increase
the engine speed sooner or before the clutch begins its
engagement. If you do, you can cause damage to
the vehicle.
Double-Clutching
You must use the double-clutching method when you
shift an unsynchronized gear set. Disengage the clutch,
shift to N (Neutral) and engage the clutch. When
upshifting, slow the engine until the engine rpm and
road speed match. When downshifting, accelerate the
engine until the engine rpm and road speed match. Then
quickly disengage the clutch and move the shift lever
to the next gear position and engage the clutch.
2-28

Eaton®Fuller®Five and Six-Speed
Transmissions and TTC Spicer
Seven-Speed Transmissions
These transmissions have gears that automatically
synchronize when you shift up or down (except 1 (First)
gear on the five-speed and seven-speed transmission
which is unsynchronized). Choose the gear that will
maintain the road speed you want while keeping
the engine above two-thirds of the governed speed.
When the engine speed drops below two-thirds of the
governed speed, shift into the next lower gear before
your engine begins to lug. When you shift down, be sure
to double-clutch if required.
Eaton®Fuller®Nine and Ten-Speed
Non-Synchronized Manual
Transmissions
If the vehicle has one of these transmissions the engine
rpm and road speed must match when upshifting and
downshifting. The label above the windshield will tell you
the operating basics you need to know.
The following are driving tips.
•Always choose an initial starting gear suitable for
the load and terrain.
•Always use double-clutching procedures when
shifting.
•Never move the range shift lever to the LO speed
gear position after HI range preselection, or
anytime the transmission is in the HI range.
•Never move the range knob or lever with the shift
lever in N (Neutral) while the vehicle is moving.
•Never make a range shift while moving in
R (Reverse).
Clutch Brake (Vehicles with
Non-Synchronized Transmission)
A clutch brake is used to stop transmission input shaft
rotation so that 1 (First) or R (Reverse) gear selection
can be initiated when the vehicle is at a standstill
and the engine is idling.
Press the clutch pedal all the way down to the floorboard
to apply the clutch brake.
When using the clutch brake, disengage the clutch pedal
and shift the transmission into either the initial starting
gear or R (Reverse). If the tooth-butting occurs between
the clutching teeth, re-engage the clutch while applying
light pressure to the shift lever. This will provide for a
smooth shift into either 1 (First) or R (Reverse) gear.
Notice:Using the clutch brake for shifting into any
gear other than 1 (First) or R (Reverse) may cause
premature wear of the clutch brake and make gear
shift effort more difficult. Do not use the clutch brake
for shifting after engaging 1 (First) or R (Reverse).
2-29

Two-Speed Rear Axle Shift Control
Operation
The rear axle shift control
switch for automatic and
manual transmissions
is located in the instrument
panel switchbank.
Press the bottom of the switch for High Range and the
top of the switch for Low Range. The switch indicator
light comes on when the High Range is selected.
Always start the vehicle in motion with the two-speed
axle in low range.
Shifting on a Downgrade
Do not shift the two-speed axle when driving on a
downgrade. The speed of the vehicle moving downhill
may make it hard to shift the axle into either Low or High
Range.
Shifting
Upshifting the Axle
To shift from Low to High Range:
1. Press the bottom of the switch to shift the axle
control from Low to High.
2. Release the accelerator pedal until the shift applies.
3. Then push the accelerator pedal.
Axle upshift can be abrupt, causing the vehicle to jerk.
Release the accelerator slowly for a smooth shift.
For manual transmissions, use the clutch while pressing
the accelerator for a smooth shift.
Downshifting the Axle
To shift from High to Low Range:
1. Press the top of the switch to shift from High to Low
Range.
2. Release the accelerator pedal.
3. Then push the accelerator pedal slowly until the
axle shifts.
2-37