maintenance CHEVROLET KODIAK 2009 Owners Manual

Seats and Restraint System............................. 1-1
Front Seats
............................................... 1-2
Rear Seats
..............................................1-10
Safety Belts
.............................................1-11
Child Restraints
.......................................1-28
Airbag System
.........................................1-48
Restraint System Check
............................1-59
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................. 2-8
Starting and Operating Your Vehicle
...........2-10
Mirrors
....................................................2-51
Storage Areas
.........................................2-53
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-20
Warning Lights, Gages, and Indicators
........3-23
Audio System(s)
.......................................3-48
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and the Vehicle
....... 4-2
Towing
...................................................4-23Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-6
Checking Things Under the Hood
...............5-22
Rear Axle
...............................................5-67
Four-Wheel Drive
.....................................5-68
Front Axle
...............................................5-69
Noise Control System
...............................5-70
Bulb Replacement
....................................5-71
Windshield Wiper Blade Replacement
.........5-71
Other Service Items
..................................5-72
Tires
......................................................5-76
Appearance Care
.....................................5-87
Vehicle Identification
.................................5-94
Electrical System
......................................5-95
Capacities and Specifications
...................5-102
Normal Maintenance Replacement Parts
....5-108
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information.................... 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
............................ 7-9
Vehicle Data Recording and Privacy
...........7-11
Index................................................................ 1
2009 Chevrolet Kodiak Owner ManualM

Q:Because I have a disability, I have to get my
vehicle modified. How can I find out whether
this will affect my airbag system?
A:If you have questions, call Customer Assistance.
The phone numbers and addresses for Customer
Assistance are in Step Two of the Customer
Satisfaction Procedure in this manual. See
Customer Satisfaction Procedure on page 7-2.
In addition, your dealer/retailer and the service manual
have information about the location of the airbag sensors,
sensing and diagnostic module and airbag wiring.
Restraint System Check
Checking the Restraint Systems
Safety Belts
Now and then, check the safety belt reminder light,
safety belts, buckles, latch plates, retractors, and
anchorages are all working properly.
Look for any other loose or damaged safety belt system
parts that might keep a safety belt system from doing
its job. See your dealer/retailer to have it repaired.Torn or frayed safety belts may not protect you in a
crash. They can rip apart under impact forces. If a belt
is torn or frayed, get a new one right away.
Make sure the safety belt reminder light is working. See
Safety Belt Reminders on page 3-26for more
information.
Keep safety belts clean and dry. SeeCare of Safety
Belts on page 5-89.
Airbags
The airbag system does not need regularly scheduled
maintenance or replacement. Make sure the airbag
readiness light is working. SeeAirbag Readiness Light
on page 3-27for more information.
Notice:If an airbag covering is damaged, opened,
or broken, the airbag may not work properly. Do
not open or break the airbag coverings. If there are
any opened or broken airbag covers, have the
airbag covering and/or airbag module replaced. For
the location of the airbag modules, seeWhat
Makes an Airbag Inflate? on page 1-53. See your
dealer/retailer for service.
1-59

Starting and Operating Your
Vehicle
New Vehicle Break-In
Notice:The vehicle does not need an elaborate
break-in. But it will perform better in the long run if
you follow these guidelines:
•Let the engine warm up before you operate your
vehicle under load.
•Keep your speed at 55 mph (88 km/h) or less for
the first 500 miles (805 km).
•Do not drive at any one speed, fast or slow, for
the first 500 miles (805 km). Do not make
full-throttle starts.
•Avoid making hard stops for the first 200 miles
(322 km) or so. During this time the new brake
linings are not yet broken in. Hard stops
with new linings can mean premature wear and
earlier replacement. Follow this breaking-in
guideline every time you get new brake linings.
•Use the lowest gear you can when you start a
loaded vehicle in motion and when going up
hills to avoid overloading the engine.
•Check and adjust engine and transmission fluid
levels often and be sure tires are properly
inflated for the load you are carrying.
•When new, parking brake linings have not yet
been broken in. When linings are new, it is
possible that the vehicle could move while the
parking brake is applied. Before using the
parking brake on grades, follow the parking
brake burnish procedure. SeeParking Brake
Burnish Procedure on page 2-43.
•If you have a Caterpillar®diesel engine, see the
Caterpillar®Diesel Engine Operation and
Maintenance Manual.
2-10

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

Cold Weather Starting (Caterpillar®
Diesel)
Because the diesel engine uses compression ignition, it
is harder to start in cold weather than a gasoline engine.
The air intake heater, use of the proper engine oil,
optional engine coolant heater and optional ether
injection system help cold weather starting. See the
Caterpillar
®Diesel Engine Operation & Maintenance
Manual for more information.
Restarting the Diesel Engine While
Moving (Automatic Transmission)
If you have to restart the engine while the vehicle is
moving, shift to N (Neutral).
Stopping the Diesel Engine
1. Apply the parking brake. SeeParking Brake (With
Hydraulic Brakes) on page 2-38orParking Brake
(With Air Brakes) on page 2-41for parking
brake apply procedure.
2. Shift into N (Neutral) for a manual transmission or
P (Park) for an automatic transmission.3. Turn the ignition key to OFF.
If the vehicle has a two-speed axle, seeTwo-Speed
Rear Axle on page 2-36.
If you have a Caterpillar
®diesel engine, see the
Caterpillar®Diesel Engine Operation & Maintenance
Manual for additional information.
Diesel Engine Warm-Up
Several factors affect how quickly the diesel engine
warms up. These can include outside temperature,
engine load, idle time and the vehicle’s option content.
The vehicle may be equipped with some features
that can help the engine reach operating temperature
sooner. Some of these features are discussed below.
Also, remember that an automatic transmission
adds heat to the cooling system through the heat
exchanger in the radiator. Because of this, vehicles
equipped with automatic transmissions are often able to
retain engine coolant heat better than manual
transmission vehicles.
See the Caterpillar
®Operation & Maintenance manual
for additional diesel engine warm-up information.
2-16

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

Parking Brake Adjustment (Hand Lever
System Only)
Make sure the parking brake burnish procedure has been
previously followed before continuing with any park brake
adjustment. SeeParking Brake Burnish Procedure on
page 2-43for more information. Parking brake
adjustment may be necessary after the burnish
procedure or at the scheduled maintenance intervals.
If the vehicle is has a hand-lever park brake system, an
in-cab adjustment may be made to the park brake
system. This will adjust the parking brake holding force.
The adjustment is made with the knob located at the
end of the hand lever.
To make an adjustment:
1. Press and hold the regular brake pedal
2. Release the parking brake
3. Turn the knob only up to a half turn to the left, top
of knob toward the driver. This will increase the
holding force of the system.
4. Check to see if the vehicle moves by slowly
removing your foot from the regular brake pedal.
5. If the vehicle moves, press the regular brake and
repeat the adjustment procedure.
2-40

Notice:Over-tightening the park brake lever can
cause damage to the park brake system.
Over-tightening is possible by turning the knob
more than half a turn.
Over-tightening is similar to driving down the road with
your regular brakes applied. If the park brake system
is over-tightened the vehicle may seem sluggish
to accelerate, and/or the park brake hand lever maybe
very hard to pull up and apply the park brake.
If the park brake is over-tightened turn the knob to the
right until it stops and follow the parking brake
adjustment procedure.
Vehicles with a foot-pedal park brake system must be
serviced to make this adjustment. SeeScheduled
Maintenance on page 6-5for more information.Parking Brake (With Air Brakes)
If the vehicle has air
brakes, you will have this
parking brake. It is located
above the audio system in
the instrument panel.
Pulling it out applies the parking brake. The parking
brake light will come on when the air parking brake is
applied.
2-41

Trailer Antilock Brake System
Warning Light
If your vehicle is connected
to a trailer with antilock
brakes, this light should
come on briefly, as a
check, when you turn on
the ignition.
When this light comes on and stays on, it means there
is something wrong in the trailer Antilock Brake
System (ABS). Have the system repaired immediately.
If an ABS equipped trailer is not connected, this
light is not functional.
Engine Coolant Temperature Gage
This gage shows
the engine coolant
temperature. If the gage
pointer moves into the
red area, your engine
coolant might have
overheated and your
engine may be too hot.
You should pull off the road, stop your vehicle and turn
off the engine as soon as possible.
SeeEngine Overheating on page 5-48. If you have a
Caterpillar
®diesel engine, also see your Caterpillar®
Operation & Maintenance Manual.
3-34