2004 CHEVROLET KODIAK clutch

Automatic Transmission
Set the parking brake and move your shift lever to
NEUTRAL (N) or PARK (P) if so equipped. Your engine
won’t start in any other position – that’s a safety
feature.
Manual Transmission
Set the parking brake, shift to 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.
Starting Your Engine
1. Without pushing the accelerator pedal, turn your
ignition key to START. When the engine starts, let
go of the key. The idle speed will go down as
your engine gets warm.
2. If the engine doesn’t 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 your engine still won’t 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:Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer. If you do not, your engine
might not perform properly.
If you ever need to have your vehicle towed, see
Towing Your Vehicle on page 4-31.
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Gasoline Engine Warm-Up
When you’ve started your engine, let it run for
20 or 30 seconds to warm up before you put a load on
the engine.
Drive at moderate speeds for the first few miles,
especially in cold weather. Running a cold engine at
high speed can damage it. SeeHigh Idle Systemunder
Starting Your Diesel Engine on page 2-14
Restarting the Gasoline Engine While
Moving (Automatic Transmission)
If you have to restart the engine while the vehicle is
moving, you’ll first have to shift the automatic
transmission to NEUTRAL (N). This safety feature
prevents starting the engine when the transmission is in
a drive gear.
Stopping the Gasoline Engine
Let your engine idle for a few seconds before turning it
off after you have finished driving your vehicle.
If you shift to NEUTRAL (N) or PARK (P), set the
parking brake.
If your 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 your engine is idling 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.
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’s always best to
refuel your vehicle at the end of each run.
Starting Your Diesel Engine
If you have a Caterpillar®diesel engine, also refer to
your Caterpillar®Diesel Engine Operation &
Maintenance Manual for starting procedure.
For vehicles with the DURAMAX™ diesel engine, also
seeStarting Your DURAMAX™ Diesel Engine on
page 2-19.
To make starting easier in cold weather (below 32°F or
0°C), the proper viscosity engine oil should be used.
SeeEngine Oil (Caterpillar
®Diesel Engine) on
page 5-20orEngine Oil (Gasoline Engine) on page 5-20
orEngine Oil (DURAMAX™ Diesel) on page 5-25. It’s
also best to heat the engine oil first. You can do this by
using an engine coolant heater.
If you ever need to have your vehicle towed, see
Towing Your Vehicle on page 4-31.
2-14

Automatic High Idle System
(Diesel Engines)
The automatic high idle feature will engage whenever
you start your vehicle and the engine is below the preset
operating temperature. This will help decrease engine
warm-up time.
Idle speed will then return to normal under any of the
following conditions:
•The engine reaches the preset operating
temperature or has been operating for at least
ten minutes.
•The brake pedal is pressed.
•The manual transmission clutch pedal is pressed
or, the automatic transmission (if equipped) is
shifted from NEUTRAL (N) or PARK (P).
•The vehicle speed exceeds about 5 mph (8 km/h).
•The throttle is pressed.
Manual High Idle System
If your vehicle has this
feature, the manual high
idle switch is located in the
instrument panel
switchbank.
This system can be used to increase your engine idle
speed whenever the following conditions are met:
•The brake pedal is not pressed.
•The vehicle speed is below about 5 mph (8 km/h)
for vehicles with diesel engines. The vehicle must
not be moving and the accelerator must not be
pressed for vehicles with gasoline engines.
•The manual transmission (if equipped) clutch pedal
is not pressed or, the automatic transmission (if
equipped) is in NEUTRAL (N) or PARK (P).
2-17

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 may change the setting to fit your needs.
For vehicles with Caterpillar
®diesel engines, manual
high idle can be used to set any desired high idle speed.
To set a new temporary engine idle speed:
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.
Exhaust Restrictor (Diesel Engines)
If your vehicle is equipped with this feature, there is an
exhaust restrictor valve located in the exhaust stream.
The valve closes to provide back pressure to the engine
for the purpose of warming the engine quickly.The exhaust restrictor operates:
•while the engine is running.
•while the vehicle is not moving.
•while the accelerator, brake and clutch pedals are
not pressed.
•while idling or driving in cold temperatures.
•when the shift lever is in NEUTRAL (N) or
PARK (P).
On vehicles equipped with a diesel engine exhaust
brake, the exhaust brake switch must be on. The
indicator in the exhaust brake switch will be lit when the
exhaust restrictor is active. The exhaust brake
indicator light in the center of the instrument panel will
also be lit whenever the exhaust restrictor is active.
When the engine coolant temperature is below 149°F
(65°C) and the outside temperature is below 50°F
(10°C), the exhaust restrictor will come on within
45 seconds of starting the engine. After running the
engine for an additional 45 seconds, the engine idle will
increase.
The exhaust restrictor will shut off and engine idle will
return to normal once the engine is warmed up, or
the transmission is shifted into range.
2-18

Starting Your DURAMAX™ Diesel
Engine
Your diesel engine starts differently than a gasoline
engine.
Automatic Transmission
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won’t start in any other position – that’s a
safety feature. To restart when you’re already moving,
use NEUTRAL (N) only.
Notice:Do not try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
Manual Transmission
Move your shift lever to neutral and hold the clutch
pedal to the floor while starting the engine. Your
vehicle won’t start if the clutch pedal is not all the way
down –that’s a safety feature.
Starting Your Engine
1. Turn your ignition key to RUN.
Observe the wait to start light. SeeWait to Start
Indicator on page 3-36. (This light may not come on
if the engine is hot.)
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 your vehicle is equipped with the RPO LLY
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 plug system.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor.
Notice:If the WAIT TO START light stays on, it
means that your vehicle could have one of several
problems, so you should have it serviced right away.
3. If the engine does not start after 15 seconds of
cranking, turn the ignition key to OFF. Wait one
minute for the starter to cool, then try the same
steps again.
2-19

When the engine is started, it will slowly ramp up to the
high idle speed after a delay of a few seconds up to
about two minutes. For this method to work properly
there must be no throttle or brake pedal faults, and the
throttle pedal must not fall below 75 percent of wide
open throttle while pressing the brake pedal.
The engine idle speed will return to normal once the
following conditions are met:
•Once engine coolant temperature reaches
150°F (65°C).
•Air intake temperature reaches 41°F (5°C).
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
PARK (P) or NEUTRAL (N).
•The clutch pedal on the manual transmission is
pressed.
•Vehicle speed is detected.
Once these inputs are removed, the engine idle speed
will slowly ramp back up 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’ve started your engine, let it run for
20 to 30 seconds before you put a load on the engine.
Butdon’tleave 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.
During this warm-up period, check your warning lights
and gages:
•If oil pressure doesn’t begin to rise within
15 seconds of starting, stop the engine and find the
cause.
•If the engine coolant temperature gage needle goes
into the hot area on the gage, stop the engine and
find the cause of the overheating.
2-22

Diesel Engine Exhaust Brake
The exhaust brake is available on vehicles equipped
with a diesel engine. It is located in the exhaust system.
The exhaust brake is used to help slow the vehicle
and may assist the vehicle’s foundation brakes. The use
of the exhaust brake will assist the braking of the
vehicle and prolong the life of the foundation brake
lining material.
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 will come on
when the exhaust brake is active. SeeExhaust
Brake Indicator Light on page 3-40for more information.
When using the exhaust brake, the proper gear range
selection is important. The exhaust brake will be
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 a DURAMAX™ (LG4) diesel
engine, do not exceed 2400 rpm. If you have a
DURAMAX™ (LB7) diesel engine, do not exceed
3600 rpm.
If you have an automatic transmission and press this
button, the transmission will downshift to a factory
default setting of fourth gear. To change the default
setting, or for more information on factory default
settings, contact your dealer for assistance.
The accelerator and clutch pedals must be released in
order for the exhaust brake to engage. The exhaust
brake will not function when the cruise control feature is
active, and will automatically shut off when the
anti-lock brake system is active.
2-25

Two-Speed Rear Axle Electric
Shift Control
If your vehicle is equipped with this feature, you’ll find a
label on the headliner above the windshield or in
another place near the driver that shows how to use it.
Be sure to follow the directions carefully.
Use the following directions based on the type of shift
control you have.
Manual Transmission
The rear axle shift control
switch for a manual
transmission is located on
the shift lever.
When the switch is up, the rear axle is in the high
range. Push the switch down to change to low range.The two-speed axle should be in low when you park the
vehicle. You’ll need to engage the transmission, even
move the vehicle a little, to be sure the axle is in the low
range. Then apply the parking brake, shift into
NEUTRAL and shut off the engine.
Also, always start the vehicle in motion with the
two-speed axle in the low range. To shift up from low to
high, do the following:
1. Move the switch up for the high range,
2. disengage the clutch, and
3. after a brief pause, engage the clutch and then
press down on the accelerator.
To shift down from high to low, do the following:
1. Move the switch down to low,
2. release the accelerator and then quickly apply
it again.
2-26