2004 CHEVROLET KODIAK radiator cap

Diesel Engine Warm-Up
Several factors affect how quickly your diesel engine
warms up. These can include outside temperature,
engine load, idle time and your vehicle’s option content.
Your 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 your Caterpillar
®Operation & Maintenance manual
for additional diesel engine warm-up information.
Engine Alarm and Automatic Shutdown
Your check gages light will come on if the system
senses high engine temperature or low engine oil
pressure. If high engine temperature or low engine oil
pressure is detected, you will also hear a tone alarm at
two beats per second. The alarm and the light will
remain on until the condition is fixed. If the engine
temperature or oil pressure condition worsens, the tone
alarm will go to five beats per second.If the system senses low engine coolant, the five beat
per second alarm and the low coolant warning light
will come on.
The five beats per second tone alarm means that your
engine will shut down in about 25–30 seconds.
There is also an engine shutdown light to indicate that
the engine will shut down. SeeEngine Shutdown
Warning Light on page 3-39.
Pull off the road and shut off the engine. Don’t start it
until the reason for the problem is known, and the
problem is fixed. If the engine shuts down when you are
still in traffic, you can restart the engine and get
another 25–30 seconds of operation. Do this only if you
have to, since there is a problem that can harm the
engine if it isn’t fixed. Engine automatic shutdown, for
gasoline engines, requires activation by your dealer.
High Idle System (Caterpillar®
Diesel and Gasoline Engines)
Your vehicle has both automatic and manual high idle
capabilities.
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Checking Coolant
The coolant surge tank is located in the engine
compartment on the driver’s side of the vehicle.
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap — even a little — when the engine and
radiator are hot.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the COLD
FILL mark or higher.
If the low coolant warning
light comes on and stays
on, it means you’re
low on engine coolant.
SeeLow Coolant Warning Light on page 3-36for further
information.
5-34

Cooling System
When you decide it’s safe to lift the hood, here’s what
you’ll see:
A. Engine Fan
B. Coolant Surge Tank
If your vehicle has a Caterpillar
®diesel engine, see the
Caterpillar®Diesel Engine Operation and Maintenance
Manual provided with your vehicle.
If the coolant inside the coolant surge tank is boiling,
don’t do anything else until it cools down. The vehicle
should be parked on a level surface.The coolant level should
be at COLD FILL or
higher. If it isn’t, you may
have a leak at the
pressure cap or in the
radiator hoses, heater
hoses, radiator, water
pump or somewhere else
in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.
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If there seems to be no leak, start the engine again.
The engine cooling fan speed should increase when idle
speed is doubled by pushing the accelerator pedal
down. If it doesn’t, your vehicle needs service. Turn off
the engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
How to Add Coolant to the Coolant
Surge Tank
If you haven’t found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level isn’t at COLD FILL or higher, add a
50/50 mixture ofclean, drinkable waterand DEX-COOL
®
coolant at the coolant surge tank, but be sure the
cooling system, including the coolant surge tank
pressure cap, is cool before you do it. SeeEngine
Coolant (Gas and DURAMAX™ engines) on page 5-32
orEngine Coolant (Caterpillar
®Diesel Engines) on
page 5-35for more information.
5-39

{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
1. Park the vehicle on a level surface. You can
remove the coolant surge tank pressure cap
when the cooling system, including the coolant
surge tank pressure cap and upper radiator hose, is
no longer hot. Turn the pressure cap slowly
counterclockwise (left) about one full turn. If you
hear a hiss, wait for that to stop. A hiss means there
is still some pressure left.
2. Then keep turning the pressure cap slowly, and
remove it.
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3. Then fill the coolant surge tank with the proper
mixture, to the FULL mark.4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower,
add more of the proper mixture to the coolant
surge tank until the level reaches slightly above the
FULL mark.
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(24)= 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.
(26)= 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.
(28)= 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.
(30)= 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.
(31)= Check EGR system as described in the service
manual. SeeService Publications Ordering Information
on page 7-7.(32)= 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.
(35)= Drain, flush and refill cooling system. SeePart C:
Recommended Fluids and Lubricants on page 6-29
for 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.
(37)= Rear axle service: Change the lubricant. See
Part C: Recommended Fluids and Lubricants on
page 6-29.
(38)= Front axle service: Re-pack upper kingpin roller
bearing.
6-22

Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brakes. See “Parking Brake” if necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. On automatic transmission vehicles, try to start the
engine in each gear. The starter should work only
in PARK (P), if equipped, or NEUTRAL (N). If
the starter works in any other position, your vehicle
needs service.
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 illumination of the low air warning lamp or for
the 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.
6-26