2009 CHEVROLET KODIAK Owners Manual

When to Inspect the Engine Air
Cleaner/Filters
For vehicle with this feature, the engine air filter life
gage will be located in the engine compartment either
on or near the air cleaner or above the switchbank in the
center of the instrument panel. It monitors the engine
air filter and indicates when the filter should be replaced.
If driving in dusty/dirty conditions, inspect the filter
each oil change.
As the filter gets dirty, the yellow indicator begins to
rise. When it reaches the red/orange change area,
replace the filter. Reset the indicator after each filter
replacement, refer toAir Filter Restriction Indicator
on page 3-46.
How to Inspect the Engine Air
Cleaner/Filter (Duramax Diesel
6.6L Engine)
{CAUTION:
Operating the engine with the air cleaner/filter off
can cause you or others to be burned. The air
cleaner not only cleans the air; it helps to stop
flames if the engine backfires. If it is not there and
the engine backfires, you could be burned. Do not
drive with it off, and be careful working on the
engine with the air cleaner/filter off.
Notice:If the air cleaner/filter is off, a backfire can
cause a damaging engine fire. And, dirt can easily get
into the engine, which will damage it. Always have
the air cleaner/filter in place when you are driving.
The engine air cleaner/filter is located in the center of
the engine compartment.
To inspect the engine air cleaner/filter, remove the filter
from the vehicle and lightly shake the filter to release
loose dust and dirt. If the filter remains caked with dirt,
a new filter is required.
5-39

How to Inspect the Engine Air Cleaner/
Filters (Gas V8 8.1L, Caterpillar 7.2L and
Isuzu 7.8L Diesel Engines)
{CAUTION:
Operating the engine with the air cleaner/filter off
can cause you or others to be burned. The air
cleaner not only cleans the air; it helps to stop
flames if the engine backfires. If it is not there and
the engine backfires, you could be burned. Do not
drive with it off, and be careful working on the
engine with the air cleaner/filter off.
Notice:If the air cleaner/filter is off, a backfire can
cause a damaging engine fire. And, dirt can easily get
into the engine, which will damage it. Always have
the air cleaner/filter in place when you are driving.
The engine air cleaner/filter is located in the center of
the engine compartment.To inspect the engine air cleaner/filter:
1. Disconnect the air
compressor hose by
pinching the connector
ring to release the
connector lock.
2. Unclip the four clips that hold the upper housing to
the lower housing and remove the upper housing.
3. Remove the filter from the vehicle and lightly shake
the filter to release loose dust and dirt. If the filter
remains caked with dirt, a new filter is required.
4. Reinstall the upper housing and make sure that the
air compressor hose is reconnected by pushing the
connector back onto the port. Listen for the
connector to click to be sure that the air compressor
hose is securely locked and connected. Isuzu 7.8L Diesel Only
5-40

Hood Inlet Seal
If the vehicle is being used in heavy snow conditions or
for snow plowing, there is a possibility of snow and
ice build up in the inlet to the air cleaner, which
can block airflow to the engine and affect impacting
engine performance.
To prevent this from happening, remove the hood
inlet seal:
1. Loosen the clamp that holds the seal to the air
cleaner.
2. Slide the seal off.3. Store the seal in the inlet, located on the underside
of the hood.
4. Store the air cleaner clamp on the coolant surge
tank. Pull the overflow tube out of the white plastic
retainer, slip the clamp over and reinstall the hose.
Replace the air cleaner seal during non-snow or non-icy
conditions.
5-41

Automatic Transmission Fluid
When to Check
A good time to check your automatic transmission fluid
level is when the engine oil is checked. See your
Allison Automatic Transmission Operator’s Manual to
find out when to change your transmission fluid
and filters.
How to Check and What to Use
The Allison Automatic Transmission Operator’s Manual
that came with the vehicle shows how to check the
automatic transmission fluid and what fluid to use.
Automatic Transmission External Filter
Your automatic transmission filter requires periodic
replacement.
Consult the Allison Automatic Transmission Operator’s
Manual that came with the vehicle for proper change
intervals.
Manual Transmission Fluid
When to Check
A good time to have it checked is when the engine oil is
checked. Refer to the Maintenance Schedule to find out
when to check and change your manual transmission
fluid. SeeScheduled Maintenance on page 6-5.
How to Check and What to Use
Check the fluid level only when your engine is off, the
vehicle is parked on a level place, and the transmission
is cool enough for you to rest your fingers on the
transmission case.
To check the transmission fluid level, do the following:
1. Remove the filler plug.
2. Check to be sure that the lubricant level is up
to the bottom of the fill opening. On heavy duty
transmissions, an inch of oil level equals about
one gallon of fluid.
3. If the fluid level is good, reinstall the plug and be
sure it is fully seated. If the fluid level is low, add
more fluid as described in the next steps. Refer to
the Maintenance Schedule to determine what
kind of fluid to use. SeePart C: Recommended
Fluids and Lubricants on page 6-31.
5-42

How to Add Fluid
To add transmission fluid, do the following:
1. Remove the filler plug.
2. Add fluid at the filler plug hole. Add only enough
fluid to bring the fluid level up to the bottom of the
fill opening. Refer to the Maintenance Schedule
to determine the proper fluid to use. SeePart
C: Recommended Fluids and Lubricants on
page 6-31.
3. Reinstall the filler plug. Be sure the plug is fully
seated.
Cooling System
When you decide it is safe to lift the hood, here is what
you will 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, do
not do anything else until it cools down. The vehicle
should be parked on a level surface.
5-43

The coolant level should
be at the FULL COLD
mark or higher. If it is not,
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 fire, and you could be burned.
Get any leak fixed before you drive the vehicle.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 does not, your vehicle needs service. Turn off the
engine.
Notice:Engine damage from running the engine
without coolant is not covered by the warranty.
Notice:Using coolant other than DEX-COOL can
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 first. Any repairs
would not be covered by the vehicle warranty.
Always use DEX-COOL (silicate-free) coolant in
your vehicle.
How to Add Coolant to the Coolant
Surge Tank
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level is not at the FULL COLD mark
or higher, add a 50/50 mixture of clean, drinkable water
and 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 (Caterpillar Diesel Engines) on
page 5-47for more information.
5-44

If no coolant is visible in the surge tank, add coolant as
follows:
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They are
under pressure, and if you turn the coolant surge
tank pressure cap — even a little — they can
come out at high speed. Never turn the cap when
the cooling system, including the coolant surge
tank pressure cap, is hot. Wait for the cooling
system and coolant surge tank pressure cap to
cool if you ever have to turn the pressure cap.
{CAUTION:
Adding only plain water to the cooling system can
be dangerous. Plain water, or some other liquid
such as alcohol, can boil before the proper coolant
mixture will. The vehicle’s coolant warning system
is set for the proper coolant mixture. With plain
water or the wrong mixture, the engine could get
too hot but you would not get the overheat
warning. The engine could catch fire 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.
5-45

{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. 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
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.3. Fill the coolant surge tank with the proper mixture,
to the FULL COLD mark.
5-46