2009 CHEVROLET KODIAK Owners Manual

72,000 Miles (115 000 km)
❑Lubricate U-joints (or every 6 months, whichever
occurs first).
75,000 Miles (120 000 km)
❑Gasoline Engine Only: Check engine oil life system.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(2) (8)
❑DURAMAX/Isuzu Diesel Without Engine Oil Life
System Only: Change engine oil and filter (or every
12 months, or every 750 hours of engine operation,
whichever occurs first).(2) (39)
❑DURAMAX/Isuzu Diesel With Engine Oil Life System
Only: Check oil life system. If engine oil and filter are
changed, reset system. See “Engine Oil (DURAMAX/
Isuzu Diesel)” in the Index.(2) (9)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Gasoline Engine: Inspect engine air cleaner filter.
If necessary, replace the filter. If vehicle is driven in
dusty/dirty conditions, inspect filter at every engine oil
change. SeeEngine Air Cleaner/Filter on page 5-38
for more information.❑Diesel Engine: Inspect engine air cleaner filter change
indicator. If necessary, replace the filter. If vehicle is
driven in dusty/dirty conditions, inspect filter change
indicator at every engine oil change. SeeEngine Air
Cleaner/Filter on page 5-38for more information.
❑Diesel Only: Replace fuel filter (or every 750 hours of
engine operation, whichever occurs first).
❑Steering system service.(12)
❑Front and rear suspension service.(13)
❑Spring-to-axle U-bolts and shackle bolts service.(15)
❑Exhaust system service (or every 6 months, whichever
occurs first).(2) (3) (16)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
6-15

❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
❑Air compressor dry element pleated paper air strainer
service (or every 2 months, or every 800 hours,
whichever occurs first).
❑Fuel tank, fuel cap and fuel lines service (or every
72 months, whichever occurs first).(2) (26) †
❑Exhaust Gas Recirculation (EGR) system inspection
(if equipped) (or every 72 months, whichever occurs
first).(2) (27)
❑Thermostatically controlled engine cooling fan
service.(3) (19)
❑Shields and underhood insulation service.(3) (4) (20)
❑Gasoline Engine: Air compressor remote mounted air
filter dry element pleated paper air strainer service (or
every 6 months or every 1800 hours, whichever
occurs first).82,500 Miles (132 000 km)
❑Gasoline Engine Only: Check engine oil life system.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(2) (8)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
6-16

90,000 Miles (144 000 km)
❑Gasoline Engine Only: Check engine oil life system.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(2) (8)
❑DURAMAX/Isuzu Diesel Without Engine Oil Life
System Only: Change engine oil and filter (or every
12 months, or every 750 hours of engine operation,
whichever occurs first).(2) (39)
❑DURAMAX/Isuzu Diesel With Engine Oil Life System
Only: Check oil life system. If engine oil and filter are
changed, reset system. See “Engine Oil (DURAMAX/
Isuzu Diesel)” in the Index.(2) (9)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Gasoline Engine: Replace engine air cleaner filter.
SeeEngine Air Cleaner/Filter on page 5-38for more
information.
❑Diesel Engine: Inspect engine air cleaner filter change
indicator. If necessary, replace the filter. If vehicle is
driven in dusty/dirty conditions, inspect filter change
indicator at every engine oil change. SeeEngine Air
Cleaner/Filter on page 5-38for more information.
❑Diesel Only: Replace fuel filter (or every 750 hours of
engine operation, whichever occurs first).
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)❑Cooling system service. Clean the cooling system filler
cap with clean water, clean the core, pressure test the
cap and the system for proper pressure capability, and
inspect condition of cooling and heater hoses and
clamps. Replace hoses if cracked, swollen, or
damaged.
❑Gasoline Engine Only: Replace fuel filter(s) (or every
12 months, whichever occurs first).(2)
❑Check restraint system.(40)
❑Steering system service.(12)
❑Front and rear suspension service.(13)
❑Spring-to-axle U-bolts and shackle bolts service.(15)
❑Exhaust system service (or every 6 months, whichever
occurs first).(2) (3) (16)
❑Inspect door hinge pins and bushings and replace as
necessary.
❑Wheel bearing (grease type) service (and whenever
hubs are removed).(22) (36)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
6-17

❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
❑Air brake system valve service (or every 3 months, or
every 900 hours, whichever occurs first).(37)
❑Air compressor dry element pleated paper air strainer
service (or every 2 months, or every 800 hours,
whichever occurs first).
❑C600, C700, and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first).(17)
❑Thermostatically controlled engine cooling fan
service.(3) (19)
❑Shields and underhood insulation service.(3) (4) (20)
❑Rear axle air shift motor service.(10)
❑Air intake system service (or every 24 months,
whichever occurs first).(3) (4) (23)❑Evaporative Control System service, if equipped, (or
every 24 months, whichever occurs first).(2) (24) †
❑Gasoline Engine: Air compressor remote mounted air
filter dry element pleated paper air strainer service (or
every 6 months or every 1800 hours, whichever
occurs first).
96,000 Miles (152 000 km)
❑Lubricate U-joints (or every 6 months, whichever
occurs first).
97,500 Miles (156 000 km)
❑Gasoline Engine Only: Check engine oil life system.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(2) (8)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (5)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(11)
❑Wheels and tires service.(14)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(6) (36)
❑Parking brake service (or every 6 months, whichever
occurs first).(21)
❑Air brake service (or every 6 months, whichever
occurs first).(32)
6-18

❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
100,000 Miles (160 000 km)
❑Diesel Only: Inspect engine drive belt; replace as
necessary.
❑Gasoline Engine Only (Vehicles with GVW of
16,000 lbs or less): Spark plug service.(2) (25)
❑Change power steering fluid (or every 36 months,
whichever occurs first).(12)
❑Replace power steering reservoir filter element
(or every 24 months, whichever occurs first).
❑Wheel bearing (oil type) service (and whenever hubs
are removed).(22) (36)
❑Except four-wheel drive: Front axle service.(31)
❑Four-wheel drive only: Front axle service.(30)❑Four-wheel drive only: Transfer case service.(30)
❑Rear axle service — Eaton
®, Rockwell®, Spicer®axles
(or every 12 months, whichever occurs first).(30)
❑Exhaust brake service, if equipped. Check for
excessive spindle free play and smooth operation.
Lubricate ball joint cap.
❑Inspect air compressor discharge port (or every
6 months or every 1,800 hours, whichever occurs
first).
❑Manual transmission (ZF 6-speed only) fluid
replacement (or every 48 months, whichever occurs
first).
❑Trailer brake hand control valve service (or every
12 months, or every 3,600 hours, whichever occurs
first).(35)
120,000 Miles (192 000 km)
❑C600, C700, and C800 Gasoline Engines Only:
Replace engine drive belts.
❑C400 and C500 Gasoline Engines Only: Engine drive
belts service (or every 12 months, whichever occurs
first).(17)
❑DURAMAX Diesel Only: Diesel Particulate
Filter (DPF) service. Then every 100,000 miles
(160 000 km).(7) (38)
6-19

150,000 Miles (240 000 km)
❑Cooling system service (or every 60 months since
last service, whichever occurs first).(2) (29)
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
❑Isuzu Diesel Only: Diesel Particulate Filter (DPF)
service (or every 4,500 hours, whichever occurs
first). Then every 150,000 miles (240 000 km),
or every 4,500 hours, whichever occurs first.(7)
200,000 Miles (320 000 km)
❑Rear axle service — Eaton®, Rockwell®, Spicer®
axles (or every 12 months, whichever occurs
first).(30)
❑Remove, disassemble, clean, and inspect the air
brake trailer supply valve (or every 2 years, or
every 7,200 hours, whichever occurs first).
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
250,000 Miles (400 000 km)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case service.(30)
❑Manual transmission (except ZF 6-speed) fluid
replacement (or every 60 months, whichever occurs
first).
300,000 Miles (480 000 km)
❑Rear axle service — Eaton®, Rockwell®, Spicer®
axles (or every 12 months, whichever occurs
first).(30)
❑Remove, disassemble, clean, and inspect the air
brake air dryer (or every 3 years, or 10,800 hours,
whichever occurs first). Replace desiccant.
❑Isuzu Diesel Only: Diesel Particulate Filter (DPF)
service (or every 4,500 hours, whichever occurs
first). Then every 150,000 miles (240 000 km),
or every 4,500 hours, whichever occurs first.(7)
Footnotes
† = The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(1)= If your vehicle has an Allison Transmission
®,
your owner manual is supplemented by an Allison
Transmission
®Operator’s Manual. Always refer to
these manuals for related maintenance services.
(2)= An Emission Control Service.
(3)= A Noise Emission Control Device.
6-20

(4)= Applies to vehicles sold in the United States and is
recommended for vehicles sold in Canada.
(5)= Check fluidlevel in brake master cylinder, power
steering pump, front and rear axles, transmission, and
hydraulic spring parking brake pump (if equipped). A low
fluid level in the brake master cylinder can indicate worn
brake linings and should be checked accordingly.
(6)= Inspect brake lines and hoses for proper hook-up,
binding, leaks, cracks, chafing, etc. Inspect disc
brake pads for wear and rotors for surface condition.
Inspect caliper assemblies. Check brake pedal for
excessive free play or travel (or every 6 months,
whichever occurs first) and have serviced if needed.
Check brakes more often if driving habits and conditions
result in frequent braking.
(7)= Check for filter ash, sensor adjustment, and
sensor hose restriction. Clean as needed. This service
can be complex; you should have your dealer/retailer
perform this service.
(8)= This vehicle has the Engine Oil Life System. This
system will show you when to change the engine oil
and filter — usually between 3,000 miles (5 000 km) and
7,500 miles (12 000 km) since your last oil change.
Under severe conditions, the indicator may come
on before 3,000 miles (5 000 km). Never drive your
gasoline engine vehicle more than 7,500 miles
(12 000 km) or 12 months without an oil and filter
change.Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information, see
Engine Oil Life System (Gasoline Engine) on page 5-35
orEngine Oil Life System (DURAMAX/Isuzu Diesel
Engines) on page 5-36orEngine Oil Life System
(Caterpillar Diesel Engine) on page 5-38.
(9)= This vehicle has the Engine Oil Life System. This
system will show you when to change the engine oil
and filter — usually between 3,000 miles (5 000 km) and
15,000 miles (24 000 km) since your last oil change.
Under severe conditions, the indicator may come
on before 3,000 miles (5 000 km). Never drive your
diesel engine vehicle more than 15,000 miles
(24 000 km), or 12 months, or 750 engine hours,
without an oil and filter change.
Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information, see
Engine Oil Life System (Gasoline Engine) on page 5-35
orEngine Oil Life System (DURAMAX/Isuzu Diesel
Engines) on page 5-36orEngine Oil Life System
(Caterpillar Diesel Engine) on page 5-38.
(10)= Inspect rear axle air shift motor for fluid leaks.
Remove plug to check fluid level. Inspect air lines
and hoses for proper hook-up, binding, leaks, etc.
Inspect at 1,000 miles (1 600 km) and 22,500 miles
(36 000 km) and then every 22,500 miles (36 000 km)
thereafter.
6-21

(11)= Chassis Lubrication Service: Lubricate all grease
fittings in front suspension, front axle, and steering
linkage. Do not lubricate kingpin bushings with air
pressure equipment; instead, use a hand grease gun to
ensure complete purge and eliminate sealer cap
distortion. Front axle tie rod ends, both upper and lower
kingpin fittings, and both steering linkage relay rod ends
should be greased with the vehicle loaded on the ground
and wheels turned straight ahead, not with the vehicle on
a hoist. Apply kingpin bushing lubricant to both upper and
lower kingpin grease fittings until new lubricant purges
from between the upper shim pack and thrust bearing.
Lubricate transmission and shift linkage, hood latches
and hood hinges, parking brake lever pivot, clevis pins
and linkage, disc brake caliper rails, clutch linkage and
release bearing (if equipped), bearing pads, propshaft
universal joints, brake camshaft bracket, slack adjusters,
pedal shaft, clutch cross shaft, clutch pedal springs, and
clutch cable bushing at transmission. Lubricate
suspension, axle, and steering linkage more often when
operating under dusty or muddy conditions and in
excessive off-road use. Frequently power-washed
vehicles will require more frequent lubrication.(12)= Check steering system:
•Look for damaged, loose, or missing parts. Inspect
the steering linkage relay rod and tie rod ends for
looseness or lack of lubricant. Also look for
parts showing signs of wear or lack of lubrication.
Replace parts as needed. Also check steering gear
mounting bolts, pitman arm nut, gear housing
upper cover and side cover attaching bolts, steering
column mounting bolts and cardan joint clamp
bolts; tighten if necessary. See the service manual.
•Inspect power steering hoses, tubes, and fittings for
leaks. Hoses and lines must not be twisted, kinked,
or tightly bent. Make sure clips, clamps, supporting
tubes, and hoses are in place and properly secured.
•Check steering gear for leakage around pitman shaft
and housing. If leakage is evident (lubricant oozing
out, not just oily film), leak should be corrected
immediately.
(13)= Check front and rear suspension. Look for
damaged, loose, or missing parts or parts showing signs
of wear or lack of lubrication. Replace parts as
needed.
6-22