2009 CHEVROLET KODIAK check engine

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)
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❑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)
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❑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

(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.
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(14)= Adjust tire pressures as indicated on the
Certification or Tire Information label for optimum tire
life. SeeTires on page 5-76for further details.
Check tires for excessive or abnormal wear or damage.
Also check for damaged wheels. Replace wheels
and/or tires as needed.
(15)= Check spring-to-axle U-bolts and shackle bolts
for proper torque. See the service manual for torque
sequence and specifications. When parts are replaced,
the torque must be checked and adjusted more often
during the first 6,000 miles (10 000 km). Check torque at
500 miles (800 km) and 2,000 miles (3 000 km) after
first use of parts.
(16)= Check complete exhaust system, including DPF
pressure lines, and cab areas near the exhaust system
for broken, damaged, missing, or out-of-position parts.
Also inspect for open seams, holes, loose connections, or
other conditions which could let exhaust fumes seep into
the driver compartment. Needed repairs should be made
at once. To help maintain system integrity, replace
exhaust pipes whenever a new muffler is put on.
(17)= Check all gasoline engine drive belts for cracks,
fraying, and wear. Replace as needed.
(18)= Adjust valve lash. Incorrect valve clearance will
result in increased engine noise and reduced engine
output.(19)= With the engine off and below normal operating
temperature, check to see that the thermostatically
controlled engine cooling fan can be rotated by hand on
viscous-operated drives. Replace as needed.
(20)= Check shields and underhood insulation for
damage or looseness. Adjust or replace as needed.
(21)= Inspect parking brake drum and linings for wear
or cracks and check linkage and adjustment.
(22)= Wheel bearing service:
•Grease type — Clean, inspect, and lubricate with
the proper wheel bearing grease at designated
intervals or when hubs are removed. SeePart C:
Recommended Fluids and Lubricants on page 6-31.
•Oil-filled type — Some wheel bearings are
lubricated by axle lubricant. When you have oil-filled
hubs, use lubricant identical to that used in the
axle. Lubricant change intervals are the same for
front and rear axles. However, you must maintain
the proper oil level between change intervals.
SeeFront Wheel Bearings with Oil-Filled Hubs on
page 5-75andPart C: Recommended Fluids
and Lubricants on page 6-31.
(23)= 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.
6-23

(24)= 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.
(25)= 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.
(26)= 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.
(27)= Check Exhaust Gas Recirculation (EGR) system
as described in the service manual. SeeService
Publications Ordering Information on page 7-10.
(28)= 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.
(29)= Drain, flush, and refill cooling system. This service
can be complex; you should have your dealer/retailer
perform this service. SeePart C: Recommended Fluids
and Lubricants on page 6-31for 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.(30)= Change the lubricant. SeePart C: Recommended
Fluids and Lubricants on page 6-31.
(31)= Front axle service: Re-pack upper kingpin roller
bearing.
(32)= Air brake service:
•Inspect brake lines and hoses for proper hook-up,
binding, leaks, cracks, chafing, etc. Inspect drum
brake linings for wear or cracks. Inspect other brake
parts at each wheel, including drums and wheel
speed sensor wiring. 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. Replace air
dryer cartridge only if excessive oil or moisture is
present. A small amount of oil in the system is normal
and should not be considered as a reason to replace
the cartridge.
•Test air lines for leaks; tighten as needed. Replace
compressor filter.
•Inspect air parking brake chamber for leaks and
damage. Inspect lines and hoses for leaks, cracks,
chafing, etc. Also check all attachments for tightness,
wear, or damage. Note: The spring brake section of
the rear brake diaphragms are non-serviceable.
6-24

•Replace the air compressor filter element, mounted
on the air compressor. For remote air compressor
intake service, refer to engine air cleaner filter
replacement.
•Remove, disassemble, clean, and inspect the safety
valve, service brake chambers, quick release valves,
quick release/double check valve combinations,
parking brake control valve, double check valves,
pressure protection valves, and ether injector
(if equipped).
•Remove, disassemble, and clean the application
valve; replace parts showing wear.
•Remove, disassemble, clean, and inspect the spring
brake control valve; replace rubber parts.
(33)= Clean and lubricate air brake automatic slack
adjuster. Check pushrod travel and auto adjustment
operation. Have serviced if needed.
(34)= Air brake chamber service: Check operation,
mounting clamps, and air lines and check for leaks.
(35)= Trailer brake hand control valve service: Check
operation; lubricate cam and follower.(36)= Tighten the wheel stud nuts to the specified torque
values at 100 miles (160 km). Thereafter, tighten them
1,000 miles (1 600 km) after each time the wheel is
removed. SeeTightening the Wheel Nuts on page 5-80.
(37)= Inspect and clean any accumulated dirt, gravel,
or other foreign objects from the valves and valve boots
as needed. Using light oil, lubricate brake pedal to
brake application valve linkage components. Check any
rubber boots for cracks, holes, or deterioration and
replace if necessary.
(38)= Estimated minimum. Actual mileage depends on
fuel and oil consumed.
(39)= If the vehicle has the Isuzu diesel engine and is
used primarily for long trip, highway service, change
the engine oil and filter every 18,000 miles (28 800 km),
or every 12 months, or every 750 hours of engine
operation, whichever occurs first.
(40)= Make sure any safety belt reminder light and
safety belt assemblies are working properly. Look
for any other loose or damaged safety belt system parts.
If you see anything that might keep a safety belt
system from doing its job, have it repaired. Have any
torn or frayed safety belts replaced.
6-25

Part B: Owner Checks and Services
These owner checks and services should be performed
at the intervals specified to help ensure vehicle
safety, dependability, and emission control performance.
For your safety and that of others, any of the
safety-related components that may have been
damaged in an accident should be checked and any
needed repairs made before operating the vehicle.
At the minimum, these routine checks should be made
every 6 months or 6,000 miles (10 000 km), whichever
occurs first. Whenever repairs are needed, have
them completed before operating the vehicle.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel fill.
Engine Oil Level Check
Notice:It is important to check the engine oil
regularly and keep it at the proper level. Failure to
keep the engine oil at the proper level can cause
damage to the engine not covered by the vehicle
warranty.Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil (DURAMAX Diesel Engine)
on page 5-24orEngine Oil (Caterpillar Diesel Engine)
on page 5-27orEngine Oil (Isuzu Diesel Engine) on
page 5-28orEngine Oil (Gasoline Engine) on page 5-32.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
(Caterpillar Diesel Engines) on page 5-47.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer fluid reservoir and add the proper fluid if
necessary. SeeWindshield Washer Fluid on page 5-50.
Tire Inflation Check
Check tire inflation cold. Make sure the tires are inflated
to the correct pressures. SeeLoading the Vehicle on
page 4-20andInflation - Tire Pressure on page 5-77.
6-26