2009 CHEVROLET KODIAK fuel cap

Seats and Restraint System............................. 1-1
Front Seats
............................................... 1-2
Rear Seats
..............................................1-10
Safety Belts
.............................................1-11
Child Restraints
.......................................1-28
Airbag System
.........................................1-48
Restraint System Check
............................1-59
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................. 2-8
Starting and Operating Your Vehicle
...........2-10
Mirrors
....................................................2-51
Storage Areas
.........................................2-53
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-20
Warning Lights, Gages, and Indicators
........3-23
Audio System(s)
.......................................3-48
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and the Vehicle
....... 4-2
Towing
...................................................4-23Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-6
Checking Things Under the Hood
...............5-22
Rear Axle
...............................................5-67
Four-Wheel Drive
.....................................5-68
Front Axle
...............................................5-69
Noise Control System
...............................5-70
Bulb Replacement
....................................5-71
Windshield Wiper Blade Replacement
.........5-71
Other Service Items
..................................5-72
Tires
......................................................5-76
Appearance Care
.....................................5-87
Vehicle Identification
.................................5-94
Electrical System
......................................5-95
Capacities and Specifications
...................5-102
Normal Maintenance Replacement Parts
....5-108
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information.................... 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
............................ 7-9
Vehicle Data Recording and Privacy
...........7-11
Index................................................................ 1
2009 Chevrolet Kodiak Owner ManualM

Notice:Extended idle should be avoided because
the DPF system is not capable of self cleaning at
idle. During extended idle operation, monitor the
instrument panel telltale lights and Driver Information
Center for messages and take appropriate indicated
action. Continued idling with the warning light/
message on could cause irreversible damage to the
DPF requiring repair and possible replacement that
might not be covered by the vehicle warranty.
When the yellow DPF indicator comes on, the filter is
dirty and needs cleaning. You will also notice a change
in the exhaust sound and engine idle speed. This is
normal. If you continue to drive and the exhaust filter is
not cleaned as required, the DPF indicator will change
from yellow to red. Continuing to drive the vehicle
with the red indicator can cause filter damage.
Vehicles with DPF have specific fuel and engine oil
requirements. SeeWhat Fuel to Use on page 5-8and
Engine Oil (DURAMAX Diesel Engine) on page 5-24
orEngine Oil (Caterpillar Diesel Engine) on page 5-27or
Engine Oil (Isuzu Diesel Engine) on page 5-28or
Engine Oil (Gasoline Engine) on page 5-32for more
information on those requirements.Notice:Permanent damage can occur to the DPF
or related components if the required Ultra Low
Sulfur Diesel (15 ppm sulfur maximum) or low ash
CJ-4 engine oil is not used. This damage would
not be covered by the vehicle warranty.
For vehicles with Power Take-Off (PTO), monitor the
instrument panel cluster for lights related to the DPF.
All engines consume some amount of engine oil. Ash
is the by-product of engine oil consumption. The ash will
become trapped in the DPF over the life of the vehicle.
Eventually, the buildup of ash will restrict the exhaust
gases and the DPF will need to be cleaned or replaced.
SeeAccessories and Modifications on page 5-3for
important information if you are considering adding
accessories or modifying the vehicle.
2-47

A. Fan Control
B. Temperature Control
C. Air Delivery Mode
ControlD. Rear Window
Defogger
On hot days, open the windows to let hot inside air
escape; then close them. This helps to reduce the time
it takes for the vehicle to cool down. It also helps the
system to operate more efficiently.
Air Delivery Mode Control:Turn clockwise or
counterclockwise to change the direction of the airflow
inside the vehicle.
Select from the following modes:
<(Maximum Air Conditioning):For maximum
cooling. The system goes into recirculation mode and
helps to maximize the air conditioner’s performance and
the vehicle’s fuel economy. This setting also cools the air
the fastest.
Y(Air Conditioning):For normal cooling on hot days.
Outside air is cooled and directed to the instrument
panel vents.
)(Bi-Level Air Conditioning):Air is divided between
the floor and instrument panel vents. The air conditioning
compressor cycles continuously in this setting as long as
the outside temperature is warm enough to activate the
compressor.
H(Vent):Air is directed to the instrument panel vents.
6(Floor):Air is directed to the floor vents. Use this
mode to send air to the rear of the vehicle. Keep the area
under the front seats free of objects that could obstruct
airflow to the rear of the vehicle.
-(Defog):This mode clears the windows of fog or
moisture. Outside air is directed to the floor and
defroster outlets. Adjust the temperature knob for
warmer or cooler air. The air conditioning compressor
may operate in this setting to dehumidify the air.
0(Defrost):This mode removes fog or frost from the
windshield more quickly. Air is directed to the
windshield, with some going to the floor outlets and
front side windows. The air conditioning compressor may
operate in this setting to dehumidify the air.
The temperature knob should be in the red area and the
fan control toward high. Do not drive the vehicle until all
the windows are clear. Vehicles With Air Conditioning
3-21

Tow Hooks
{CAUTION:
These hooks, when used, are under a lot of force.
Always pull the vehicle straight out. Never pull on
the hooks at a sideways angle. The hooks could
break off and you or others could be injured from
the chain or cable snapping back.
Notice:Never use tow hooks to tow the vehicle.
Your vehicle could be damaged and it would not be
covered by warranty.
If your vehicle has tow hooks, the hooks are at the front
and, on some models, the rear of the vehicle. You
may need to use them if you are stuck off-road and need
to be pulled to some place where you can continue
driving.
Loading the Vehicle
It is the responsibility of the Final Stage manufacturer to
install a Certification label on your vehicle. This label
shows how much weight your vehicle can properly carry.
It may also show the size of the vehicle’s original tires,
and the inflation pressures needed to obtain the gross
weight capacity of your vehicle. This is called the Gross
Vehicle Weight Rating (GVWR). The tire information
could also be shown on a separate Tire Information label.
The GVWR includes the weight of the vehicle, all
occupants, fuel, and cargo.
4-20

Service............................................................5-3
Accessories and Modifications..........................5-3
California Proposition 65 Warning.....................5-4
California Perchlorate Materials Requirements.....5-4
Doing Your Own Service Work.........................5-5
Engine Fan Breakage.....................................5-6
Fuel................................................................5-6
Gasoline Octane............................................5-6
Gasoline Specifications....................................5-7
Additives.......................................................5-7
Diesel Engine Fuel.........................................5-8
What Fuel to Use...........................................5-8
Very Cold Weather Operation.........................5-11
Water in Fuel...............................................5-11
Running Out of Fuel.....................................5-17
Fuel Filter Replacement.................................5-18
Fuels in Foreign Countries.............................5-19
Filling the Tank............................................5-20
Filling a Portable Fuel Container.....................5-22
Checking Things Under the Hood....................5-22
Hood Latches...............................................5-23
Engine Oil (DURAMAX Diesel Engine).............5-24
Engine Oil (Caterpillar Diesel Engine)..............5-27
Engine Oil (Isuzu Diesel Engine).....................5-28
Engine Oil (Gasoline Engine)..........................5-32
Engine Oil Life System (Gasoline Engine)........5-35Engine Oil Life System (DURAMAX/Isuzu
Diesel Engines).........................................5-36
Engine Oil Life System (Caterpillar
Diesel Engine)..........................................5-38
Engine Air Cleaner/Filter................................5-38
Automatic Transmission Fluid.........................5-42
Manual Transmission Fluid.............................5-42
Cooling System............................................5-43
Engine Coolant (Caterpillar Diesel Engines)......5-47
Coolant Surge Tank Pressure Cap..................5-47
Engine Overheating.......................................5-48
Engine Fan Noise.........................................5-49
Power Steering Fluid.....................................5-49
Windshield Washer Fluid................................5-50
Brakes........................................................5-52
Battery........................................................5-61
Jump Starting...............................................5-62
Rear Axle.......................................................5-67
Rear Axle Shift Motor....................................5-68
Four-Wheel Drive............................................5-68
Front Axle......................................................5-69
Noise Control System.....................................5-70
Tampering with Noise Control System
Prohibited.................................................5-70
Bulb Replacement..........................................5-71
Section 5 Service and Appearance Care
5-1

Windshield Wiper Blade Replacement..............5-71
Other Service Items........................................5-72
Fuel Filter....................................................5-72
Primary Fuel Filter and Water Separator..........5-73
Secondary Fuel Filter and Water Separator/
Heater (Caterpillar Diesel)............................5-74
Front Wheel Bearings with
Oil-Filled Hubs..........................................5-75
Tires..............................................................5-76
Inflation - Tire Pressure.................................5-77
Wheel Loading.............................................5-78
Dual Tire Operation.......................................5-78
When It Is Time for New Tires.......................5-78
Buying New Tires.........................................5-79
Wheel Alignment and Tire Balance..................5-80
Tightening the Wheel Nuts.............................5-80
Wheel Replacement......................................5-84
If a Tire Goes Flat........................................5-85
Appearance Care............................................5-87
Interior Cleaning...........................................5-87
Fabric/Carpet...............................................5-88
Instrument Panel, Vinyl, and Other
Plastic Surfaces........................................5-89
Care of Safety Belts......................................5-89
Weatherstrips...............................................5-89
Washing Your Vehicle...................................5-90Cleaning Exterior Lamps/Lenses.....................5-90
Finish Care..................................................5-90
Windshield and Wiper Blades.........................5-91
Aluminum or Chrome-Plated Wheels
and Trim..................................................5-92
Tires...........................................................5-92
Sheet Metal Damage.....................................5-93
Finish Damage.............................................5-93
Underbody Maintenance................................5-93
Chemical Paint Spotting.................................5-93
Vehicle Identification
......................................5-94
Vehicle Identification Number (VIN).................5-94
Service Parts Identification Label.....................5-94
Electrical System............................................5-95
Add-On Electrical Equipment..........................5-95
Headlamp Wiring..........................................5-95
Windshield Wiper Fuses................................5-95
Fusible Links................................................5-95
Power Windows and Other Power Options..........5-96
Fuses and Circuit Breakers............................5-96
Instrument Panel Fuse Block..........................5-96
Underhood Fuse Block..................................5-99
Capacities and Specifications........................5-102
Normal Maintenance Replacement Parts.........5-108
Maintenance Replacement Parts...................5-108
Engine Drive Belt Routing............................5-110
Section 5 Service and Appearance Care
5-2

Water In Fuel Light
Problem Recommended Action
Light comes on
intermittently.Drain water from the fuel
filter.
Light stays on at
temperatures above
freezing.Drain the fuel filter
immediately. If no water
can be drained and the
light stays on, see your
dealer/retailer for
assistance.
Light stays on at
temperatures below
freezing.Drain the fuel filter
immediately. If no water
can be drained, water
may be frozen in the
water drain system, or in
the fuel lines. Move the
vehicle to a warm location
to thaw out, and then
drain the filter system.
Light stays on
immediately after
refueling, and a large
amount of water was
possibly pumped into the
fuel tank.Fuel tank purging is
required. See your
dealer/retailer for
assistance.Notice:Driving when this warning indicator is on,
can damage the fuel injection system and the engine.
If the indicator comes on right after a refuel, it means
water was pumped into the fuel tank. Turn off the
engine immediately. Then, have the water drained
at once.
To drain water, do the following:
1. Stop and park the vehicle in a safe place. Turn off
the engine and apply the parking brake.
2. Remove the fuel cap.
3. Place a fuel-resistant container under the fuel filter.
The filter drain valve is located on the bottom of the
fuel filter.
If the vehicle has the 6.6L engine, the fuel filter is
located in the engine compartment on the driver side
of the vehicle. If the vehicle has either the 7.2L or
7.8L engine, the fuel filters are located in the engine
compartment on the driver side of the vehicle, and on
the driver side frame rail in front of the fuel tank.
5-12

4. Open the drain valve
by turning two to three
turns. When fuel
empties from the valve,
all the water has
been drained. Close
the valve hand-tight.
5. Remove the fuel-resistant container and properly
dispose of the contaminated fuel. To find out how to
properly dispose of contaminated diesel fuel, see
Engine Oil (DURAMAX Diesel Engine) on page 5-24
orEngine Oil (Caterpillar Diesel Engine) on
page 5-27orEngine Oil (Isuzu Diesel Engine) on
page 5-28orEngine Oil (Gasoline Engine) on
page 5-32.6. Install the fuel cap.
7. Start the engine and let it run for a few minutes.
If the engine stalls, the fuel system may need to
be primed. While draining the water from the
fuel filter, air may enter the fuel system. If air has
entered the fuel system, the fuel system will need
to be primed.
If the water-in-fuel light comes on again after driving a
short distance or the engine runs rough or stalls, a large
amount of water has probably been pumped into the
fuel tank. The fuel tank should be purged.
Fuel Priming
If the vehicle has a Caterpillar®diesel engine, see the
Caterpillar®Diesel Engine Operation and Maintenance
Manual provided with the vehicle.
If the vehicle has a DURAMAX
®diesel engine, in order
for the fuel system to work properly, the fuel lines
must be full of fuel and contain no air. If air gets into the
fuel lines, it will be necessary to prime the fuel lines
to eliminate air before operating the vehicle.
5-13