2007 Chevrolet C5500 Kodiak Service and Repair Manual

This factory service and repair manual for the 2007 Chevrolet C5500 Kodiak accounts for two engines, four bodies and six order codes: the turbocharged 6.6-liter diesel of 403 cubic inches and the 8.1-liter gasoline V8 of 496, carried in a two-door conventional cab and chassis, a crew cab and chassis, a cutaway chassis or a motorhome cutaway. Procedures are grouped by system, so engine work, chassis work and body electrical work each stand on their own rather than being folded together.

Engines covered

• 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
• 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door cab & chassis, conventional
• Cab & chassis, crew cab
• Motorhome, cutaway
• Cab & chassis, cutaway

Trims covered

• C5C042
• C5C044
• C5E042
• C5E044
• C5U042
• C5V042

Known issues on the 2007 C5500 Kodiak. Six recalls touch this model year, every one of them on equipment mounted to the chassis rather than built into it. A battery isolator cable lug can be installed facing the isolator, pressed against its cooling fins, where a short can overheat the cables and start a fire. A ceiling air conditioning unit's heater element may be defective and throw smoke or sparks. And a rear air suspension bracket has cracked in service, degrading handling badly enough to risk a loss of control. Two owner complaints are recorded, both on the engine and its cooling.