engine CHEVROLET KODIAK 2004 Owners Manual

Notice:If the jumper cables are removed in the
wrong order, electrical shorting may occur and
damage the vehicle. The repairs would not be
covered by your warranty. Remove the jumper
cables in the correct order, making sure that the
cables do not touch each other or other metal.
A. Heavy, Unpainted Metal Engine Part or Remote
Negative (−) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (−) Terminals
C. Dead Battery or Remote Positive (+) TerminalTo disconnect the jumper cables from both vehicles, do
the following:
1. Disconnect the black negative (−) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (−) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the positive (+) remote terminal cover to its
original position.
Jumper Cable Removal
5-60

Noise Control System
Tampering with Noise Control
System Prohibited
The following information relates to compliance with
federal noise emission standards for vehicles with
a Gross Vehicle Weight Rating (GVWR) of more than
10,000 lbs (4 536 kg). The Maintenance Schedule
provides information on maintaining the noise control
system to minimize degradation of the noise emission
control system during the life of your vehicle. The noise
control system warranty is given in your warranty
booklet.
These standards apply only to vehicles sold in the
United States.
Federal law prohibits the following acts or the causing
thereof:
1. The removal or rendering inoperative by any
person, other than for purposes of maintenance,
repair or replacement, of any device or element of
design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser or while it is in
use; or2. The use of the vehicle after such device or element
of design has been removed or rendered inoperative
by any person.
Among those acts presumed to constitute tampering are
the acts listed below.Insulation:
•
Removal of the noise shields or any underhood
insulation.
Engine:
•
Removal or rendering engine speed governor (if
equipped) inoperative so as to allow engine
speed to exceed manufacturer specifications.
Fan and Drive:
•
Removal of fan clutch (if equipped) or rendering
clutch inoperative.
•Removal of the fan shroud (if equipped).
Air Intake:
•
Removal of the air cleaner silencer.
•Modification of the air cleaner.
Exhaust:
•
Removal of the muffler and/or resonator.
•Removal of the exhaust pipes and exhaust pipe
clamps.
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2. Push the release lever and slide the wiper assembly
toward the driver’s side of the vehicle.
3. Install a new blade by reversing Steps 1 and 2.
Other Service Items
Fuel Filter
Fuel Filter (Gasoline Engines)
The steel fuel filter is located near the engine
compartment on the driver’s side of the vehicle. See
your Maintenance Schedule for recommended service
intervals.
If your vehicle is equipped with the optional Davco
spin-on type filter, it is located on the driver’s side
frame rail.
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Fuel Filter (Diesel Engines)
If you have a diesel engine, your fuel filter is located in
the engine compartment on the driver’s side of the
vehicle, or along the driver’s side frame rail. SeeFuel
Filter Replacementearlier in this section for further
information.
Also seeScheduled Maintenance on page 6-5for
recommended service intervals.
Primary Fuel Filter and Water
Separator
If you have a diesel
engine, you may have this
spin-on filter. It is located
on the driver’s side
frame rail.It has a clear plastic drain bowl at the bottom. Check
the drain bowl occasionally for any water or particles.
To drain the bowl, do the following:
1. Shut off the engine.
2. Partially open the drain valve at the bottom of the
filter.
SeeEngine Oil (Caterpillar
®Diesel Engine) on
page 5-20orEngine Oil (Gasoline Engine) on page 5-20
orEngine Oil (DURAMAX™ Diesel) on page 5-25for
proper disposal procedures.
5-65

Secondary Fuel Filter and Water
Separator/Heater
If you have a Caterpillar®
diesel engine, you may
also have this spin-on filter
and fuel separator/heater.
It will be mounted in
the engine compartment
on the driver’s side of
the vehicle.
It has a metal drain bowl at the bottom. Occasionally,
check the bowl for any water or particles.
To check or drain the bowl, do the following:
•Shut off the engine.
•Push up on the spring loaded drain valve until clear
fuel is flowing from the valve.
The particles or water will drain out first. SeeEngine Oil
(Caterpillar
®Diesel Engine) on page 5-20orEngine
Oil (Gasoline Engine) on page 5-20orEngine Oil
(DURAMAX™ Diesel) on page 5-25for proper disposal
procedures.
Automatic Ether Injection System
If you have a Caterpillar®
diesel engine, you may
have this feature. The
ether cylinder is located in
the engine compartment
on the driver’s side of
the vehicle.
To change an empty ether cylinder, follow these steps.
1. Loosen the screw head on the cylinder-to-bracket
clamp.
2. Spread the clamp apart.
3. Clean any dirt from the neck of the cylinder and the
top of the valve before you take out the cylinder.
4. Check the inside of the valve for any foreign matter.
Clean the valve as necessary.
5. Cover the valve to protect it from dirt and take out
the cylinder.
5-66

Vehicle Identication
Vehicle Identication Number (VIN)
This is the legal identifier for your vehicle. It appears on
a plate in the front corner of the instrument panel, on
the driver’s side. You can see it if you look through the
windshield from outside your vehicle. The VIN also
appears on the Vehicle Certification and Service Parts
labels and the certificates of title and registration.
Engine Identication
The 8th character in your VIN is the engine code. This
code will help you identify your engine, specifications
and replacement parts.
Service Statement
One of these statements is on your GVW Rating label.
Here is what each one means.
TRUCK SERVICE:A vehicle made to carry property or
special equipment. It is made for uniform frame
loading. That includes using the vehicle to pull a full
trailer.
TRUCK-TRACTOR:A vehicle made to draw other
vehicles. It is made to carry part of the load of the trailer.
It is made for point frame loading, usually for a
semi-trailer (fifth-wheel).
MAX. VERT. CG:The highest allowable vertical center
of gravity, at the highest allowable GVWR. It is
measured from the level ground in inches.
TRUCK-CANADA:A vehicle first sold in Canada with a
non-school bus application, or cab models with regular
production option RQ2 (truck service).
TRACTOR-CANADA:A cab model first sold in Canada
with regular production option RQ3 (truck-tractor
service).
5-85

Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker inside the motor and a circuit breaker or fuse in
the fuse block. If the motor overheats, the wipers will
stop until the motor cools. If the overload is caused by
an electrical problem, be sure to get it fixed.
Fusible Links
A fusible link is a short piece of wire several gauge
sizes smaller than the circuit it protects. It will melt in an
overload situation, opening the circuit.
Your starter and other circuits have these fusible links.
The size is printed on the insulation. If the insulation
is burned beyond recognition, consult your GM dealer
for the proper size. Replace a fusible link with one of the
same size and insulation type. Fusible link insulation
is a special purpose high-temperature material.
The hydraulic brake booster motor feed circuit and
starter circuit are protected by a fusible link. Vehicles
with a diesel engine have a fusible link for the intake
heater feed circuit.
Power Windows and Other Power
Options
Circuit breakers in the fuse panel protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens. This
protects the circuit until the current load returns to
normal or the problem is fixed.
Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers,
maxi-fuses and fusible links. This greatly reduces the
chance of a fire caused by an electrical problem. There
may be a fuse taped to the wiring harness near the
hydraulic brake booster.
5-87

Underhood Fuse Block
When a circuit goes out, the problem could be in either
the primary or secondary underhood fuse blocks.
These blocks uses blade-type fuses.
Both underhood fuse
blocks are located in the
engine compartment,
on the passenger’s side of
the vehicle.
To access the fuse blocks, gently squeeze both sides of
the cover to unlatch the tabs at the top. Then, unsnap
both attachments at the bottom and remove the cover.
Be sure to replace fuses with fuses of the same
rating. Do not use fuses of higher amperage than those
indicated on the fuse block.Relay Usage
NOTE 1 LG4 Powertrain Control Valve,
L18/LB7 Fuel Pump, LG5 Heated
Fuel
IGN B Ignition
STARTER Starter
HORN Horn
IGN A Ignition Primary Underhood
Fuse Block
Primary Underhood Fuse Block
5-91

Relay Usage
PTO Power Take-Off
REVERSE Reverse
NEUTRAL
STARTNeutral Start
Fuse Usage
RR DEFOG Rear Defog
ENG 1 Engine 1
ENG 3 Engine 3
PCM-B Powertrain Control Module
BLANK Empty
ENG 4 Engine 4
ENG 2 Engine 2
HTD FUEL Heated Fuel
BLANK EmptyFuse Usage
BLANK Empty
BLANK Empty
A/C COMP Air Conditioning Compressor
ABS 1 Anti-Lock Brake System 1
ABS 2 Anti-Lock Brake System 2
ABS 3 Anti-Lock Brake System 3
ENGINE Engine
E/A PUMP Electronic/Automatic Pump
HORN Horn
NOTE 2L18/LB7 Fuel, LG4 Powertrain
Control Valve, LG5 Electronic
Control Module
BLANK Empty
STUD A Spare
STUD B Spare
5-92

Fuse Usage
IGN 1 Ignition 1
IGN 4 Ignition 4
IGN 3 Ignition 3
BATT/HAZ Battery/Hazard Warning Flashers
HEADLAMP Headlamps
LIGHTING Interior/Exterior Lamps
HVAC Comfort Control System
NOTE C4/C5 Electric Brake,
C6/C7/C8 Brake Lamps
Capacities and Specications
Capacities and Specications
Engine RPO
7.2L L6 HEUI Fuel System LG5
8.1L V8 SPFI Fuel System L18
7.8L L6 Common Rail Fuel System LG4
6.6L V8 Common Rail Fuel System LB7/LLY Secondary Underhood
Fuse Block
5-93