maintenance schedule CHEVROLET KODIAK 2004 Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
.............................................. 1-8
Child Restraints
.......................................1-27
Air Bag System
.......................................1-48
Restraint System Check
............................1-61
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................. 2-8
Theft-Deterrent Systems
............................2-10
Starting and Operating Your Vehicle
...........2-11
Mirrors
....................................................2-39
Storage Areas
.........................................2-41
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-23
Audio System(s)
.......................................3-45
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-31Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-6
Checking Things Under the Hood
...............5-18
Rear Axle
...............................................5-61
Noise Control System
...............................5-62
Bulb Replacement
....................................5-63
Windshield Wiper Blade Replacement
.........5-63
Other Service Items
..................................5-64
Tires
......................................................5-68
Appearance Care
.....................................5-76
Vehicle Identification
.................................5-85
Electrical System
......................................5-86
Capacities and Specifications
.....................5-93
Normal Maintenance Replacement Parts
....5-100
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
............................ 7-6
Index.................................................................1
2004 Chevrolet Kodiak Owner ManualM

A reading in the low pressure zone may be caused by a
dangerously low oil level or other problem.
If you have a Caterpillar
®diesel engine, also see your
Caterpillar®Operation & Maintenance Manual.
{CAUTION:
Do not keep driving if the oil pressure is low. If
you do, your engine can become so hot that it
catches re. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice:Lack of proper engine oil maintenance may
damage the engine. The repairs would not be
covered by your warranty. Always follow the
maintenance schedule in this manual for changing
engine oil.
Low Oil Level Light
This light should come on
as a check, when you start
your engine. If the light
fails to come on, have it
repaired as soon as possible
so you will be aware when
the oil level is low.
If this light comes on and stays on, it means your
engine is low on oil. You need to check the oil level
right away. SeeEngine Oil (Caterpillar
®Diesel Engine)
on page 5-20orEngine Oil (Gasoline Engine) on
page 5-20orEngine Oil (DURAMAX™ Diesel) on
page 5-25for further information.
3-38

Manual Transmission Fluid
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
Scheduled Maintenance on page 6-5.
Refer to the Maintenance Schedule to determine what
kind of fluid to use. SeePart C: Recommended
Fluids and Lubricants on page 6-29.
When to Check
A good time to have it checked is when the engine oil is
checked. See your Maintenance Schedule to find out
when to change your transmission fluid.
How to Check and What to Use
Check the fluid level only when your engine is off, the
vehicle is parked on a level place and the transmission
is cool enough for you to rest your fingers on the
transmission case.
Then, follow these steps:
1. Remove the filler plug.
2. Check to be sure that the lubricant level is up to the
bottom of the fill opening. On heavy duty
transmissions (an inch of oil level equals about one
gallon of fluid.)
3. If the fluid level is good, install the plug and be sure
it is fully seated. If the fluid level is low, add more
fluid as described in the next steps.
How to Add Fluid
Here’s how to add fluid. Refer to the Maintenance
Schedule to determine the proper fluid to use. SeePart
C: Recommended Fluids and Lubricants on page 6-29.
1. Remove the filler plug.
2. Add fluid at the filler plug hole. Add only enough
fluid to bring the fluid level up to the bottom of the
fill opening.
3. Install the filler plug. Be sure the plug is fully
seated.
Engine Coolant (Gas and
DURAMAX™ engines)
If your vehicle has a Caterpillar®diesel engine, the
Caterpillar®Operation & Maintenance Manual provided
with your vehicle has information regarding the
proper coolant to use.
The cooling system in your vehicle is filled with
DEX-COOL
®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add
only DEX-COOL
®extended life coolant.
5-32

5. Then replace the
pressure cap. Be sure
the pressure cap is
hand-tight and
fully seated.
Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing and/or high outside
temperatures, the fan speed increases when the clutch
engages. So you may hear an increase in fan noise.
This is normal and should not be mistaken as thetransmission slipping or making extra shifts. It is merely
the cooling system functioning properly. The fan will
slow down when additional cooling is not required and
the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch disengages.
Power Steering Fluid
See your Maintenance Schedule for when to check your
power steering fluid.
How To Check Power Steering Fluid
Check your power steering fluid only when the engine is
warm. If the engine isn’t warm, you probably won’t
get an accurate reading.
If the fluid level is between the MIN and MAX marks,
you have enough. If you need fluid, add only enough of
the proper fluid to bring it in between the MIN and
MAX marks.
5-43

Brakes
Brake Fluid
If your vehicle has hydraulic brakes, there is a brake
master cylinder. Refer to the Maintenance Schedule to
determine when to check your brake fluid.
{CAUTION:
Do not add brake uid before you check the
level. If you do, you could get too much brake
uid. Brake uid could spill on the hot engine
and it can catch re. You could be burned and
your vehicle could be damaged. See “Checking
Brake Fluid” in this section.
5-46

What to Add
Use the proper fluid listed in your Maintenance
Schedule. Use new brake fluid from a sealed
container only.
Always clean the brake fluid reservoir cap/cover and the
area around the cap/cover before removing it. This
will help keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or
they may not even work at all. This could
cause a crash. Always use the proper brake
uid.Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system
parts so badly that they will have to be replaced.
Do not let someone put in the wrong kind of
uid, and do not use DOT-5 silicone brake uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeAppearance
Care on page 5-76.
5-48

Air Brake Systems
If your vehicle has air brakes, it is important to get rid of
moisture in your system. Moisture will damage your
system if it is not removed daily.
There are two ways to do this. One is automatic if your
air-brake vehicle has the optional moisture ejector. If
your vehicle does not have that option, you must drain
the air reservoirs occasionally to be sure the air
dryer is working properly.
Drain the air brakes at full system pressure. To be sure
you are at full pressure, check your air pressure
gage. It should read at least 100 psi (692 kPa).
Moisture Ejector
If you have air brakes with a moisture ejector, the valve
automatically ejects moisture from the reserve tank
when the air compressor cycles.
Air Dryer
If your vehicle has air brakes, it may have an air dryer.
This collects and removes dirt, moisture or other
foreign matter from the air prior to entering the brake
system. It is mounted on the passenger’s side frame rail.
If your dryer is a Bendix-Westinghouse, it has a filter
that you need to change at intervals. SeeScheduled
Maintenance on page 6-5for more about servicing this
filter.
5-50

Electric Air Compressor
Your vehicle may have an electric air compressor. This
compressor is used to run options that require
pressurized air, such as air horn, air seat, exhaust
restrictor or an exhaust brake.
The air compressor is used when vehicles are not
equipped with an air brake system.
The air supply for this
system must be
maintained by releasing
the drain valve to eject any
moisture that may have
built up in the system.
It is recommended that this system be drained on a
weekly basis.
Clutch Pedal Free Travel
If you have a manual transmission, your clutch will need
adjustment when pedal free travel gets down to about
1/4 inch (32 mm), as measured at the clutch pedal pad.
You should have 1 1/2 to 2 inches (38 to 51 mm) of
clutch pedal free travel. SeeScheduled Maintenance on
page 6-5for more information.
If your clutch ever needs service, be sure to use only
GM clutch replacement parts.
Chassis Lubrication
Your Maintenance Schedule provides all of the required
chassis lubrication intervals and identifies proper
lubricants to use. Be sure to see your Maintenance
Schedule before performing any chassis lubrication
service. To determine location of chassis lubrication
items, use the following charts.
5-51

Rear Axle
When to Check and Change Lubricant
Refer to the Maintenance Schedule to determine
how often to check the lubricant and when to change it.
SeeScheduled Maintenance on page 6-5.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the bottom of the filler plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the filler plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart C: Recommended
Fluids and Lubricants on page 6-29.
Rear Axle Shift Motor
When to Check and Change Fluid
If you have an optional air-shift two-speed, controlled
traction, or locking differential type rear axle, a good time
to check the fluid level in the axle shift motor is when
the rear axle lubricant is checked. Use refrigerant
oil (shift motor only).
How to Check Fluid
Remove the plug on the front plate of the axle shift
motor, add enough fluid to raise the level to the bottom
of the filler plug hole, then replace the plug.
What to Use
Refer to your Maintenance Schedule to determine what
kind of lubricant to use. SeePart C: Recommended
Fluids and Lubricants on page 6-29.
5-61

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.
5-62