service CHEVROLET KODIAK 2004 Owners Manual

United States
GM Medium Duty Truck
Customer Assistance Center
P.O. Box 44947
Detroit, MI 48244
1-800-TO-CHEVY (1-800-862-4389)
1-800-833-2438 (For Text Telephone devices (TTYs))
Roadside Assistance: 1-800-TO-CHEVY
Fax Number: 313-381-0022
From Puerto Rico:
1-800-496-9992 (English)
1-800-496-9993 (Spanish)
Fax Number: 313-381-0022
From U.S. Virgin Islands:
1-800-496-9994
Fax Number: 313-381-0022
Canada
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
1-800-263-3777 (English)
1-800-263-7854 (French)
1-800-263-3830 (For Text Telephone devices (TTYs))
Roadside Assistance: 1-800-268-6800
All Overseas Locations
Please contact the local General Motors Business Unit.
Mexico, Central America and
Caribbean Islands/Countries (Except
Puerto Rico and U.S. Virgin Islands)
General Motors de Mexico, S. de R.L. de C.V.
Customer Assistance Center
Paseo de la Reforma # 2740
Col. Lomas de Bezares
C.P. 11910, Mexico, D.F.
01-800-508-0000
Long Distance: 011-52-53 29 0 800
Roadside Assistance Program
GM Medium Duty Truck’s Roadside Assistance provides
stranded owners with towing service for disabled
vehicles during the base warranty period. This service
combines the efforts of trained telephone representatives
with a network of GM Medium Duty Truck’s dealer
services.
7-4

In addition, once GM collects or receives data, GM may
•use the data for GM research needs,
•make it available for research where appropriate
confidentiality is to be maintained and need is
shown, or
•share summary data which is not tied to a specific
vehicle with non-GM organizations for research
purposes.
Others, such as law enforcement, may have access to
the special equipment that can read the information
if they have access to the vehicle or SDM.
If your vehicle is equipped with OnStar
®, please check
the OnStar®subscription service agreement or
manual for information on its operations and data
collection.
Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
7-6

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you’ll notify us.
Please call us at 1-800-862-4389, or write:
GM Medium Duty Truck
Customer Assistance Center
P.O. Box 44947
Detroit, MI 48244In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-7

Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
Owner’s Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner’s manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner’s Manual and
Warranty Booklet.
RETAIL SELL PRICE: $35.00
Without Portfolio: Owner’s Manual only.
RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P. O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-8

Audio System(s).............................................3-45
AM-FM Radio.............................................3-46
Care of Your Cassette Tape Player................3-57
Care of Your CD Player...............................3-59
Care of Your CDs........................................3-59
Chime Level Adjustment...............................3-59
Fixed Mast Antenna.....................................3-59
Radio with Cassette.....................................3-48
Radio with CD............................................3-53
Setting the Time..........................................3-45
Theft-Deterrent Feature................................3-57
Understanding Radio Reception.....................3-57
Automatic Ether Injection System......................5-66
Automatic Transmission...........................2-13, 2-19
Fluid..........................................................5-31
Operation...................................................2-28
Automatic Transmission External Filter...............5-31
Automatic Transmission Shift Indicator Check......6-26
Axle, Two-Speed Rear Axle Electric
Shift Control...............................................2-26
B
Battery..........................................................5-55
Battery Replacement......................................... 2-5
Bench Seat, Split............................................. 1-6
Body Lubrication Service..................................6-25Brake
Diesel Engine Exhaust.................................2-25
Exhaust Indicator Light.................................3-40
Parking Warning Light..................................3-34
System Warning Light..................................3-31
Trailer Hand Control Valve.............................. 4-9
Brake Adjustment............................................5-49
Brake Fluid....................................................5-46
Brake Pedal Travel.........................................5-49
Brake System Check.......................................6-26
Brakes..........................................................5-46
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-11
Bucket Seats................................................... 1-2
Bulb Replacement
Replacement Bulbs......................................5-63
C
Canada........................................................... 7-4
Canadian Owners................................................ ii
Capacities and Specifications............................5-93
Carbon Monoxide...................................4-25, 2-37
2

Compact Disc Messages..................................3-56
Control of a Vehicle.......................................... 4-5
Coolant
Engine Temperature Gage............................3-35
Heater, Engine............................................2-23
Low Warning Light.......................................3-36
Surge Tank Pressure Cap.............................5-35
Cooling System..............................................5-38
Cooling System Capacity.................................5-94
Cruise Control................................................3-10
Current and Past Model Order Forms.................. 7-8
Customer Assistance Information
Customer Assistance for Text Telephone
(TTY) Users.............................................. 7-3
Customer Assistance Offices........................... 7-3
Customer Satisfaction Procedure..................... 7-2
Reporting Safety Defects to General Motors...... 7-7
Reporting Safety Defects to the Canadian
Government.............................................. 7-7
Reporting Safety Defects to the United
States Government.................................... 7-6
Roadside Assistance Program......................... 7-4
Service Publications Ordering Information......... 7-7
D
Daytime Running Lamps..................................3-14
Daytime Running Lamps Indicator Light.............3-41
Defensive Driving............................................. 4-2Defogging and Defrosting.................................3-20
Defroster Check..............................................6-27
Diesel Engine
Exhaust Brake............................................2-25
Fuel............................................................ 5-8
Starting......................................................2-14
Starting Your DURAMAX™...........................2-19
Diesel Engine Warm-Up...................................2-16
Differential Lock Control, Inter-Axle....................4-10
Differential Lock Control, Rear Axle...................4-10
Differential Lock Indicator Light.........................3-40
Doing Your Own Service Work........................... 5-4
Dome Lamps.................................................3-15
Door
Locks.......................................................... 2-6
Power Door Locks......................................... 2-7
Door Latches Check........................................6-27
Double-Clutching.............................................2-30
Driver
Position, Safety Belt.....................................1-13
Driving
At Night.....................................................4-17
City...........................................................4-21
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-22
Hill and Mountain Roads..............................4-23
In Rain and on Wet Roads...........................4-18
Winter........................................................4-25
4

Driving on Snow or Ice....................................4-26
Driving Through Deep Standing Water...............4-20
Driving Through Flowing Water.........................4-20
Dual Tire Operation.........................................5-69
E
Eaton®Fuller®Five and Six-Speed
Transmissions and TTC Spicer Seven-Speed
Transmissions.............................................2-30
Eaton
®Fuller®Nine and Ten-Speed
Non-Synchronized Manual Transmissions........2-32
Electric Air Compressor...................................5-51
Electrical Connections......................................4-36
Electrical System
Add-On Equipment......................................5-86
Fuses and Circuit Breakers...........................5-87
Fusible Links..............................................5-87
Headlamp Wiring.........................................5-86
Power Windows and Other Power Options......5-87
Windshield Wiper Fuses...............................5-87
Elevated Idle/Exhaust Restrictor........................2-21
Engine
Air Cleaner/Filter.........................................5-30
Battery.......................................................5-55
Change Engine Oil Light...............................3-39
Check and Service Engine Soon Light............3-37Engine (cont.)
Checks Before Operating..............................2-22
Coolant..............................................5-32, 5-35
Coolant Heater............................................2-23
Coolant Temperature Gage...........................3-35
Diesel Engine Exhaust Brake........................2-25
Drive Belt Routing......................................5-103
Exhaust.....................................................2-37
Fan Noise..................................................5-43
Oil .....................................................5-20, 5-25
Overheating................................................5-36
Overspeed Warning Light..............................3-39
Reduced Power Light...................................3-41
Shutdown Warning Light...............................3-39
Starting Your Diesel.....................................2-14
Starting Your DURAMAX™ Diesel..................2-19
Starting Your Gasoline..................................2-12
Engine Alarm and Automatic Shutdown..............2-16
Engine Coolant Level Check.............................6-24
Engine Cooling System Service........................6-26
Engine Cover Check.......................................6-28
Engine Oil Additives................................5-23, 5-29
Engine Oil Level Check...................................6-24
Engine Road Speed Governor..........................3-25
Engine Speed Limiting.....................................3-25
Engine Starter Over-Crank Protection.................2-12
Event Data Records (EDR)................................ 7-5
Exhaust Brake Indicator Light...........................3-40
5

I
If No Steam Is Coming From Your Engine..........5-37
If Steam Is Coming From Your Engine...............5-36
If You Are Caught in a Blizzard.........................4-27
If You Are Stuck in Sand, Mud, Ice or Snow.......4-29
If Your Diesel Engine Won’t Start......................2-20
Ignition Positions.............................................2-12
Illuminated Entry.............................................3-16
Infants and Young Children, Restraints...............1-29
Inflation - Tire Pressure...................................5-68
Instrument Panel
Cluster.......................................................3-24
Overview..................................................... 3-4
Switchbank.................................................3-16
Instrument Panel Brightness Control..................3-15
Instrument Panel Fuse Block............................5-88
Inter-Axle Differential Lock Control.....................4-10
Interior Lamps................................................3-15
J
Jump Starting.................................................5-56
K
Key Lock Cylinders Service..............................6-28
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps
Exterior......................................................3-13
Interior.......................................................3-15
Lamps Check.................................................6-27
Lap Belt........................................................1-22
Lap-Shoulder Belt...........................................1-13
Light
Air Bag Off .................................................3-28
Air Bag Readiness.......................................3-27
Anti-Lock Brake System Warning...................3-34
Brake System Warning.................................3-31
Change Engine Oil......................................3-39
Charging System.........................................3-30
Check Gages Warning.................................3-42
Daytime Running Lamps Indicator..................3-41
8

Light (cont.)
Differential Lock Indicator..............................3-40
Engine Overspeed Warning...........................3-39
Engine Shutdown Warning............................3-39
Exhaust Brake Indicator................................3-40
Low Coolant Warning...................................3-36
Low Oil Level.............................................3-38
Low Washer Fluid Warning...........................3-42
Malfunction Indicator....................................3-37
Parking Brake Warning.................................3-34
Range Inhibit Warning Indicator.....................3-31
Reduced Engine Power................................3-41
Safety Belt Reminder...................................3-26
Safety Belt Reminder Tone...........................3-26
Service Transmission Warning.......................3-31
Trailer Anti-Lock Brake System Warning..........3-35
Wait to Start Indicator..................................3-36
Water in Fuel Warning.................................3-43
Loading Your Vehicle.......................................4-33
Lockout Feature..............................................2-10
Locks
Door........................................................... 2-6
Power Door.................................................. 2-7
Loss of Control...............................................4-16
Low Coolant Warning Light..............................3-36
Low Washer Fluid Warning Light.......................3-42
Lumbar Adjustments.......................................... 1-3M
Maintenance, Normal Replacement Parts..........5-100
Maintenance Schedule
At Each Fuel Fill.........................................6-24
At Least Once a Year..................................6-28
At Least Twice a Year..................................6-25
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-24
Part C - Recommended Fluids and
Lubricants...............................................6-29
Part D - Maintenance Record........................6-31
Scheduled Maintenance................................. 6-5
Scheduled Maintenance Supplements............... 6-4
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Malfunction Indicator Light................................3-37
Manual Seats................................................... 1-2
Manual Transmission.......................2-13, 2-19, 2-26
Fluid..........................................................5-32
Operation...................................................2-30
Manual Windows.............................................. 2-8
Marker Lamp Defeat Switch.............................3-14
9

Matching Transmitter(s) to Your Vehicle............... 2-5
Mexico, Central America and Caribbean
Islands/Countries (Except Puerto Rico and
U.S. Virgin Islands)....................................... 7-4
Mirrors
Manual Rearview Mirror................................2-39
Outside Convex Mirrors................................2-40
Outside Heated Mirrors................................2-41
Outside Manual Mirrors................................2-39
Outside Power Mirrors..................................2-40
Mirrors and Sun Visors Check..........................6-27
Model Reference................................................ vi
Moisture Ejector..............................................5-50
MyGMLink.com................................................ 7-3
N
New Vehicle Break-In......................................2-11
Noise Control System, Tampering......................5-62
Normal Maintenance Replacement Parts...........5-100
O
Odometer......................................................3-25
Off-Road Recovery..........................................4-14Oil
Change Engine Oil Light...............................3-39
Engine...............................................5-20, 5-25
Low Oil Level Light......................................3-38
Pressure Gage............................................3-37
Older Children, Restraints................................1-27
Online Owner Center........................................ 7-3
Other Service Items
Air Conditioning System...............................5-67
Automatic Ether Injection System...................5-66
Front Wheel Bearings with Oil-Filled Hubs.......5-67
Fuel Filter...................................................5-64
Primary Fuel Filter and Water Separator.........5-65
Secondary Fuel Filter and Water Separator/
Heater....................................................5-66
Other Warning Devices...................................... 3-6
Outlet Adjustment............................................3-22
Outside
Convex Mirrors............................................2-40
Heated Mirrors............................................2-41
Manual Mirrors............................................2-39
Power Mirrors.............................................2-40
Overdrive Defeat.............................................2-29
Overspeed Warning Light.................................3-39
Owners, Canadian............................................... ii
Owner’s Information.......................................... 7-8
10