relay CHEVROLET KODIAK 2004 User Guide

60,000 Miles (96 000 km)
❑Gasoline Engine Only: Check Oil Life System.
If engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(3) (9)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
❑Gasoline Engine Only (Vehicles with GVW greater
than 16,000 lbs.): Spark plug service.(3) (28)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Gasoline Engine: Replace engine air cleaner filter.
Diesel Engine: Inspect engine air cleaner filter
change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Replace fuel filter(s) (or every 12 months, whichever
occurs first).(3)
❑Inspect door hinge pins and bushings and replace as
necessary.❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months,
whichever occurs first).(3) (4) (17)
❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every
3 months, or every 900 hours, whichever occurs
first).(42)
6-12

❑C600, C700 and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first).(18)
❑Thermostatically controlled engine cooling fan
service.(4) (20)
❑Shields and underhood insulation service.(4) (5) (21)
❑Air compressor dry element pleated paper air
strainer service (or every 2 months or every
800 hours, whichever occurs first).
67,500 Miles (108 000 km)
❑Gasoline Engine Only: Check Oil Life System. If
engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(3) (9)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Cooling system service. Clean the cooling system filler
cap with clean water, clean the core, pressure test the
cap and the system for proper pressure capability and
inspect condition of cooling and heater hoses and
clamps. Replace hoses if cracked, swollen or
damaged.
❑Wheel bearing (grease type) service (or every 24
months, whichever occurs first, and whenever hubs
are removed).(23) (46)❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every
3 months, or every 900 hours, whichever occurs
first).(42)
❑Rear axle air shift motor service.(11)
❑Air intake system service (or every 24 months,
whichever occurs first).(4) (5) (24)
❑Evaporative Control System service (if equipped) (or
every 24 months, whichever occurs first).(3) (26) †
6-13

70,000 Miles (112 000 km)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
75,000 Miles (120 000 km)
❑Gasoline Engine Only: Check Oil Life System. If
engine oil and filter are changed, reset system. See
“Engine Oil (Gasoline Engine)” in the Index.(3) (9)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Gasoline Engine: Inspect engine air cleaner filter if you
are driving in dusty conditions and replace filter if
necessary. Diesel Engine: Inspect engine air cleaner
filter change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months, whichever
occurs first).(3) (4) (17)❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months, whichever
occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every
3 months, or every 900 hours, whichever occurs
first).(42)
❑Fuel tank, fuel cap and fuel lines service (or every
72 months, whichever occurs first).(3) (30) †
❑EGR system inspection (if equipped) (or every
72 months, whichever occurs first).(3) (31)
❑Thermostatically controlled engine cooling fan
service.(4) (20)
❑Shields and underhood insulation service.(4) (5) (21)
6-14

80,000 Miles (128 000 km)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
❑Air compressor dry element pleated paper air strainer
service (or every 2 months or every 800 hours,
whichever occurs first).
82,500 Miles (132 000 km)
❑Gasoline Engine Only: Check Oil Life System. If
engine oil and filter are changed, reset system.
See “Engine Oil (Gasoline Engine)” in the
Index.(3) (9)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every
3 months, or every 900 hours, whichever occurs
first).(42)
❑Wheel bearings service – Eaton Axle (oil-filled) (or
every 24 months, whichever occurs first).(23) (46)
90,000 Miles (144 000 km)
❑Gasoline Engine Only: Check Oil Life System. If
engine oil and filter are changed, reset system.
See “Engine Oil (Gasoline Engine)” in the
Index.(3) (9)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
6-15

❑Gasoline Engine: Replace engine air cleaner filter.
Diesel Engine: Inspect engine air cleaner filter
change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Cooling system service. Clean the cooling system
filler cap with clean water, clean the core, pressure
test the cap and the system for proper pressure
capability and inspect condition of cooling and heater
hoses and clamps. Replace hoses if cracked,
swollen or damaged.
❑Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever
hubs are removed).(23) (46)
❑Replace fuel filter(s) (or every 12 months, whichever
occurs first).(3)
❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months,
whichever occurs first).(3) (4) (17)❑Inspect door hinge pins and bushings and replace as
necessary.
❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)
❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every
3 months, or every 900 hours, whichever occurs
first).(42)
❑C600, C700 and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first).(18)
6-16

❑Thermostatically controlled engine cooling fan
service.(4) (20)
❑Shields and underhood insulation service.(4) (5) (21)
❑Rear axle air shift motor service.(11)
❑Air intake system service (or every 24 months,
whichever occurs first).(4) (5) (24)
❑Evaporative Control System service (if equipped) (or
every 24 months, whichever occurs first).(3) (26) †
97,500 Miles (156 000 km)
❑Gasoline Engine Only: Check Oil Life System. If
engine oil and filter are changed, reset system.
See “Engine Oil (Gasoline Engine)” in the
Index.(3) (9)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Wheels and tires service.(15)
❑Hydraulic brake service (or every 6 months,
whichever occurs first).(7) (46)
❑Parking brake service (or every 6 months, whichever
occurs first).(8)
❑Air brake service (or every 6 months, whichever
occurs first).(39)❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(40)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first). Lubricate
linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(41)
❑Trailer brake hand control valve service (or every 3
months, or every 900 hours, whichever occurs
first).(42)
100,000 Miles (160 000 km)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
❑Diesel Only: Inspect engine drive belt; replace as
necessary.
❑Gasoline Engine Only (Vehicles with GVW of
16,000 lbs. or less): Spark plug service.(3) (28)
❑Change power steering fluid (or every 36 months,
whichever occurs first).(13)
6-17

(11)= Inspect rear axle air shift motor for fluid leaks.
Remove plug to check fluid level. Inspect air lines
and hoses for proper hook-up, binding, leaks, etc.
Inspect at 1,000 miles (1 600 km) and 22,500 miles
(36 000 km) and then every 22,500 miles (36 000 km)
thereafter.
(12)= Chassis Lubrication Service: Lubricate all grease
fittings in front suspension, front axle and steering
linkage. DO NOT lubricate kingpin bushings with air
pressure equipment; instead, use a hand grease gun to
ensure complete purge and eliminate sealer cap
distortion. Front axle tie rod ends, both upper and lower
kingpin fittings and both steering linkage relay rod
ends should be greased with the vehicle loaded on the
ground and wheels turned straight ahead, NOT with
the vehicle on a hoist. Apply kingpin bushing lubricant to
both upper and lower kingpin grease fittings until new
lubricant purges from between the upper shim pack and
thrust bearing. Lubricate transmission and shift
linkage, hood latches and hood hinges, parking brake
lever pivot, clevis pins and linkage, disc brake caliper
rails, clutch linkage and release bearing (if equipped),
bearing pads, propshaft universal joints, brake camshaft
bracket, slack adjusters, pedal shaft, clutch cross
shaft, clutch pedal springs and clutch cable bushing at
transmission. Lubricate suspension, axle and steeringlinkage more often when operating under dusty or
muddy conditions and in excessive off-road use.
Frequently power-washed vehicles will require more
frequent lubrication.
(13)= Check steering system:
•Look for damaged, loose or missing parts. Inspect
the steering linkage relay rod and tie rod ends for
looseness or lack of lubricant. Also look for
parts showing signs of wear or lack of lubrication.
Replace parts as needed. Also check steering gear
mounting bolts, pitman arm nut, gear housing
upper cover and side cover attaching bolts, steering
column mounting bolts and cardan joint clamp
bolts; tighten if necessary. (See service manual.)
•Inspect power steering hoses, tubes and fittings for
leaks. Hoses and lines must not be twisted, kinked
or tightly bent. Make sure clips, clamps, supporting
tubes and hoses are in place and properly
secured.
•Check steering gear for leakage around pitman
shaft and housing. If leakage is evident (lubricant
oozing out, not just oily film), leak should be
corrected immediately.
6-20