suspension CHEVROLET KODIAK 2004 User Guide

Center Console Storage Area
Your vehicle may have a center console compartment
between the bucket or suspension seats.
The back of your center bench seat may also fold
forward to reveal a console compartment.
The release strap for the
center console is located
between the center
seat and passenger’s seat.To expose the storage compartment, pull the strap to
release the seatback. Then fold the seatback forward.
To open the storage compartment, press the release
button and lift the lid rearward. With the lid closed, it can
be used as a clipboard to hold papers in place.
Before returning the seatback to the upright position,
make sure the console is snapped shut. Lift the
seatback all the way up until it clicks. Push and pull on
the seatback to make sure the seat is locked in
place.
2-42

This switchbank is located in the center of the instrument
panel.
e(Marker Lamp Defeat Switch):See “Marker Lamp
Defeat Switch” underExterior Lamps on page 3-13.
j(Manual High Idle Switch):See “Manual High Idle
System” underStarting Your Diesel Engine on
page 2-14.
i(Traction Control Switch):SeeTraction Control
System (TCS) on page 4-11.
f(Outside Heated Mirror Switch):SeeOutside
Heated Mirrors on page 2-41.
g(Power Take Off Switch):SeePower Take-Off
(PTO) on page 4-36.
h(Rear Air Suspension Dump Control
Switch):See “Rear Air Suspension Dump Control”
underTwo-Speed Rear Axle Electric Shift Control
on page 2-26.
k(Rear Axle Shift Control Switch):See “Air Shift
Control” (Automatic Transmission) underTwo-Speed
Rear Axle Electric Shift Control on page 2-26.
Exhaust Brake Switch:SeeDiesel Engine Exhaust
Brake on page 2-25.
l(Differential Lock Control Switch):SeeRear
Axle Differential Lock Control on page 4-10.
cd(Air Bag Off Switch):SeeAir Bag Off Switch
on page 1-55.
If your vehicle does not have some of the features
controlled by these switches, there will be a blank switch
marker in its place.
Accessory Power Outlets
With accessory power outlets, you can plug in auxiliary
electrical equipment such as a cellular telephone or
CB radio.
The accessory power outlets are located on the
passenger’s side of the instrument panel.
To use an outlet, pull the cover down. When not using
it, always cover the outlet with the protective cap.
These circuits are protected by a fuse and have
maximum current levels.
Notice:Leaving electrical equipment on for
extended periods will drain the battery. Always turn
off electrical equipment when not in use and do
not plug in equipment that exceeds the maximum
amperage rating.
3-17

The GVW Rating label is provided by the final
manufacturer and should be on the door or door jamb. It
also tells you the maximum weights for the front and rear
axles, called Gross Axle Weight Rating (GAWR). To find
out the actual loads on your front and rear axles, you
need to go to a weigh station and weigh your vehicle.
Your dealer can help you with this. Be sure to spread out
your load equally on both sides of the center line.
Never exceed the GVWR for your vehicle, or the GAWR
for either the front or rear axle.
And, if you do have a heavy load, you should spread
it out.
{CAUTION:
Do not load your vehicle any heavier than the
GVWR, or either the maximum front or rear
GAWR. If you do, parts on your vehicle can
break, and it can change the way your vehicle
handles. These could cause you to lose
control and crash. Also, overloading can
shorten the life of your vehicle.
Using heavier suspension components to get added
durability might not change your weight ratings. Ask your
dealer to help you load your vehicle the right way.Notice:Overloading your vehicle may cause
damage. Repairs would not be covered by your
warranty. Do not overload your vehicle.
If you put things inside your vehicle – like suitcases,
tools, packages or anything else – they will go as fast as
the vehicle goes. If you have to stop or turn quickly,
or if there is a crash, they’ll keep going.
{CAUTION:
Things you put inside your vehicle can strike
and injure people in a sudden stop or turn, or
in a crash.
Put things in the cargo area of your
vehicle. Try to spread the weight evenly.
Never stack heavier things, like suitcases,
inside the vehicle so that some of them
are above the tops of the seats.
Do not leave an unsecured child restraint
in your vehicle.
When you carry something inside the
vehicle, secure it whenever you can.
Do not leave a seat folded down unless
you need to.
4-34

10,000 Miles (16 000 km)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
15,000 Miles (24 000 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. SeeEngine 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)
❑Thermostatically controlled engine cooling fan
service.(4) (20)
❑Shields and underhood insulation service.(4) (5) (21)
6-6

30,000 Miles (48 000 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)
❑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. SeeEngine 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)
❑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)
❑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)
6-8

45,000 Miles (72 000 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)
❑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.
❑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)❑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)
6-10

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

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

❑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

(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