brake CHEVROLET KODIAK 2004 Workshop Manual

Loss of Control
Let us review what driving experts say about what
happens when the three control systems (brakes,
steering and acceleration) do not have enough friction
where the tires meet the road to do what the driver
has asked.
In any emergency, do not give up. Keep trying to steer
and constantly seek an escape route or area of less
danger.
Skidding
In a skid, a driver can lose control of the vehicle.
Defensive drivers avoid most skids by taking reasonable
care suited to existing conditions, and by not
“overdriving” those conditions. But skids are always
possible.
The three types of skids correspond to your vehicle’s
three control systems. In the braking skid, your wheels
are not rolling. In the steering or cornering skid, too much
speed or steering in a curve causes tires to slip and lose
cornering force. And in the acceleration skid, too much
throttle causes the driving wheels to spin.
A cornering skid is best handled by easing your foot off
the accelerator pedal.If you have the Traction Control System, remember: It
helps avoid only the acceleration skid. If you do not have
this system, or if the system is off, then an acceleration
skid is also best handled by easing your foot off the
accelerator pedal.
Of course, traction is reduced when water, snow, ice,
gravel or other material is on the road. For safety,
you will want to slow down and adjust your driving to
these conditions. It is important to slow down on slippery
surfaces because stopping distance will be longer and
vehicle control more limited.
While driving on a surface with reduced traction, try
your best to avoid sudden steering, acceleration
or braking (including engine braking by shifting to a
lower gear). Any sudden changes could cause the tires
to slide. You may not realize the surface is slippery
until your vehicle is skidding. Learn to recognize warning
clues — such as enough water, ice or packed snow
on the road to make a “mirrored surface” — and slow
down when you have any doubt.
If you have the anti-lock braking system, remember: It
helps avoid only the braking skid. If you do not have
anti-lock, then in a braking skid (where the wheels are
no longer rolling), release enough pressure on the
brakes to get the wheels rolling again. This restores
steering control. Push the brake pedal down steadily
when you have to stop suddenly. As long as the wheels
are rolling, you will have steering control.
4-16

The heavier the rain, the harder it is to see. Even if your
windshield wiper blades are in good shape, a heavy
rain can make it harder to see road signs and
traffic signals, pavement markings, the edge of the road
and even people walking.
It is wise to keep your wiping equipment in good shape
and keep your windshield washer tank filled with
washer fluid. Replace your windshield wiper inserts
when they show signs of streaking or missing areas on
the windshield, or when strips of rubber start to
separate from the inserts.Driving too fast through large water puddles or even
going through some vehicle washes can cause
problems, too. The water may affect your brakes. Try to
avoid puddles. But if you can not, try to slow down
before you hit them.
{CAUTION:
Wet brakes can cause accidents. They will not
work as well in a quick stop and may cause
pulling to one side. You could lose control of
the vehicle.
After driving through a large puddle of water
or a vehicle wash, apply your brake pedal
lightly until your brakes work normally.
4-19

Here are some tips that can make your drive through
steep country safer:
•Keep the vehicle in good shape. Check all fluid
levels and also the brakes, tires, cooling system
and transmission. These parts can work hard
on mountain roads.
•Know how to go down hills. The most important
thing to know is this: let your engine do some of
the slowing down. Shift to a lower gear when you go
down a steep or long hill.
{CAUTION:
If you do not shift down, your brakes could get
so hot that they would not work well. You
would then have poor braking or even none
going down a hill. You could crash. Shift down
to let your engine assist your brakes on a
steep downhill slope.
{CAUTION:
Coasting downhill in NEUTRAL (N) or with the
ignition off is dangerous. Your brakes will have
to do all the work of slowing down. They could
get so hot that they would not work well. You
would then have poor braking or even none
going down a hill. You could crash. Always
have your engine running and your vehicle in
gear when you go downhill.
•Know how to go uphill. Use lower gears. They help
cool your engine and transmission, and you can
climb the hill better.
•Stay in your own lane when driving on two-lane
roads in hills or mountains. Do not swing wide
or cut across the center of the road. Drive at speeds
that let you stay in your own lane.
•As you go over the top of a hill, be alert. There
could be something in your lane, like a stalled car or
an accident.
•You may se highway signs on mountains that warn
of special problems. Examples are long grades,
passing or no-passing zones, a falling rocks area,
winding roads and special truck lanes. Be alert
to these and take appropriate action.
4-24

Unless you have the anti-lock braking system, you will
want to brake very gently, too. If you do have anti-lock,
seeBraking on page 4-6. This system improves your
vehicle’s stability when you make a hard stop on a
slippery road. Whether you have the anti-lock braking
system or not, you will want to begin stopping
sooner than you would on dry pavement. Without
anti-lock brakes, if you feel your vehicle begin to slide,
let up on the brakes a little. Push the brake pedal
down steadily to get the most traction you can.
Remember, unless you have anti-lock, if you brake so
hard that your wheels stop rolling, you will just slide.
Brake so your wheels always keep rolling and you can
still steer.
•Whatever your braking system, allow greater
following distance on any slippery road.
•Watch for slippery spots. The road might be fine
until you hit a spot that is covered with ice. On
an otherwise clear road, ice patches may appear in
shaded areas where the sun can not reach:
around clumps of trees, behind buildings or under
bridges. Sometimes the surface of a curve or
an overpass may remain icy when the surrounding
roads are clear. If you see a patch of ice ahead
of you, brake before you are on it. Try not to brake
while you are actually on the ice, and avoid
sudden steering maneuvers.
If You Are Caught in a Blizzard
If you are stopped by heavy snow, you could be in a
serious situation. You should probably stay with
your vehicle unless you know for sure that you are near
help and you can hike through the snow. Here are
some things to do to summon help and keep yourself
and your passengers safe:
•Turn on your hazard flashers.
•Tie a red cloth to your mirror arm to alert police that
you have been stopped by the snow.
4-27

{CAUTION:
These hooks, when used, are under a lot of
force. Always pull the vehicle straight out.
Never pull on the hooks at a sideways angle.
The hooks could break off and you or others
could be injured from the chain or cable
snapping back.
Notice:Never use tow hooks to tow the vehicle.
Your vehicle could be damaged and it would not be
covered by warranty.
Towing
Towing Your Vehicle
Consult your dealer or a professional towing service if
you need to have your disabled vehicle towed. See
Roadside Assistance Program on page 7-4.
Releasing Air-Operated Parking Brakes
If your vehicle has air brakes, you could have a
special towing problem. If your vehicle has to be towed
because of a complete loss of air pressure from
both systems, the parking brakes will have automatically
engaged. The tow operator can release the brakes
manually by using the following steps. Then your vehicle
can be towed with all wheels or only the rear wheels
on the ground.
1. Block the wheels of the vehicle.
4-31

2. Remove the release stud and nut from the side of
the brake chamber. Some chambers have studs
which are visible at all times.3. Remove the rubber
cap from the rear of
the chamber.
4. Put the release stud, nut and flat washer into the
chamber.
5. Turn the stud clockwise a quarter of a turn.
4-32

6. Turn the stud nut
clockwise several turns
to release the brakes.
Follow the same
procedure to release
the other brake.
7. At the repair facility, apply air pressure of at least
70 psi (480 kPa) to the brake chambers, either
from an external air supply or the vehicle’s
air system.
8. Turn the stud nut counterclockwise several turns.
Remove the stud from the chamber.
9. Replace the stud and washer and tighten the nut
into the side of the chamber.
10. Replace the rubber cap.Loading Your Vehicle
There is a GVW Rating label on your vehicle that shows
how much weight it may properly carry. It also shows
the size of your original tires and the inflation pressures
needed to obtain the gross weight capacity of your vehicle.
This is called the Gross Vehicle Weight Rating (GVWR).
The GVWR includes the weight of the vehicle, all
occupants, fuel and cargo.
4-33

Trailer Connections
(C4/C5 Models Only)
Heavy-Duty Trailer Wiring Package
Your vehicle may be equipped with an eight-wire trailer
towing harness. This harness, with a seven-pin
universal heavy-duty trailer connector, is attached to a
bracket on the platform hitch.
The Center High-Mounted Stoplamp (CHMSL) wire is
tied next to the trailer wiring harness for use with a
trailer.The eight-wire harness contains the following trailer
circuits:
•Yellow: Left Stop/Turn Signal
•Dark Green: Right Stop/Turn Signal
•Brown: Taillamps
•White: Ground
•Light Green: Back-up Lamps
•Light Blue: CHMSL
•Red: Battery Feed
•Dark Blue: Trailer Brake
4-35

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Two Safety Cautions about Engine Fan
Breakage...................................................5-5
Fuel................................................................5-6
Gasoline Octane............................................5-6
Gasoline Specifications....................................5-6
Additives.......................................................5-7
Diesel Engine Fuel.........................................5-8
What Fuel to Use...........................................5-8
Very Cold Weather Operation.........................5-10
Water in Fuel...............................................5-10
Running Out of Fuel.....................................5-15
Fuel Filter Replacement.................................5-15
Fuels in Foreign Countries.............................5-16
Filling Your Tank..........................................5-17
Filling a Portable Fuel Container.....................5-18
Checking Things Under the Hood....................5-18
Hood Latches...............................................5-19
Engine Oil (Caterpillar
®Diesel Engine).............5-20
Engine Oil (Gasoline Engine)..........................5-20
Engine Oil (DURAMAX™ Diesel).....................5-25
Engine Air Cleaner/Filter................................5-30
Automatic Transmission Fluid.........................5-31
Manual Transmission Fluid.............................5-32Engine Coolant (Gas and
DURAMAX™ engines)................................5-32
Engine Coolant (Caterpillar
®Diesel Engines).....5-35
Coolant Surge Tank Pressure Cap..................5-35
Engine Overheating.......................................5-36
Cooling System............................................5-38
Engine Fan Noise.........................................5-43
Power Steering Fluid.....................................5-43
Windshield Washer Fluid................................5-44
Brakes........................................................5-46
Battery........................................................5-55
Jump Starting...............................................5-56
Rear Axle.......................................................5-61
Rear Axle Shift Motor....................................5-61
Noise Control System.....................................5-62
Tampering with Noise Control System
Prohibited.................................................5-62
Bulb Replacement..........................................5-63
Replacement Bulbs.......................................5-63
Windshield Wiper Blade Replacement..............5-63
Other Service Items........................................5-64
Fuel Filter....................................................5-64
Primary Fuel Filter and Water Separator..........5-65
Secondary Fuel Filter and Water
Separator/Heater.......................................5-66
Section 5 Service and Appearance Care
5-1

To drain water, do the following:
1. Stop and park the vehicle in a safe place. Turn off
the engine and apply the parking brake.
2. Remove the fuel cap.
3. Place a fuel-resistant container under the fuel filter.
The filter drain valve is located on the bottom of the
fuel filter. The fuel filter is located in the engine
compartment on the passenger’s side of the vehicle,
or on the driver’s side frame rail near the engine.
4. Open the drain valve
by turning two to three
turns. When fuel
empties from the valve,
all the water has
been drained. Close
the valve hand tight.5. Remove the fuel-resistant container and properly
dispose of the contaminated fuel. To find out how
to properly dispose of contaminated diesel fuel, see
Engine Oil (Caterpillar
®Diesel Engine) on
page 5-20orEngine Oil (Gasoline Engine) on
page 5-20orEngine Oil (DURAMAX™ Diesel) on
page 5-25for more information.
6. Install the fuel cap.
7. Start the engine and let it run for a few minutes. If
the engine stalls, the fuel system may need to be
primed. While draining the water from the fuel filter,
air may enter the fuel system. If air has entered
the fuel system the fuel system will need to
be primed.
If the water in fuel light comes on again after driving a
short distance or the engine runs rough or stalls, a large
amount of water has probably been pumped into the
fuel tank. The fuel tank should be purged.
5-12