wheel CHEVROLET KODIAK 2004 Repair Manual

(14)= Check front and rear suspension. Look for
damaged, loose or missing parts or parts showing signs
of wear or lack of lubrication. Replace parts as
needed.
(15)= Adjust tire pressures as indicated on the GVW
Rating label for optimum tire life. SeeTires on page 5-68
for further details. Check tires for excessive or
abnormal wear or damage. Also check for damaged
wheels. Replace wheels and/or tires as needed.
(16)= Check spring-to-axle U-bolts and shackle bolts
for proper torque. See the service manual for torque
sequence and specifications. When parts are replaced,
the torque must be checked and adjusted more often
during the first 6,000 miles (10 000 km). Check torque at
500 miles (800 km) and 2,000 miles (3 000 km) after
first use of parts.
(17)= Check complete exhaust system and cab areas
near the exhaust system for broken, damaged,
missing or out-of-position parts. Also inspect for open
seams, holes, loose connections or other conditions
which could let exhaust fumes seep into the driver
compartment. Needed repairs should be made at once.
To help maintain system integrity, replace exhaust
pipes whenever a new muffler is put on.(18)= Check all gasoline engine drive belts for cracks,
fraying and wear. Replace as needed.
(20)= With the engine off and below normal operating
temperature, check to see that the thermostatically
controlled engine cooling fan can be rotated by hand on
viscous-operated drives. Replace as needed.
(21)= Check shields and underhood insulation for
damage or looseness. Adjust or replace as needed.
23)= Wheel bearing service:
•Grease type – Clean, inspect and lubricate with the
proper wheel bearing grease at designated intervals
or when hubs are removed. SeePart C:
Recommended Fluids and Lubricants on page 6-29.
•Oil-filled type – Some wheel bearings are lubricated
by rear axle lubricant. When you have oil-filled
hubs, use lubricant identical to that used in your rear
axle. Lubricant change intervals are the same for
front and rear axles. However, you must maintain oil
level at the OIL LEVEL mark between change
intervals. SeePart C: Recommended Fluids and
Lubricants on page 6-29.
6-21

(39)= Air brake service:
•Inspect brake lines and hoses for proper hook-up,
binding, leaks, cracks, chafing, etc. Inspect drum
brake linings for wear or cracks. Inspect other brake
parts at each wheel, including drums and wheel
speed sensor wiring. Check brake pedal for
excessive free play or travel (or every 6 months,
whichever occurs first) and have serviced if needed.
Check brakes more often if driving habits and
conditions result in frequent braking. Replace air
dryer cartridge only if excessive oil or moisture
is present. A small amount of oil in the system is
normal and should not be considered as a reason to
replace the cartridge.
•Test air lines for leaks; tighten as needed. Replace
compressor filter.
•Inspect air parking brake chamber for leaks and
damage. Inspect lines and hoses for leaks,
cracks, chafing, etc. Also check all attachments for
tightness, wear or damage. Note: The spring
brake section of the rear brake diaphragms are
non-serviceable.
•Replace the air compressor filter element, mounted
on the air compressor. For remote air compressor
intake service, refer to engine air cleaner filter
replacement.
•Remove, disassemble, clean and inspect the safety
valve, standard brake chambers, quick release
valves, quick release/double check valve
combinations, parking brake control valve, double
check valves, pressure protection valves and
alcohol injector (if equipped).
•Remove, disassemble and clean the application
valve; replace parts showing wear.
•Remove, disassemble, clean and inspect the spring
brake control valve; replace rubber parts.
(40)= Clean and lubricate air brake automatic slack
adjuster. Check pushrod travel and auto adjustment
operation. Have serviced if needed.
(41)= Air brake chamber service: Check operation,
mounting, clamps and air lines and check for leaks.
(42)= Trailer brake hand control valve service: Check
operation; lubricate cam and follower.
(46)= Tighten the wheel stud nuts to the specified
torque values at 100 miles (160 km). Thereafter, tighten
them 1,000 miles (1 600 km) after each time the
wheel is removed. SeeTightening the Wheel Nuts on
page 5-71.
6-23

Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brakes. See “Parking Brake” if necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. On automatic transmission vehicles, try to start the
engine in each gear. The starter should work only
in PARK (P), if equipped, or NEUTRAL (N). If
the starter works in any other position, your vehicle
needs service.
Automatic Transmission Shift Indicator
Check
Check that the indicator points to the gear chosen.
Steering Check
Be alert for any changes in steering action, abnormal
front tire wear or steering wheel position. An inspection
or service is needed when the steering wheel is
harder to turn or has too much free play, or if there are
strange sounds when turning or parking.
Brake System Check
Be alert to illumination of the low air warning lamp or for
the tone alarm, or changes in braking action, such as
repeated pulling to one side, unusual sounds when
braking or increased brake pedal travel. Make sure air
brake system reservoirs are drained daily with full
system air pressure, and check system for leaks. Any of
these conditions could indicate the need for brake
system inspection and/or service.
Engine Cooling System Service
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser.
To help ensure proper operation, a pressure test of
the cooling system and pressure cap is recommended
at least once a year.
6-26

Usage Fluid/Lubricant
Manual
Transmission
(Except ZF
6–Speed)Synthetic Manual Transmission Fluid
(GM Part No. U.S. 12345724, in
Canada 10953510).
Manual
Transmission
(ZF 6–Speed)TranSynd™ Synthetic Transmission
Fluid (GM Part No. U.S. 12378515,
in Canada 88900701).
Automatic
TransmissionSee the Allison
Transmission
®Operator’s Manual for
correct transmission fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Chassis
LubricationChassis Lubricant (GM Part No. U.S.
12377985, in Canada 88901242) or
lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Front Wheel
Bearing Grease
(Except Oil
Filled Hubs)Wheel bearing lubricant meeting
requirements of NLGI #2, Category
GC or GC-LB (GM Part No. U.S.
1051344, in Canada 993037).
Usage Fluid/Lubricant
Front Wheel
Bearing Grease
with Oil Filled
HubsSAE 75W-90 Synthetic Axle
Lubricant for Medium Duty Trucks
(GM Part No. U.S. 12345841, in
Canada 10953512t).
Rear Axle and
Rear HubsSAE 75W-90 Synthetic Axle
Lubricant for Medium Duty Trucks
(GM Part No. U.S. 12345841, in
Canada 10953512).
Rear Axle Shift
Motor LubricantRefrigerant Oil (GM Part No.U.S.
5416939, in Canada 10953496).
Propshafts and
SplinesWheel bearing lubricant meeting
requirements of NLGI #2, Category
GC or GC-LB (GM Part No. U.S.
1051344, in Canada 993037).
Cab — Door
Hinges and
LatchesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Weatherstrip
ConditioningDielectric Silicone Grease (GM Part
No. U.S. 12345579, in Canada
992887).
Weatherstrip
SqueaksSynthetic Grease with Teflon,
Superlube (GM Part No. U.S.
12371287, in Canada 10953437).
6-30

A
Accessory Power Outlets.................................3-17
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-61
Adding Washer Fluid.......................................5-44
Additives, Fuel................................................. 5-7
Add-On Electrical Equipment............................5-86
Adjusting the Speakers
(Balance/Fade)............................3-47, 3-50, 3-54
Air Bag
Off Light.....................................................3-28
Readiness Light..........................................3-27
Air Bag System..............................................1-48
Adding Equipment to Your Air Bag-Equipped
Vehicle...................................................1-61
Air Bag Off Switch.......................................1-55
How Does an Air Bag Restrain?....................1-53
Servicing Your Air Bag-Equipped Vehicle.........1-60
What Makes an Air Bag Inflate?....................1-53
What Will You See After an Air Bag Inflates? . . 1-54
When Should an Air Bag Inflate?...................1-53
Where Are the Air Bags?..............................1-52
Air Brake.......................................................2-35
Air Brake System Warning Light........................3-33
Air Brake Systems..........................................5-50
Air Cleaner/Filter, Engine.................................5-30
Air Conditioning System...................................5-67Air Connections..............................................4-36
Air Dryer.......................................................5-50
Air Pressure Gage..........................................3-44
Air Shift Control (Automatic Transmission)..........2-27
Air Suspension...............................................2-27
Air Suspension Seats........................................ 1-6
Airbag Sensing and Diagnostic Module (SDM)...... 7-5
All Overseas Locations...................................... 7-4
Allison Transmission
®External Filters...............5-100
Aluminum or Chrome-Plated Wheels..................5-82
AM ...............................................................3-57
AM-FM Radio.................................................3-46
Antenna, Fixed Mast.......................................3-59
Anti-lock Brake System (ABS)............................ 4-7
Anti-Lock Brake, System Warning Light..............3-34
Anti-Lock Brakes, Trailer System
Warning Light.............................................3-35
Appearance Care............................................5-76
Care of Safety Belts....................................5-79
Chemical Paint Spotting...............................5-83
Cleaning the Inside of Your Vehicle................5-77
Cleaning the Outside of Your Vehicle..............5-80
Finish Damage............................................5-83
Sheet Metal Damage...................................5-82
Underbody Maintenance...............................5-83
Vehicle Care/Appearance Materials................5-84
Weatherstrips..............................................5-79
Ashtrays........................................................3-18
1

Exhaust Restrictor (Diesel Engines)...................2-18
Exhaust System Check....................................6-27
Express-Down Feature.....................................2-10
Extender, Safety Belt.......................................1-26
Exterior Lamps...............................................3-13
F
Filter
Engine Air Cleaner......................................5-30
Filter Minder Gage..........................................3-44
Finding a Station............................3-46, 3-49, 3-53
Finish Care....................................................5-80
Finish Damage...............................................5-83
Fixed Mast Antenna........................................3-59
Flat Tire........................................................5-75
Flat Tire, Changing.........................................5-76
Fluid
Automatic Transmission................................5-31
Manual Transmission....................................5-32
Power Steering...........................................5-43
Windshield Washer......................................5-44
Fluid Leaks Check..........................................6-28
FM ...............................................................3-57
Folding the Rear Seat (Crew Cab).................... 1-7
Footnotes......................................................6-19
Fore-and-Aft Adjustment.................................... 1-4Four-Wheel and Six-Wheel Drum Brakes
(Air Only)...................................................5-49
Four-Wheel Disc Brakes
(Hydraulic Only)..........................................5-49
Front Wheel Bearings with Oil-Filled Hubs..........5-67
Fuel............................................................... 5-6
Additives...................................................... 5-7
Diesel Engine Fuel........................................ 5-8
Filling a Portable Fuel Container....................5-18
Filling Your Tank..........................................5-17
Filter..........................................................5-64
Filter Replacement.......................................5-15
Fuels in Foreign Countries............................5-16
Gage.........................................................3-42
Gasoline Octane........................................... 5-6
Gasoline Specifications.................................. 5-6
Primary Filter and Water Separator................5-65
Running Out of Fuel....................................5-15
Secondary Filter and Water Separator/Heater....5-66
Very Cold Weather Operation........................5-10
Water in Fuel..............................................5-10
Water in Warning Light.................................3-43
What Fuel to Use.......................................... 5-8
Fuel Filter (Diesel Engines)..............................5-65
Fuel Filter (Gasoline Engines)...........................5-64
Fuel Priming..................................................5-13
Fuses
Fuses and Circuit Breakers...........................5-87
Windshield Wiper.........................................5-87
6

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

Rear Seat Outside Passenger Positions
(Crew Cab Models)....................................1-23
Rear Seat Passengers, Safety Belts..................1-23
Rear Wheel Park Brake Burnish Procedure........2-34
Rear Window Defogger....................................3-21
Rearview Mirrors.............................................2-39
Reclining Seatbacks.......................................... 1-4
Reduced Engine Power Light............................3-41
Releasing Air-Operated Parking Brakes..............4-31
Remote Keyless Entry System............................ 2-3
Remote Keyless Entry System, Operation............ 2-4
Replacement Bulbs.........................................5-63
Replacing Brake System Parts..........................5-49
Replacing Restraint System Parts
After a Crash..............................................1-62
Reporting Safety Defects
Canadian Government................................... 7-7
General Motors............................................. 7-7
United States Government.............................. 7-6
Restarting the Diesel Engine While Moving
(Automatic Transmission)..............................2-15
Restarting the Gasoline Engine While Moving
(Automatic Transmission)..............................2-14
Restraint System Check...................................6-25
Checking Your Restraint Systems...................1-61
Replacing Restraint System Parts
After a Crash..........................................1-62Restraint Systems
Checking....................................................1-61
Replacing Parts...........................................1-62
Resynchronization............................................. 2-6
Right Front Passenger Position, Safety Belts......1-22
Rims and Wheels...........................................5-69
Roadside
Assistance Program....................................... 7-4
Rocking Your Vehicle To Get It Out...................4-30
Routing, Engine Drive Belt..............................5-103
Running Out of Fuel........................................5-15
Running Your Engine While You Are Parked.......2-38
S
Safety Belt
Reminder Light............................................3-26
Reminder Tone............................................3-26
Safety Belts
Care of......................................................5-79
Center Passenger Position............................1-22
Driver Position............................................1-13
How to Wear Safety Belts Properly................1-13
Questions and Answers About Safety Belts.....1-12
Rear Seat Passengers.................................1-23
Right Front Passenger Position......................1-22
12

Storage Areas................................................2-41
Center Console Storage Area........................2-42
Stuck in Sand, Mud, Ice or Snow......................4-29
Sun Visors.....................................................2-10
Switchbanks, Instrument Panel..........................3-16
T
Tachometer....................................................3-26
Theft-Deterrent, Radio.....................................3-57
Theft-Deterrent Systems...................................2-10
Tilt Wheel........................................................ 3-7
Tire Inflation Check.........................................6-24
Tires.....................................................5-68, 5-82
Changing a Flat Tire....................................5-76
Dual Tire Operation.....................................5-69
If a Tire Goes Flat.......................................5-75
Inflation - Tire Pressure................................5-68
Rims and Wheels........................................5-69
Tightening the Wheel Nuts............................5-71
Wheel Alignment and Tire Balance.................5-70
Wheel Replacement.....................................5-74
When It Is Time for New Tires......................5-70
To Use the Engine Coolant Heater....................2-24
Top Strap......................................................1-38
Towing
Power Take-Off (PTO)..................................4-36
Your Vehicle...............................................4-31Traction
Control System (TCS)..................................4-11
Tractor Protection (Breakaway) Valve Check.......6-28
Trailer
Connections................................................4-35
Trailer Brake Hand Control Valve........................ 4-9
Trailer Connections
(C7/C8 Models Only)...................................4-36
Transmission
Fluid, Automatic...........................................5-31
Fluid, Manual..............................................5-32
Service Warning Light..................................3-31
Temperature Gage.......................................3-40
Transmission Fluid Capacity.............................5-98
Transmission Operation, Automatic....................2-28
Transmission Operation, Manual........................2-30
Trip Odometer................................................3-25
Turn and Lane-Change Signals.......................... 3-8
Turn Signal/Multifunction Lever........................... 3-7
Two-Speed Rear Axle......................................2-33
Two-Speed Rear Axle Electric Shift Control.........2-26
U
Underbody Flushing Service.............................6-28
Underbody Inspection......................................6-28
Underhood Fuse Block....................................5-91
Understanding Radio Reception........................3-57
14

United States................................................... 7-4
Used Replacement Wheels..............................5-75
Using Cleaner on Fabric..................................5-78
Using the Clutch.............................................2-30
Using the Tow Hooks......................................4-30
V
Vehicle
Control........................................................ 4-5
Damage Warnings........................................... iv
Loading......................................................4-33
Symbols......................................................... iv
Vehicle Data Collection and Event
Data Records............................................... 7-5
Vehicle Identification
Number (VIN).............................................5-85
Service Parts Identification Label...................5-86
Service Statement.......................................5-85
Vehicle Storage..............................................5-55
Ventilation Adjustment......................................3-22
Visors...........................................................2-10
Voltmeter Gage..............................................3-30
W
Wait to Start Indicator......................................3-36
Warning Lights, Gages and Indicators................3-23Warnings
Hazard Warning Flashers............................... 3-5
Other Warning Devices.................................. 3-6
Safety and Symbols......................................... iii
Vehicle Damage.............................................. iv
Washer Fluid, Low Warning Light......................3-42
Washing Your Vehicle......................................5-80
Water
Fuel..........................................................5-10
Water in Fuel Warning Light.............................3-43
Weatherstrip Lubrication...................................6-25
What Fuel to Use............................................. 5-8
What Fuel to Use in Canada.............................. 5-9
What Kind of Engine Oil to Use................5-22, 5-28
What to Do with Used Oil........................5-25, 5-29
What to Use..................................5-33, 5-44, 5-61
Wheels
Alignment and Tire Balance..........................5-70
Front Bearings with Oil-Filled Hubs................5-67
Replacement...............................................5-74
Rims.........................................................5-69
Tightening the Wheel Nuts............................5-71
When to Add Engine Oil..........................5-21, 5-27
When to Change Engine Oil.............................5-29
When to Change Engine Oil
(GM Oil Life System)...................................5-24
When to Check..............................5-31, 5-32, 5-69
15