brake CHEVROLET KODIAK 2004 Manual PDF

Item Number Item Remarks
19 Release Bearing, Clutch Cross Shaft Two fittings, apply chassis lubricant.
20 Clutch Release Fork Two fittings.
* Applies to some vehicles.
** Applies to air brakes only.
$ Applies to hydraulic brakes only.
Tandem Axle ModelsItem
Number Item Remarks
1 Brake Camshafts One fitting each.
2 Propshaft U-JointOne fitting each
joint. Lubricate
with GM Part
No. 1051344, Wheel
Bearing Lubricant
3 Rear AxlesFill to level of filler
plug.
4Brake Shoe
Roller PinsApply engine oil
at pin to shoe
joint only.
5 Rear Spring PinOne fitting
each side.
5-54

Jump Starting
If your battery (or batteries) has run down, you may
want to use another vehicle and some jumper cables to
start your vehicle. Be sure to follow the steps below
to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
They contain acid that can burn you.
They contain gas that can explode or
ignite.
They contain enough electricity to
burn you.
If you do not follow these steps exactly, some
or all of these things can hurt you.
Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not work, and it could damage your vehicle.
1. Check the other vehicle. It must have a 12-volt
battery (or batteries) with a negative ground system.Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
If you have a diesel engine vehicle with two
batteries (or more), you should know before you
begin that, especially in cold weather, you may not
be able to get enough power from a single
battery in another vehicle to start your diesel engine.
If your vehicle has more than one battery, use the
one closest to the starter – this will reduce electrical
resistance.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren’t touching
each other. If they are, it could cause a ground
connection you don’t want. You wouldn’t be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake firmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in neutral before setting the parking brake.
Notice:If you leave your radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered
by your warranty. Always turn off your radio and
other accessories when jump starting your vehicle.
5-56

Wheel Replacement
Replace any wheel that is bent, cracked or badly rusted
or corroded. If wheel nuts keep coming loose, replace
the wheel. If the wheel leaks air, replace it.
Your dealer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.
If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new GM
original equipment parts. This way, you will be sure to
have the right wheel, wheel bolts and wheel nuts
for your vehicle.
{CAUTION:
A leaking wheel could fail without warning.
A wheel designed for tubeless tires could be
leaking because it is damaged. Don’t use
an inner tube or some other thing to try to
stop the leaking. Get a new wheel or the
proper type.
{CAUTION:
Without the correct wheel, you may not be able
to stop properly, and you could have other
problems like a tire air-out. You could have a
collision. If you don’t go to your dealer to get a
new wheel, be sure you get the correct one.
Each new wheel should match the original
wheel in load-carrying capacity, ination
pressure capacity, diameter, width, offset and
mounting conguration.
Using wheels and tires with higher load-carrying limits
than the original wheels and tires doesn’t change
the GAWR or the GVWR of your vehicle. See “Loading
Your Vehicle” for more information.
Notice:The wrong wheel can cause trouble in
bearing life, brake cooling, speedometer/odometer
calibration, headlamp aim, bumper height, vehicle
ground clearance, stopping distance and tire
clearance to the body and chassis. You could also
have other problems like a tire air-out.
5-74

Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been used
or how far it’s been driven. It could fail
suddenly and cause a crash. If you have to
replace a wheel, use a new GM original
equipment wheel.
If a Tire Goes Flat
It’s unusual for a tire to “blow out” while you’re driving,
especially if you maintain your tires properly. If air
goes out of a tire, it’s much more likely to leak out
slowly. But if you should ever have a “blow out,” here
are a few tips about what to expect and what to do:
If a front tire fails, the flat tire will create a drag that pulls
the vehicle toward that side. Take your foot off the
accelerator pedal and grip the steering wheel firmly.
Steer to maintain lane position, and then gently brake to
a stop well out of the traffic lane.
A rear blowout, particularly on a curve, acts much like a
skid and may require the same correction you’d use
in a skid. In any rear blowout, remove your foot from the
accelerator pedal. Get the vehicle under control by
steering the way you want the vehicle to go. It may be
very bumpy and noisy, but you can still steer. Gently
brake to a stop –– well off the road if possible.
If a tire goes flat, avoid further tire and wheel damage
by driving slowly to a level place and turn on your
hazard warning flashers. The next part tells you what
to do.
5-75

Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker inside the motor and a circuit breaker or fuse in
the fuse block. If the motor overheats, the wipers will
stop until the motor cools. If the overload is caused by
an electrical problem, be sure to get it fixed.
Fusible Links
A fusible link is a short piece of wire several gauge
sizes smaller than the circuit it protects. It will melt in an
overload situation, opening the circuit.
Your starter and other circuits have these fusible links.
The size is printed on the insulation. If the insulation
is burned beyond recognition, consult your GM dealer
for the proper size. Replace a fusible link with one of the
same size and insulation type. Fusible link insulation
is a special purpose high-temperature material.
The hydraulic brake booster motor feed circuit and
starter circuit are protected by a fusible link. Vehicles
with a diesel engine have a fusible link for the intake
heater feed circuit.
Power Windows and Other Power
Options
Circuit breakers in the fuse panel protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens. This
protects the circuit until the current load returns to
normal or the problem is fixed.
Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers,
maxi-fuses and fusible links. This greatly reduces the
chance of a fire caused by an electrical problem. There
may be a fuse taped to the wiring harness near the
hydraulic brake booster.
5-87

Fuse Usage
RH PARK LP Right-hand Parking Lamps
LH PARK LP Left-hand Parking Lamps
RADIO U Radio
PWR WINDOW Power Windows
BRAKE ISO Brake Warning Lamp
SPARE Spare Fuse
L-RR TRUCK Left Rear Trailer Wiring
SPARE Spare Fuse
SPARE Spare Fuse
SPARE Spare Fuse
R-RR TRUCK Right Rear Trailer Wiring
SPARE Spare Fuse
Relay Usage
BRAKE LAMPC4/C5 Brake Lamps,
C6/C7/C8 Tractor/Trailer Wiring
IGN 4 IgnitionRelay Usage
MARKER LP Sidemarker and Clearance Lamps
HTD FUEL LB7/LG4 Heated Fuel
AIR HTR LG4 Air Heater
ECU MAINTAIN LG4 Electronic Control Unit
DRL Daytime Running Lamps
CHMSL ISO Center High Mounted Stop Lamp
HTD MIRR Heated Mirrors
R-TRN TLR Right Trailer Turn Signal
L-TRN TLR Left Trailer Turn Signal
SPARE Spare Relay
SPARE Spare Relay
SPARE Spare Relay
5-89

Circuit Breaker Usage
1 Stoplamps
2 Center High Mounted Stop Lamps
3 Parking Lamps
4 Powertrain Control Module
5 Auxiliary Wiring
6 Heater/Air Conditioning
7 Hazard Warning FlashersCircuit Breaker Usage
8 Power Post
9 Courtesy Lamps
10Warning Lights, Gages and
Indicators
11 Crank
12 Rear Axle
13Trailer Turn Signals/Hazard Warning
Flashers
14 Radio/Chime
15 Daytime Running Lamps
16 Air Bag System
17 Exterior/Interior Lamps
18 Parking Brake
19 Accessory Power
20 Ignition
21 Sidemarker Lamps
22 Turn Signal/Backup Lamps
23 Transmission
24 Chassis
A Spare
B Spare Fuse Block 2
5-90

Relay Usage
PTO Power Take-Off
REVERSE Reverse
NEUTRAL
STARTNeutral Start
Fuse Usage
RR DEFOG Rear Defog
ENG 1 Engine 1
ENG 3 Engine 3
PCM-B Powertrain Control Module
BLANK Empty
ENG 4 Engine 4
ENG 2 Engine 2
HTD FUEL Heated Fuel
BLANK EmptyFuse Usage
BLANK Empty
BLANK Empty
A/C COMP Air Conditioning Compressor
ABS 1 Anti-Lock Brake System 1
ABS 2 Anti-Lock Brake System 2
ABS 3 Anti-Lock Brake System 3
ENGINE Engine
E/A PUMP Electronic/Automatic Pump
HORN Horn
NOTE 2L18/LB7 Fuel, LG4 Powertrain
Control Valve, LG5 Electronic
Control Module
BLANK Empty
STUD A Spare
STUD B Spare
5-92

Fuse Usage
IGN 1 Ignition 1
IGN 4 Ignition 4
IGN 3 Ignition 3
BATT/HAZ Battery/Hazard Warning Flashers
HEADLAMP Headlamps
LIGHTING Interior/Exterior Lamps
HVAC Comfort Control System
NOTE C4/C5 Electric Brake,
C6/C7/C8 Brake Lamps
Capacities and Specications
Capacities and Specications
Engine RPO
7.2L L6 HEUI Fuel System LG5
8.1L V8 SPFI Fuel System L18
7.8L L6 Common Rail Fuel System LG4
6.6L V8 Common Rail Fuel System LB7/LLY Secondary Underhood
Fuse Block
5-93

Scheduled Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown after 100,000 miles
(166 000 km) should be repeated at the same miles (km)
after those intervals for the life of this vehicle.
Gasoline engine vehicles have a computer that lets you
know when to change your engine oil. This is not
based on mileage, but on engine revolutions and engine
operating temperature. When the computer has
calculated that the oil needs changing, the GM Oil Life
System will indicate that a change is necessary.
The “Footnotes” at the end of this Maintenance
Schedule further explain maintenance services.
SeeService Publications Ordering Information on
page 7-7.
100 Miles (160 km)
❑Wheel stud nut service.(46)
1,000 Miles (1 600 km)
❑Wheel stud nut service.(46)
❑Rear axle air shift motor service.(11)
7,500 Miles (12 000 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)
6-5