brake CHEVROLET KODIAK 2006 Repair Manual

Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
Hood Latches
To tilt the hood forward, pull back and up on each of the
hood latches, located above the wheel wells on both
sides of the vehicle.
5-22

What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly dispose of clothing or
rags containing used engine oil. See the manufacturer’s
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
filter before disposal. Never dispose of oil by putting it
in the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Instead, recycle it by
taking it to a place that collects used oil. If you have a
problem properly disposing of your used oil, ask
your dealer, a service station, or a local recycling center
for help.
Engine Oil Life System
(Caterpillar
®Diesel Engine)
How to Reset the Engine Oil
Life System
The Engine Oil Life System calculates when to change
your engine oil and filter based on vehicle use.
Anytime your oil is changed, reset the system so it can
calculate when the next oil change is required. If a
situation occurs where you change your oil prior to a
change engine oil light being turned on, reset the
system.
To reset the Engine Oil Life System, do the following:
1. Turn the ignition key to RUN with the engine off.
2. Fully apply and hold the brake pedal while you fully
press and release the accelerator pedal, pausing
slightly at each press and each release, three times
within five seconds.
3. Turn the key to OFF.
If the change engine oil light comes back on when you
start your vehicle, the Engine Oil Life System has
not reset. Repeat the procedure.
5-34

Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing and/or high outside
temperatures, the fan speed increases when the clutch
engages. So you may hear an increase in fan noise.
This is normal and should not be mistaken as the
transmission slipping or making extra shifts. It is merely
the cooling system functioning properly. The fan will
slow down when additional cooling is not required and
the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch disengages.
Power Steering Fluid
SeeScheduled Maintenance on page 6-5to determine
when to check your power steering fluid.
How To Check Power Steering Fluid
Check your power steering fluid only when the engine is
warm. If the engine is not warm, you probably will not
get an accurate reading.
If the fluid level is between the MIN (Minimum) and
MAX (Maximum) marks, you have enough. If you need
fluid, add only enough of the proper fluid to bring it
in between the MIN and MAX marks.
If your power steering fluid level is low, this can cause
the brake or service brakes soon warning lights to come
on. In addition, the steering effort and emergency
brake distance could increase.
If either light remains on after you have added power
steering fluid to the proper level, then shut off the engine
for 10 seconds. This should reset the brake warning
lights. If one or both lights stay on, see “Hydraulic Brake
System Warning Lights” underBrake System Warning
Light on page 3-33for more information.
What to Use
To determine what kind of fluid to use, seePart C:
Recommended Fluids and Lubricants on page 6-33.
Notice:When adding power steering uid or
making a complete uid change, always use the
proper uid. Failure to use the proper uid can
cause leaks and damage hoses and seals.
5-47

Brakes
Brake Fluid
If your vehicle has
hydraulic brakes, there is a
brake master cylinder in
the engine compartment
on the driver side of
the vehicle. Refer to the
Maintenance Schedule to
determine when to
check your brake fluid.
{CAUTION:
Do not add brake uid before you check the
level. If you do, you could get too much brake
uid. Brake uid could spill on the hot engine
and it can catch re. You could be burned and
your vehicle could be damaged. See “Checking
Brake Fluid” in this section.
Checking Brake Fluid
Apply the brake pedal several times with the ignition off.
Then clean one of the reservoir caps and the area
around the cap, and remove it.
The fluid level should be
even with the bottom ring
of the filler opening.
The brake fluid reservoir is
located in the engine
compartment on the driver
side of the vehicle.
If it is low, add enough fluid to fill the reservoir to the
proper level.
5-49

What to Add
Use the proper fluid listed in your Maintenance
Schedule. Use new brake fluid from a sealed
container only.
Always clean the brake fluid reservoir cap/cover and the
area around the cap/cover before removing it. This
will help keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or
they may not even work at all. This could
cause a crash. Always use the proper brake
uid.Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system
parts so badly that they will have to be replaced.
Do not let someone put in the wrong kind of
uid, and do not use DOT-5 silicone brake uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeWashing
Your Vehicle on page 5-87.
5-50

Four-Wheel Disc Brakes
(Hydraulic Only)
Your vehicle has four-wheel disc brakes.
Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
your brakes.
Brake linings should always be replaced as complete
axle sets.
Four-Wheel and Six-Wheel Drum
Brakes (Air Only)
The brake drums should be removed and inspected
each time the tires are removed for rotation or changing.
When you have the front brakes replaced, have the
rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in
pedal travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a brake stop, your brakes adjust
for wear.
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together
if the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality
GM brake parts. When you replace parts of your braking
system — for example, when your brake linings wear
down and you need new ones put in — be sure you get
new approved GM replacement parts. If you do not,
your brakes may no longer work properly. For example,
if someone puts in brake linings that are wrong for
your vehicle, the balance between your front and rear
brakes can change — for the worse. The braking
performance you have come to expect can change in
many other ways if someone puts in the wrong
replacement brake parts.
5-51

Air Brake Systems
If your vehicle has air brakes, it is important to get rid of
moisture in your system. Moisture will damage your
system if it is not removed daily.
There are two ways to do this. One is automatic through
the air brake vehicle’s air dryer with intregal automatic
moisture ejector that purges air from the system through
a self-contained reservoir. The other way to drain
moisture from the air brake system is to manually
activate drain valves at each reservoir. Drain the air
reservoirs occasionally to be sure the air dryer is
working properly.
Drain the air brakes at full system pressure. To be sure
you are at full pressure, check your air pressure
gage. It should read at least 100 psi (692 kPa).
Air Dryer
If your vehicle has air brakes, it will have an air dryer.
This collects and removes dirt, moisture, or other foreign
matter from the air prior to entering the brake system.
The dryer also acts as a moisture ejector. It
automatically ejects the moisture when the compressor
cycles. The purge tank has a manual drain valve
that must be drained every day. See “Air Brake
Systems” for the manual drain procedure. The air dryer
is mounted on the passenger side frame rail.
The dryer has a filter that you need to change at
intervals. SeeScheduled Maintenance on page 6-5for
more about servicing this filter.
5-52

Electric Air Compressor
Your vehicle may have an electric air compressor. This
compressor is used to run options that require
pressurized air, such as air horn, air seat, 7.8L engine
exhaust restrictor, or 7.8L engine exhaust brake.
The air compressor is used when vehicles are not
equipped with an air brake system.
The air supply for this
system must be
maintained by releasing
the drain valve to eject any
moisture that may have
built up in the system.
It is recommended that this system be drained on a
weekly basis.
Clutch Pedal Free Travel
If you have a V8 engine and a manual transmission,
your clutch will need adjustment when pedal free travel
gets down to about 1/4 inch (32 mm), as measured
at the clutch pedal pad. You should have 1 1/2 to
2 inches (38 to 51 mm) of clutch pedal free travel.
If your clutch ever needs service, be sure to use only
GM clutch replacement parts.
Chassis Lubrication
Your Maintenance Schedule provides all of the required
chassis lubrication intervals and identifies proper
lubricants to use. Be sure to see your Maintenance
Schedule before performing any chassis lubrication
service. To determine location of chassis lubrication
items, use the following charts.
5-53

Item Number Item Remarks
1 Brake Camshaft** One fitting each (apply sparingly).
2 Steering Column Slip Joint* One fitting.
3 Steering Drag Link Ends One fitting each end.
4 Pivot Points and Hinges Apply chassis lubricant.
5 Pivot Points and Hinges Apply chassis lubricant.
6 Slack Adjuster** One fitting.
7Brake Cam Roller Pins at interface
of pin and shoe**Apply engine oil.
8 Front Steering KnucklesOne fitting each side, lower bushing.
(Hand-operated grease gun only.)
Hand-pack upper bearing.
9 Front Wheel Bearings Hand-pack or lubricate.
10 Steering Tie Rod Ends One fitting each end.
11 Spring Slip Pads* (Multi-Leaf Only) Apply chassis lubricant.
12 Clutch Release Bearing* Cup or fitting.
5-55

Item Number Item Remarks
13 Battery Terminal (except “ST” type) Keep coated with petroleum jelly.
14 Transmission Fill to level of filler plug.
15 Propshaft U-JointsLubricate with GM Part No. 1051344
Wheel Bearing Lubricant.
16 Parking Brake Clevis Pin$ Apply chassis lubricant.
17 Parking Brake Lever Pivot*, $ Apply chassis lubricant.
18Clutch Release Cross Shaft,
Master Cylinder$Apply chassis lubricant,
fill to 1/4 inch (6 mm) below opening.
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.
5-56