brake CHEVROLET KODIAK 2007 Owners Manual

(2)= An Emission Control Service.
(3)= A Noise Emission Control Device.
(4)= Applies to vehicles sold in the United States
and is recommended for vehicles sold in Canada.
(5)= Check fluid level in brake master cylinder,
power steering pump, front and rear axles,
transmission, and hydraulic spring parking brake
pump (if equipped). A low fluid level in the
brake master cylinder can indicate worn brake
linings and should be checked accordingly.
(6)= Inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chafing, etc.
Inspect disc brake pads for wear and rotors for
surface condition. Inspect caliper assemblies.
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.(7)= This vehicle has the Engine Oil Life System.
This system will show you when to change the
engine oil and filter — usually between 3,000 miles
(5 000 km) and 12,000 miles (20 000 km) since
your last oil change. Under severe conditions,
the indicator may come on before 3,000 miles
(5 000 km). Never drive your 7.8L diesel engine
vehicle more than 12,000 miles (20 000 km),
or 12 months, or 600 engine hours, without an
oil and filter change.
Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information,
seeEngine Oil Life System (Gasoline Engine)
on page 276orEngine Oil Life System
(DURAMAX
®Diesel) on page 278orEngine
Oil Life System (Caterpillar®Diesel Engine)
on page 279.
384

(11)= 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 steering linkage more often when
operating under dusty or muddy conditions and in
excessive off-road use. Frequently power-washed
vehicles will require more frequent lubrication.(12)= 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 the
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.
386

(13)= 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.
(14)= Adjust tire pressures as indicated on the
Certification or Tire Information label for optimum
tire life. SeeTires on page 321for further
details. Check tires for excessive or abnormal
wear or damage. Also check for damaged wheels.
Replace wheels and/or tires as needed.
(15)= 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.
(16)= 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.
(17)= Check all gasoline engine drive belts for
cracks, fraying, and wear. Replace as needed.
(18)= Adjust valve lash. Incorrect valve clearance
will result in increased engine noise and reduced
engine output.
(19)= 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.
(20)= Check shields and underhood insulation
for damage or looseness. Adjust or replace
as needed.
(21)= Inspect parking brake drum and linings for
wear or cracks and check linkage and adjustment.
387

(28)= Inspect Electronic Vacuum Regulator
Valve (EVRV) filter for excessive contamination
or plugging. If needed, clean filter with solution
of soap and water, let dry and install.
(29)= Drain, flush, and refill cooling system.
This service can be complex; you should
have your dealer perform this service. See
Part C: Recommended Fluids and Lubricants
on page 397for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap, and
neck. Pressure test cooling system and pressure
cap. For Caterpillar
®diesel engines, always
refer to the Caterpillar®Diesel Engine Operation &
Maintenance Manual for coolant recommendations
and change intervals.
(30)= Change the lubricant. See
Part C: Recommended Fluids and
Lubricants on page 397.
(31)= Front axle service: Re-pack upper
kingpin roller bearing.(32)= 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.
389

•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, service brake chambers, quick
release valves, quick release/double check
valve combinations, parking brake control
valve, double check valves, pressure
protection valves, and ether 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.
(33)= Clean and lubricate air brake automatic
slack adjuster. Check pushrod travel and
auto adjustment operation. Have serviced
if needed.(34)= Air brake chamber service: Check operation,
mounting clamps, and air lines and check for leaks.
(35)= Trailer brake hand control valve service:
Check operation; lubricate cam and follower.
(36)= 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 325.
(37)= Inspect and clean any accumulated dirt,
gravel, or other foreign objects from the valves and
valve boots as needed. Using light oil, lubricate
brake pedal to brake application valve linkage
components. Check any rubber boots for cracks,
holes, or deterioration and replace if necessary.
390

At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light (if
equipped) and all your belts, buckles, latch plates,
retractors, and anchorages are working properly.
Look for any other loose or damaged safety
belt system parts. If you see anything that might
keep a safety belt system from doing its job,
have it repaired. Have any torn or frayed safety
belts replaced.
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace
blade inserts that appear worn or damaged or
that streak or miss areas of the windshield. Also
seeWindshield and Wiper Blades on page 336.
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them
last longer, seal better, and not stick or squeak.
Apply silicone grease with a clean cloth. During
very cold, damp weather more frequent application
may be required. Part C tells you what to use.
Body Lubrication Service
Lubricate all exposed surfaces such as door
checks, door lock bolts, lock strike plates, door
hinge bushings, latches, and dovetail bumper
wedges. Where oil holes are provided, a dripless
oil can be used. The seat adjusters, seat track,
door weatherstrips, and rubber cap bumpers
should also be lubricated. Part C tells you what to
use. More frequent lubrication may be required
when exposed to a corrosive environment.
Parking Brake Check
Park on a fairly steep hill and hold the vehicle with
the parking brake only. This checks holding ability.
392

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.
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.
On manual transmission vehicles, the starter
should work only when the clutch pedal is
all the way down.
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.
393

Lamps Check
Check panel lighting, warning lights, indicator
lights, and interior lamps. On the outside,
check: license plate lamps, sidemarker lamps,
reflectors or lights on outside mirrors, headlamps,
parking lamps, identification and clearance
lamps, taillamps, brake lamps, turn signals,
backup lamps, and hazard warning flashers.
Have headlamp aim checked at once if beams
seem improperly aimed.
Glass, Mirrors, Lamps and/or
Reectors Condition Check
Look for broken, scratched, dirty, or damaged
glass, mirrors, lamps, or reflectors that could
reduce the view or visibility or cause injury.
Replace, clean or repair promptly.
Door Latches Check
Check that doors close, latch, and lock tightly.
Check for broken, damaged, or missing parts that
might prevent tight latching.
Hood Latches Check
Check that the hood closes firmly. Check for
broken, damaged, loose, or missing parts
that might prevent tight latching. Make sure the
secondary latch (if equipped) keeps the hood
from opening all the way when the primary latch
is released.
Fluid Leaks Check
Check for fuel, coolant, oil, or other fluid leaks by
looking at the surface beneath the vehicle after
it has been parked for awhile.
395

Underbody Inspection
Corrosive materials used for ice, snow removal,
and dust control can collect on the underbody.
If these materials are not removed, accelerated
corrosion (rust) can occur on underbody parts
such as fuel lines, frame, floor pan, and exhaust
system. At least every spring, flush these materials
from the underbody with plain water. Take care
to clean well any areas where mud and other
debris can collect. Sediment packed in closed
areas of the frame should be loosened before
being flushed.
Engine Cover Check
Check that the cab’s engine cover and seal
(if equipped) are not torn or damaged.
Be sure that the cover is clamped down firmly
to the floor.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part C.
Underbody Flushing Service
At least every spring, use plain water to flush
any corrosive materials from the underbody.
Take care to clean thoroughly any areas where
mud and other debris can collect.
Tractor Protection (Breakaway)
Valve Check
On air brake models, remove, disassemble,
clean, and inspect the tractor protection
(breakaway) valve.
396

Usage Fluid/Lubricant
Engine Coolant
(Gasoline
Engine &
DURAMAX
®/
Isuzu Diesel)50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant (Gas
and DURAMAX®/Isuzu Engines)
on page 284orEngine Coolant
(Caterpillar
®Diesel Engines)
on page 287.
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid
or equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Clutch Bearing
LubricantClutch Bearing Lubricant
(GM Part No. 12378484 or
equivalent NLGI #3 consistency).
Exhaust Brake
Ball Joint Cap
LubricantHigh-Temperature Grease
(GM Part No. U.S. 1051344,
in Canada 903037) or
NLGI #3 consistency.
Usage Fluid/Lubricant
Power Steering
SystemDEXRON
®-VI Automatic
Transmission Fluid.
Manual
TransmissionSynthetic Manual Transmission
Fluid (GM Part No. U.S. 12345724,
in Canada 10953510).
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.
398