2004 CHEVROLET KODIAK maintenance

A reading in the low pressure zone may be caused by a
dangerously low oil level or other problem.
If you have a Caterpillar
®diesel engine, also see your
Caterpillar®Operation & Maintenance Manual.
{CAUTION:
Do not keep driving if the oil pressure is low. If
you do, your engine can become so hot that it
catches re. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice:Lack of proper engine oil maintenance may
damage the engine. The repairs would not be
covered by your warranty. Always follow the
maintenance schedule in this manual for changing
engine oil.
Low Oil Level Light
This light should come on
as a check, when you start
your engine. If the light
fails to come on, have it
repaired as soon as possible
so you will be aware when
the oil level is low.
If this light comes on and stays on, it means your
engine is low on oil. You need to check the oil level
right away. SeeEngine Oil (Caterpillar
®Diesel Engine)
on page 5-20orEngine Oil (Gasoline Engine) on
page 5-20orEngine Oil (DURAMAX™ Diesel) on
page 5-25for further information.
3-38

If your vehicle has dual fuel tanks, the reading on the
gage is the total fuel left in both tanks.
Here are four concerns of some operators. None of
these shows a problem with your fuel gage:
•The gage moves a little when you turn a corner or
speed up.
•The gage does not go back to empty when you turn
off the ignition.
•At the gas station, the pump shuts off before the
gage reads full.
•It takes a little more or less fuel to fill up than the
gage indicated.
If you have a Caterpillar
®diesel engine, also see your
Caterpillar®Operation & Maintenance Manual.
Water in Fuel Warning Light
If your vehicle is equipped
with a diesel engine, you
may have this light.
This light will come on to warn you that there is water in
the fuel system. For more information on how this
light works, seeWater in Fuel on page 5-10.
3-43

Air Filter Restriction Indicator
If your vehicle has this
feature, the gage is
located above the
switchbank in the center of
the instrument panel. It
monitors the engine
air filter.
As the filter gets dirty, the yellow indicator will begin to
rise. When it reaches 25 inches of vacuum on the
scale, the filter should be replaced.
After replacing the filter, reset the gage by pressing in
the yellow reset button at the bottom of the gage.
If you have a Caterpillar
®diesel engine, also see your
Caterpillar®Operation & Maintenance Manual.
Air Pressure Gage
If your vehicle has air
brakes, the air pressure
gage is located above the
switchbank in the center
of the instrument panel.
This gage shows the air pressure for both your front
and rear brake systems.
If the needle on the gage indicates that the air pressure
is below 60 to 75 psi (415 to 517 kPa), the low air
warning light will come on. An alarm will also sound if
this happens.
The yellow pointer shows the pressure available for the
front system, while the green pointer shows pressure
for the rear. There should be no more than 4 psi
(28 kPa) difference showing between the systems.
Don’t drive until both pointers are showing at least
115 psi (793 kPa), so you’ll have enough air if you need
to apply your brakes.
3-44

Automatic Ether Injection System....................5-66
Front Wheel Bearings with Oil-Filled Hubs........5-67
Air Conditioning System.................................5-67
Tires..............................................................5-68
Inflation - Tire Pressure.................................5-68
Rims and Wheels.........................................5-69
Dual Tire Operation.......................................5-69
When It Is Time for New Tires.......................5-70
Wheel Alignment and Tire Balance..................5-70
Tightening the Wheel Nuts.............................5-71
Wheel Replacement......................................5-74
If a Tire Goes Flat........................................5-75
Changing a Flat Tire.....................................5-76
Appearance Care............................................5-76
Cleaning the Inside of Your Vehicle.................5-77
Care of Safety Belts......................................5-79
Weatherstrips...............................................5-79
Cleaning the Outside of Your Vehicle..............5-80
Sheet Metal Damage.....................................5-82Finish Damage.............................................5-83
Underbody Maintenance................................5-83
Chemical Paint Spotting.................................5-83
Vehicle Care/Appearance Materials..................5-84
Vehicle Identication......................................5-85
Vehicle Identification Number (VIN).................5-85
Service Statement.........................................5-85
Service Parts Identification Label.....................5-86
Electrical System............................................5-86
Add-On Electrical Equipment..........................5-86
Headlamp Wiring..........................................5-86
Windshield Wiper Fuses................................5-87
Fusible Links................................................5-87
Power Windows and Other Power Options.......5-87
Fuses and Circuit Breakers............................5-87
Capacities and Specications..........................5-93
Normal Maintenance Replacement Parts.........5-100
Engine Drive Belt Routing............................5-103
Section 5 Service and Appearance Care
5-2

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-7.
Your vehicle has an air bag system. Before attempting
to do your own service work, seeServicing Your Air
Bag-Equipped Vehicle on page 1-60.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeePart D: Maintenance Record on page 6-31.{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts and
other fasteners. “English” and “metric”
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
5-4

Diesel Engine Fuel
For the Caterpillar®diesel, see the Caterpillar®
Operation & Maintenance Manual for information
concerning fuel usage.
Notice:Diesel fuel or fuel additives not
recommended in this manual could damage your
fuel system and engine. Your warranty would
not cover this damage. And:
Diesel fuel that has been mixed with engine oil
or automatic transmission uid could damage
your engine and emission controls.
Aftermarket diesel fuel additives are not tested
by General Motors. Some additives, particularly
those which contain alcohol or water
emulsiers, may damage your fuel system. If
you believe that unique circumstances call for a
fuel additive to be used, consult your dealer
for advice.
If you ever run out of diesel fuel, it can be
difficult to restart your engine. To avoid all this,
never let your tank get empty.
If you run out of fuel,Running Out of Fuel on page 5-15,
tells you how to restart your engine.
What Fuel to Use
In the United States, for best results use Number 2–D
diesel fuel year-round (above and below freezing
conditions) as oil companies blend Number 2–D fuel to
address climate differences. Number 1–D diesel fuel
may be used in very cold temperatures (when it
stays below 0°F or−18°C); however, it will produce a
power and fuel economy loss. Avoid the use of Number
1–D diesel fuel in warm or hot climates. It may result
in stalling, poor starting when the engine is hot and may
damage the fuel injection system.
At a minimum, the diesel fuel you use should meet
specifications ASTM D975-02 (Grade Low Sulfur) in the
United States. In addition, the Engine Manufacturers
Association (EMA) has identified properties of an
improved diesel fuel for better engine performance and
durability. Diesel fuels corresponding to the EMA
Recommended Guideline on Premium Diesel Fuel
(FQP-1A) could provide better starting, less noise and
better vehicle performance. If there are questions
about the fuel you are using, contact your fuel supplier.
It is acceptable to use diesel fuel containing up to
5% biodiesel (B5), but the final blended fuel must meet
the same specification, ASTM D975–02 (Grade Low
Sulfur), as other fuels used in your vehicle, and
the biodiesel used for making this fuel must meet the
ASTM D6751–02 specification.
5-8

When you tilt the hood far enough, the cables will
support it.
When you close the hood, make sure both latches are
secured.
Engine Oil (Caterpillar®Diesel
Engine)
See your Caterpillar®Operation & Maintenance Manual
for information on oil quality and viscosities as well
as the temperature range chart.
Engine Oil (Gasoline Engine)
If the low oil light appears
on the instrument cluster, it
means you need to
check your engine oil level
right away. For more
information, seeLow Oil
Level Light on page 3-38.
You should check your engine oil level regularly; this is
an added reminder.
5-20

Manual Transmission Fluid
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
Scheduled Maintenance on page 6-5.
Refer to the Maintenance Schedule to determine what
kind of fluid to use. SeePart C: Recommended
Fluids and Lubricants on page 6-29.
When to Check
A good time to have it checked is when the engine oil is
checked. See your Maintenance Schedule to find out
when to change your transmission fluid.
How to Check and What to Use
Check the fluid level only when your engine is off, the
vehicle is parked on a level place and the transmission
is cool enough for you to rest your fingers on the
transmission case.
Then, follow these steps:
1. Remove the filler plug.
2. Check to be sure that the lubricant level is up to the
bottom of the fill opening. On heavy duty
transmissions (an inch of oil level equals about one
gallon of fluid.)
3. If the fluid level is good, install the plug and be sure
it is fully seated. If the fluid level is low, add more
fluid as described in the next steps.
How to Add Fluid
Here’s how to add fluid. Refer to the Maintenance
Schedule to determine the proper fluid to use. SeePart
C: Recommended Fluids and Lubricants on page 6-29.
1. Remove the filler plug.
2. Add fluid at the filler plug hole. Add only enough
fluid to bring the fluid level up to the bottom of the
fill opening.
3. Install the filler plug. Be sure the plug is fully
seated.
Engine Coolant (Gas and
DURAMAX™ engines)
If your vehicle has a Caterpillar®diesel engine, the
Caterpillar®Operation & Maintenance Manual provided
with your vehicle has information regarding the
proper coolant to use.
The cooling system in your vehicle is filled with
DEX-COOL
®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add
only DEX-COOL
®extended life coolant.
5-32