2004 CHEVROLET KODIAK suspension

60,000 Miles (96 000 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)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
❑Gasoline Engine Only (Vehicles with GVW greater
than 16,000 lbs.): Spark plug service.(3) (28)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Gasoline Engine: Replace engine air cleaner filter.
Diesel Engine: Inspect engine air cleaner filter
change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Replace fuel filter(s) (or every 12 months, whichever
occurs first).(3)
❑Inspect door hinge pins and bushings and replace as
necessary.❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months,
whichever occurs first).(3) (4) (17)
❑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)
6-12

70,000 Miles (112 000 km)
❑DURAMAX™ Diesel Only: Change engine oil
and filter (or every 12 months, whichever occurs
first).(2) (3)
75,000 Miles (120 000 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)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Gasoline Engine: Inspect engine air cleaner filter if you
are driving in dusty conditions and replace filter if
necessary. Diesel Engine: Inspect engine air cleaner
filter change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months, whichever
occurs first).(3) (4) (17)❑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)
❑Fuel tank, fuel cap and fuel lines service (or every
72 months, whichever occurs first).(3) (30) †
❑EGR system inspection (if equipped) (or every
72 months, whichever occurs first).(3) (31)
❑Thermostatically controlled engine cooling fan
service.(4) (20)
❑Shields and underhood insulation service.(4) (5) (21)
6-14

❑Gasoline Engine: Replace engine air cleaner filter.
Diesel Engine: Inspect engine air cleaner filter
change indicator. If necessary, replace the filter. If
vehicle is driven in dusty/dirty conditions, inspect filter
change indicator at every engine oil change. See
Engine Air Cleaner/Filter on page 5-30for more
information.† (3)
❑DURAMAX™ Diesel Only: Replace fuel filter.
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑Cooling system service. Clean the cooling system
filler cap with clean water, clean the core, pressure
test the cap and the system for proper pressure
capability and inspect condition of cooling and heater
hoses and clamps. Replace hoses if cracked,
swollen or damaged.
❑Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever
hubs are removed).(23) (46)
❑Replace fuel filter(s) (or every 12 months, whichever
occurs first).(3)
❑Steering system service.(13)
❑Front and rear suspension service.(14)
❑Spring-to-axle U-bolts and shackle bolts service.(16)
❑Exhaust system service (or every 6 months,
whichever occurs first).(3) (4) (17)❑Inspect door hinge pins and bushings and replace as
necessary.
❑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)
❑C600, C700 and C800 Gasoline Engines Only:
Engine drive belts service (or every 12 months,
whichever occurs first).(18)
6-16

(11)= Inspect rear axle air shift motor for fluid leaks.
Remove plug to check fluid level. Inspect air lines
and hoses for proper hook-up, binding, leaks, etc.
Inspect at 1,000 miles (1 600 km) and 22,500 miles
(36 000 km) and then every 22,500 miles (36 000 km)
thereafter.
(12)= 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 steeringlinkage more often when operating under dusty or
muddy conditions and in excessive off-road use.
Frequently power-washed vehicles will require more
frequent lubrication.
(13)= 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 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.
6-20

(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

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you’ll notify us.
Please call us at 1-800-862-4389, or write:
GM Medium Duty Truck
Customer Assistance Center
P.O. Box 44947
Detroit, MI 48244In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-7

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

Safety Belts (cont.)
Safety Belt Extender....................................1-26
Safety Belt Use During Pregnancy.................1-21
Safety Belts Are for Everyone......................... 1-8
Safety Warnings and Symbols.............................. iii
Scheduled Maintenance..................................... 6-5
Scheduled Maintenance Supplements.................. 6-4
Seat Adjuster Check........................................6-27
Seatback Adjustment......................................... 1-3
Seats
Air Suspension Seats.................................... 1-6
Manual........................................................ 1-2
Rear Seat Operation...................................... 1-7
Reclining Seatbacks...................................... 1-4
Split Bench Seat........................................... 1-6
Securing a Child Restraint
Center Rear Seat Position (Crew Cab) or
Center Front Position................................1-41
Rear Outside Seat Position...........................1-39
Right Front Seat Position..............................1-43
Service........................................................... 5-3
Doing Your Own Work................................... 5-4
Engine Soon Light.......................................3-37
Publications Ordering Information..................... 7-7
Transmission Warning Light..........................3-31
Two Safety Cautions about Engine Fan
Breakage.................................................. 5-5Service Bulletins............................................... 7-8
Service Engine Soon Light...............................3-37
Service Manuals............................................... 7-7
Servicing Your Air Bag-Equipped Vehicle............1-60
Setting Preset Stations....................3-47, 3-49, 3-54
Setting the Time.............................................3-45
Setting the Tone (Bass/Treble)..........3-47, 3-49, 3-54
Sheet Metal Damage.......................................5-82
Shoulder Belt Height Adjuster...........................1-15
Skidding........................................................4-16
Sliding Rear Windows.....................................2-10
Some Other Rainy Weather Tips.......................4-20
Special Fabric Cleaning Problems.....................5-78
Specifications, Capacities.................................5-93
Speedometer..................................................3-25
Split Bench Seat.............................................. 1-6
Starter Motor Operation...................................2-13
Starter Switch Check.......................................6-26
Starting Your Diesel Engine..............................2-14
Starting Your DURAMAX™ Diesel Engine...........2-19
Starting Your Engine...............................2-13, 2-19
Starting Your Gasoline Engine..........................2-12
Steering........................................................4-12
Steering Check...............................................6-26
Steering in Emergencies..................................4-13
Steering Tips..................................................4-12
Stopping the Diesel Engine..............................2-15
Stopping the Gasoline Engine...........................2-14
13