2004 CHEVROLET KODIAK air filter

Low Washer Fluid Warning Light.....................3-42
Check Gages Warning Light...........................3-42
Fuel Gage...................................................3-42
Water in Fuel Warning Light...........................3-43
Air Filter Restriction Indicator..........................3-44
Air Pressure Gage........................................3-44
Hourmeter Gage...........................................3-45
Audio System(s).............................................3-45
Setting the Time...........................................3-45
AM-FM Radio...............................................3-46Radio with Cassette......................................3-48
Radio with CD..............................................3-53
Theft-Deterrent Feature (Non-RDS Radios).......3-57
Radio Reception...........................................3-57
Care of Your Cassette Tape Player.................3-57
Care of Your CDs.........................................3-59
Care of Your CD Player................................3-59
Fixed Mast Antenna......................................3-59
Chime Level Adjustment................................3-59
Section 3 Instrument Panel
3-2

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

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Two Safety Cautions about Engine Fan
Breakage...................................................5-5
Fuel................................................................5-6
Gasoline Octane............................................5-6
Gasoline Specifications....................................5-6
Additives.......................................................5-7
Diesel Engine Fuel.........................................5-8
What Fuel to Use...........................................5-8
Very Cold Weather Operation.........................5-10
Water in Fuel...............................................5-10
Running Out of Fuel.....................................5-15
Fuel Filter Replacement.................................5-15
Fuels in Foreign Countries.............................5-16
Filling Your Tank..........................................5-17
Filling a Portable Fuel Container.....................5-18
Checking Things Under the Hood....................5-18
Hood Latches...............................................5-19
Engine Oil (Caterpillar
®Diesel Engine).............5-20
Engine Oil (Gasoline Engine)..........................5-20
Engine Oil (DURAMAX™ Diesel).....................5-25
Engine Air Cleaner/Filter................................5-30
Automatic Transmission Fluid.........................5-31
Manual Transmission Fluid.............................5-32Engine Coolant (Gas and
DURAMAX™ engines)................................5-32
Engine Coolant (Caterpillar
®Diesel Engines).....5-35
Coolant Surge Tank Pressure Cap..................5-35
Engine Overheating.......................................5-36
Cooling System............................................5-38
Engine Fan Noise.........................................5-43
Power Steering Fluid.....................................5-43
Windshield Washer Fluid................................5-44
Brakes........................................................5-46
Battery........................................................5-55
Jump Starting...............................................5-56
Rear Axle.......................................................5-61
Rear Axle Shift Motor....................................5-61
Noise Control System.....................................5-62
Tampering with Noise Control System
Prohibited.................................................5-62
Bulb Replacement..........................................5-63
Replacement Bulbs.......................................5-63
Windshield Wiper Blade Replacement..............5-63
Other Service Items........................................5-64
Fuel Filter....................................................5-64
Primary Fuel Filter and Water Separator..........5-65
Secondary Fuel Filter and Water
Separator/Heater.......................................5-66
Section 5 Service and Appearance Care
5-1

Running Out of Fuel
If the diesel engine stalls and you think that you’ve run
out of fuel, do this:
{CAUTION:
Diesel fuel is ammable. It could start a re if
it gets on hot engine parts. You could be
burned. Do not let too much fuel ow from the
air bleed valve, and wipe up any spilled fuel
with a cloth.
To restart your engine:
1. If you’re parked on a level surface, add at least
two gallons of fuel. However, if you’re parked on
a slope, you may need to add up to five gallons
of fuel.
2. Follow the fuel priming procedure earlier in this
section to prime the fuel filter.
3. Close the air bleed valve.4. Turn the ignition key to START for 10 to
15 seconds at a time until your engine starts. If the
engine tries to run, but does not run smoothly,
increase the rpm a little using the accelerator pedal.
This will help force air through the system.
Fuel Filter Replacement
If you want to change the diesel engine fuel filter
yourself, here’s how to do it:
{CAUTION:
Diesel fuel is ammable. It could start a re if
something ignites it, and you could be burned.
Do not let it get on hot engine parts, and keep
matches or other ignition sources away.
First, drain any water from the filter following the
procedure for draining water listed previously.
Your vehicle’s engine should be off until the end of this
procedure.
5-15

Engine Air Cleaner/Filter
The engine air cleaner/filter
is located in the center of
the engine compartment.
When to Inspect the Engine Air
Cleaner/Filter
If your vehicle has a filter
change indicator, inspect
the air cleaner/filter change
indicator at every oil
change and replace the
filter when the indicator
tells you to.
Vehicles without a change indicator, inspect the air
cleaner/filter at every oil change and replace at the first
oil change after 25,000 miles (40 000 km).
How to Inspect the Engine Air
Cleaner/Filter
Locate the filter change indicator. When the change
indicator turns black or is in the red/orange area, replace
the filter and reset the indicator.
5-30

To inspect the air cleaner/filter, remove the filter from
the vehicle and lightly shake filter to release loose dust
and dirt. If the filter remains “caked” with dirt, a new
filter is required.
{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned. The
air cleaner not only cleans the air, it helps to
stop ame if the engine backres. If it is not
there and the engine backres, you could
be burned. Do not drive with it off, and be
careful working on the engine with the air
cleaner/lter off.
Notice:If the air cleaner/lter is off, a backre can
cause a damaging engine re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/lter in place when you
are driving.
Automatic Transmission Fluid
When to Check
A good time to have it checked is when the engine oil is
checked. See your Allison Automatic Transmission
Operator’s Manual to find out when to change your
transmission fluid and filters.
How to Check and What to Use
The Allison Automatic Transmission Operator’s Manual
that came with the vehicle shows how to check the
automatic transmission fluid and what fluid to use.
Automatic Transmission External Filter
Your automatic transmission filter requires periodic
replacement.
Consult the Allison Automatic Transmission Operator’s
Manual that came with the vehicle for proper change
intervals.
5-31

Part Engine
(RPO Code)GM Part
NumberACDelco®Part
NumberOther Part
Numbers
Engine Air Cleaner/Filter
6.6L (LB7/LLY) (C4/C5 Models)
6.6L (LB7/LLY) (C6/C7/C8 Models)
7.2L (LG5)
7.8L (LG4) (C4/C5 Models)
7.8 L (LG4) (C6/C7/C8 Models)
8.1L (L18)88937527
88937548***
—
8837527
88937548***
25313349—
—
—
—
—
A1518C—
—
Donaldson P522606
—
—
—
Engine Oil Filter
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)88917036
—
94392475
89028862PF2232
—
—
PF454—
CAT 1R0739
—
—
Fuel Filter
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)97256734
—
94392474
——
915 Primary**
—
GF626*—
—
—
—
Power Steering Fluid Filter
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)88892858
88892858
88892858
88892858—
—
—
——
—
—
—
5-101

Part Engine
(RPO Code)GM Part
NumberACDelco®Part
NumberOther Part
Numbers
Pressure Caps
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)15075118
—
15075118
15997145—
—
—
——
—
—
—
Secondary Fuel Filter
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)—
—
15098649
25055052—
—
—
——
CAT 1R0751
—
—
Spark Plugs
6.6L (LB7/LLY)
7.2L (LG5)
7.8L (LG4)
8.1L (L18)—
—
—
——
—
—
41-983—
—
—
—
*Optional Davco (K28) D350921 spin-on type filter located on driver’s side frame rail.
**Optional Cold Weather (KUK) Racor B6484GM spin-on type filter located on driver’s side frame rail.
***Optional air filter (GM Part No. 88937525) for C6/C7/C8 Models. Fits inside standard size filter (GM Part No.
88937548) listed previously.
5-102