2004 CHEVROLET KODIAK service interval

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, exhaust
restrictor or an 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 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. SeeScheduled Maintenance on
page 6-5for more information.
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.
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2. Push the release lever and slide the wiper assembly
toward the driver’s side of the vehicle.
3. Install a new blade by reversing Steps 1 and 2.
Other Service Items
Fuel Filter
Fuel Filter (Gasoline Engines)
The steel fuel filter is located near the engine
compartment on the driver’s side of the vehicle. See
your Maintenance Schedule for recommended service
intervals.
If your vehicle is equipped with the optional Davco
spin-on type filter, it is located on the driver’s side
frame rail.
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Fuel Filter (Diesel Engines)
If you have a diesel engine, your fuel filter is located in
the engine compartment on the driver’s side of the
vehicle, or along the driver’s side frame rail. SeeFuel
Filter Replacementearlier in this section for further
information.
Also seeScheduled Maintenance on page 6-5for
recommended service intervals.
Primary Fuel Filter and Water
Separator
If you have a diesel
engine, you may have this
spin-on filter. It is located
on the driver’s side
frame rail.It has a clear plastic drain bowl at the bottom. Check
the drain bowl occasionally for any water or particles.
To drain the bowl, do the following:
1. Shut off the engine.
2. Partially open the drain valve at the bottom of the
filter.
SeeEngine Oil (Caterpillar
®Diesel Engine) on
page 5-20orEngine Oil (Gasoline Engine) on page 5-20
orEngine Oil (DURAMAX™ Diesel) on page 5-25for
proper disposal procedures.
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Part A: Scheduled Maintenance
Services
In this part are scheduled maintenance services which
are to be performed at the mileage intervals specified.
Using Your Maintenance Schedule
We at General Motors want to help keep your vehicle in
good working condition. But we do not know exactly
how you will drive it. You may drive very short distances
only a few times a week. Or you may drive long
distances all the time in very hot, dusty weather. You
may use your vehicle in making deliveries or in
many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your dealer.
This part tells you the maintenance services you should
have done and when to schedule them.
When you go to your dealer for your service needs, you
will know that GM-trained and supported service
people will perform the work using genuine GM parts.The proper fluids and lubricants to use are listed in
Part C. Make sure whoever services your vehicle uses
these. All parts should be replaced and all necessary
repairs done before you or anyone else drives the
vehicle.
This schedule is for vehicles that:
•carry passengers and cargo within recommended
limits. You will find limits on your vehicle’s GVW
Rating label. SeeLoading Your Vehicle on
page 4-33.
•are driven on reasonable road surfaces within legal
driving limits.
•use the recommended fuel. SeeWhat Fuel to Use
on page 5-8.
Scheduled Maintenance
Supplements
If your vehicle has a Caterpillar®diesel engine, your
owner’s manual is supplemented by the Caterpillar®
Diesel Engine Operation & Maintenance Manual. If your
vehicle has an Allison transmission, your owner’s
manual is supplemented by an Allison
Transmission
®Operator’s Manual. Always refer to these
manuals for related maintenance services.
6-4

Scheduled Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown after 100,000 miles
(166 000 km) should be repeated at the same miles (km)
after those intervals for the life of this vehicle.
Gasoline engine vehicles have a computer that lets you
know when to change your engine oil. This is not
based on mileage, but on engine revolutions and engine
operating temperature. When the computer has
calculated that the oil needs changing, the GM Oil Life
System will indicate that a change is necessary.
The “Footnotes” at the end of this Maintenance
Schedule further explain maintenance services.
SeeService Publications Ordering Information on
page 7-7.
100 Miles (160 km)
❑Wheel stud nut service.(46)
1,000 Miles (1 600 km)
❑Wheel stud nut service.(46)
❑Rear axle air shift motor service.(11)
7,500 Miles (12 000 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)
❑Check fluid levels (or every 3 months, whichever
occurs first).(1) (6)
❑Chassis lubrication service (or every 6 months,
whichever occurs first).(12)
❑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)
6-5

300,000 Miles (480 000 km)
❑Remove, disassemble, clean and inspect the air
brake air dryer (or every 3 years, or 10,800 hours,
whichever occurs first). Replace desiccant on
Bendix-Westinghouse units.
Footnotes
† = The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(1)= If your vehicle has an Allison automatic
transmission, your GM owner’s manual is supplemented
by an Allison Transmission
®Operator’s Manual.
Always refer to these manuals for related maintenance
services.
(2)= Refer to the Caterpillar
®Diesel Engine Operation
and Maintenance Manual for oil recommendations
and change intervals.
(3)= An Emission Control Service.
(4)= A Noise Emission Control Device.
(5)= Applies only to vehicles sold in the United States.(6)= Check fluid level in brake master cylinder, power
steering pump, axle, 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.
(7)= 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.
(8)= Inspect parking brake drum and linings for wear or
cracks and check linkage and adjustment.
(9)= This vehicle has the GM 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
7,500 miles (12 000 km) since your last oil change.
Under severe conditions, the indicator may come on
before 3,000 miles (5 000 km). Never drive your vehicle
more than 7,500 miles (12 000 km) or 12 months
without an oil and filter change.
Remember to reset the Oil Life System whenever the oil
is changed. For more information, seeChange Engine
Oil Light on page 3-39.
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(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

(24)= Check the air intake system installation to see
that gaskets are seated properly and all hose
connections, fasteners and other components are tight.
Tighten connections and fasteners or replace parts
as required.
(26)= Evaporative Control System Service (if equipped):
Check all fuel and vapor lines and hoses for proper
connections and correct routing (or every 24 months,
whichever occurs first). Replace parts as needed.
(28)= Replace spark plugs. Inspect wires for damage.
Check the wire boot and boot heat shield fit at spark
plugs and coil. Replace parts as needed.
(30)= Check the fuel tank, fuel cap and fuel lines for
damage which could cause leakage. Inspect fuel cap for
correct sealing ability and any indications of damage.
Check fuel cap gasket for even filler neck imprint.
Replace parts as needed.
(31)= Check EGR system as described in the service
manual. SeeService Publications Ordering Information
on page 7-7.(32)= 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.
(35)= Drain, flush and refill cooling system. SeePart C:
Recommended Fluids and Lubricants on page 6-29
for 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.
(37)= Rear axle service: Change the lubricant. See
Part C: Recommended Fluids and Lubricants on
page 6-29.
(38)= Front axle service: Re-pack upper kingpin roller
bearing.
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