2005 CHEVROLET KODIAK power steering

❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑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).(34)
100,000 Miles (160 000 km)
❑Diesel Only: Inspect engine drive belt; replace as
necessary.
❑Gasoline Engine Only (Vehicles with GVW of
16,000 lbs or less): Spark plug service.(2) (25)
❑Change power steering fluid (or every 36 months,
whichever occurs first).(12)
❑Replace power steering reservoir filter element (or
every 24 months, whichever occurs first).
❑Except four-wheel drive: Front axle service.(31)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case service.(30)
❑Rear axle service — Eaton
®, Rockwell®, Spicer®
axles (or every 12 months, whichever occurs
first).(30)❑Exhaust brake service, if equipped. Check for
excessive spindle free play and smooth operation.
Lubricate ball joint cap.
❑Inspect air compressor discharge port (or every
6 months or every 1,800 hours, whichever
occurs first).
❑Manual transmission (ZF 6-speed only) fluid
replacement (or every 48 months, whichever
occurs first).
❑Trailer brake hand control valve service (or every
12 months, or every 3,600 hours, whichever
occurs first).(35)
120,000 Miles (192 000 km)
❑C600, C700, and C800 Gasoline Engines Only:
Replace engine drive belts.
❑C400 and C500 Gasoline Engines Only: Engine drive
belts service (or every 12 months, whichever occurs
first).(17)
150,000 Miles (240 000 km)
❑Cooling system service (or every 60 months since
last service, whichever occurs first).(2) (29)
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
6-20

200,000 Miles (320 000 km)
❑Remove, disassemble, clean, and inspect the air
brake trailer supply valve (or every 2 years, or
every 7,200 hours, whichever occurs first).
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
250,000 Miles (400 000 km)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case service.(30)
❑Rear axle service — Eaton
®, Rockwell®, Spicer®
axles (or every 36 months, whichever occurs
first).(30)
❑Manual transmission (except ZF 6-speed) fluid
replacement (or every 60 months, whichever
occurs first).
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.
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 Transmission
®, your
GM owner manual is supplemented by an Allison
Transmission
®Operator’s Manual. Always refer to these
manuals for related maintenance services.
(2)= An Emission Control Service.
(3)= A Noise Emission Control Device.
(4)= Applies only to vehicles sold in the United States.
(5)= 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.
6-21

(10)= 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.
(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.
(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.
6-23

Part C: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number, or specification may be obtained from
your dealer.
Usage Fluid/Lubricant
Engine Oil
(Gasoline
Engine)Engine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. GM Goodwrench
®
oil meets all the requirements for
your vehicle. To determine the
proper viscosity for your vehicle’s
engine, see “Engine Oil” in
the Index.
Engine Oil
(DURAMAX
®
Diesel Engine)Engine oil with the letters CI-4 or
CH-4 is best for your vehicle. The
CI-4 or CH-4 designation may
appear either alone or in
combination with other API
designations, such as API CI-4/SL.
These letters show American
Petroleum Institute levels of quality.
To determine the preferred viscosity
for your vehicle’s diesel engine, see
“Engine Oil” in the Index.
Engine Oil
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine oil
recommendations.
Usage Fluid/Lubricant
Engine Coolant
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine
coolant recommendations.
Engine Coolant
(Gasoline
Engine &
DURAMAX
®
Diesel)50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. See “Engine Coolant” in
the Index.
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.
Power Steering
SystemDEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specification”
on the label.
Manual
Transmission
(Except ZF
6-Speed)Synthetic Manual Transmission Fluid
(GM Part No. U.S. 12345724, in
Canada 10953510).
6-32

F
Filter
Engine Air Cleaner......................................5-33
Filter Minder Gage..........................................3-43
Finish Damage...............................................5-85
Fixed Mast Antenna........................................3-59
Flat Tire........................................................5-78
Fluid
Automatic Transmission................................5-34
Manual Transmission....................................5-35
Power Steering...........................................5-45
Windshield Washer......................................5-46
Four-Wheel Drive....................................2-33, 5-62
Front Axle......................................................5-63
Front Wheel Bearings with Oil-Filled Hubs..........5-69
Fuel............................................................... 5-6
Additives...................................................... 5-6
Diesel Engine Fuel........................................ 5-7
Filling a Portable Fuel Container....................5-19
Filling Your Tank..........................................5-18
Filter..........................................................5-66
Filter Replacement.......................................5-16Fuel (cont.)
Fuels in Foreign Countries............................5-17
Gage.........................................................3-42
Gasoline Octane........................................... 5-6
Gasoline Specifications.................................. 5-6
Primary Filter and Water Separator................5-67
Running Out of Fuel....................................5-15
Secondary Filter and Water
Separator/Heater......................................5-68
Very Cold Weather Operation........................5-10
Water in Fuel..............................................5-10
Water in Warning Light.................................3-43
What Fuel to Use.......................................... 5-8
Fuses
Fuses and Circuit Breakers...........................5-89
Instrument Panel Fuse Block.........................5-89
Underhood Fuse Block.................................5-92
Windshield Wiper.........................................5-88
6

Other Service Items (cont.)
Primary Fuel Filter and Water Separator.........5-67
Secondary Fuel Filter and Water Separator/
Heater....................................................5-68
Other Warning Devices...................................... 3-6
Outlet Adjustment............................................3-23
Outside
Convex Mirrors............................................2-46
Heated Mirrors............................................2-46
Manual Mirrors............................................2-45
Power Mirrors.............................................2-45
Overspeed Warning Light.................................3-39
Owners, Canadian............................................... ii
P
Parking.........................................................2-38
Air Brake....................................................2-40
Hydraulic Brakes.........................................2-38
Over Things That Burn.................................2-43
Propshaft Brake Burnish Procedure................2-39
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-27
Part C - Recommended Fluids and Lubricants....6-32
Part D - Maintenance Record...........................6-34
Passing.........................................................4-13Power
Accessory Outlets........................................3-19
Door Locks.................................................. 2-7
Electrical System.........................................5-89
Reduced Engine Light..................................3-41
Steering Fluid.............................................5-45
Windows...................................................... 2-9
Propshaft Brake Burnish Procedure...................2-39
Q
Questions and Answers About Safety Belts.........1-13
R
Radios..........................................................3-44
AM-FM Radio.............................................3-45
Care of Your Cassette Tape Player................3-58
Care of Your CD Player...............................3-59
Care of Your CDs........................................3-59
Radio with Cassette.....................................3-48
Radio with CD............................................3-53
Setting the Time..........................................3-45
Theft-Deterrent............................................3-57
Understanding Reception..............................3-57
Range Inhibit Warning Indicator........................3-31
10