2005 CHEVROLET KODIAK Owners Manual

Priming the 6.6L DURAMAX®Diesel
Engine
If your vehicle is equipped with the 6.6L DURAMAX®
diesel engine, it has a priming pump which is part of the
engine mounted fuel filter. The vent valve and the
fuel filter primer pump are located on top of the fuel filter
housing. The priming pump is hand operated and is
designed to bring fuel to the engine to eliminate any air
that may be in the fuel lines.
To prime the 6.6L DURAMAX
®diesel engine,
do the following:
1. Make sure there is fuel in the tank.
2. Make sure the fuel filter had been installed and
properly tightened.
3. Make sure the fuel lines are properly connected
and the fuel filter is cool enough to touch.4. Remove any dirt from the fuel filter head and vent
valve by wiping with a cloth.
5. Open the fuel filter vent
valve by turning the
screw counterclockwise
several full turns.
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6. Repeatedly push down
on the fuel filter primer
pump with the palm of
your hand. Let the
pump return upward
between pushes.
7. Operate the priming pump until a small amount of
fuel seeps from the vent valve. When you see the
fuel, the filter is now full of fuel and the system
should be primed.
8. Close the vent valve.
9. Clean any fuel which accumulated on the fuel filter.
10. Start the engine and let it idle for a few minutes.
11. Check the filter for leaks.Priming the 7.8L DURAMAX®Diesel Engine
If your vehicle is equipped with the 7.8L DURAMAX®
diesel engine, use the following procedure to prime the
engine:
1. Make sure there is fuel in the fuel tank.
2. Make sure the specified fuel filter is properly
installed.
3. Make sure the fuel lines are securely connected.
4. Make sure the fuel filter is cool to the touch.
5. Use a clean cloth to remove dirt and oil from the
fuel filter head and breather valve.
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6. Use the palm of your hand to repeatedly press and
release the plunger (1) at the top of the fuel filter
priming pump. Continue until the plunger resistance
becomes firm. This may take from 20 to 100 times,
depending upon fuel tank location.
7. Turn the fuel filter breather valve screw (2)
counterclockwise several turns to open the
breather valve.
8. Use the palm of your hand to repeatedly press and
release the plunger (1) at the top of the fuel filter
priming pump until fuel begins to seep from
the breather valve.
9. Tighten the fuel filter breather screw (2) to the
specified torque, 4.9Y(43 in. lbs).
10. Use the palm of your hand to press and release the
plunger (1) at the top of the fuel filter priming pump
about 20 more times. This sends fuel to the engine.
11. Use a clean cloth to remove any fuel from the fuel
filter and surrounding area.
12. Start the engine and allow it to idle for a few minutes.
13. Check the fuel filter for leakage.Running Out of Fuel
If the diesel engine stalls and you think that you have
run out of fuel, do this to restart your engine:
{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.
1. If you are parked on a level surface, add at least
2 gallons (7.6 liters) of fuel. However, if you are
parked on a slope, you may need to add up
to 5 gallons (18.9 liters) 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.
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Fuel Filter Replacement
If you want to change the diesel engine fuel filter
yourself, here is 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 by following the
water draining procedure earlier in this section.
Your vehicle’s engine should be off until the end of this
procedure.The fuel filter is located in the engine compartment on
the passenger’s side of the vehicle, or on the driver’s
side frame rail in front of the fuel tank.
1. Apply the parking brake.
2. Unplug the water
sensor wire connected
to the fuel filter and
unscrew the filter
element.
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3. Remove the filter element. If there is any dirt on the
filter sealing surface, clean it off. Remove and
reuse the water sensor float switch located on the
bottom of the fuel filter.
4. Install the new filter element.
5. Reinstall and tighten the filter container and
reconnect the water sensor wire to the filter.
6. Use the fuel filter priming procedure earlier in this
section to prime the fuel filter.
7. Tighten the air bleed valve by turning it clockwise
until hand-tight.
8. Start your engine and let it idle for five minutes.
Check your fuel filter and air bleed valve for leaks.Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be
hard to find. Never use leaded gasoline or any other
fuel not recommended in the previous text on fuel.
Costly repairs caused by use of improper fuel wouldn’t
be covered by your warranty.
To check on fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you’ll be driving.
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Filling the Tank
{CAUTION:
Fuel vapor is highly ammable. It burns
violently, and that can cause very bad injuries.
Do not smoke if you are near fuel or refueling
your vehicle. Keep sparks, ames and smoking
materials away from fuel.The fuel cap can be on either or both sides of your
vehicle depending on option content.
To take off the cap, turn it slowly to the left
(counterclockwise).
{CAUTION:
If you get fuel on yourself and then something
ignites it, you could be badly burned. Fuel can
spray out on you if you open the fuel cap too
quickly. This spray can happen if your tank is
nearly full, and is more likely in hot weather.
Open the fuel cap slowly and wait for any
“hiss” noise to stop. Then unscrew the cap
all the way. C4/C5 Models
C6/C7/C8 Models
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When you put the cap back on, turn it to the right
(clockwise) until it is tight.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. SeeMalfunction Indicator Lamp on
page 3-36.
If you have dual tanks, fill the driver’s side tank, or
forward tank, first. The fuel gage will give better
readings this way. Your gage will show the total fuel
left in both tanks.Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
5-19

Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
Hood Latches
To tilt the hood forward, pull back and up on each of the
hood latches, located above the wheel wells on both
sides of the vehicle.
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