2006 CHEVROLET KODIAK Owners Manual

Fuel Priming
If your vehicle has a Caterpillar®diesel engine, see the
Caterpillar®Diesel Engine Operation and Maintenance
Manual provided with your vehicle.
If your vehicle has a DURAMAX
®diesel engine, in
order for the fuel system to work properly, the fuel lines
must be full of fuel and contain no air. If air gets into
the fuel lines, it will be necessary to prime the fuel lines
to eliminate air before operating the vehicle.
Air can get into the fuel lines if any of the following
happen:
•The vehicle runs out of fuel.
•The fuel filter is removed for servicing or
replacement.
•The fuel lines are removed or disconnected for
servicing.
•The fuel filter water drain valve is opened while the
engine is running.If one or more of the above occurred, it is very likely
that air has entered your fuel system and that you will
need to prime the fuel system before operating the
vehicle.
Air in the fuel lines will not harm the engine or the
vehicle. However, the engine may not be able to start
until the fuel system is primed and the air is removed.
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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.
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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.
Your check engine light may come on if the vehicle has
run out of fuel. This light may stay on for a few drive
cycles after the condition is corrected, but will eventually
clear itself.
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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.If your vehicle has the 6.6L engine, the fuel filter is
located in the engine compartment on the driver’s side
of the vehicle. If your vehicle has either the 7.2L or
7.8L engine, the fuel filters are located in the engine
compartment on the driver’s side of the vehicle, and 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 would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-19

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 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.
When you put the cap back on, turn it clockwise until it
is tight. C4/C5 Models shown,
C6/C7/C8 Models
with Gasoline Engines
similar
C6/C7/C8 Models with
Diesel Engines
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