2009 CHEVROLET KODIAK Owners Manual

5. Open the fuel filter vent
valve by turning the
screw counterclockwise
several full turns.
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 fuel is seen,
the filter is full of fuel and the system should be
primed.
8. Close the vent valve.
9. Clean any fuel that accumulated on the fuel filter.
10. Start the engine and let it idle for a few minutes.
11. Check the filter for leaks.
5-15

Priming the 7.8L Duramax®Diesel Engine
If the 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.
6. Use the palm of your hand to repeatedly press
and release the plunger 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
counterclockwise several turns to open the
breather valve.
8. Use the palm of your hand to repeatedly press and
release the plunger 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 to the specified
torque, 4.9Y(43 lbs. in.).
10. Use the palm of your hand to press and release the
plunger 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.
5-16

Running Out of Fuel
If the diesel engine stalls and you think that you have
run out of fuel, do this to restart the engine:
{CAUTION:
Diesel fuel is flammable. It could start a fire if it
gets on hot engine parts. You could be burned. Do
not let too much fuel flow from the air bleed valve,
and wipe up any spilled fuel with a cloth.
1. If parked on a level surface, add at least 2 gallons
(7.6 liters) of fuel. However, if parked on a slope, up
to 5 gallons (18.9 liters) of fuel might need to be
added.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 the 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.
The service engine soon 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.
5-17

Fuel Filter Replacement
If you want to change the diesel engine fuel filter
yourself, here is how to do it:
{CAUTION:
Diesel fuel is flammable. It could start a fire 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.
The vehicle’s engine should be off until the end of this
procedure.If the vehicle has the 6.6L engine, the fuel filter is located
in the engine compartment on the driver side of the
vehicle. If the vehicle has either the 7.2L or 7.8L engine,
the fuel filters are located in the engine compartment
on the driver side of the vehicle, and on the driver 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.
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.
5-18

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 the engine and let it idle for five minutes.
Check the fuel filter and air bleed valve for leaks.
How to Reset Fuel Filter Change
Light - DURAMAX 6.6L (LMM) Engine
The engine controller calculates when to change the fuel
filter based on vehicle and fuel use. Whenever the
fuel filter is changed, reset the fuel filter light so
the engine controller can calculate when the next fuel
filter change is required. If the fuel filter is ever changed
prior to a change fuel filter light being turned on,
reset the fuel filter change light.To reset the Fuel Filter Change light:
1. Turn the ignition key to ON/RUN with the engine off
2. Fully press the accelerator and brake pedals at the
same time for 10 seconds. If the Fuel Filter Change
light flashes for 5 seconds, the system is resetting.
3. Turn the key to OFF.
If the Fuel Filter Change light comes back on when you
start the vehicle, the light has not been reset. Repeat
the procedure. SeeChange Fuel Filter Warning Light on
page 3-45for more information.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel might 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 the vehicle 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 flammable. It burns violently,
and that can cause very bad injuries. Do not
smoke if you are near fuel or refueling the vehicle.
Keep sparks, flames and smoking materials away
from fuel.
The fuel cap can be on either or both sides of the
vehicle depending on option content.
To take off the cap, turn it slowly counterclockwise. Fuel caps for all
gasoline applications,
and all diesel between
frame rail fuel tank
applications
Fuel caps for all side
mounted diesel
applications
5-20

{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 the 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 reinstalling the cap, turn it clockwise until it is
tight.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer/retailer can get one
for you. If you get the wrong type, it may not fit
properly. This may cause the malfunction indicator
lamp to light and may damage the fuel tank and
emissions system. SeeMalfunction Indicator Lamp
on page 3-36.If the vehicle has dual tanks, fill the driver side tank,
or forward tank, first. The fuel gage will give better
readings this way. The gage will show the total fuel left
in both tanks.
If the vehicle is a C4/C5 model and has dual tanks, the
engine must be off when refueling or the fuel transfer
system may become inoperable.
If the vehicle has a single tank with dual fillers, where
there is a filler on each side of the vehicle, do not
attempt to fill the tank through both fillers at the same
time. Do not fill the tank with both caps removed or
over-filling the tank and fuel spillage can result.
5-21

Filling a Portable Fuel Container
{CAUTION:
Never fill a portable fuel container while it is in the
vehicle. Static electricity discharge from the
container can ignite the fuel vapor. You can be
badly burned and the vehicle damaged if this
occurs. To help avoid injury to you and others:
•Dispense fuel only into approved containers.
•Do not fill 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 fill nozzle in contact with the inside
of the fill opening before operating the nozzle.
Contact should be maintained until the filling
is complete.
•Do not smoke while pumping fuel.
•Do not use a cellular phone while
pumping fuel.
Checking Things Under
the Hood
{CAUTION:
Things that burn can get on hot engine parts and
start a fire. These include liquids like fuel, oil,
coolant, brake fluid, windshield washer and other
fluids, 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.
5-22