2009 CHEVROLET KODIAK fuel pump

Fuel Gage
Your fuel gage is located
on the right side of your
instrument panel cluster.
When the ignition is on, your fuel gage lets you know
about how much fuel you have left. When the gage first
shows empty, you’ll still have a little fuel left, but you
should get more fuel soon.
If your vehicle has dual fuel tanks, the reading on the
gage is the total fuel left in both tanks.Here are four concerns of some operators. None of
these shows a problem with your fuel gage:•The gage moves a little when you turn a corner or
speed up.
•The gage does not go back to empty when you turn
off the ignition.
•At the gas station, the pump shuts off before the
gage reads full.
•It takes a little more or less fuel to fill up than the
gage indicated.
If you have a Caterpillar
®diesel engine, also see your
Caterpillar®Operation & Maintenance Manual.
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In the United States, for best results use No. 2-D diesel
fuel year-round (above and below freezing conditions) as
oil companies blend No. 2-D fuel to address climate
differences. No. 1-D diesel fuel can be used in very cold
temperatures (when it stays below 0°F or−18°C);
however, it will produce a power and fuel economy loss.
Avoid the use of No. 1-D diesel fuel in warm or hot
climates. It can result in stalling, poor starting when the
engine is hot, and could damage the fuel injection
system.
It is acceptable to use diesel fuel containing up to
5% biodiesel (B5), but the final blended fuel must meet
the same specification, ASTM D 975 (Grades No. 2-D or
No. 1-D S15 commonly known as Ultra Low Sulfur
diesel), as other fuels used in your vehicle, and the
biodiesel used for making this fuel must meet the latest
version of ASTM specification D 6751. Biodiesel is
produced from vegetable oils or animal fat that have been
chemically modified to reduce the possibility of damage
to the fuel system and engine. Higher concentration (i.e.,
greater than B5) biodiesel-containing fuels or the use
of unmodified bio-oils blended into diesel fuel at any
concentration is not recommended and could damage the
fuel system and engine. Such damage would not be
covered by your warranty. If there are questions about
the biodiesel-containing fuels you are using, contact your
fuel supplier.Because of the cleansing properties of biodiesel,
switching from straight diesel to a biodiesel blend can
prematurely restrict the fuel filter with normal deposits in
the fuel system. A fuel filter replacement might be
required sooner than the recommended interval.
Diesel fuel can foam when you fill the tank. This can
cause the automatic pump nozzle to shut off, even
though the tank is not full. If this happens, just wait for
the foaming to stop and then try filling the tank more
slowly. SeeFilling the Tank on page 5-20.
{CAUTION:
Heat coming from the engine can cause the fuel to
expand and force the fuel out of the tank. If
something ignites the fuel, a fire could start and
people could be burned. To help avoid this, try
filling the tank more slowly and fill the fuel tank
only until the automatic nozzle shuts off. Do not try
to top it off.
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Very Cold Weather Operation
Follow the instructions listed previously under the
heading “What Fuel to Use.”
Notice:Never use home heating oil or gasoline in
your vehicle’s diesel engine. They can cause
engine damage.
In cold weather, the fuel filter could become clogged
(waxed). To unclog it, move the vehicle to a warm
garage area and warm the filter to between 32°F and
50°F (0°C to 10°C). You will not need to replace it.
Additional information on the fuel filter follows.
Water in Fuel
{CAUTION:
Diesel fuel containing water is still flammable. You
could be burned. If you ever try to drain water
from the fuel, keep sparks, flames, and smoking
materials away from the mixture.Notice:If there is water in the diesel fuel and the
weather is warm or humid, fungus and bacteria can
grow in the fuel. They can damage the fuel system.
A diesel fuel biocide can be used to sterilize the
fuel system. However, the fuel system may still need
to be cleaned. Your dealer/retailer can advise you
of the appropriate solution.
If the fuel tank needs to be purged to remove water,
see your dealer/retailer or a qualified technician.
Improper purging can damage the fuel system.
Sometimes, water can be pumped into the fuel tank
along with the diesel fuel. This can happen if a service
station does not regularly inspect and clean its fuel
tanks, or if it gets contaminated fuel from its suppliers.
If this happens, the
water-in-fuel light, if
equipped, will come on in
the instrument panel. If it
does, the water must be
drained. Your dealer/
retailer can show you
how to do this.
If the light comes on, use this chart to determine what
action to take.
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Water In Fuel Light
Problem Recommended Action
Light comes on
intermittently.Drain water from the fuel
filter.
Light stays on at
temperatures above
freezing.Drain the fuel filter
immediately. If no water
can be drained and the
light stays on, see your
dealer/retailer for
assistance.
Light stays on at
temperatures below
freezing.Drain the fuel filter
immediately. If no water
can be drained, water
may be frozen in the
water drain system, or in
the fuel lines. Move the
vehicle to a warm location
to thaw out, and then
drain the filter system.
Light stays on
immediately after
refueling, and a large
amount of water was
possibly pumped into the
fuel tank.Fuel tank purging is
required. See your
dealer/retailer for
assistance.Notice:Driving when this warning indicator is on,
can damage the fuel injection system and the engine.
If the indicator comes on right after a refuel, it means
water was pumped into the fuel tank. Turn off the
engine immediately. Then, have the water drained
at once.
To drain water, do the following:
1. Stop and park the vehicle in a safe place. Turn off
the engine and apply the parking brake.
2. Remove the fuel cap.
3. Place a fuel-resistant container under the fuel filter.
The filter drain valve is located on the bottom of the
fuel filter.
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.
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4. Open the drain valve
by turning two to three
turns. When fuel
empties from the valve,
all the water has
been drained. Close
the valve hand-tight.
5. Remove the fuel-resistant container and properly
dispose of the contaminated fuel. To find out how to
properly dispose of contaminated diesel fuel, see
Engine Oil (DURAMAX Diesel Engine) on page 5-24
orEngine Oil (Caterpillar Diesel Engine) on
page 5-27orEngine Oil (Isuzu Diesel Engine) on
page 5-28orEngine Oil (Gasoline Engine) on
page 5-32.6. Install the fuel cap.
7. Start the engine and let it run for a few minutes.
If the engine stalls, the fuel system may need to
be primed. While draining the water from the
fuel filter, air may enter the fuel system. If air has
entered the fuel system, the fuel system will need
to be primed.
If the water-in-fuel light comes on again after driving a
short distance or the engine runs rough or stalls, a large
amount of water has probably been pumped into the
fuel tank. The fuel tank should be purged.
Fuel Priming
If the vehicle has a Caterpillar®diesel engine, see the
Caterpillar®Diesel Engine Operation and Maintenance
Manual provided with the vehicle.
If the 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.
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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 the fuel system and the fuel system
needs to be primed 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.
Priming the 6.6L Duramax®Diesel Engine
If the 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 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.
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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.
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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.
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