1993 Chevrolet C3500 HD 6.5 F, StandardFACTORY OEM SERVICE PROCEDURE

Removal ("G" Series)

  1. Disconnect negative battery cables. Remove engine cover and intake manifold. Rotate snorkel up, and remove air cleaner inlet hose. Remove hood latch. Disconnect cable and move aside.
  2. Remove windshield washer bottle, fan shroud bolts and upper fan shroud. Disconnect rubber hose from oil fill tube. Disconnect oil fill tube attaching nuts, and remove oil fill tube. Remove oil fill tube grommet.
  3. Rotate engine as necessary and remove pump drive gear bolts. Remove fuel filter and bracket, including line to injection pump. Disconnect wire looms from injection lines, and injection lines at brackets.
  4. Disconnect oil pan dipstick tube from left cylinder head. Disconnect electrical connections at injection pump. Disconnect detent cable (if equipped). Disconnect accelerator cable.
  5. Remove injection lines. Tag lines for reassembly reference. Cap all openings. Disconnect fuel return line. Scribe or paint mark on front cover and pump flange. Remove injection pump mount nuts. Remove injection pump. See Figure. Cap all openings.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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