2002 GMC C3500 HD 6.5 F, AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the cap seal into filter housing.
    Fig 1: Fuel Heater Threaded Cap Nut, Cap Seal & Fuel Heater
    G01599475Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel heater.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the threaded cap nut.

    Tighten 

    Tighten the cap nut securely by hand.

    Fig 2: Fuel Heater
    G01599476Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel manager/filter. Refer to Fuel Filter/Heater Element Housing Replacement .
    Fig 3: Fuel Manager/Filter
    G01599477Courtesy of GENERAL MOTORS CORP.
  5. Install the mounting bolts that connect the fuel manager/filter to the intake manifold.

    Tighten 

    Tighten the mounting bolts to 25 N.m (18 lb ft).

    Fig 4: Fuel Manager/Filter Mounting Bolts
    G01599478Courtesy of GENERAL MOTORS CORP.
  6. Open the air bleed valve on top of the fuel manager/filter to bleed air from fuel supply system. Refer to Fuel Feed and Fuel Return Pipe Purge Procedure .
    Fig 5: Opening Air Bleed Valve
    G01599479Courtesy of GENERAL MOTORS CORP.
  7. Install the upper intake manifold cover.
    Fig 6: Upper Intake Manifold Cover
    G01599480Courtesy of GENERAL MOTORS CORP.
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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.