2002 GMC C3500 HD 6.5 F, AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Insert a new O-ring seal.
    NOTE: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.
  2. Install the sending unit assembly into the fuel tank.
  3. Install the hoses onto the sender assembly.
    Fig 1: Installing Fuel Sender Assembly
    G01599575Courtesy of GENERAL MOTORS CORP.
  4. Install the cam lock assembly.
  5. Turn the cam lock clockwise in order to lock.
  6. Install the fuel tank. Refer to Fuel Tank Replacement (Extended Cab Side Tank)  or Fuel Tank Replacement (Pickup Side Tank)  or Fuel Tank Replacement (Cab and Chassis Rear Tank)  or Fuel Tank Replacement (Cab and Chassis Side Tank) .
  7. Connect the negative battery cable.
  8. Check the system for leaks.
    1. 8.1. Turn ON the ignition switch for 2 seconds. The scan tool can be used to activate the fuel pump to check for fuel system leaks.
    2. 8.2. Turn OFF the ignition switch for 10 seconds.
    3. 8.3. Again, turn the ignition switch to the ON position.
    4. 8.4. Check for fuel leaks.
    Fig 2: Cam Lock Assembly
    G01599576Courtesy of GENERAL MOTORS CORP.
Chapter Navigation
Return to Chapter: Fuel Sender Assembly Replacement
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.