Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

2002 GMC C3500 HD 6.5 F, AutomaticFACTORY OEM SERVICE PROCEDURE

Removal Procedure

Remove the fuel tank filler cap.
CAUTION: Refer to BATTERY DISCONNECT CAUTION .
Disconnect the negative battery cables.
Raise the vehicle on a hoist.
Remove 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) .
Remove the sender unit by turning the cam lock counterclockwise using the J 36608 fuel sender tool.

Fig 1: Cam Lock Assembly
Courtesy of GENERAL MOTORS CORP.

Important: Do not damage the rubber insulator or the strainer.
Remove the sending unit by pulling up.
Inspect the attaching hose for signs of deterioration.
Inspect the strainer.

Fig 2: Removing Fuel Sender Assembly
Courtesy of GENERAL MOTORS CORP.

Chapter Navigation

Return to Chapter: Fuel Sender Assembly Replacement

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.