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, StandardFACTORY OEM SERVICE PROCEDURE
Removal Procedure
CAUTION:
Refer to BATTERY DISCONNECT CAUTION
.
Important: Clean all the line fittings that will be loosened or removed.
- Remove the negative battery cables.
- Remove the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER
and INTAKE MANIFOLD REPLACEMENT - LOWER
.
Important: Before any further service work is to be done, cover the intake ports with the J 39664 .
- Remove the injection line clips at the loom brackets.
- Remove the injection lines at the nozzles.
- Cap the lines and the nozzles immediately.
- Do not bend the injection lines.
- Remove the injection lines at the pump. Refer to Fuel System Description .
- Cap the lines and the pump fittings immediately.
- Tag the lines for installation.
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.