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 8.1 G, AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

Important: The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.

Install the new seal on the fuel tank.
NOTE: Refer to the FASTENER NOTICE in Cautions and Notices.
Install the fuel sender assembly into the fuel tank.
Install the fuel sender assembly retaining ring using the J 39765.
Install the fuel tank. Refer to Fuel Tank Replacement (Side) or Fuel Tank Replacement (Rear) .

Fig 1: 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.