2002 GMC C3500 HD 8.1 G, StandardFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  2. Note the position of the fuel strainer (2) on the fuel sender.
  3. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand.
  4. Pull the strainer off the fuel sender. Discard the strainer after inspection.
  5. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  6. Disconnect the fuel pump electrical connector (5).
  7. Remove the electrical connector retaining clip (6) from the fuel level sensor.
  8. Disconnect the sensor electrical connector (7) from under the fuel sender cover.
  9. Remove the fuel level sensor retaining clip (4).
  10. Squeeze the locking tangs and remove the fuel level sensor (3).
  11. Remove the fuel pressure sensor (1).
    Fig 1: Fuel Strainer & Fuel Level Sensor Components
    G01598934Courtesy 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.