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Home >> Chevrolet >> 2002 >> C3500 HD 6.5 F, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 6.5L >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure
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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.
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