Home » GM 6.5 » GM/Detroit 6.5L ENGINE CONTROLS – Fuel Sender Assembly Replacement

GM/Detroit 6.5L ENGINE CONTROLS – Fuel Sender Assembly Replacement

Removal Procedure
Tools Required
J 36608 Fuel Sender Tool
1. Remove the fuel tank filler cap.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
2. Disconnect the negative battery cable(s).
3. Raise the vehicle on a hoist.
4. Remove the fuel tank. Refer to Fuel Tank Replacement.
5. Remove the sender unit by turning the cam lock counterclockwise using the J 36608 fuel sender tool.

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

Installation Procedure
1. Insert a new O-ring seal.
Notice: 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.

4. Install the cam lock assembly.
5. Turn the cam lock clockwise in order to lock it.
6. Install the fuel tank. Refer to Fuel Tank Installation.
7. Connect the negative battery cable.
8. Check the system for leaks.
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.
8.2. Turn OFF the ignition switch for 10 seconds.
8.3. Again, turn the ignition switch to the ON position.
8.4. Check for fuel leaks.


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