Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Fuel Filter

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Draining Water



  1. Attach a small piece of hose to the drain cock onto the water-in-fuel sensor.

    Click image to see an enlarged view

    Fig. Attach a hose to the drain cock onto the water-in-fuel sensor-6.6L engines

  2.  
  3. Place an approved fuel-resistant container under the fuel filter.
  4.  
  5. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock.

    Click image to see an enlarged view

    Fig. Open the drain cock until the water contaminated fuel seeps from the drain cock-6.6L engines

  6.  
  7. Perform the purging procedure until only diesel fuel drains from the assembly.
  8.  
  9. Tighten the drain cock.
  10.  
  11. Remove the container and hose.
  12.  

  1. Attach a small piece of hose to the drain cock onto the water-in-fuel sensor.

    Click image to see an enlarged view

    Fig. Attach a hose to the drain cock onto the water-in-fuel sensor-6.6L engines

  2.  
  3. Place an approved fuel-resistant container under the fuel filter.
  4.  
  5. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock.

    Click image to see an enlarged view

    Fig. Open the drain cock until the water contaminated fuel seeps from the drain cock-6.6L engines

  6.  
  7. Operate the priming pump until only diesel fuel is visible. Allow the pump to return upward between pushes.

    Click image to see an enlarged view

    Fig. Operate the priming pump until only diesel fuel is visible-6.6L engines

  8.  
  9. Tighten the drain cock.
  10.  
  11. Remove the container and hose.
  12.  

Removal & Installation



  1. Disconnect the negative battery cables.
  2.  
  3. If necessary, remove the wheelhouse liner for additional access.
  4.  
  5. Drain the fuel from the fuel filter as follows:
    1. Install a hose on the water drain on the water-in-fuel sensor.
    2.  
    3. Place the other end of the hose into an approved container.
    4.  
    5. Drain as much fuel as possible from the fuel filter housing.
    6.  
    7. Tighten the water drain on the water-in-fuel sensor.
    8.  

  6.  
  7. Remove or disconnect the following:

    Water-in-fuel sensor harness connector
     
    Fuel filter from the fuel filter/heater element housing
     
    Water-in-fuel sensor from the fuel filter

    Click image to see an enlarged view

    Fig. Exploded view of the fuel filter-6.6L engines

     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Check the fuel filter/heater element housing and the filter for a dislocated filter seal or foreign debris. Contamination on the filter/heater housing may cause leakage at the fuel filter. Coat the seal with clean engine oil.



    Water-in-fuel sensor in the fuel filter
     



    Fuel filter on the fuel filter/heater element housing
     
    Water-in-fuel harness connector
     
    Negative battery cables
     

  2.  
  3. Purge the fuel system:
  4.  

  1. Disconnect the negative battery cables.
  2.  
  3. If necessary, remove the wheelhouse liner for additional access.
  4.  
  5. Drain the fuel from the fuel filter as follows:
    1. Install a hose on the water drain on the water-in-fuel sensor.
    2.  
    3. Place the other end of the hose into an approved container.
    4.  
    5. Drain as much fuel as possible from the fuel filter housing.
    6.  
    7. Tighten the water drain on the water-in-fuel sensor.
    8.  

  6.  
  7. Remove or disconnect the following:

    Water-in-fuel sensor harness connector
     
    Fuel filter from the fuel filter/heater element housing
     
    Water-in-fuel sensor from the fuel filter

    Click image to see an enlarged view

    Fig. Exploded view of the fuel filter (2)-6.6L engines

     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Check the fuel filter/heater element housing and the filter for a dislocated filter seal or foreign debris. Contamination on the filter/heater housing may cause leakage at the fuel filter. Coat the seal with clean engine oil.



    Water-in-fuel sensor in the fuel filter
     



    Fuel filter on the fuel filter/heater element housing
     
    Water-in-fuel harness connector
     
    Negative battery cables
     

  2.  
  3. Prime the fuel system:
    1. Pump the primer located on top of the fuel filter 30 times or until stiff.
    2.  
    3. Try to start and run the engine. If the engine does not start, repeat the previous step.
    4.  
    5. Allow the engine to run for 5 minutes at idle.
    6.  
    7. Check for fuel leaks and clear all Diagnostic Trouble Codes (DTCs).
    8.  

  4.  

6.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Turn the ignition OFF . Remove the fuel tank cap to release any pressure or vacuum in the tank.
    NOTE
    It is not necessary to drain all the fuel from the header in order to change the element since the fuel will remain in the header's cavity.



    Click image to see an enlarged view

    Fig. Exploded view of the fuel filter assembly-6.5L diesel engines

  4.  
  5. Remove or disconnect the following:

    Open the air bleed valve to relieve residual pressure
     
    Element nut, turning it by hand to the left. If necessary, a strap wrench may be used to loosen the nut.
     
    Element by lifting straight up and out of the header assembly
     

  6.  

To install:

  1. Be sure the mating surface between the element assembly and the header assembly is clean.
  2.  
  3. Install or connect the following:

    New element by aligning the widest key slot located under the element assembly cap with the widest key in the header assembly.
     

  4.  
  5. Carefully push the element downward until the mating surfaces make contact.

    Element nut and tighten securely by hand
     

  6.  
  7. If not already done, open the air bleed valve on top of the fuel manager/filter assembly, then connect a length of hose placing the other end in a suitable container.
    NOTE
    Be extremely cautious when handling diesel fuel. Do not expose the fuel to sparks or open flames. Also, be cautious as the fuel coming out of the drain hose could be hot.

  8.  
  9. Disconnect the fuel injection pump shutdown solenoid wire.
  10.  
  11. Crank the engine for 10-15 seconds, then wait 1 minute for the starter motor to cool. Repeat until clear fuel is observed coming from the air bleed.
  12.  
  13. Close the air bleed valve, reconnect the injection pump solenoid wire and replace the fuel tank cap.
  14.  
  15. Start the engine, allow it to idle for 5 minutes and check the fuel manager/filter assembly for leaks.
  16.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Turn the ignition OFF . Remove the fuel tank cap to release any pressure or vacuum in the tank.
    NOTE
    It is not necessary to drain all the fuel from the header in order to change the element since the fuel will remain in the header's cavity.



    Click image to see an enlarged view

    Fig. Exploded view of the fuel filter assembly-6.5L diesel engines

  4.  
  5. Remove or disconnect the following:

    Open the air bleed valve to relieve residual pressure
     
    Element nut, turning it by hand to the left. If necessary, a strap wrench may be used to loosen the nut.
     
    Element by lifting straight up and out of the header assembly
     

  6.  

To install:

  1. Be sure the mating surface between the element assembly and the header assembly is clean.
  2.  
  3. Install or connect the following:

    New element by aligning the widest key slot located under the element assembly cap with the widest key in the header assembly.
     

  4.  
  5. Carefully push the element downward until the mating surfaces make contact.

    Element nut and tighten securely by hand
     

  6.  
  7. If not already done, open the air bleed valve on top of the fuel manager/filter assembly, then connect a length of hose placing the other end in a suitable container.
    NOTE
    Be extremely cautious when handling diesel fuel. Do not expose the fuel to sparks or open flames. Also, be cautious as the fuel coming out of the drain hose could be hot.

  8.  
  9. Disconnect the fuel injection pump shutdown solenoid wire.
  10.  
  11. Crank the engine for 10-15 seconds, then wait 1 minute for the starter motor to cool. Repeat until clear fuel is observed coming from the air bleed.
  12.  
  13. Close the air bleed valve, reconnect the injection pump solenoid wire and replace the fuel tank cap.
  14.  
  15. Start the engine, allow it to idle for 5 minutes and check the fuel manager/filter assembly for leaks.
  16.  

6.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cables.
  4.  
  5. Drain the fuel from the fuel filter as follows:
    1. Install a hose on the water drain on the water-in-fuel sensor.
    2.  
    3. Place the other end of the hose into an approved container.
    4.  
    5. Drain as much fuel as possible from the fuel filter housing.
    6.  
    7. Tighten the water drain on the water-in-fuel sensor.
    8.  

  6.  
  7. Remove or disconnect the following:

    Water-in-fuel sensor harness connector
     
    Fuel filter from the fuel filter/heater element housing
     
    Water-in-fuel sensor from the fuel filter

    Click image to see an enlarged view

    Fig. Exploded view of the fuel filter (2)-6.6L engine

     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Check the fuel filter/heater element housing and the filter for a dislocated filter seal or foreign debris. Contamination on the filter/heater housing may cause leakage at the fuel filter. Coat the seal with clean engine oil.



    Water-in-fuel sensor in the fuel filter
     



    Fuel filter on the fuel filter/heater element housing
     
    Water-in-fuel harness connector
     
    Negative battery cables
     

  2.  
  3. Prime the fuel system:
    1. Pump the primer located on top of the fuel filter 30 times or until stiff.
    2.  
    3. Try to start and run the engine. If the engine does not start, repeat the previous step.
    4.  
    5. Allow the engine to run for 5 minutes at idle.
    6.  
    7. Check for fuel leaks and clear all Diagnostic Trouble Codes (DTCs).
    8.  

  4.  

 
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