Express, Savana, G1500, G2500, G3500, 1998-2005

Removal & Installation


On gasoline engines, the fuel filter is integral with the fuel pump/sender assembly in the fuel tank. Refer to the Fuel Pump removal procedure.

6.5L Engine

  1. Turn the ignition OFF . Remove the fuel tank cap to release any pressure or vacuum in the tank.
    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

  3. 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


To install:

  1. Be sure the mating surface between the element assembly and the header assembly is clean.
  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.

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

    Element nut and tighten securely by hand

  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.
    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.

  9. Disconnect the fuel injection pump shutdown solenoid wire.
  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.
  13. Close the air bleed valve, reconnect the injection pump solenoid wire and replace the fuel tank cap.
  15. Start the engine, allow it to idle for 5 minutes and check the fuel manager/filter assembly for leaks.

Gasoline Engines

On 2005 gasoline engines the fuel filter is integral with the fuel pump/sender assembly in the fuel tank.

The fuel filter is normally located along the frame rail of the vehicle. On some vehicles however, it may have been relocated to the engine compartment. When in doubt, trace a fuel line from the engine backward or from the tank forward in order to locate the filter.

Some vehicles utilize a spin-on fuel filter located on the frame rail. This filter can be turned counterclockwise after the fuel pressure is relieved.

Click image to see an enlarged view

Fig. The spin-on fuel filter is serviced in the same manner as a spin-on oil filter

  1. Before servicing the vehicle, refer to the Precautions section.
  3. Properly relieve the fuel system pressure.
  5. Remove or disconnect the following:

    Negative battery cable
    Fuel line connections from the filter or unscrew the filter in the case of the spin-on type
    In line filters, remove the bolt from the filter mounting clamp, then remove the clamp and filter assembly. Separate the filter from the clamp.


To install:

The inline filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the system, with the arrow facing away from the fuel tank.

  1. Install or connect the following:

    In line filters place filter in clamp
    Install filter and clamp
    Spin-on filters, lubricate the gasket before installation. Then tighten the filter an additional 3 / 4 of a turn from the point when the gasket touches the filter adapter. Always check for leaks after a new filter is installed.