1996 - 2000 OBS GM 6.5L Turbo Diesel Fuel Sender Diagnosis & Fuel Tank Replacement (Chevy & GMC)

This is another EPIC repair video with great detail covering how to diagnose and replace the fuel sender in most trucks with the General Motors 6.5L turbo diesel engines. Symptoms of a fuel sender failure include the fuel gauge not moving at all, grossly inaccurate or inconsistent fuel level readings, or wide swings of fuel gauge needle movement when the vehicle is not even moving. Due to two plus decades of corrosion complications, we end up having to also remove and replace the fuel tank, hose clamps, and the rear section of both the feed and return OEM fuel lines so BONUS DIY procedure footage for you all. ;-)

The vehicle illustrated is a 1999 Chevrolet Suburban LT K1500, and most of this video is going to be unique to the old body style (OBS) 90s Suburban trucks from Chevy, GMC and Holden in 96 97 98 99 and 00, but there are some procedures and GM technical information applicable to all 1990s GM 6.5L diesels as well. The behaviors shown in the video are usually indicative of a fuel sender problem, but can also be an actual fuel gauge problem (the aircore motor) so I include a upper righthand card link to another video for repairing the gauge aircore motor.

Procedures covered in this video:
- Removal & re-installation of instrument cluster assembly
- Fuel sender / fuel gauge electrical diagnosis of inaccurate readings
- Removal & re-installation of fuel tank off-road shield
- Removal & re-installation of fuel tank, hoses, liners, and straps
- Removal & re-installation of fuel sender, gasket, and lock ring
- Removal & re-installation of rear frame rail mounted fuel lines
- Removal & re-connection of fuel lines to fuel sender
- Bleeding of air from fuel lines

The eBay and Amazon search links below are paid links, for which I may be compensated and earn a commission, if you choose to buy the parts and tools shown in this video thru them:

6.5L diesel Suburban ONLY Spectra Premium GM43B fuel tank: https://ebay.us/mQiIWp or https://amzn.to/3lK160y

6.5L diesel Tahoe and Yukon Spectra Premium GM51B fuel tank: https://ebay.us/iYwmyV or https://amzn.to/3ylF946

GM 25124032 (ACDelco TR11) locking cam: https://ebay.us/2gOFLt or https://amzn.to/4dMgrdi

GM 22515965 (ACDelco G10) tank seal: https://ebay.us/5cMvjc or https://amzn.to/3K8yBsh

WARNING: ALL aftermarket 6.5L diesel fuel senders only use gasoline rated fuel pickup strainer material WITHOUT a bypass valve. You HAVE to monitor these inferior strainers for blockage annually.

Here's another for the appropriate (code VPG) fuel sender for the 6.5L diesel Suburbans ONLY; GM 19179693, GM 25027459, ACDelco FLS1089, Spectra FG12V, and Dorman 692-097: https://ebay.us/E80pLb or https://amzn.to/3lJ0etk

If you DO NOT have a Suburban but have a 6.5L diesel truck with (code VPE) then it would be these fuel senders; GM 19180462, GM 25027416, Spectra FG12Y, and Dorman 692-213 would be more appropriate: https://ebay.us/TqwI36 or https://amzn.to/3g9LJNU

If you DO NOT have a Suburban but have a 6.5L diesel truck with (code VRB) then it would be one of these fuel senders; GM 19179420, GM 25028613, ACDelco FLS1061, and Spectra FG01E would be more appropriate: https://ebay.us/pxpY1W or https://amzn.to/33GrpyE

Here's a link for the replacement fuel line sections and hose clamps I used GM 15722220, GM 15722276, GM 12338017, and GM 11609970: https://ebay.us/bHeZ0P

Stanadyne performance formula diesel injection pump fuel additive I mentioned in the video: https://ebay.us/anTr6V or https://amzn.to/3lK1GLM

Rust-Oleum rust reformer conversion: https://ebay.us/FgfBbA or https://amzn.to/3lIbeHd

And finally one for the Harbor Freight style transmission jack I used in the video: https://ebay.us/t58yL6 or https://amzn.to/3g9q4FJ

And if I've saved you some $$ here, consider some coins for the coffee tip-jar! https://ko-fi.com/drshock

1996 1997 1998 1999 2000

Chapters:
0:00 - Problem overview
1:18 - Electrical checks
15:47 - Fuel tank removal
31:10 - Fuel sender removal
37:33 - Corrosion analysis
41:02 - Frame fuel line removal
51:09 - Replacement fuel lines replacement
53:29 - Replacement fuel tank & sender prep
1:07:28 - Installation of new tank assembly
1:13:07 - Fuel line bleeding
1:14:51 - Retesting

#drshock #65diesel #dieselsuburban #chevytrucks #suburban

Disclaimer: DrShock, the alias for the human content creator for this YouTube channel, is not responsible for any damages, injuries, losses, or liabilities associated with any repairs, upgrades, or maintenance performed on yours, or any other, vehicle whatsoever. No warranty, express or implied, is made as to the accuracy or completeness of any information provided within this channel. Viewing and using the “as-is" information of this channel is totally at your own risk. Always wear personal protection equipment and follow appropriate vehicle manufacturer service manual guidelines with original manufacturer parts only when performing any repairs, upgrades, or maintenance upon any vehicle.