GM Service Manual Online
For 1990-2009 cars only

The fuel supply is stored in the fuel tank. Fuel is drawn from the fuel tank and into the primary filter by the fuel lift pump and then through the secondary filter and then into the injection pump. The unused fuel is returned to the fuel tank by a separate return line.

Fuel Tank

The fuel tank is held in place by metal straps and a cross strap attached to the frame rail. Typical location is mounted on the frame rail.

Fuel Filler Cap

The fuel tank filler neck is equipped with a threaded-type cap. The threaded part of the cap requires several turns counterclockwise in order to remove.

Fuel Sender Unit

The fuel sender is located inside of the fuel tank and is attached to the top of the fuel tank.

The fuel sender has a float, wire float arm, and a rheostat. The fuel level is sensed by the position of the float and the float arm which operates the 90 ohm rheostat. As the float position changes, the amount of current passing through the rheostat varies, thus changing the gage reading on the instrument panel.

Fuel Strainer

A woven plastic strainer is located on the lower end of the fuel sender pickup tube in the fuel tank. This strainer prevents large debris from entering in the fuel line unless the strainer becomes completely submerged in water.

Fuel Lift Pump

Fuel Lift Pump


Object Number: 27783  Size: MF
(1)Inlet Port
(2)Pressure Spring
(3)Primary Winding
(4)Secondary Winding
(5)Piston and Valve Assembly
(6)Inlet Valve
(7)Outlet Valve
(8)Cylinder
(9)Teflon Ring

The electric fuel lift pump mounts on the left frame rail and is used to deliver fuel at a low pressure (at least 4 psi or 21 kPa) at the rate of 0.24 liter (½ pint) in 15 seconds (15 GPH). The fuel lift pump is controlled by the PCM.

When the key is in turned ON, the PCM energizes the fuel pump relay which sends a voltage to the fuel lift pump. The lift pump remains ON during the glow plug cycle. If the engine is not started immediately after the glow plug cycle, the PCM shuts the fuel lift pump OFF and waits until engine RPM is greater than zero and then turns the relay back ON. As a backup system to the fuel pump relay, the fuel lift pump can also be turned ON by the oil pressure switch. When the engine oil pressure reaches 28 kPa (4 psi), and the fuel pump relay does not complete the circuit, the oil pressure switch will close and complete the circuit to run the fuel lift pump.

Fuel Manager/Filter (Primary)


Object Number: 256086  Size: SH

The primary (coarse) fuel manager/filter is an in-line type filter which combines several different functions by acting as a fuel filter, a water separator, a water detector, a water drain, and a fuel heater. The main function of the primary fuel manager/filter is to filter heavy debris.

The primary (coarse) fuel manager/filter mounts on the frame. The filter is located between the fuel tank and the secondary filter. Fuel is drawn from the fuel tank and into the primary filter and the through the fuel lift pump and then into the secondary filter and then out to the injection pump.

The primary fuel manager/filter has a replaceable fuel heater element and a water in fuel sensor. The fuel manager/filter has an air bleed valve on the filter housing which is used to purge air from the fuel system.

Fuel Manager/Filter (Secondary)


Object Number: 256088  Size: SH

The secondary (fine) fuel manager/filter is an in-line type filter which combines several different functions by acting as a fuel filter, a water separator, a water detector, a water drain, and a fuel heater. The main function of the secondary fuel manager/filter is to filter fine debris not caught by the primary filter.

The secondary (fine) fuel manager/filter mounts on the frame. The filter is located between the primary filter and the injection pump. Fuel flows from the fuel tank and then through the primary filter and the through the fuel lift pump and then into the secondary filter and then out to the injection pump.

The secondary fuel manager/filter has a replaceable fuel heater element and a water in fuel sensor. The fuel manager/filter has an air bleed valve on the filter housing which is used to purge air from the fuel system.

Fuel Filter (Primary)

The primary (coarse) fuel filter element separates particles larger than 150 microns from fuel moving through it under lift pump pressure. The primary and the secondary fuel filters are not interchangeable.

Fuel Filter (Secondary)

The secondary (fine) fuel filter element separates particles larger than 10 microns from fuel moving through it under lift pump pressure. The primary and the secondary fuel filters are not interchangeable.

Water In Fuel Sensor (Primary/Secondary)

The Water In Fuel sensor is located on the bottom of the filter. The design of the fuel manager/filter includes an area that allows water droplets (as small as one micron) to separate from the fuel and collect in a lower portion of the housing. The water in fuel sensor will detect a certain amount of water in the fuel inside of the filter housing and then turn the Water the Fuel lamp ON in the instrument cluster.

When the ignition switch is first turned to the run position, the Water in Fuel lamp will come ON for 2 to 5 seconds. This action provides a bulb check.

If the Water In Fuel lamp is illuminated both the primary and secondary filters must be drained of water.

Fuel Heater (Primary/Secondary)

The fuel heater operates when the temperature of fuel at the inlet of the filter housing is cold enough to possibly cause waxing that could restrict the flow to the injection pump. A control circuit inside of the fuel heater completes the circuit for the heater element when the fuel heater senses a temperature below 8°C (46°F). A fuel heater is located on top of both primary and secondary filters.

Rubber Fuel Hoses

The fuel feed and return pipes and hoses extend from the fuel sender to the fuel manager/filter. They are secured with clamps and are routed along the frame side member.

Some fuel feed pipes have threaded connections that are sealed with replaceable O-ring seals. These O-ring seals are made of special material, and should only be serviced with the correct service part.