1994 - 2002 GM OBS 6.5L V8 Diesel Engine Fuel Filter Manager & Fuel Hoses Replacement (Chevy & GMC)

In this video we will go over fuel system maintenance for the GM 6.5L V8 diesel engine focusing on replacing aging rubber fuel hoses and rebuilding, and replacing, the Stanadyne FFM (Fuel Filter Manager or just Fuel Manager) assembly. This fuel system maintenance is specific to the electronic fuel injection version of the 6.5L diesel engine, with the Stanadyne DS4 injection pump only.

The truck illustrated is a 1999 Chevrolet K1500 Suburban LT, but the procedure will be the same for any 1994 thru 2002 GM OBS C/K truck with the 6.5L diesel engine. Chevrolet, GMC, and Holden for Tahoe, Yukon, Silverado, Cheyenne, Sierra, Blazer, and Suburban across C1500, K1500, C2500, K2500, C3500, and K3500 weight ratings.

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 (note several of the parts are discontinued by GM/Stanadyne):

Fuel Filter Manager (FFM) assembly GM 10226035 / Stanadyne FM100 top loading: https://ebay.us/GQYUSU or https://amzn.to/3Qcpfhs

Fuel Filter GM 10154635 / ACDelco TP1256 / Stanadyne 31712: https://ebay.us/yQZPSn
Fuel Filter Nut GM 12511963 / Stanadyne 28694: https://ebay.us/C5z1dl or https://amzn.to/3Q9RZHw

Fuel heater assembly GM 12511964 / Stanadyne 29241: https://ebay.us/wpZ4uR or https://amzn.to/3WDZ1a1
Fuel heater o-ring GM 12511962 / Stanadyne 28869: https://ebay.us/neSDyO or https://amzn.to/3IgaDeQ

Water in fuel sensor GM 12375515 / Stanadyne 29257: https://ebay.us/JKlvOE or https://amzn.to/3VFJFjY
Water in fuel sensor o-ring GM 12511959 / Stanadyne 27602: https://ebay.us/6xNbDn

Fuel Manager pre-filter screen Stanadyne 29244: https://ebay.us/PyelCy

Fuel hose 1/4" bulk line GM 9438257 rated GM 6165-M: https://ebay.us/ZbripQ
Fuel hose 1/4" bulk line GM 9439402 rated GM 6163-M: https://ebay.us/VofPRJ
Fuel hose 5/16" bulk line GM 9439550 rated GM 6165-M: https://ebay.us/YwYqkm

Fuel filter manager inlet 90 degree elbow 3/8" GM 10228324: https://ebay.us/XYpdZJ
Fuel injection pump inlet molded hose 1/4" GM 10229337: https://ebay.us/PzyxHl or https://amzn.to/3vxKDEe

Fuel line 1/4" - 5/16" worm clamp GM 25518880: https://ebay.us/zX4pgK or https://amzn.to/3Z3DgC1

Fuel hose plastic conduit wrap GM 8919355: https://ebay.us/yvKy03

Upper intake manifold crossover gasket GM 10137537: https://ebay.us/AXsxyo or https://amzn.to/3YYQWyh
Permatex 81158 black adhesive sealant: https://ebay.us/vJESu9 or https://amzn.to/3VDQ674

Fuel injector return hose GM 14066305: https://ebay.us/syjeCg or https://amzn.to/3WVlKho
Fuel injector return cap GM 14066301: https://ebay.us/qhBuOx

GM factory service manual: https://ebay.us/I3s5TZ

Stanadyne Service Bulletin 469: https://www.stanadyne.com/dealerporta...

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

1994 1995 1996 1997 1998 1999 2000 2001 2002

Chapters:
0:00 - Project overview
0:20 - Removing the engine cover
0:27 - Locating and removing the injection pump return hose
1:36 - Removing the intake manifold crossover assembly
3:34 - Locating and removing the injection pump feed hose
4:29 - Locating and removing the fuel filter manager drain hoses
6:30 - Locating and removing the FFM
7:44 - FFM teardown and rebuild considerations
12:21 - Service manual technical information
14:18 - Parts explosion and part numbers
20:23 - Fuel heater assembly testing
25:06 - Water in fuel sensor testing
27:21 - FFM reassembly & installation
30:48 - Final reassembly

#drshock #obstruck #obstrucks

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.