Replacing The Fuel Filter On A 2005 Sierra Hd 2500: Step-By-Step Guide

If you're experiencing issues with your GMC Sierra HD's fuel delivery, it might be time to replace the fuel filter. The fuel filter is always located between the fuel tank and the engine, and it's important to replace it regularly to prevent contamination and damage to your fuel pump, carburetor, or fuel injectors. The process of replacing the fuel filter in a 2001-2016 GMC Sierra HD is relatively straightforward and can be done by following a few simple steps. However, it's important to note that the location of the fuel filter may vary depending on the model year of your vehicle.

Tools required

To replace the fuel filter in a 2001-2016 GMC Sierra 2500/3500 HD, you will need the following tools:

• A trim fastener removal tool, or a flathead screwdriver
• A 10mm socket and socket wrench
• Medium-sized channel lock style pliers
• A wrench, deep socket, or pliers
• A pick tool or a small flathead screwdriver
• A small angled pliers

Additional Tools for Replacing the Fuel Filter Housing:

If you are replacing the entire fuel filter housing, you will also need the following additional tools:

• A 12mm bolt
• Stainless steel hose clamps (recommended)

Removing the air intake tube

To remove the air intake tube of a 2005 Sierra HD 2500, you will need a trim fastener removal tool or a flathead screwdriver, a 10mm socket and socket wrench, and medium-size channel lock style pliers.

First, locate the air intake tube between the air filter housing and the turbocharger. Place your tools and parts within easy reach. Ensure you have adequate lighting and space to work.

Next, carefully remove the center air intake tube. You may need to refer to a repair manual for your vehicle to locate the exact position of the tube and any clips or bolts holding it in place. Once you have identified these, use your tools to carefully remove the tube. Place it aside in a safe place, ensuring it is not damaged.

Now, you need to remove the passenger side inner fender. This is held in place by plastic body clips and two 10mm bolts. Again, carefully remove these and place the fender aside.

At this point, the air intake tube should be exposed, and you can carefully lift it out. Ensure you do not damage any surrounding components and that you have enough room to manoeuvre the tube out.

Finally, check that you have removed any necessary bolts or clips holding the tube in place. Place these in a safe location, as you will need them for reinstallation.

Draining the water/fuel

Before you start, make sure you have a container to hand to catch the water/fuel mixture. You'll also need a trim fastener removal tool or a flathead screwdriver, a 10mm socket and socket wrench, and medium-size channel lock-style pliers.

First, remove the centre air intake tube between the air filter housing and the turbocharger. Then, remove the passenger side inner fender. This is held in place by plastic body clips and two 10mm bolts.

Now you can find the water-fuel separator drain valve at the bottom of the fuel filter. Open the bleed screw at the top of the fuel filter housing, then open the water separator drain valve. Drain the water/fuel into your container, then dispose of it properly.

Disconnect the water-in-fuel sensor electrical connector, then rotate the fuel filter counter-clockwise (from the bottom) and remove it. Keep the filter upright to avoid spilling any fuel. Drain the remaining fuel from the filter and dispose of it.

Removing the old filter

To remove the old fuel filter from your 2005 Sierra HD 2500, follow these steps:

First, remove the centre air intake tube between the air filter housing and the turbocharger. Then, remove the passenger side inner fender. This is held in place by plastic body clips and two 10mm bolts.

Next, locate the water-fuel separator drain valve at the bottom of the fuel filter. Open the bleed screw at the top of the fuel filter housing, and then open the water separator drain valve. Drain the water/fuel into a container and then dispose of it safely.

Disconnect the water-in-fuel sensor electrical connector, and then rotate the fuel filter counter-clockwise (from the bottom) and remove it. Keep the filter upright to avoid spilling any remaining fuel. Drain the remaining fuel from the filter and dispose of it.

Check that the old gasket isn't stuck to the fuel filter head. Using a wrench, deep socket, or pliers, remove the water-in-fuel sensor assembly from the bottom of the filter. If the new fuel filter comes with a new o-ring, replace the old one. If the water in the fuel sensor assembly is damaged, it must be replaced with a new one.

Finally, lubricate the new o-ring with clean engine oil before installing it.

Installing the new filter

To install the new fuel filter, follow these steps:

First, check if the new fuel filter comes with an O-ring for the water-in-fuel sensor assembly. If it does, replace the old O-ring with the new one. Lubricate the new O-ring with clean engine oil before installing it. Next, check if the new fuel filter comes with a new gasket. If so, replace the old gasket with the new one and lubricate the new gasket with clean engine oil before installing it.

Now you can install the new fuel filter. Do this in the reverse order of removal. Don't fill the new filter with fuel—you will prime it after installation. Make sure that the water-in-fuel sensor wire doesn't get tangled up in the process. Install by hand only—do not tighten with tools.

Open the bleed valve fuel filter head and pump the plunger on top of the fuel filter housing. Keep going until all the air escapes and the fuel starts to flow out of the bleed valve. When that happens, close the bleed valve, being careful not to over-tighten it.

Finally, reinstall the inner fender and intake tube. Start the engine and slide underneath your truck to check for leaks. The engine will run rough for the first 30 seconds. If it doesn't smooth out after about a minute, re-bleed the system and repeat the pumping process.

Frequently asked questions