2005 Chevrolet SSR AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position and support the fuel tank.
  2. Connect the fuel sender electrical connector (1).
    3. Fig 2: Locating Fuel Tank Components
    GM887432Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank straps (2).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel tank strap bolts (1).

    Tighten:  Tighten the bolts to 32 N.m (24 lb ft).

  5. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
    6. Fig 3: Locating Fuel Tank Fittings
    GM899732Courtesy of GENERAL MOTORS CORP.
  6. Remove the caps from the fuel and EVAP pipes.
  7. Connect the fuel feed, return and EVAP pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    8. Fig 4: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel tank pressure sensor electrical connector (3).
  9. Connect the EVAP vent valve electrical connector (2).
    10. Fig 5: Identifying Fuel Pipe/Hose Components
    GM730806Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel hose (2) to the fuel tank.

    Tighten:  Tighten the clamp (1) to 2.5 N.m (22 lb in).

  11. Lower the vehicle.
  12. Refill the fuel tank.
  13. Install the fuel fill cap.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  15. Inspect for leaks.
    1. Turn the ignition ON, with the engine OFF for 10 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
  16. Install the frame brace. Refer to Frame Brace Replacement in Frame and Underbody.
  17. Lower the vehicle.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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