2005 Hummer H2 4D Utility PickupFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Connect the EVAP pipe to the fuel tank roll over valves and the retaining clips.
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  3. Connect the fuel feed and return pipes to the fuel sender and the retaining clips.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel fill hose and the vent hose to the fuel tank.

    Tighten:  Tighten the hose clamps to 2.5 N.m (22 lb in).

    5. Fig 1: Fuel Sender & Fuel Pressure Sensor Electrical Connectors
    GM863091Courtesy of GENERAL MOTORS CORP.
  5. With the aid of an assistant, support and partially raise the fuel tank front end first.
  6. Connect the fuel sender and the fuel pressure sensor electrical connectors.
    7. Fig 2: Fuel Tank Straps & Attaching Bolts
    GM863085Courtesy of GENERAL MOTORS CORP.
  7. Fully raise the fuel tank.
  8. Install the fuel tank straps.
  9. Install the fuel tank strap attaching bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    10. Fig 3: Fuel Fill Hose & Hose Clamps
    GM832912Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel fill hose and the vent hose to the pipes.

    Tighten: 

    • Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
    • Tighten the vent hose clamp to 2.5 N.m (22 lb in).

  11. Install the fuel fill pipe to the fuel tank.
  12. Remove the caps from the fuel and EVAP pipes.
    13. Fig 4: EVAP Vent Pipe
    GM863079Courtesy of GENERAL MOTORS CORP.
  13. Connect the EVAP vent pipe to the fuel canister.
  14. Connect the chassis fuel pipes at the fuel filter.
    15. Fig 5: Installing Fuel Tank Protective Shield
    GM863084Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel tank protective shield.

    Tighten:  Tighten fuel tank protective shield bolts to 25 N.m (18 lb ft).

  16. Lower the vehicle.
  17. Refill the fuel tank.
  18. Install the fuel filler cap.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  20. Use the following procedure in order to inspect for leaks:
    1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  21. Install the engine sight shield. Refer to Engine Sight Shield Replacement (6.0L (LQ4)) in Engine Mechanical.
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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