2005 Hummer H2 4D Utility PickupFACTORY OEM SERVICE PROCEDURE

Removal Procedure

    Fig 1: Fuel Fill Hose & Hose Clamps
    GM832912Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  4. Remove the fuel fill pipe from the fuel tank.
  5. Disconnect the chassis fuel pipes at the fuel filter.
  6. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
    7. Fig 2: EVAP Vent Pipe
    GM863079Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the EVAP vent pipe at the fuel canister.
    8. Fig 3: Fuel Fill Hose & Hose Clamps
    GM832912Courtesy of GENERAL MOTORS CORP.
  8. Loosen the vent hose and filler hose clamp.
  9. Disconnect the vent hose and filler hose from the pipe.
  10. Remove the fuel tank protective shield.
    11. Fig 4: Fuel Tank Straps & Attaching Bolts
    GM863085Courtesy of GENERAL MOTORS CORP.
  11. With the aid of an assistant, support the fuel tank.
    12. NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
  12. Remove the fuel tank strap attaching bolts.
  13. Remove the fuel tank straps.
  14. Carefully lower the rear of the fuel tank slightly.
    15. Fig 5: Fuel Sender & Fuel Pressure Sensor Electrical Connectors
    GM863091Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
  18. Remove the fuel feed and return pipes from the fuel sender and the retaining clips.
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Remove the EVAP pipe from the fuel tank roll over valves and the retaining clips.
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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