Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2005 Hummer H2 V8-6.0LFACTORY OEM SERVICE PROCEDURE
Fuel Sender Assembly Replacement
FUEL SENDER ASSEMBLY REPLACEMENT
TOOLS REQUIRED
J 44402 Fuel Tank Sending Unit Wrench
REMOVAL PROCEDURE
1. Remove the fuel tank.
2. Remove fuel lines from sender assembly.
3. Remove the fuel sender assembly retaining ring using the J 44402.
4. Remove the fuel sender assembly and the seal. Discard the seal.
5. Clean the fuel sender sealing surfaces.
CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
INSTALLATION PROCEDURE
1. Install the new seal on the fuel tank.
CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.
2. Install the fuel sender assembly into the fuel tank.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the fuel sender assembly retaining ring using the J 44402.
4. Install fuel lines to sender assembly.
5. Install the fuel tank.
Factory Service Tools
Use the Manual With the Right Hardware
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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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