GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 HUMMER 🢒 2003 🢒 H2 🢒 General Information 🢒 Maintenance and Lubrication 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 832912 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  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. Object Number: 863079 Size: SH
  7. Disconnect the EVAP vent pipe at the fuel canister.

    8. Object Number: 832912 Size: SH
  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. Object Number: 863085 Size: SH
  11. With the aid of an assistant, support the fuel tank.

    12. Notice: 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. Object Number: 863091 Size: SH
  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.

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. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the fuel fill hose and the vent hose to the fuel tank.

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


    Object Number: 863091 Size: SH
  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. Object Number: 863085 Size: SH
  7. Fully raise the fuel tank.
  8. Install the fuel tank straps.
  9. Install the fuel tank strap attaching bolts.

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


    Object Number: 832912 Size: SH
  10. Connect the fuel fill hose and the vent hose to the pipes.

    11. 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. Object Number: 863079 Size: SH
  13. Connect the EVAP vent pipe to the fuel canister.
  14. Connect the chassis fuel pipes at the fuel filter.

    15. Object Number: 863084 Size: SH
  15. Install the fuel tank protective shield.

    16. 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 Disconnection and Connection .
  20. Use the following procedure in order to inspect for leaks:
    21. 20.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    20.2. Turn OFF the ignition for 10 seconds.
    20.3. Turn ON the ignition, with the engine OFF.
    20.4. Inspect for fuel leaks.
  21. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .