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Home >> Hummer >> 2005 >> H2 4D Utility Pickup >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Introduction >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Fuel Sender Assembly
    GM386369Courtesy of GENERAL MOTORS CORP.
    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.
  1. Install the new seal on the fuel tank.
  2. Install the fuel sender assembly into the fuel tank.
    3. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  3. Use the J 45722  in order to install the fuel sender lock ring. See Special Tools . Turn the fuel sender lock ring in a clockwise direction.
  4. Install fuel lines to the sender assembly. Refer to Fuel Hose/Pipes Assembly Replacement .
  5. Install the fuel tank. Refer to Fuel Tank Replacement .
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