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Home >> Hummer >> 2009 >> H2 4D Utility Pickup >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 6.2L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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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 EVAP pipes to the fuel sender and the retaining clips.
    4. Fig 1: View Of Fuel Sender & Fuel Pressure Sensor Electrical Connectors
    GM863091Courtesy of GENERAL MOTORS CORP.
  4. Support and partially raise the fuel tank.
  5. Connect the fuel sender and the fuel pressure sensor electrical connectors.
    6. Fig 2: View Of Fuel Tank Straps & Attaching Bolts
    GM863085Courtesy of GENERAL MOTORS CORP.
  6. Fully raise the fuel tank.
  7. Install the fuel tank straps.
    8. CAUTION: Refer to Fastener Caution .
  8. Install the fuel tank strap attaching bolts.

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

    9. Fig 3: View Of Fuel Fill Hose & Hose Clamps
    GM832912Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel fill hose and the vent hose to the tank.

    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).

    10. Fig 4: View Of EVAP Vent Pipe At Fuel Canister
    GM863079Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP vent pipe to the fuel canister.
  11. Connect the chassis fuel pipes.
    12. Fig 5: View Of Fuel Tank Protective Shield
    GM863084Courtesy of GENERAL MOTORS CORP.
  12. Install the fuel tank protective shield.

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

  13. Refill the fuel tank.
  14. Install the fuel filler cap.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  16. 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.
  17. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
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