2007 Yukon Denali Fuel Pump Access Door

Fixxer

TYF Newbie
Joined
Jul 20, 2018
Posts
6
Reaction score
10
Hello,
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
You must be logged in to see this image or video!

Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
You must be logged in to see this image or video!

I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to screw the door down. Save the piece that you cut out- well be using it later.
You must be logged in to see this image or video!

The floor piece that i cut out
You must be logged in to see this image or video!

Measurements
You must be logged in to see this image or video!

You must be logged in to see this image or video!

I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
You must be logged in to see this image or video!

Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
You must be logged in to see this image or video!

Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.

So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you ;)
 

Wolfbraid

Full Access Member
Joined
Aug 30, 2018
Posts
282
Reaction score
268
Location
Winston Salem, NC
One TIP...somehow let the next owner know you did this...put a note in the owners manual, put a sign on the fuel tank.. something.

I had a 95 tahoe with the big tank, had to drain and wrestle that thing(still with gas in it, ran out of cars and cans to fill up) after we got the tank out we found the convenient access hole someone else made/used... Glad we dropped it anyway since the previous person hacked up the wiring for some reason.
 

GoldmistXL

TYF Newbie
Joined
Oct 24, 2019
Posts
13
Reaction score
15
Hello,
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
You must be logged in to see this image or video!

Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
You must be logged in to see this image or video!

I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to screw the door down. Save the piece that you cut out- well be using it later.
You must be logged in to see this image or video!

The floor piece that i cut out
You must be logged in to see this image or video!

Measurements
You must be logged in to see this image or video!

You must be logged in to see this image or video!

I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
You must be logged in to see this image or video!

Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
You must be logged in to see this image or video!

Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.

So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you ;)

Thank you so much for posting this. For some reason the photos have disappeared. Can you please post another photo or two showing the location of the access door. Would really appreciate it. Thanks!!!
 

HiHoeSilver

Away!
Joined
Feb 28, 2017
Posts
10,829
Reaction score
14,263
Location
Chicago
Hello,
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
You must be logged in to see this image or video!

Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
You must be logged in to see this image or video!

I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to screw the door down. Save the piece that you cut out- well be using it later.
You must be logged in to see this image or video!

The floor piece that i cut out
You must be logged in to see this image or video!

Measurements
You must be logged in to see this image or video!

You must be logged in to see this image or video!

I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
You must be logged in to see this image or video!

Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
You must be logged in to see this image or video!

Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.

So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you ;)

Thank you so much for posting this. For some reason the photos have disappeared. Can you please post another photo or two showing the location of the access door. Would really appreciate it. Thanks!!!

The OP probably used a host like photobucket. Uploading directly to the server with the "upload a file" button would be preferable and ensure this great post's longevity.
 

Fixxer

TYF Newbie
Joined
Jul 20, 2018
Posts
6
Reaction score
10
Measurements:
You must be logged in to see this image or video!

You must be logged in to see this image or video!



Hole trimming:
You must be logged in to see this image or video!

You must be logged in to see this image or video!
You must be logged in to see this image or video!
 
Last edited:

Fixxer

TYF Newbie
Joined
Jul 20, 2018
Posts
6
Reaction score
10
Replace:
You must be logged in to see this image or video!
You must be logged in to see this image or video!

You must be logged in to see this image or video!
 

Geotrash

Dave
Supporting Member
Joined
Feb 16, 2018
Posts
866
Reaction score
1,578
Location
Richmond, VA
Sweet! What tools did you use for the cutting? And, what did you attach the bolts to?
 

sandspyder

TYF Newbie
Joined
Jul 2, 2021
Posts
1
Reaction score
0
Hello,
I just got done installing a fuel pump in a 07 Denali. I decided to cut an access hole instead of dropping the full tank. I thought I would share my measurements and photos with you in hopes that it might help someone else who wants to do the same.
You must be logged in to see this image or video!

Drill out all of the spot welds inside where your cut is going to be. You'll notice that there is some heavier structure towards the back and right sides of the hole. The object of this exercise is to cut just enough of that structure to get your pump out while leaving as much as possible to support your door.
You must be logged in to see this image or video!

I trimmed out the back structure a little too much. The next time, i will leave a little more of a lip to ***** the door down. Save the piece that you cut out- well be using it later.
You must be logged in to see this image or video!

The floor piece that i cut out
You must be logged in to see this image or video!

Measurements
You must be logged in to see this image or video!

You must be logged in to see this image or video!

I used that piece that i cut out earlier to support the lower left part of the door. I drilled and tapped it with some M6-M10 bolts. Be extra careful when cutting in this area because there is only an inch of clearance to the tank. When i was drilling the bolt holes, i put a piece of metal underneath to keep the drill from going too far and damaging the tank.
You must be logged in to see this image or video!

Out with the old and in with the new. Be careful not to spill gas everywhere. The sender has one or two quarts of gas in it when you pull it out.
You must be logged in to see this image or video!

Access back in with black RTV for sealant. I added another piece of metal under the left side for extra support, and simply drilled and tapped in the m6-m16 bolts. The bolts with stars are holding the support for the door, that's why i added the note.

So there you go. I used a swazall to make the cut. Like i said, just take your time and keep your blade depth to a minimum. Be extra careful on the front drivers side of the hole as there is only an inch of clearance under your cut. I hope this helps someone who wants to be able to change their fuel pump easily in the future. I hope to make more of these in the future. I will share my measurements with you ;)
Why isn't it showing the pictures?
 

Forum statistics

Threads
113,146
Posts
1,538,096
Members
69,797
Latest member
Richardhubble
Top