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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 100 (Engine Control System & Fuel - 4.8L, 5.3L, 6.0L And 6.2L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (1500 SWB - 98.4L (26 gal) Tank) >> Removal Procedure

Removal Procedure

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IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
    Fig 1: View Of Fuel Fill Hose, Pipe Bracket Bolts & Quick Connect Fitting
    GM1704319Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Dual Tanks - Front)  or Fuel Tank Draining (Dual Tanks - Rear)  or Fuel Tank Draining (Single Tank) .
  3. Disconnect the fuel tank vent line quick connect fitting (5) from the fuel fill pipe line. Refer to Quick Connect Fitting Service - Plastic Collar .
    4. Fig 2: View Of EVAP Lines, Fuel Feed Lines & Fittings
    GM1704490Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line. Refer to Quick Connect Fitting Service - Plastic Collar .
  5. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line. Refer to Quick Connect Fitting Service - Plastic Collar .
  6. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
    7. Fig 3: View Of Fuel Tank EVAP Lines & Canister
    GM1704492Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel tank EVAP lines (1) from the EVAP canister. Refer to Quick Connect Fitting Service - Plastic Collar .
  8. Cap the EVAP lines in order to prevent possible EVAP system contamination.
  9. Using an adjustable jack, support the fuel tank.
  10. Remove the fuel tank strap bolts.
    11. NOTE: Refer to Damage to Fuel Tank Straps Notice .
  11. Remove the fuel tank straps.
  12. With the aid of an assistant, carefully lower the rear of the fuel tank.
  13. Slide the front of the tank away from the frame.
  14. Lower the fuel tank slightly until the chassis wiring harness electrical connectors can be accessed.
    15. Fig 4: View Of Chassis Wiring Harness Electrical Connectors
    GM1704493Courtesy of GENERAL MOTORS CORP.
  15. Disengage the chassis wiring harness electrical connector, connector position assurance (CPA) retainer at the module.
  16. Disconnect the chassis wiring harness electrical connectors (1) from the module and the fuel pressure sensor.
    17. Fig 5: View Of Fuel Tank & Straps (Single Tank)
    GM1224293Courtesy of GENERAL MOTORS CORP.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. If replacing the fuel tank proceed to the next step, otherwise proceed to step 18 in the installation procedure.
    20. Fig 6: View Of EVAP Line Clip & Retainer
    GM1704504Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel feed line from the retaining feature (2) in the fuel tank.
  21. Open the fuel/EVAP line clip (1) and remove the fuel feed line from the clip.
  22. Disconnect the fuel feed line quick connect fitting at the fuel tank module. Refer to Quick Connect Fitting Service - Plastic Collar .
    23. Fig 7: View Of Fuel Feed Line
    GM1704506Courtesy of GENERAL MOTORS CORP.
  23. Remove the fuel feed line from the fuel tank.
    24. Fig 8: View Of Fuel Tank Shield & Retainers
    GM1704741Courtesy of GENERAL MOTORS CORP.
  24. Remove the fuel tank shield retainers (2 and 3) and shields (1 and 4).
    25. Fig 9: View Of Fuel Tank Clips
    GM1704505Courtesy of GENERAL MOTORS CORP.
  25. Remove the EVAP line from the fuel tank clips (2 and 6).
  26. Open the fuel tank clips (1, 3, 4, and 5) and remove the EVAP lines from the clips.
  27. Disconnect the EVAP line quick connect fittings at the fuel tank module and fuel tank vent valve. Refer to Quick Connect Fitting Service - Plastic Collar .
    28. Fig 10: View Of Fuel Tank EVAP Lines
    GM1704507Courtesy of GENERAL MOTORS CORP.
  28. Remove the EVAP lines from the fuel tank.
    29. Fig 11: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
  29. Using the J 45722  , remove the lock ring. See Special Tools .
    30. Fig 12: View Of Quick Connect Fittings At Module Cover
    GM1254425Courtesy of GENERAL MOTORS CORP.
  30. Carefully lift the module from the fuel tank, enough to access the quick connect fittings (1) under the module cover. Disconnect the quick connect fittings. Refer to Quick Connect Fitting Service - Plastic Collar .
  31. Remove the fuel tank module.
  32. Remove and discard the fuel tank module seal.
    33. Fig 13: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  33. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
  34. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  35. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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