LEMON Manuals: Even more car manuals for everyone
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 (2500 LWB - 43.5L (11.5 gal) Tank-Rear) >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Vapor Line Quick Connect Fittings (Rear Tank)
    GM1372821Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced perform the following steps, otherwise proceed to step 14.
  2. Install the NEW fuel tank module seal onto the fuel tank.
  3. Pull the vent line in the fuel tank up as far as possible for ease of installation.
  4. Position the fuel tank module part way into the fuel tank.
  5. Connect the quick connect fittings to the module cover. Refer to Quick Connect Fitting Service - Plastic Collar .
  6. Install the fuel tank module into the fuel tank.
  7. Place the lock ring into position.
    8. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
  8. Rotate the lock ring counterclockwise using the J 45722  . See Special Tools .
    9. Fig 3: View Of Fuel Tank EVAP Lines
    GM1705754Courtesy of GENERAL MOTORS CORP.
  9. Install the EVAP lines to the fuel tank.
    10. Fig 4: View Of EVAP Line Clips
    GM1705753Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP line quick connect fittings to the fuel tank module. Refer to Quick Connect Fitting Service - Plastic Collar .
  11. Install the EVAP lines to the clip (3).
  12. Install the EVAP line to the clip (2) and close the clip.
  13. Install the EVAP line to the clip (1) on the fuel tank.
    14. Fig 5: View Of Sending Unit Electrical Connector (Rear Tank)
    GM1238175Courtesy of GENERAL MOTORS CORP.
  14. With the aid of an assistant, install the tank onto the jack.
  15. Partially raise the fuel tank.
  16. Connect the chassis harness electrical connector (2) to the fuel tank module.
    17. Fig 6: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  17. Remove the caps from the fuel and EVAP lines.
  18. Install the fuel and EVAP intermediate lines.
    19. Fig 7: View Of EVAP Lines & Quick Connect Fittings
    GM1705751Courtesy of GENERAL MOTORS CORP.
  19. Connect the fuel and EVAP intermediate lines to the rear tank. Refer to Quick Connect Fitting Service - Plastic Collar .
    20. Fig 8: View Of Fuel Tank & Straps
    GM1224381Courtesy of GENERAL MOTORS CORP.
  20. With the aid of an assistant, completely raise the rear tank.
  21. Install the fuel tank straps.
    22. NOTE: Refer to Fastener Notice .
  22. Install the fuel tank strap bolts.

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

  23. Remove the adjustable jack from under the fuel tank.
    24. Fig 9: View Of Fuel Pressure Sensor Electrical Connector
    GM1372719Courtesy of GENERAL MOTORS CORP.
  24. Connect the chassis harness electrical connector (1) to the fuel pressure sensor.
    25. Fig 10: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1372710Courtesy of GENERAL MOTORS CORP.
  25. Connect the fuel and EVAP intermediate line quick connect fittings to the front tank. Refer to Quick Connect Fitting Service - Plastic Collar .
    26. Fig 11: View Of EVAP Canister & Quick Connect Fittings
    GM1372543Courtesy of GENERAL MOTORS CORP.
  26. Connect the rear fuel tank EVAP line quick connect fittings to the EVAP canister. Refer to Quick Connect Fitting Service - Plastic Collar .
    27. Fig 12: View Of Spare Tire Hoist Crossmember & Bolts
    GM1705750Courtesy of GENERAL MOTORS CORP.
  27. Install the spare tire hoist crossmember and bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  28. Install the rear exhaust insulator.
    29. Fig 13: View Of Fuel Hoses & Clamp
    GM1704321Courtesy of GENERAL MOTORS CORP.
  29. Install the fuel fill hose (1, 3) to the fuel tank.
  30. Tighten the fuel fill hose clamp (2) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  31. Lower the vehicle.
    32. Fig 14: View Of Spare Tire & Stowage Lock Cylinder
    GM1704585Courtesy of GENERAL MOTORS CORP.
  32. Install the spare tire.
  33. Install the spare tire stowage lock cylinder.
    34. Fig 15: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  34. Install the fuel tank filler housing.
  35. Install the fuel tank filler housing to fuel tank fill pipe bolts.

    Tighten:  Tighten the bolts to 2.3 N.m (20 lb in).

    36. Fig 16: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  36. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2).

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

  37. Refill the fuel tank.
  38. Install the fuel fill cap.
  39. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  40. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
  41. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
scientia non olet · About LEMON Manuals