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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 (2500 LWB - 98.4L (26 gal) Tank-Front) >> Installation Procedure

Installation Procedure

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    Fig 1: View Of Fuel Tank Module Quick Connect Fitting
    GM1705662Courtesy 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 fitting (1) 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
    GM1705659Courtesy of GENERAL MOTORS CORP.
  9. Install the EVAP lines to the fuel tank.
    10. Fig 4: View Of Fuel Tank Clips
    GM1705656Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP line quick connect fittings at the fuel tank module. Refer to Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (1500 LWB - 117.3L (31 gal) Tank)  or Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (1500 LWB - 117.3L (31 gal) Tank w/E85)  or Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (1500 SWB - 98.4L (26 gal) Tank)  or Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (1500 LWB - 98.4L (26 gal) Tank w/E85)  or Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank (2500 LWB - 43.5L (11.5 gal) Tank-Rear) .
  11. Install the EVAP lines to the fuel tank clips (2-7) and close the clips.
  12. Install the EVAP line to the fuel tank clip (1).
    13. Fig 5: View Of Fuel Tank Shield & Retainers
    GM1705654Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank shield (2) and retainers (1).
    14. Fig 6: View Of Fuel Tank Module Chassis Harness Electrical Connector
    GM1705648Courtesy of GENERAL MOTORS CORP.
  14. Place the fuel tank onto a suitable jack.
  15. With the aid of an assistant, partially raise the fuel tank.
  16. Connect the chassis harness electrical connector (1) to the fuel tank module.
  17. Engage the CPA retainer.
    18. Fig 7: View Of Fuel Tank & Straps (Front Tank)
    GM1224378Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When installing the fuel tank, ensure that the EVAP line is correctly routed over the frame.
  18. With the aid of an assistant, completely raise the fuel tank.
  19. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice .
  20. Install the fuel tank strap bolts.

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

  21. Remove the adjustable jack from under the fuel tank.
    22. Fig 8: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  22. Remove the caps from the fuel and EVAP lines.
  23. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Quick Connect Fitting Service - Plastic Collar .
  24. Install the lines to the clip on the side of the fuel tank and close the clip.
    25. Fig 9: View Of Fuel Feed & EVAP Lines At Fuel Tank
    GM1372476Courtesy of GENERAL MOTORS CORP.
  25. Connect the chassis fuel feed and EVAP line quick connect fittings to the fuel tank line quick connect fittings. Refer to Quick Connect Fitting Service - Plastic Collar 
    26. Fig 10: View Of Vapor Line At Fuel Tank
    GM1372488Courtesy of GENERAL MOTORS CORP.
  26. Connect the EVAP line quick connect fitting (1) to the fuel tank vent valve. Refer to Quick Connect Fitting Service - Plastic Collar .
    27. Fig 11: View Of Fuel Hoses & Clamp
    GM1704321Courtesy of GENERAL MOTORS CORP.
  27. Connect the fill pipe EVAP line quick connect fitting (2) to the fuel tank vent valve. Refer to Quick Connect Fitting Service - Plastic Collar .
  28. Install the fuel fill hose to the fuel tank.
  29. Tighten the fuel fill hose clamp at the fuel tank.

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

  30. Lower the vehicle.
  31. Refill the fuel tank.
  32. Install the fuel fill cap.
  33. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  34. 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.
  35. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
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