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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) >> Removal Procedure

Removal Procedure

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IMPORTANT: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.
    Fig 1: View Of Fuel Hoses & Clamp
    GM1704321Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to the 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 fill pipe evaporative emission (EVAP) line quick connect fitting (2) from the fuel tank vent valve. Refer to Quick Connect Fitting Service - Plastic Collar .
    4. Fig 2: View Of Vapor Line At Fuel Tank
    GM1372488Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the EVAP line quick connect fitting (1) from the fuel tank vent valve. Refer to Quick Connect Fitting Service - Plastic Collar .
    5. Fig 3: View Of Fuel Feed & EVAP Lines At Fuel Tank
    GM1372476Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the chassis fuel feed and EVAP line quick connect fittings from the fuel tank line quick connect fittings. Refer to Quick Connect Fitting Service - Plastic Collar .
    6. Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  6. Open the clip on the side of the fuel tank retaining the intermediate lines.
  7. Disconnect the fuel and EVAP intermediate line quick connect fittings from the front tank lines. Refer to Quick Connect Fitting Service - Plastic Collar .
  8. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.
    9. Fig 5: View Of Fuel Tank & Straps (Front Tank)
    GM1224378Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Damage to Fuel Tank Straps Notice .
  9. Using an adjustable jack, support the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
    12. IMPORTANT: When lowering the fuel tank, ensure that the EVAP line does not get caught on anything.
  12. With the aid of an assistant, carefully lower the fuel tank until the electrical connectors can be accessed.
    13. Fig 6: View Of Fuel Tank Module Electrical Connector
    GM1705648Courtesy of GENERAL MOTORS CORP.
  13. Disengage the connector position assurance (CPA) retainer.
  14. Disconnect the chassis harness electrical connector (1) from the fuel tank module.
  15. Completely lower the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 14 in the installation procedure.
    18. Fig 7: View Of Fuel Tank Shield & Retainers
    GM1705654Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel tank shield retainers (1) and shield (2).
    19. Fig 8: View Of Fuel Tank Clips
    GM1705656Courtesy of GENERAL MOTORS CORP.
  19. Remove the EVAP line from the fuel tank clip (1).
  20. Open the fuel tank clips (2-7) and remove the fuel/EVAP lines from the clips.
  21. Disconnect the fuel/EVAP line quick connect fittings from the fuel tank module. Refer to Quick Connect Fitting Service - Plastic Collar .
    22. Fig 9: View Of Fuel Tank EVAP Lines
    GM1705659Courtesy of GENERAL MOTORS CORP.
  22. Remove the fuel/EVAP lines from the fuel tank.
    23. Fig 10: View Of Special Tool & Lock Ring
    GM1705661Courtesy of GENERAL MOTORS CORP.
  23. Using the J 45722  remove the lock ring. See Special Tools .
    24. Fig 11: View Of Fuel Module Quick Connect Fitting
    GM1705662Courtesy of GENERAL MOTORS CORP.
  24. Carefully lift the module from the fuel tank, enough to access the quick connect fitting (1) under the module cover. Disconnect the quick connect fitting. Refer to Quick Connect Fitting Service - Plastic Collar .
  25. Remove the fuel tank module.
  26. Remove and discard the fuel tank module seal.
    27. Fig 12: 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.
  27. 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.
  28. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  29. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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