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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 466 (Engine Controls/Fuel - 5.3L, 6.0L, 6.2L - Repair Instructions) >> Repair Instructions >> Fuel Tank Replacement (1500 SWB - 98.4L (26 gal) Tank + E85) >> Removal Procedure

Removal Procedure

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NOTE:

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: Fuel Tank Vent Line Quick Connect Fitting, Hose Clamp, Bracket Bolts & Fill Hose
    GM1964115Courtesy of GENERAL MOTORS COMPANY
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) , Fuel Pressure Relief (CH-48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Dual Tanks - Front) , Fuel Tank Draining (Dual Tanks - Rear) , Fuel Tank Draining (Single Tank) .
  3. Disconnect the fuel tank vent line quick connect fitting (5) from the fuel fill pipe vent line. Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 2: View Of EVAP Lines, Fuel Feed Lines & Fittings
    GM1704490Courtesy of GENERAL MOTORS COMPANY
  4. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
  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 COMPANY
  7. Disconnect the fuel tank EVAP lines (1) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap the EVAP lines in order to prevent possible EVAP system contamination.
    9. Fig 4: Fuel Tank EVAP Line Quick Connect Fitting
    GM1851987Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the fuel tank EVAP line quick connect fitting (1) at the fuel tank vent valve. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Using an adjustable jack, support the fuel tank.
    11. Fig 5: View Of Fuel Tank & Straps (Single Tank)
    GM1224293Courtesy of GENERAL MOTORS COMPANY
  11. Remove the fuel tank strap bolts.
    12. CAUTION:

    Refer to Damage to Fuel Tank Straps Caution .

  12. Remove the fuel tank straps.
    13. NOTE:

    Carefully lower the fuel tank until the EVAP line can be repositioned.

  13. With the aid of an assistant, carefully lower the rear of the fuel tank.
  14. Slide the front of the tank away from the frame.
  15. Lower the fuel tank slightly until the chassis wiring harness electrical connectors can be accessed.
    16. Fig 6: View Of Chassis Wiring Harness Electrical Connectors
    GM1704493Courtesy of GENERAL MOTORS COMPANY
  16. Disengage the chassis wiring harness electrical connector, connector position assurance (CPA) retainer at the module.
  17. Disconnect the chassis wiring harness electrical connectors (1) from the module and the fuel pressure sensor.
    18. Fig 7: View Of Fuel Tank & Straps (Single Tank)
    GM1224293Courtesy of GENERAL MOTORS COMPANY
  18. Completely lower the fuel tank.
  19. With the aid of an assistant, Place the fuel tank in a suitable work area.
  20. If replacing the fuel tank proceed to the next step, otherwise proceed to step 18 in the installation procedure.
    21. Fig 8: View Of EVAP Line Clip & Retainer
    GM1704926Courtesy of GENERAL MOTORS COMPANY
  21. Remove the fuel feed line from the retaining feature (2) in the fuel tank.
  22. Open the fuel/EVAP line clip (1) and remove the fuel feed line from the clip.
  23. Disconnect the fuel feed line quick connect fitting at the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
    24. Fig 9: View Of Fuel Feed Line
    GM1704927Courtesy of GENERAL MOTORS COMPANY
  24. Remove the fuel feed line from the fuel tank.
    25. Fig 10: View Of Fuel Tank Shields & Retainers
    GM1704928Courtesy of GENERAL MOTORS COMPANY
  25. Remove the fuel tank shield retainers (2 and 3) and shields (1 and 4).
    26. Fig 11: View Of Fuel Tank Clips
    GM1704930Courtesy of GENERAL MOTORS COMPANY
  26. Remove the EVAP line from the fuel tank clips (2 and 6).
  27. Open the fuel tank clips (1, 3, 4, and 5) and remove the EVAP lines from the clips.
  28. Disconnect the EVAP line quick connect fittings at the fuel tank module and fuel tank vent valves. Refer to Plastic Collar Quick Connect Fitting Service .
    29. Fig 12: View Of Fuel Tank EVAP Lines
    GM1704932Courtesy of GENERAL MOTORS COMPANY
  29. Remove the EVAP lines from the fuel tank.
    30. Fig 13: View of Special Tool & Lock Ring
    GM1704934Courtesy of GENERAL MOTORS COMPANY
  30. Using the J-45722  wrench, remove the lock ring.
    31. Fig 14: View Of Fuel Tank Module & Quick Connect Fitting
    GM1704935Courtesy of GENERAL MOTORS COMPANY
  31. 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 Plastic Collar Quick Connect Fitting Service .
  32. Remove the fuel tank module.
  33. Remove and discard the fuel tank module seal.
    34. Fig 15: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • 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.
  34. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
  35. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  36. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced
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