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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 (2500 LWB - 4.35L (11.5 gal) Tank Rear) >> Removal Procedure

Removal Procedure

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NOTE:

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 Spare Tire & Stowage Lock Cylinder
    GM1704585Courtesy of GENERAL MOTORS COMPANY
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Without CH-48027) , Fuel Pressure Relief (CH-48027) .
  2. Remove the spare tire stowage lock cylinder.
  3. Remove the spare tire.
  4. Drain the fuel tank. Refer to Fuel Tank Draining (Dual Tanks - Front) , Fuel Tank Draining (Dual Tanks - Rear) , Fuel Tank Draining (Single Tank) .
  5. Remove the rear exhaust insulator.
    6. Fig 2: View Of Spare Tire Hoist Crossmember & Bolts
    GM1705750Courtesy of GENERAL MOTORS COMPANY
  6. Remove the spare tire hoist crossmember bolts and crossmember.
    7. Fig 3: View Of EVAP Canister & Quick Connect Fittings
    GM1372543Courtesy of GENERAL MOTORS COMPANY
  7. Disconnect the rear fuel tank EVAP line quick connect fittings from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    8. Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1372710Courtesy of GENERAL MOTORS COMPANY
  8. Disconnect the fuel and EVAP intermediate line quick connect fittings from the front tank. Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 5: View Of Fuel Pressure Sensor Electrical Connector
    GM1372719Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the chassis harness electrical connector (1) from the fuel pressure sensor.
    10. Fig 6: View Of Fuel Tank & Straps
    GM1224381Courtesy of GENERAL MOTORS COMPANY
  10. Support the fuel tank with a suitable jack.
  11. Remove the fuel tank strap bolts.
    12. CAUTION:

    Refer to Damage to Fuel Tank Straps Caution .

  12. Remove the fuel tank straps.
  13. With the aid of an assistant, lower the rear tank until the intermediate line connections can be reached.
    14. Fig 7: View Of EVAP Lines & Quick Connect Fittings
    GM1705751Courtesy of GENERAL MOTORS COMPANY
  14. Disconnect the fuel and EVAP intermediate line quick connect fittings from the rear tank. Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 8: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS COMPANY
  15. Remove the fuel and EVAP intermediate lines.
  16. Cap the fuel and EVAP lines in order to prevent possible EVAP/fuel system contamination.
    17. Fig 9: View Of Sending Unit Electrical Connector (Rear Tank)
    GM1238175Courtesy of GENERAL MOTORS COMPANY
  17. Disconnect the chassis harness electrical connector (2) from the fuel tank module.
  18. Completely lower the fuel tank.
  19. With the aid of an assistant, remove the tank from the jack.
  20. If replacing the fuel tank proceed to the next step, otherwise proceed to step 14 in the installation procedure.
    21. Fig 10: View Of EVAP Line Clips
    GM1705753Courtesy of GENERAL MOTORS COMPANY
  21. Remove the EVAP line from the clip (1) on the fuel tank.
  22. Open the EVAP line clip (2) and remove the EVAP line from the clip.
  23. Remove the EVAP lines from the clip (3).
  24. Disconnect the EVAP line quick connect fittings from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
    25. Fig 11: View Of Fuel Tank EVAP Lines
    GM1705754Courtesy of GENERAL MOTORS COMPANY
  25. Remove the EVAP lines from the fuel tank.
    26. Fig 12: Rotating Lock Ring (Rear Tank)
    GM1372822Courtesy of GENERAL MOTORS COMPANY
  26. Using the J-45722  wrench, remove the lock ring.
    27. Fig 13: View Of Vapor Line Quick Connect Fittings (Rear Tank)
    GM1372821Courtesy of GENERAL MOTORS COMPANY
  27. Carefully lift the module from the fuel tank, enough to access the quick connect fitting under the module cover. Disconnect the quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  28. Remove the fuel tank module.
  29. Remove and discard the fuel tank module seal.
    30. Fig 14: 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.
  30. 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.
  31. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  32. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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