GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 HUMMER 🢒 2009 🢒 H3 🢒 Engine 🢒 Engine Controls and Fuel - 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 1560072 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Drain the fuel tank. Refer to Fuel Tank Draining.
  3. Raise and support the vehicle enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle.
  4. Remove the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement.
  5. Loosen the fuel fill hose clamp (3) at the fuel tank.
  6. Remove the fuel fill hose from the fuel tank.
  7. Disconnect the evaporative emission (EVAP) vapor line (5) from the fuel fill neck vapor line (1). Refer to Plastic Collar Quick Connect Fitting Service.
  8. Completely raise the vehicle.

    9. Object Number: 1560085 Size: SH
  9. Remove the fuel tank shield rear upper bolt.

    10. Object Number: 1560087 Size: SH
  10. Remove the fuel tank shield lower bolts (1).
  11. Remove the fuel tank shield (2).
  12. Position an adjustable jack under the fuel tank for support.

    13. Object Number: 1564232 Size: SH

    Caution: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  13. Remove the upper fuel tank strap bolt.
  14. Remove the upper fuel tank strap.

    15. Object Number: 1560083 Size: SH
  15. Remove the fuel tank front strap bolt.
  16. Remove the fuel tank front strap.

    17. Object Number: 1560079 Size: SH
  17. Remove the fuel tank rear strap bolt.

    18. Object Number: 1560081 Size: SH
  18. Remove the fuel tank rear strap.
  19. With the aid of an assistant, carefully lower the fuel tank until the electrical connections can be accessed.

    20. Object Number: 1560074 Size: SH
  20. Disconnect the following electrical connectors from the fuel tank:
    21. • The fuel tank pressure sensor (1)
    • The fuel tank module (2)
  21. Disconnect the fuel feed line at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service.
  22. Completely lower the fuel tank and place the fuel tank in a suitable work area.
  23. If the fuel tank is not being replaced, proceed to the Installation Procedure.

Disassembly Procedure

    Object Number: 1564233 Size: SH
  1. Using a flare nut wrench and a back up wrench, disconnect the fuel feed line (1) fitting from the fuel tank module.
  2. Disengage and remove the fuel feed line (1) from the fuel tank.
  3. Disconnect the EVAP vapor line (2) from the fuel tank vent valve, and fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  4. Disengage and remove the EVAP vapor line (2) from the retaining clip.
  5. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement.

Assembly Procedure

    Object Number: 1564233 Size: SH
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement.
  2. Install and engage the EVAP vapor line (2) to the retaining clip.
  3. Connect the EVAP vapor line (2) to the fuel tank vent valve, and fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  4. Install and engage the fuel feed line (1) to the fuel tank.
  5. Using a flare nut wrench and a back up wrench, connect the fuel feed line (1) fitting to the fuel tank module and tighten the fitting to 30 N·m (22 lb ft).

Installation Procedure

    Object Number: 1560074 Size: SH
  1. With the aid of an assistant, place the fuel tank onto the jack and support the fuel tank.
  2. Partially raise the fuel tank until the electrical connections can be made.
  3. Connect the fuel feed line at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service.
  4. Connect the following electrical connectors to the fuel tank:
    5. • The fuel tank pressure sensor (1)
    • The fuel tank module (2)

    Object Number: 1560081 Size: SH
  5. Install the fuel tank rear strap.

    6. Object Number: 1560079 Size: SH
  6. Install the fuel tank rear strap bolt until snug.

    7. Object Number: 1560083 Size: SH
  7. Install the fuel tank front strap.
  8. Install the fuel tank front strap bolt until snug.

    9. Caution: Refer to Fastener Caution in the Preface section.

  9. Tighten the fuel tank strap bolts to 32 N·m (24 lb ft).

    10. Object Number: 1564232 Size: SH
  10. Install the upper fuel tank strap.
  11. Install the upper fuel tank strap bolt and tighten to 32 N·m (24 lb ft).
  12. Remove the adjustable jack from under the fuel tank.

    13. Object Number: 1560087 Size: SH
  13. Position the fuel tank shield (2) to the frame.
  14. Install the fuel tank shield lower bolts (1) and tighten to 10 N·m (89 lb in).

    15. Object Number: 1560085 Size: SH
  15. Install the fuel tank shield rear upper bolt and tighten to 10 N·m (89 lb in).
  16. Lower the vehicle only enough to gain access to the fuel tank through the wheelhouse.

    17. Object Number: 1560072 Size: SH
  17. Install the fuel fill hose to the fuel tank. Position the fuel fill hose orientation notch (2) in line with the tab (4) on the fuel tank.
  18. Tighten the fuel fill hose clamp (3) and tighten to 2.5 N·m (22 lb in).
  19. Connect the EVAP vapor line (5) to the fuel fill neck vapor line (1). Refer to Plastic Collar Quick Connect Fitting Service.
  20. Install the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement.
  21. Lower the vehicle.
  22. Refill the fuel tank.
  23. Install the fuel fill cap.
  24. Inspect for leaks.
    25. 24.1. Turn ON the ignition, with the engine OFF for 10 seconds.
    24.2. Turn OFF the ignition for 10 seconds.
    24.3. Turn ON the ignition, with the engine OFF.
    24.4. Inspect for fuel leaks.