H3 2006

Removal & Installation

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Specific to:

Hummer H3 2006-2010

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle enough to access the top of the fuel tank through the wheelhouse liner.
  6.  
  7. Remove the left rear wheelhouse liner.
  8.  
  9. Loosen the fuel fill hose clamp at the fuel tank.

    Click image to see an enlarged view

    Fig. Loosen the fuel fill hose clamp at the fuel tank

  10.  
  11. Remove the fuel fill hose from the fuel tank.
  12.  
  13. Disconnect the Evaporative Emission (EVAP) vapor line from the fuel fill neck vapor line (1).
  14.  
  15. Completely raise the vehicle.
  16.  
  17. Remove the fuel tank shield rear upper bolt.

    Click image to see an enlarged view

    Fig. Remove the fuel tank shield rear upper bolt

  18.  
  19. Remove the fuel tank shield lower bolts.

    Click image to see an enlarged view

    Fig. Remove the fuel tank shield lower bolts (1) and the fuel tank shield (2)

  20.  
  21. Remove the fuel tank shield.
  22.  
  23. Position an adjustable jack under the fuel tank for support.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  24.  
  25. Remove the upper fuel tank strap bolt.

    Click image to see an enlarged view

    Fig. Remove the upper fuel tank strap bolt

  26.  
  27. Remove the upper fuel tank strap.
  28.  
  29. Remove the fuel tank rear strap bolt.
  30.  
  31. Remove the fuel tank rear strap.

    Click image to see an enlarged view

    Fig. Remove the fuel tank rear strap

  32.  
  33. With the aid of an assistant, carefully lower the fuel tank until the electrical connections can be accessed.
  34.  
  35. Disconnect the following electrical connectors from the fuel tank:

    The fuel tank pressure sensor
     
    The fuel tank module

    Click image to see an enlarged view

    Fig. Disconnect the fuel tank pressure sensor (1) and the fuel tank module (2) electrical connectors

     

  36.  
  37. Disconnect the fuel feed line at the fuel tank.
  38.  
  39. Completely lower the fuel tank and place the fuel tank in a suitable work area.
  40.  

To install:

  1. With the aid of an assistant, place the fuel tank onto the jack and support the fuel tank.
  2.  
  3. Partially raise the fuel tank until the electrical connections can be made.
  4.  
  5. Connect the fuel feed line at the fuel tank.
  6.  
  7. Connect the following electrical connectors to the fuel tank:

    The fuel tank pressure sensor
     
    The fuel tank module
     

  8.  
  9. Install the fuel tank rear strap.
  10.  
  11. Install the fuel tank rear strap bolt until snug.
  12.  
  13. Install the fuel tank front strap.
  14.  
  15. Install the fuel tank front strap bolt until snug.
  16.  
  17. Tighten the fuel tank strap bolts. Tighten the bolts to 24 ft. lbs. (32 Nm).
  18.  
  19. Remove the adjustable jack from under the fuel tank.
  20.  
  21. Position the fuel tank shield to the frame.
  22.  
  23. Install the fuel tank shield lower bolts.
  24.  
  25. Install the fuel tank shield rear upper bolt.
  26.  
  27. Lower the vehicle only enough to gain access to the fuel tank through the wheelhouse.
  28.  
  29. Install the fuel fill hose to the fuel tank. Position the fuel fill hose orientation notch in line with the tab on the fuel tank.
  30.  
  31. Tighten the fuel fill hose clamp.
  32.  
  33. Connect the EVAP vapor line to the fuel fill neck vapor line.
  34.  
  35. Install the left rear wheelhouse liner.
  36.  
  37. Lower the vehicle.
  38.  
  39. Refill the fuel tank.
  40.  
  41. Install the fuel fill cap.
  42.  
  43. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  44.  

 
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