Hummer H1 (2006+). Manual — part 175

3-42 Fuel, Emissions, and Exhaust

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Figure 3-27: Fuel Tank and Components

FUEL TANK

FUEL LEVEL

GASKET

SHIELD

TRANSMITTER

ACCESS PLATE

MAIN

PLUG

SHIELD

INSULATOR

BOTTOM

OUTER

ACCESS PLATE

O-RING (12)

FRONT STRAP

FRONT STRAP

RETAINER

FUEL TANK

SPACER

VENT LINE

ACCESS PLATE

FUEL

TANK

JUMPER

HARNESS

STRAINER

FITTING

GASKET

SPACER

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Fuel, Emissions, and Exhaust 3-43

Fuel Level Transmitter

Removal

1.

Remove the screws, lock washers and the fuel level transmitter from the tank access plate (Figure 3-27).

2.

Remove the locknuts, washers, access plate and the gasket from the tank.

3.

Remove the access plate retainer and O-rings from the tank. Discard the O-rings.

Check the fuel level transmitter operation as follows:

1.

Hold the transmitter in the upright or empty position.

2.

Using an ohmmeter, check the resistance value at the terminals. Resistance should be 268 ± 20

1.

3.

Hold the transmitter in the inverted position simulating a full tank. Resistance should fall to 19.3 ± 8

1.

Figure 3-28: Fuel Level Transmitter

Installation

1.

Thoroughly clean all the gasket surfaces.

2.

Place the new O-rings on the access plate retainer studs and position the access plate retainer in the tank (Figure 3-28).

3.

Set the gasket and the access plate over the studs and onto the tank.

4.

Apply the liquid teflon thread sealant to the studs and loosely install the washers and the locknuts until no clearance exists
between the access plate, gasket and the tank.

5.

Snug the access plate locknuts in small increments and in a systematic circular pattern. Tighten the locknuts until the gasket
bulges or until maximum torque of 72 lb-in. is obtained.

6.

Apply the liquid teflon thread sealant to the transmitter mounting screws.

7.

Secure the gasket and the transmitter to the access plate using the same method as indicated for the access plate above.

8.

Cap all the tank fittings and perform a leak check. Apply leak check solution or soapy water around the access plate and the
transmitter gaskets and the fasteners. Pump 3 p.s.i. of compressed air into the tank and verify absence of leaks.

Auxiliary Fuel Tank

Removal

1.

Drain the auxiliary fuel tank.

2.

Remove the tank filler neck housing from the wheel house.

3.

Remove the rear close out panel.

4.

Remove the bolts attaching the auxiliary fuel tank filler neck and housing to the body.

5.

Disconnect the fuel filler neck at the tank and vent line at the housing.

6.

Support the auxiliary tank with a floor jack positioned under the fuel tank skid plate.

GASKET

SCREW

LOCK WASHER

TRANSMITTER

FLAT WASHER

3-44 Fuel, Emissions, and Exhaust

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NOTE:

Do not loosen or remove the bolts attaching the tank to the skid plate. The tank and skid plate will be removed as an as-

sembly.

7.

Remove the bolts and nuts attaching the fuel tank skid plate to the left and right frame brackets and the rear cross member.

8.

Lower the tank enough to reach the fuel lines. Then disconnect the fuel lines, the fuel level transmitter wires, and the vent line.
Mark the lines and the wires for assembly reference (Figure 3-29).

NOTE:

The fuel supply and return lines are equipped with quick connect fittings. To disconnect, first lift and remove the fitting re-

tainer from each fitting. Then pull the fittings free of the tank fuel tubes.

9.

Lower the jack and remove the tank from under the vehicle.

10. Remove the fuel level transmitter and the access plate. (Refer to section 3).

Installation

1.

If a new tank is being installed, transfer the fuel tank skid plate to the new tank.

2.

Place the tank on a floor jack and position it under the vehicle.

3.

Raise the tank enough to reach the feed lines.

4.

Attach the vent line and the fuel level transmitter wires.

5.

Connect the fuel lines. Push each line onto the fuel tank tube. Secure the lines with the retainers. Be sure the retainers are
firmly seated in the line fittings.

6.

Raise and align the fuel tank skid plate with the frame brackets and the rear cross member.

7.

Install the fuel tank attaching bolts and nuts and tighten securely.

8.

Install the fuel filler tube housing and the fuel filler cap.

9.

Install the fuel filler tube shield in the wheelhouse.

10. Install the rear close out panel.

11. Refill the fuel tank.

12. Verify the tank operation and the fuel level reading.

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Fuel, Emissions, and Exhaust 3-45

Figure 3-29: Auxiliary Fuel Tank Components

TANK

FUEL LEVEL

GASKET

AUXILIARY

SKID PLATE

FRAME

ACCESS PLATE

O-RING (8)

ROLLOVER

ACCESS PLATE

FUEL

ACCESS

PLATE

TRANSMITTER

STRAINER

FUEL TANK

GASKET

VALVE

RETAINER

MOUNTING

BRACKETS