Hummer H2. Manual — part 1454

Fig. 102: Fuel Sender & Fuel Pressure Sensor Electrical Connectors
Courtesy of GENERAL MOTORS CORP.

1. Remove the caps from the fuel pipes.

2. Connect the rear fuel feed pipe and the rear fuel return pipe to the fuel sender and the fuel tank clips.

3. Install the fuel tank. Refer to Fuel Tank Replacement .

FUEL FILLER HOSE REPLACEMENT

Removal Procedure

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to

avoid possible contamination of the fuel system.

2. Drain the fuel below the level of the filler tube and hose assembly. Refer to Fuel Tank Draining

Procedure .

3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2004 Hummer H2

2004 ENGINE PERFORMANCE Engine Controls (Introduction) - 4.8L, 5.3L, and 6.0L - Hummer H2

Fig. 103: Fuel Fill Hose & Hose Clamps
Courtesy of GENERAL MOTORS CORP.

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

5. Loosen the fuel fill hose clamp at the fuel fill pipe.

6. Remove the fuel fill hose and the hose clamps.

7. Cap the fuel tank opening.

Installation Procedure

2004 Hummer H2

2004 ENGINE PERFORMANCE Engine Controls (Introduction) - 4.8L, 5.3L, and 6.0L - Hummer H2

Fig. 104: Fuel Fill Hose & Hose Clamps
Courtesy of GENERAL MOTORS CORP.

1. Uncap the fuel tank opening.

2. Install the fuel fill hose and the hose clamps to the fuel fill pipe.

Tighten: Tighten the hose clamps to 2.5 N.m (22 lb in).

3. Lower the vehicle.

NOTE:

Refer to Fastener Notice in Cautions and Notices.

2004 Hummer H2

2004 ENGINE PERFORMANCE Engine Controls (Introduction) - 4.8L, 5.3L, and 6.0L - Hummer H2

4. Refill the fuel system.

FUEL SYSTEM CLEANING

Fuel Tank Cleaning

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure

(Single Battery) in Engine Electrical.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .

3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .

4. Remove the fuel tank. Refer to Fuel Tank Replacement .

5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

6. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump.

7. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel

pump inlet.

8. Flush the fuel tank with hot water.

9. Pour the water out of the fuel sender assembly opening. Rock the tank to be sure that removal of the

water from the tank is complete.

10. Remove the fuel rail assembly. Refer to Fuel Rail Assembly Replacement .

11. Drain the fuel from the fuel rail. It will be necessary to remove the fuel injectors from the fuel rail to

properly clear all debris from the fuel rail and fuel injectors. Use light shop air to remove any debris from
the fuel rail and injectors.

12. Replace the fuel injector O-rings.

13. Use light shop air in the opposite direction of the fuel flow in order to remove any debris from the fuel

lines. Catch any fuel from the fuel lines with an approved gasoline container.

14. Install the injectors to the fuel rail.

15. Install the fuel rail assembly onto the engine. Refer to Fuel Rail Assembly Replacement .

16. If equipped with a serviceable fuel filter, replace the fuel filter.

17. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

18. Install the fuel tank. Refer to Fuel Tank Replacement .

19. Refill the fuel tank.

20. Install the fuel filler cap.

IMPORTANT:

z

Only use oil free compressed air to blow out the fuel pipes.

z

Inspect the fuel tank internally and clean the fuel tank if you find a
plugged fuel filter.

IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a

hazardous material. Handle the fuel and water mixture in accordance with
all applicable local, state, and federal laws and regulations.

2004 Hummer H2

2004 ENGINE PERFORMANCE Engine Controls (Introduction) - 4.8L, 5.3L, and 6.0L - Hummer H2