Hummer H2. Manual — part 1452

Fig. 96: Fuel Sender Assembly
Courtesy of GENERAL MOTORS CORP.

1. Install the new seal on the fuel tank.

2. Install the fuel sender assembly into the fuel tank.

3. Install the fuel sender assembly retaining ring using the J 44402 .

4. Install fuel lines to sender assembly. Refer to Fuel Hose/Pipes Assembly Replacement .

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

FUEL HOSE/PIPES REPLACEMENT - CHASSIS

Removal Procedure

CAUTION: Drain the fuel from the fuel sender assembly into an approved

container in order to reduce the risk of fire and personal injury. Never
store the fuel in an open container.

IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel

sender is installed in the tank. When installing the fuel sender assembly,
assure that the fuel pump strainer does not block full travel of the float
arm.

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

Fig. 97: View Of Rear Engine
Courtesy of GENERAL MOTORS CORP.

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

2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to

avoid possible contamination of the fuel system.

3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to Quick Connect Fitting(s)

Service (Metal Collar) .

2004 Hummer H2

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

4. Cap the fuel rail pipes.

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

6. Remove the left hand catalytic converter. Refer to Catalytic Converter Replacement (Right Hand) in

Engine Exhaust.

7. Remove the fuel pipes from the bellhousing stud clip (4).

8. Remove the fuel pipes from the transmission bracket clip.

Fig. 98: Chassis Fuel Feed Hose & Fuel Filter
Courtesy of GENERAL MOTORS CORP.

9. Disconnect the chassis fuel feed hose at the fuel filter. Refer to Quick Connect Fitting(s) Service

(Plastic Collar) .

10. Cap the rear fuel pipes.

11. Note the position of the fuel pipes for aid in installation.

2004 Hummer H2

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

12. Remove the fuel pipes from the retaining clips.

13. Remove the fuel pipes.

Installation Procedure

1. Install the fuel pipes into the retaining clips.

IMPORTANT:

z

When replacing the fuel pipes, always replace them with original
equipment or parts that meet the GM specifications for those parts.
The replacement pipes must have the same type of fittings as the
original pipes in order to ensure the integrity of the connection.

z

DO NOT use copper or aluminum tubing to replace steel tubing. Only
tubing meeting the 124-M specification or the equivalent is capable
of meeting all pressure, corrosion and vibration characteristics
necessary to ensure the durability standard required.

2004 Hummer H2

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