Hummer H1 (2002+). Manual - part 42

 

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Hummer H1 (2002+). Manual - part 42

 

 

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 Fuel, Emissions, and Exhaust  3-29

®

5745159

Figure 3-37:   Fuel Tank Vent Line Locations

(Typical)

Fuel Tank Vent Line Service 

Removal 

1.

Remove fuel tank. Refer to procedure in this section. 

2.

Remove clip and fuel tank vent line hose from vent line
(Figure 3-37).

3.

Remove vent line clamps and disenagage lines.

4.

Remove tie strap securing vent line to fuel lines. Discard
tie strap.

5.

Disconnect fuel tank vent lines at tank fittings.

Installation 

1.

Connect vent lines to tank fitting.

2.

Secure vent line to fuel lines with new tie strap  (Figure 3-37).

3.

Secure vent lines in brackets with clamps and bolts.

4.

Install fuel tank.

FUEL TANK VENT FILTER REPLACEMENT

The fuel tank vent filter is located just above the surge tank at
the passenger side of the engine compartment (Figure 3-37). 

The filter is serviced as an assembly and should be replaced if
restricted or damaged. 

To replace the filter, remove the filter retaining clamp bolt, pull
the filter out of the clamp, and disconnect it from the vent line.
Be sure the replacement filter is properly secured in the clamp
afterward. Also, use a new vent line clamp if the original is
worn, or distorted. 

Figure 3-38:   Fuel Tank Vent Filter Location

MAIN OR AUXILIARY TANK FUEL LINE 
REPLACEMENT (ALL)

Removal

1.

Drain tank with portable, air powered equipment.

2.

Remove main or auxiliary fuel tank as described in this section.

3.

Disconnect any electrical wires, linkage parts, cables, or
lines as needed if insufficient slack exists.

4.

Disconnect fuel lines at main tank tubes.

5.

Remove line clamps and tie straps.

6.

Disconnect lines at fuel tank selector valve and remove
lines.

7.

Disconnect supply line at fuel pump.

8.

On all models, if front lines are to be replaced, disconnect
lines at fuel pump and return fittings.

9.

Remove supply and/or return lines as needed
(Figure 3-39).

Installation

1.

Route new lines as needed (Figure 3-39). Be sure lines are 
not kinked, pinched, or touching hot or rotating parts.

2.

Connect front fuel lines to fuel pump and return fitting at
injection pump. Then connect lines to fuel selector valve.

3.

Secure lines to frame clamps, brackets, P-clips, and tie
straps as needed.

4.

Connect rear lines to auxiliary or main tank as required.

5.

Install main or auxiliary fuel tank as described in this
section.

6.

Verify that fuel lines are securely connected and properly
routed.

7.

Refill fuel tank.

8.

Check tank operation. Verify proper transmitter operation
and selector switch function.

FUEL TANK

VENT LINE

FUEL LINES

VENT LINE

BRACKETS

VENT LINE FILTER

FUEL TANK

VENT LINE

ELBOW

BODY

BRACKET

3-30

Fuel, Emissions, and Exhaust

___________________________________________

®

FUEL SELECTOR VALVE

The selector valve is used on models equipped with an auxil-
iary fuel tank  (Figure 3-39). The valve is electrically operated
by a switch in the passenger compartment. The switch will be
mounted on the instrument panel.

Valve function is to switch fuel supply from main to auxiliary
tank (and back) when needed.

Quick connect fittings are used to attach each of the six fuel
lines to the valve. The plastic, two-piece style fittings are used.

The valve is mounted on a bracket attached to the passenger
side frame rail. Valve position is forward of the fuel tank and
B-pillar area.

The valve is not a serviceable part and must be replaced when
diagnosis indicates this is necessary.

Selector Valve Replacement

The valve is accessible from under the vehicle. Disconnect the
battery and remove the valve-to-bracket bolts first. Then dis-
connect the fuel lines one at a time and tag them for reference.
Last, disconnect the valve-to-switch harness and remove the
valve. Reverse the process to install the valve.

Figure 3-39:   Fuel Lines, Connections, and Attachment 

VALVE

MOUNTING

BRACKET

RETURN LINE

(AUXILIARY TANK)

CLAMP

(TYPICAL)

FUEL LINE

BRACKET

FUEL LINE

BRACKET

S-CLIP

(TYPICAL)

SUPPLY LINE

(AUXILIARY TANK)

VALVE-TO-PUMP

AND INJECTOR LINES

FUEL SELECTOR VALVE

TANK-TO-VALVE 

LINES

FUEL LINE

BRACKET

TIE STRAP

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 Fuel, Emissions, and Exhaust  3-31

®

5745159

FUEL FILTER SERVICE

Fuel Filter Replacement

Removal 

1.

Loosen the hose clamps securing the CTIS compressor (if 
equipped) to its mounting bracket and slide the compres-
sor forward to gain access to the fuel filter.

2.

Disconnect fuel inlet and outlet hoses from filter
(Figure 3-40:).

3.

Disconnect drain hose from fuel filter.

4.

Disconnect filter harness connectors.

5.

Remove filter attaching bolts and remove fuel filter from
bracket.

Disassembly

1.

Remove retaining nut and filter element from header.

2.

Remove sensor and O-ring.

3.

Loosen cap nut and remove fuel heater, seal, spring, and
screen. 

Assembly

1.

Install screen, spring, cap seal, and fuel heater and tighten 
cap nut. 

2.

Install O-ring and sensor.

3.

Install filter element and retaining nut. 

Figure 3-40:   Fuel Filter Mounting

Installation 

1.

Install fuel filter on bracket and secure with washers and 
bolts (Figure 3-40:).

2.

Connect sensor and fuel heater harnesses to body harness
connectors.

3.

Connect drain hose to fuel filter.

4.

Connect inlet and outlet hoses to fuel filter.

5.

Slide the CTIS compressor rearward into place and tighten
the hose clamps securing the compressor to the mounting
bracket.

Purging Air From Fuel Filter

1.

Loosen fuel filter air bleed valve one-half turn (Figure 3-41).

2.

Run engine until fuel exits from air valve.

3.

Tighten air valve.

Figure 3-41:   Fuel Filter Components

FUEL FILTER

OUTLET HOSE

BRACKET

INLET HOSE

DRAIN

HOSE

SENSOR HARNESS

MOUNTING

FUEL HEATER

HARNESS

NUT

ELEMENT

FILTER

SENSOR

O-RING

FUEL HEATER

SPRING

CAP NUT

CAP SEAL

FILTER

AIR BLEED

VALVE

HOUSING

RETAINING

SCREEN

ELEMENT

(WATER IN

FUEL)

3-32

Fuel, Emissions, and Exhaust

___________________________________________

®

Fuel Filter Drain Hose and Valve Replace-
ment

NOTE: To remove fuel filter drain valve only, perform steps 3
and 4.

Removal

1.

Disconnect fuel filter drain hose from fuel filter  
(Figure 3-42).

2.

Remove two tie straps and separate drain hose from
transmission oil cooler lines.

3.

Remove two tie straps and separate drain hose from
transmission oil cooler lines.

4.

Disconnect drain hose at drain valve.

5.

Remove nut and drain valve from body

Installation

1.

Install drain valve on body and tighten nut.

2.

Connect drain hose to valve.

3.

Connect drain hose to fuel filter.

4.

Secure drain hose to transmission oil cooler lines with two
tie straps.

5.

Start engine and check for leaks.

Figure 3-42:   Fuel Filter Drain Hose And Valve Location

FUEL FILTER

FUEL FILTER

DRAIN HOSE

BODY

DRAIN VALVE

TIE STRAPS

TRANSMISSION

OIL COOLER

LINES

 

 

 

 

 

 

 

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