Hummer H1 (2002+). Instruction - page 40

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Fuel, Emissions, and Exhaust 3-21

®

5745159

Air Cleaner Filter Element Service

Removal

1.

Remove ring clamp, cover, and gasket from air cleaner
(Figure 3-24).

2.

Remove nut and washer assembly and filter element from
air cleaner stud.

Figure 3-24: Air Cleaner Filter Element

Removal/Installation

Inspection

1.

Clean components with compressed air, examine for wear
or damage, and replace if necessary.

2.

Remove dust or sand by gently tapping around filter
element.

3.

Remove dirt and dust from filter element by directing flow
of compressed air from inside to outside of filter element.

Installation

1.

Slide filter element onto air cleaner stud and install nut and
washer. Tighten nut and washer to 18-35 lb-in. (2-4 N•m)
(Figure 3-24).

NOTE: To avoid damage to hood, ensure ring clamp bolt is
between the three and six o’clock positions.

2.

Install gasket, cover, and ring clamp on air cleaner
assembly. Tighten ring clamp bolt to 27-35 lb-in. (3-4
N•m).

AIR HORN

Removal

1.

Loosen clamp and remove air induction hose from air horn
(Figure 3-25).

Figure 3-25: Air Horn Mounting

2.

Remove CTIS air inlet hose and elbow from air horn.

3.

Loosen clamps that secure the air horn to the CDR valve
and turbo charger inlet hose.

4.

Remove air horn.

5.

Cover turbo charger opening to prevent dirt entry.

Installation

1.

Connect air induction hose to air horn (Figure 3-25).

2.

Connect air horn to turbo inlet. Tighten clamp to 44 lb-in
(5 N•m).

3.

Tighten air induction clamp to air horn. Tighten clamp to
44-53 lb-in (5-6 N•m).

4.

Connect CDR hose to CDR tube on air horn. Tighten to 44
lb-in (5 N•m).

5.

Apply sealant to CTIS air inlet elbow and install into
coupling on air horn. Tighten hose clamp.

RING

CLAMP

COVER

GASKET

FILTER

ELEMENT

AIR CLEANER

STUD

AIR

CLEANER

9-S03-002

AIR

INDUCTION
HOSE

CTIS AIR

INLET ELBOW

TUBRO
CHARGER
INLET
HOSE

CDR
HOSE

3-22

Fuel, Emissions, and Exhaust

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®

Air Induction Hose Replacement

Removal

1.

Loosen induction hose clamps.

2.

Remove hose from air horn and air cleaner (Figure 3-26).

Figure 3-26: Air Induction Hose Attachment

Installation

1.

Install induction hose on air horn and air cleaner.

2.

Tighten hose clamps to 44 lb-in. (5 N•m) (Figure 3-26).

WEATHERCAP REPLACEMENT

Removal

Remove clamp and weathercap from air intake duct
(Figure 3-27).

Figure 3-27: Weathercap Mounting

Installation

Install weathercap on air intake duct. Tighten clamp to 44-53
lb-in. (5-6 N•m).

FUEL TANK DRAINING

The fuel tank should only be drained with portable air powered
drain equipment. This type of equipment is OSHA approved
and will drain the tank through the filler neck.

The tank should be drained prior to removal. Follow the drain
equipment manufacturer’s instructions explicitly.

Figure 3-28: Fuel Tank Filler Cap

AIR HORN

AIR INDUCTION

HOSE

WEATHERCAP

AIR INTAKE

DUCT

S03-007

FUEL TANK

FILLER CAP

FILLER HOUSING

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Fuel, Emissions, and Exhaust 3-23

®

5745159

DRAINAGE BRACKET REPLACEMENT

Removal

1.

Remove air cleaner assembly.

2.

Remove three screws and drainage bracket from body
(Figure 3-29).

Figure 3-29: Drainage Bracket Location

Installation

1.

Position drainage bracket on body and install bracket
screws (Figure 3-29).

2.

Install air cleaner assembly.

AIR INTAKE VENT LINE REPLACEMENT

Removal

Remove air intake vent line from tee fitting and air cleaner fit-
ting (Figures 3-27 and 3-29)

.

Figure 3-30: Air Intake Vent Line Routing

Installation

Install air intake vent line on tee fitting and air cleaner fitting
(Figures 3-27 and 3-29)

.

Figure 3-31: Air Cleaner Vent Line Fitting Location

DRAINAGE BRACKET

AIR INTAKE SUPPORT

AIR INTAKE VENT LINE

TEE FITTING

AIR INTAKE VENT LINE

VENT LINE FITTING

3-24

Fuel, Emissions, and Exhaust

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®

MAIN FUEL TANK

Removal

1.

Drain tank with recommended equipment.

2.

Remove bolts attaching fuel filler housing to body.

3.

Remove vapor canister shield and bracket. Then disconnect
tank vent lines, and hoses at branch tee in fuel filler housing.

4.

Remove clamps attaching filler tube to vent line or body.

5.

Disconnect filler housing ground strap.

6.

Loosen clamps securing connecting hose to filler tube and
housing (Figure 3-32).

Figure 3-32: Filler Tube-to-Tank Attachment

7.

Remove fuel filler housing and filler neck.

8.

Raise vehicle.

9.

Remove rear propeller shaft.

10. Rotate rear axle yoke to a vertical position. Tank may not

clear yoke otherwise.

11. Support tank with transmission jack or other suitable

support device.

12. Remove bolts and nuts attaching front and rear upper

straps to lower straps (Figure 3-33).

Figure 3-33: Fuel Tank Mounting Strap Attachment

13. Disconnect vent lines at fuel tank.
14. Lower tank enough for access to transmitter wires and fuel

lines.

15. Disconnect transmitter wires.
16. Disconnect but do not remove rollover valve line.
17. Lower and remove fuel tank.

FILLER TUBE

CLAMP

HOUSING

STRAP

UPPER

LOWER STRAP

FUEL TANK

SUPPORT STRAP

LOWER

STRAP

STRAP

BRACKET

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