2009 Hummer H3 AlphaFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: Locating Fuel Tank Electrical Connectors
    GM1560074Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, place the fuel tank onto the jack and support the fuel tank.
  2. Partially raise the fuel tank until the electrical connections can be made.
  3. Connect the fuel feed line at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Connect the following electrical connectors to the fuel tank:
    • The fuel tank pressure sensor (1)
    • The fuel tank module (2)
    5. Fig 2: View Of Fuel Tank Rear Strap
    GM1560081Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel tank rear strap.
    6. Fig 3: Identifying Fuel Tank Rear Strap Bolt
    GM1560079Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel tank rear strap bolt until snug.
    7. Fig 4: Identifying Fuel Tank Front Strap Bolt
    GM1560083Courtesy of GENERAL MOTORS CORP.
  7. H3 graphic is shown, but H3T fuel strap is secured from bottom.
  8. Install the fuel tank front strap.
  9. Install the fuel tank front strap bolt until snug.
    10. CAUTION: Refer to Fastener Caution .
  10. Tighten the fuel tank strap bolts to 32 N.m (24 lb ft).
  11. Install the upper fuel tank strap bolt and tighten to 32 N.m (24 lb ft).
  12. Remove the adjustable jack from under the fuel tank.
    13. Fig 5: Identifying Fuel Tank Shield & Lower Bolts
    GM1560087Courtesy of GENERAL MOTORS CORP.
  13. Position the fuel tank shield (2) to the frame.
  14. Install the fuel tank shield lower bolts (1) and tighten to 10 N.m (89 lb in).
    15. Fig 6: Identifying Fuel Tank Shield Rear Upper Bolt
    GM1560085Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel tank shield rear upper bolt and tighten to 10 N.m (89 lb in).
  16. Lower the vehicle only enough to gain access to the fuel tank through the wheelhouse.
    17. Fig 7: Identifying Fuel Tank Connections
    GM1560072Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel fill hose to the fuel tank. Position the fuel fill hose orientation notch (2) in line with the tab (4) on the fuel tank.
  18. Tighten the fuel fill hose clamp (3) and tighten to 2.5 N.m (22 lb in).
  19. Connect the EVAP vapor line (5) to the fuel fill neck vapor line (1). Refer to Plastic Collar Quick Connect Fitting Service .
  20. Install the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement (Pickup) or Rear Wheelhouse Panel Liner Replacement (SUV) .
  21. Lower the vehicle.
  22. Refill the fuel tank.
  23. Install the fuel fill cap.
  24. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.