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HOMESERVICE MANUALSCHEVROLET2008HHR LS, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 3 (ENGINE CONTROLS AND FUEL - 2.0L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet HHR LS, Automatic

Removal Procedure

2008 Chevrolet HHR LS, AutomaticSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM2035304Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  2. Remove the intake manifold. Refer to Intake Manifold Replacement .
    3. Fig 2: Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel injector insulator.
    4. Fig 3: High Pressure Fuel Pump Connector & Clip
    GM1826282Courtesy of GENERAL MOTORS CORP.
  4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027)  or Fuel Pressure Relief (With CH 48027) .
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the intermediate fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    7. Fig 4: Fuel Rail Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  8. Remove the fuel rail bolts (1).
    9. IMPORTANT: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.
  9. Carefully remove the fuel rail (2).
  10. If the fuel injectors have been removed with the fuel rail, reinstall the injectors. Refer to Direct Fuel Injector Replacement .
    11. Fig 5: Fuel Injector
    GM1829979Courtesy of GENERAL MOTORS CORP.
  11. Remove and discard the fuel injector upper O-ring seal (1).
  12. Inspect the plastic spacer (2) for damage, remove if damaged.
    13. Fig 6: Fuel Rail Fuel Pressure Sensor
    GM1829977Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

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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.