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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 INSTRUCTIONSHIGH PRESSURE FUEL PUMP REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet HHR LS, Automatic

Installation Procedure

2008 Chevrolet HHR LS, AutomaticSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Fuel Pump Roller Lifter
    GM1769961Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, if necessary.
  2. Install the high pressure fuel pump roller lifter, if necessary.
    3. Fig 2: High Pressure Fuel Pump & Bolts
    GM1769960Courtesy of GENERAL MOTORS CORP.
  3. Install a NEW high pressure fuel pump O-ring.
  4. Position the NEW high pressure fuel pump gasket to the cylinder head.
    5. IMPORTANT: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes prior to installing.
  5. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump.
  6. Install the NEW high pressure fuel pump bolts hand tight.
  7. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  8. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    9. Fig 3: View Of High Pressure Fuel Pipe
    GM2035280Courtesy of GENERAL MOTORS CORP.
  9. Install the NEW high pressure fuel pipe.
  10. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight.
  11. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.
    12. Fig 4: View Of High Pressure Fuel Pipe & Intake Manifold
    GM2035279Courtesy of GENERAL MOTORS CORP.
  12. Place the fuel feed pipe onto the intake manifold.
  13. Install the fuel feed pipe bolts hand tight.
    14. NOTE: Refer to Fastener Notice .
  14. Tighten the fuel feed pipe to fuel pump fitting hand tight.

    Tighten: 

    1. Tighten the fuel feed pipe bolts to 10 N.m (89 lb in).
    2. Tighten the fuel feed pipe to fuel pump fitting to 30 N.m (22 lb ft).
    3. Tighten the high pressure fuel pipe fittings to 32 N.m (24 lb ft).
    4. Tighten the high pressure fuel pump bolts evenly to 15 N.m (11 lb ft).

    15. Fig 5: Identifying High Pressure Fuel Pump Insulator
    GM2035277Courtesy of GENERAL MOTORS CORP.
  15. Install the high pressure fuel pump insulator.
    16. Fig 6: View Of High Pressure Fuel Pump Cover
    GM2035276Courtesy of GENERAL MOTORS CORP.
  16. Position the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    18. Fig 7: View Of Engine Wiring Harness & High Pressure Fuel Pump
    GM2035275Courtesy of GENERAL MOTORS CORP.
  18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  19. Install the engine wiring harness clip (3) to the fuel pump cover.
  20. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  21. Install the low side fuel pressure service port cap.
  22. Tighten the fuel fill cap.
RENDER: 1.0x

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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.