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HOMESERVICE MANUALSCHEVROLET2008HHR LT, 2.4 P, AUTOMATICREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS AND FUEL - 2.4L - INTRODUCTION (2 OF 2)REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet HHR LT, 2.4 P, Automatic

Installation Procedure

2008 Chevrolet HHR LT, 2.4 P, AutomaticSECTION Installation Procedure
IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.
    Fig 1: View Of Fuel Rail
    GM1578472Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  3. Carefully push the fuel injectors into the cylinder head ports.
    4. NOTE: Refer to Fastener Notice .
  4. Install the fuel rail bolts.

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

    5. Fig 2: TAC, Fuel Injector Harness & Generator Electrical Connectors
    GM1623764Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel injector harness electrical connector (2).
  6. Connect the MAP sensor electrical connector.
    7. Fig 3: Fuel Injector Harness Electrical Connector Clip
    GM1623549Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel injector harness electrical connector clips (4 and 5) to the intake manifold.
    8. Fig 4: EVAP Canister Purge Valve Tube
    GM1623766Courtesy of GENERAL MOTORS CORP.
  8. Connect the EVAP purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 5: Fuel Feed Line
    GM1625417Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel feed line quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  12. Inspect for fuel 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.
    4. Inspect for fuel leaks.
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.