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HOMESERVICE MANUALSCHEVROLET2008HHR LT, 2.4 P, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 130 (ENGINE CONTROLS AND FUEL - 2.2L OR 2.4L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet HHR LT, 2.4 P, Automatic

Installation Procedure

2008 Chevrolet HHR LT, 2.4 P, AutomaticSECTION Installation Procedure
WARNING: This page is about a different car, the 2009 Chevrolet HHR. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Fuel Tank Electrical Harness
    GM1636804Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, perform the following steps. Install the fuel tank module. Refer to Fuel Pump Module Replacement .
  2. Install and connect the fuel tank electrical harness.
    3. Fig 2: Identifying Fuel Tank Vent Pipe
    GM1636697Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 3: Identifying Fuel Feed Intermediate Pipe
    GM1636696Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 4: Identifying Fuel Tank Vent Pipe
    GM1636693Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 5: View Of Fuel Tank & Straps
    GM1636706Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, place the fuel tank on the suitable jack.
  7. Using the adjustable jack, carefully raise the fuel tank into position.
  8. Position the fuel tank straps.
    9. CAUTION: Refer to Fastener Caution .
  9. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft).

  10. Remove adjustable jack from under the fuel tank.
    11. Fig 6: View Of Exhaust Pipe Insulators
    GM1631769Courtesy of GENERAL MOTORS CORP.
  11. Raise the exhaust and install the muffler insulators to the underbody hangers.
  12. Install the exhaust pipe insulators to the underbody hangers.
    13. Fig 7: Identifying Fuel Tank Electrical Connector
    GM1636801Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel tank electrical connector (1) to the pass through connector.
    14. Fig 8: Identifying Fuel Fill Pipe Hose
    GM1636704Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel fill pipe hose to the fuel tank.
  15. Tighten the fuel fill pipe hose clamp (2) at the fuel tank.

    Tighten:  Tighten the clamp to 4.5 N.m (40 lb in).

  16. Connect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service .
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  20. 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, with the engine OFF.
    4. Inspect for fuel leaks.
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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.