Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008HHR LT, 2.4 P, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 277 (ENGINE CONTROLS AND FUEL - 2.2L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL TANK FUEL PUMP MODULE 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 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Fuel Sender Assembly Components

Courtesy of GENERAL MOTORS CORP.

Install a NEW O-ring seal (3) onto the fuel sender.
Install the fuel sender assembly (2) into the fuel tank far enough to connect the vapor line quick connect fitting on the underside of the sender cover.

Fig 2: Identifying Sender Assembly Vapor Line Quick Connect Fitting

Courtesy of GENERAL MOTORS CORP.

Connect the vapor line quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service .
Align the cover "paddle" or anti-rotation feature with the corresponding feature in the top of the fuel tank.
Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.

Fig 3: Identifying Lock Ring

Courtesy 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.