HHR 2006-2008

Removal & Installation

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2.2L Engine California Partial Zero Emission Vehicles (PZEV)



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure. Refer to Relieving Fuel System Pressure.
  6.  
  7. Drain the fuel tank:
    CAUTION
    Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion. Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Disconnect the fuel tank line quick connect fitting from the fuel feed line.
  12.  
  13. Cap or plug the fuel feed line and the fuel tank line in order to prevent fuel loss and/or system contamination.

    Click image to see an enlarged view

    Fig. Disconnect the fuel tank Evaporative Emission (EVAP) line quick connect fittings (2) & (3) from the EVAP canister

  14.  
  15. Disconnect the fuel tank Evaporative Emission (EVAP) line quick connect fitting (3) from the EVAP canister.
  16.  
  17. Disconnect the fuel fill pipe fresh air line quick connect fitting (2) from the EVAP canister.
  18.  
  19. Cap or plug the EVAP/fresh air lines and canister fittings in order to prevent system contamination.
  20.  
  21. Disconnect the fuel tank vent line quick connect fitting (1) from the fill pipe recirculation line.
  22.  
  23. Loosen the fuel fill hose clamp at the fuel tank.
  24.  
  25. Remove the fuel fill hose from the fuel tank.
  26.  
  27. Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.
  28.  
  29. Disconnect the fuel tank harness electrical connectors from the body harness pass thru connector.
  30.  
  31. Disconnect the fuel tank harness electrical connector from the fuel tank pressure sensor.
  32.  
  33. Disconnect the fuel tank harness electrical connector from the EVAP canister vent solenoid valve.
  34.  
  35. Remove the harness retainers from the underbody.

    Click image to see an enlarged view

    Fig. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust

  36.  
  37. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.
  38.  
  39. Remove the fuel tank harness clips from the underbody.

    Click image to see an enlarged view

    Fig. Remove fuel tank straps and remove the fuel tank down and toward the right side of the vehicle

  40.  
  41. Use a suitable jack to support the fuel tank during the fuel tank strap and tank removal.
  42.  
  43. Remove the left fuel tank strap bolts and strap.
  44.  
  45. Remove the right fuel tank strap bolts and strap.
  46.  
  47. In order to clear the exhaust muffler assembly, slowly lower the right side of the fuel tank. Use care when feeding the fuel, EVAP lines, and electrical harness around rear axle.
  48.  
  49. Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
  50.  
  51. If the fuel tank is to be replaced, remove the following components:

    Fuel level sensor
     
    Fuel pump
     
    Fuel pump fuel reservoir pump fuel strainer
     

  52.  

To install:

  1. If the fuel tank was replaced, install the following components:

    Fuel pump fuel reservoir pump fuel strainer
     
    Fuel level sensor
     
    Fuel pump
     

  2.  
  3. Use a suitable jack to support the fuel tank during the fuel tank and strap installation.
  4.  
  5. Install the left side of the fuel tank over the exhaust muffler assembly.
  6.  
  7. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care when feeding the fuel, EVAP lines, and electrical harness over the rear axle.
  8.  
  9. Install the right fuel tank strap and bolts.
  10.  
  11. Install the left fuel tank strap and bolts.
  12.  
  13. Tighten the fuel tank strap bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the fuel tank harness clips to the underbody.
  16.  
  17. Raise the exhaust muffler assembly into position and install the insulators to the underbody hanger.
  18.  
  19. Connect the fuel tank harness electrical connector to the fuel tank pressure sensor.
  20.  
  21. Connect the fuel tank harness electrical connector to the EVAP canister vent solenoid valve.
  22.  
  23. Install the harness retainers to the underbody.
  24.  
  25. Connect the fuel tank harness electrical connectors to the body harness pass thru connector.
  26.  
  27. Remove the cap or plug from the fuel tank and vent line openings.
  28.  
  29. Connect the fuel fill hose to the fuel tank.
  30.  
  31. Tighten the fuel fill hose clamp. Tighten the clamp to 40 lb in (5 Nm).
  32.  
  33. Connect the fuel tank vent line quick connect fitting to the fill pipe recirculation line.
  34.  
  35. Remove the caps or plug from the EVAP/fresh air lines and canister fittings.
  36.  
  37. Connect the fuel fill pipe fresh air line quick connect fitting to the EVAP canister.
  38.  
  39. Connect the fuel tank EVAP line quick connect fitting to the EVAP canister.
  40.  
  41. Remove the cap or plug from the fuel feed line and the fuel tank line.
  42.  
  43. Connect the fuel tank line quick connect fitting to the fuel feed line.
  44.  
  45. Lower the vehicle.
  46.  
  47. Refill the fuel tank.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Inspect for fuel leaks using the following procedure:
    1. Turn the ignition switch ON, but do not start the engine. Wait 2 seconds.
    2.  
    3. Turn the ignition switch OFF and wait 10 seconds.
    4.  
    5. Turn the ignition switch ON, but do not start the engine.
    6.  
    7. Inspect for fuel leaks.
    8.  

  52.  

Except 2.2L California Partial Zero Emission Vehicles (PZEV)



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure. Refer to Relieving Fuel System Pressure.
  6.  
  7. Drain the fuel tank:
    CAUTION
    Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion. Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.



    Click image to see an enlarged view

    Fig. Insert J 43290 (2) through the J 42960-2 (1) and into the filler pipe. Continue to insert the J 43290 (2) into the filler pipe until the hose exits the valve (1) and reaches the bottom of the tank

    1. Remove the fuel filler cap.
    2.  
    3. Install J 42960-2, or equivalent, into the fuel fill pipe in order to hold the door open.
    4.  
    5. Insert J 43290 (2) through the J 42960-2 (1) and into the filler pipe.
    6.  
    7. Continue to insert the J 43290 (2) into the filler pipe until the hose exits the valve (1) and reaches the bottom of the tank.
    8.  
    9. Use an air operated pump device in order to drain as much fuel through the J 43290 (1) as possible.

      Click image to see an enlarged view

      Fig. Disconnect the fuel pump module fuel feed (2) and return line (1) quick connect fittings from the fuel filter

    10.  

  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Disconnect the fuel pump module fuel feed (2) and return line (1) quick connect fittings from the fuel filter.
  12.  
  13. Cap or plug the fuel filter feed and return line fittings in order to prevent fuel loss and/or system contamination.
  14.  
  15. Cap or plug the fuel pump module feed and return lines in order to prevent fuel loss and/or system contamination.

    Click image to see an enlarged view

    Fig. Disconnect the fuel tank Evaporative Emission (EVAP) line quick connect fittings (2) & (3) from the EVAP canister

  16.  
  17. Disconnect the fuel tank Evaporative Emission (EVAP) line quick connect fittings (2) & (3) from the EVAP canister.
  18.  
  19. Cap or plug the EVAP lines and canister fittings in order to prevent system contamination.
  20.  
  21. Disconnect the fuel tank vent line quick connect fitting from the fill pipe recirculation line.
  22.  
  23. Loosen the fuel fill hose clamp at the fuel tank.
  24.  
  25. Remove the fuel fill hose from the fuel tank.
  26.  
  27. Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.
  28.  
  29. Disconnect the fuel tank harness electrical connectors from the body harness pass thru connector.
  30.  
  31. Disconnect the fuel tank harness electrical connector from the fuel tank pressure sensor.
  32.  
  33. Disconnect the fuel tank harness electrical connector from the EVAP canister vent solenoid valve.
  34.  
  35. Remove the harness retainers from the underbody.

    Click image to see an enlarged view

    Fig. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust

  36.  
  37. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.
  38.  
  39. Use a suitable jack to support the fuel tank during the fuel tank strap and tank removal.
  40.  
  41. Remove the left fuel tank strap bolts and strap.
  42.  
  43. Remove the right fuel tank strap bolts and strap.
  44.  
  45. In order to clear the exhaust muffler assembly, slowly lower the right side of the fuel tank. Use care when feeding the fuel, EVAP lines, and electrical harness around rear axle.
  46.  
  47. Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
  48.  
  49. If the fuel tank is to be replaced, remove the fuel pump module. Refer to Fuel Pump removal and installation in the Fuel section.

    Click image to see an enlarged view

    Fig. Remove fuel tank straps and remove the fuel tank down and toward the right side of the vehicle

  50.  

To install:

  1. If the fuel tank was replaced, install the fuel pump module. Refer to Fuel Pump removal and installation in the Fuel section.
  2.  
  3. Use a suitable jack to support the fuel tank during the fuel tank and strap installation.
  4.  
  5. Install the left side of the fuel tank over the exhaust muffler assembly.
  6.  
  7. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care when feeding the fuel, EVAP lines, and electrical harness over the rear axle.
  8.  
  9. Install the right fuel tank strap and bolts.
  10.  
  11. Install the left fuel tank strap and bolts.
  12.  
  13. Tighten the fuel tank strap bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Raise the exhaust muffler assembly into position and install the insulators to the underbody hanger.
  16.  
  17. Connect the fuel tank harness electrical connector to the fuel tank pressure sensor.
  18.  
  19. Connect the fuel tank harness electrical connector to the EVAP canister vent solenoid valve.
  20.  
  21. Install the harness retainers to the underbody.
  22.  
  23. Connect the fuel tank harness electrical connectors to the body harness pass thru connector.
  24.  
  25. Remove the cap or plug from the fuel tank and vent line openings.
  26.  
  27. Connect the fuel fill hose to the fuel tank. Align the "D" notch on the fill hose with the "D" notch on the fuel tank.
  28.  
  29. Tighten the fuel fill hose clamp to 40 inch lbs. (5 Nm).
  30.  
  31. Connect the fuel tank vent line quick connect fitting to the fill pipe recirculation line.
  32.  
  33. Remove the caps or plugs from the EVAP lines.
  34.  
  35. Connect the fuel tank EVAP line quick connect fittings to the EVAP canister.
  36.  
  37. Remove the caps or plugs from the fuel pump module fuel feed and return lines.
  38.  
  39. Remove the caps or plugs from the fuel filter feed and return line fittings.
  40.  
  41. Connect the fuel pump module fuel feed and return line quick connect fittings to the fuel filter.
  42.  
  43. Lower the vehicle.
  44.  
  45. Refill the fuel tank.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Inspect for fuel leaks using the following procedure:
    1. Turn the ignition switch ON, but do not start the engine. Wait 2 seconds.
    2.  
    3. Turn the ignition switch OFF and wait 10 seconds.
    4.  
    5. Turn the ignition switch ON, but do not start the engine.
    6.  
    7. Inspect for fuel leaks.
    8.  

  50.  

 
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