HHR 2006-2008

Fuel Pump

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Removal & Installation




CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.


    WARNING
    Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Disconnect the fuel feed and return lines from the fuel filter.
  12.  
  13. Cap or plug the fuel tank feed and return pipes to prevent fuel loss and/or contamination.
  14.  
  15. Disconnect the Evaporative Emission (EVAP) pipe fittings, for access to disconnect the fuel filler hose from the tank.
  16.  
  17. Cap or plug the EVAP purge and vapor pipes to prevent contamination.
  18.  
  19. Loosen the fuel filler hose clamp at the fuel tank.
  20.  
  21. Disconnect the fuel filler hose from the fuel tank.
  22.  
  23. Disconnect the fuel pump module harness electrical connector from the vehicle underbody connector.
  24.  
  25. Release the exhaust extension pipe insulators from the underbody hangers.
  26.  
  27. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam.
  28.  
  29. Have an assistant support the fuel tank during fuel tank strap removal, and during tank removal.
  30.  
  31. Remove the left fuel tank strap bolts and the strap.
  32.  
  33. Remove the right tank strap bolts and the strap.
  34.  
  35. In order to clear the exhaust extension pipe, slowly lower the right side of the fuel tank. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness to clear the axle.
  36.  
  37. Once the tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
    NOTE
    Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer.

  38.  
  39. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank.
  40.  
  41. Release the fuel pump module electrical harness from the retaining slot on the tank.
  42.  
  43. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor.

    Click image to see an enlarged view

    Fig. Using tool J 39765 (1), or equivalent, carefully rotate to release the fuel pump module retaining lock ring

  44.  
  45. Using tool J 39765, or equivalent, carefully rotate to release the fuel pump module retaining lock ring.
  46.  
  47. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness.
  48.  
  49. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening.
    CAUTION
    When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

  50.  
  51. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank.
  52.  
  53. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container.
    WARNING
    Do NOT reuse the old fuel pump module-to-fuel tank seal.

  54.  
  55. Remove and discard the fuel pump module-to-fuel tank seal.
  56.  

To install:

  1. Install a NEW fuel pump module-to-fuel tank seal.
    NOTE
    The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

  2.  
  3. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module to the fuel tank.
  4.  
  5. Slowly lower the fuel pump module assembly into the tank. Ensure that the fuel level sensor harness connector is positioned properly.
  6.  
  7. Install the fuel pump module retaining lock ring over the module pipes and electrical harness, and into position on the top of the module.
    NOTE
    Ensure that the fuel pump module retaining lock ring is fully seated within the fuel tank retaining tab slots.

  8.  
  9. Carefully rotate to fully secure the fuel pump module retaining lock ring.
  10.  
  11. Connect the fuel pump module harness electrical connector to the fuel tank pressure sensor.
  12.  
  13. Secure the fuel pump module electrical harness into the retaining slot on the tank.
    NOTE
    Ensure that the fuel tank rear shield is positioned properly on the pump module pipe retainer.

  14.  
  15. Secure the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank.
  16.  
  17. Have an assistant support the fuel tank during fuel tank and fuel tank strap installation.
  18.  
  19. Begin to install the left side of the fuel tank over the exhaust pipe.
  20.  
  21. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness over the rear axle.
  22.  
  23. Install the right fuel tank strap and strap bolts.
  24.  
  25. Install the left fuel tank strap and strap bolts.
  26.  
  27. Tighten the fuel tank strap bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  28.  
  29. Raise the exhaust into position and install the muffler insulators to the underbody hanger.
  30.  
  31. Install the exhaust extension pipe insulators to the underbody hangers.
  32.  
  33. Connect the fuel pump module harness electrical connector to the vehicle underbody connector.
  34.  
  35. Connect the fuel filler hose to the fuel tank.
  36.  
  37. Tighten the fuel filler hose clamp at the fuel tank. Tighten the clamp to 40 inch lbs. (5 Nm).
  38.  
  39. Remove the caps or plugs from the EVAP purge and vapor pipes.
  40.  
  41. Connect the EVAP purge pipe and vapor pipe to the EVAP canister.
  42.  
  43. Remove the caps or plugs from the fuel tank feed and return pipes.
  44.  
  45. Connect the fuel feed and return lines to the fuel filter.
  46.  
  47. Lower the vehicle.
  48.  
  49. Refill the fuel tank.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  54.  

 
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