HHR 2006-2008

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.0L Engine

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.
  2.  
  3. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Remove the fuel injector insulator.
  8.  
  9. Relieve the high side fuel system pressure.
  10.  
  11. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
  12.  
  13. Remove the high pressure fuel pump cover bolts.
  14.  
  15. Remove the high pressure fuel pump cover.
  16.  
  17. Remove the engine wiring harness clip from the high pressure fuel pump cover.
  18.  
  19. Remove the high pressure fuel pump insulator.
  20.  
  21. Loosen the high pressure fuel pipe fitting at the fuel pump.
  22.  
  23. Loosen the high pressure fuel pipe fitting at the fuel rail.
  24.  
  25. Remove and discard the high pressure fuel pipe.
  26.  
  27. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  28.  
  29. Remove the fuel rail bolts.
  30.  
  31. Carefully remove the fuel rail.
    NOTE
    The fuel injectors may come out of the cylinder head with the fuel rail.

  32.  
  33. Remove and discard the direct fuel injector hold down clamps.
  34.  
  35. Remove the direct fuel injectors.

    Click image to see an enlarged view

    Fig. Direct fuel injector removal 2.0L engine

  36.  
  37. If necessary, use a slide hammer and the J-37281-A injector removal adapter in order to remove the direct fuel injectors.
  38.  
  39. Remove and discard the upper O-ring seal and plastic spacer from the injector.
  40.  
  41. Carefully remove and discard the lower nylon seal from the injector.

    Click image to see an enlarged view

    Fig. Direct fuel injector view

  42.  

To install:

  1. Install a new plastic spacer onto the fuel injector.
  2.  
  3. Lubricate a new O-ring seal with silicon free engine oil
  4.  
  5. Carefully install the new O-ring seal onto the fuel injector.
  6.  
  7. From the EN-48266 , position the EN 48266-1 to the injector tip.
  8.  
  9. Install a new seal onto the EN 48266-1.

    Click image to see an enlarged view

    Fig. Fuel injector with EN 48266-1 tool and O-ring

  10.  
  11. Pull the new seal by hand over the EN 48266-1 and into the groove in the injector.
  12.  
  13. Remove the EN 48266-1 from the injector tip.
  14.  
  15. From the EN-48266, install the EN 48266-2 to the injector tip.

    Click image to see an enlarged view

    Fig. Fuel injector with EN 48266-2 tool installed

  16.  
  17. Using the EN 48266-2, resize the seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.
  18.  
  19. Remove the EN 48266-2.
  20.  
  21. Install the direct fuel injectors to the cylinder head.
  22.  
  23. Install the new direct fuel injector hold down clamps.
  24.  
  25. Place the fuel rail into position.
  26.  
  27. Install the outer fuel rail bolts first, hand tight and install the remaining bolts, hand tight.
  28.  
  29. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  30.  
  31. Tighten the fuel rail bolts in the sequence shown to:
    1. Tighten the bolts a first pass to 16 ft. lbs. (22 Nm).
    2.  
    3. Tighten the bolts a final pass to 16 ft. lbs. (22 Nm).

      Click image to see an enlarged view

      Fig. Fuel rail tightening sequence 2.0L engine

    4.  

  32.  
  33. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  34.  
  35. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil
  36.  
  37. Install the new high pressure fuel pipe.
  38.  
  39. Tighten the new high pressure fuel pipe fitting to the fuel rail hand tight.
  40.  
  41. Tighten the new high pressure fuel pipe fitting to the fuel pump hand tight.
  42.  
  43. Tighten the fittings to 24 ft. lbs. (32 Nm).
  44.  
  45. Install the high pressure fuel pump insulator.
  46.  
  47. Install the high pressure fuel pump cover.
  48.  
  49. Install the high pressure fuel pump cover bolts and tighten to 89 inch lbs. (10 Nm).
  50.  
  51. Connect the engine wiring harness electrical connector to the high pressure fuel pump
  52.  
  53. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
  54.  
  55. Install the fuel injector insulator.
  56.  
  57. Install the intake manifold.
  58.  
  59. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  60.  
  61. Inspect for leaks using the following procedure:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn OFF the ignition, for 10 seconds.
     
    Turn ON the ignition, with the engine OFF.
     
    Inspect for fuel leaks.
     

  62.  
  63. Install the low side fuel pressure service port cap.
  64.  
  65. Tighten the fuel fill cap.
  66.  
  67. Install the intake manifold cover.
  68.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Disconnect the fuel line fitting.
  8.  
  9. Disconnect the fuel injector harness connectors.
  10.  
  11. Remove the fuel rail attaching studs.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.



    Click image to see an enlarged view

    Fig. Fuel rail removal-2.2L engine

  12.  
  13. Remove the fuel rail using the following procedure:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    2.  
    3. Rotate the fuel rail in order to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  14.  
  15. Remove the fuel injector retainer clip.
  16.  
  17. Remove the fuel injectors from the fuel rail.
    NOTE
    Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly.



    Click image to see an enlarged view

    Fig. Fuel injectors-2.2L engine

  18.  
  19. Remove and discard the fuel injector O-rings.
  20.  

To install:


NOTE
Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil.

  1. Install the O-rings on the fuel injector.
  2.  
  3. Install the fuel injector clip on the fuel injector.
    NOTE
    The fuel injector will click when the injector is installed correctly.

  4.  
  5. Install the fuel injector in the fuel rail with the connector facing upward.
    NOTE
    Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  6.  
  7. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    2.  
    3. Align the injectors by rotating the fuel rail forward.
    4.  
    5. Carefully push the fuel injectors into the cylinder head ports.
    6.  

  8.  
  9. Install the fuel rail attaching studs. Tighten the fuel rail studs to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  12.  
  13. Connect the fuel line fitting.
  14.  
  15. Install the air cleaner outlet resonator.
  16.  
  17. Connect the negative battery cable..
  18.  
  19. 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.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

2.4L Engine
  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. Remove the air cleaner outlet duct.

    Click image to see an enlarged view

    Fig. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail

  8.  
  9. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail.
  10.  
  11. Cap or plug the fuel line and the fuel rail to prevent contamination.
  12.  
  13. Disconnect the engine harness electrical connector from the fuel injector harness.
  14.  
  15. Remove the fuel injector harness connector clip from the intake manifold.
  16.  
  17. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  18.  
  19. Remove the fuel rail bolts.
    WARNING
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector electrical connector terminals and spray tips.

  20.  
  21. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
  22.  
  23. Remove the fuel rail.
  24.  
  25. Remove the fuel injectors.

    Click image to see an enlarged view

    Fig. Remove the fuel rail bolts and fuel rail-2.4L Engine

  26.  

To install:


NOTE
Install NEW lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  2.  
  3. Carefully push the fuel injectors into the cylinder head ports.
  4.  
  5. Install the fuel rail bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the engine harness electrical connector to the MAP sensor.
  8.  
  9. Connect the engine harness electrical connector to the fuel injector harness.
  10.  
  11. Install the fuel injector harness connector clip to the intake manifold.
  12.  
  13. Remove the caps or plugs from the fuel line and the fuel rail.
  14.  
  15. Connect the fuel feed line quick connect fitting (4) to the fuel rail.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. 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.  

  20.  
  21. Install the air cleaner outlet duct.
  22.  

 
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