HHR 2006-2008

Fuel System Service Precautions


Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.

To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied.
Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts.
Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container.
Always keep a dry chemical (Class B) fire extinguisher near the work area.
Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.
Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications.
Always replace worn fuel fitting O-rings with new ones. Do not substitute fuel hose, or equivalent, where fuel pipe is installed.

In order to reduce the risk of fire and personal injury observe the following items:

Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.
Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 239°F (115°C) for more than one hour, or more than 194°F (90°C) for any extended period.
Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)