HHR 2006-2008

Relieving Fuel System Pressure

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2.0L Engine



High Pressure Side

CAUTION
Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.


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. Install a scan tool to the vehicle and command the fuel pump relay OFF, allowing the low pressure fuel pump to shut off.
  2.  
  3. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in approximately 20-30 seconds.
  4.  
  5. Turn the ignition OFF.
  6.  
  7. Using the scan tool, verify that there is little to no fuel pressure, if there still is fuel pressure repeat step 2.
    WARNING
    If a scan tool is not available, WAIT at LEAST 2 hours after the engine has been run, before removing the high pressure fuel line.

  8.  
  9. Remove the high pressure fuel line.
  10.  

Low Pressure Side W/O Fuel Gauge

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. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  2.  
  3. Remove the engine cover, if required.
  4.  
  5. Remove the fuel rail service port cap.
  6.  
  7. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve.
  8.  
  9. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  10.  
  11. Install the fuel rail service port cap.
  12.  
  13. Install fuel cap.
  14.  

Low Pressure Side With Fuel Gauge

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. Remove the engine cover, if required.
  2.  
  3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  4.  
  5. Remove the fuel rail service port cap.
  6.  
  7. Wrap a shop towel around the fuel rail service port.
  8.  
  9. Connect the adapter to the fuel rail service port.
  10.  
  11. Connect service port adapter to pressure tester.
  12.  
  13. Place the relief hose on the tester into an approved gasoline container.
  14.  
  15. Open the valve on the tester in order to bleed any fuel from the fuel rail.
  16.  
  17. Close the valve on the tester.
  18.  
  19. Remove the relief hose on the tester from the approved gasoline container.
  20.  
  21. Disconnect service port adapter and tester.
  22.  
  23. Install the fuel rail service port cap.
  24.  
  25. Install fuel cap.
  26.  

2.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    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.



    Click image to see an enlarged view

    Fig. Fuel bleed procedure-2.2L engine

  2.  
  3. Turn the ignition OFF.
  4.  
  5. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine.
  6.  
  7. Loosen the fuel filler cap to relieve the fuel tank vapor pressure.
  8.  
  9. Remove the cap from the fuel pressure service port.
  10.  
  11. Connect tool SA9127E or J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gauge in order to avoid spillage.
    CAUTION
    Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

  12.  
  13. Install the bleed hose into an approved fuel container.
  14.  
  15. Open the bleed valve on the in order to bleed the fuel system pressure. The fuel connections are now safe for servicing.
  16.  
  17. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage.
  18.  
  19. Disconnect the gauge from the fuel pressure service port connection.
  20.  
  21. Drain any fuel remaining in the gauge into an approved fuel container.
  22.  
  23. Install the cap to the fuel pressure service port.
  24.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    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.

  2.  

If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse.

  1. Remove the engine cover, if required.
  2.  
  3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  4.  
  5. Remove the fuel rail service port cap.
    CAUTION
    Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete.

  6.  
  7. Wrap a shop towel around the fuel rail service port.

    Click image to see an enlarged view

    Fig. Connect the CH-48027-3 to the fuel rail service port. Connect the CH-48027-2 to the CH-48027-3

  8.  
  9. Connect the CH-48027-3 (4) to the fuel rail service port.
  10.  
  11. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
  12.  
  13. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  14.  
  15. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  16.  
  17. Close the valve on the CH-48027-2 (2).
  18.  
  19. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  20.  
  21. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
    1. The fuel pipe connections.
    2.  
    3. The hose connections.
    4.  
    5. The areas surrounding the connections.
    6.  

  22.  
  23. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  24.  
  25. Disconnect the CH-48027-3 (4) from the fuel rail service port.
  26.  
  27. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  28.  
  29. Install the fuel rail service port cap.
  30.  
  31. Install the engine cover, if required.
  32.  
  33. Tighten the fuel fill cap.
  34.  

 
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