OEM 2009 Chevrolet HHR Fuel Rail

2009 Chevrolet HHR Fuel Rail Parts Questions & Experts Answers

• Q: How to replace the Fuel Injection Fuel Rail Assembly on 2009 Chevrolet HHR?

  A: The first step for replacing a fuel injection Fuel Rail assembly requires lowering fuel system pressure in the high side. The engine wiring harness electrical connector should detach from the Fuel Injector wiring harness before removing the Intake Manifold. After relieving the high side fuel system pressure you can start by removing the Fuel Injector insulator followed by disconnecting the engine wiring harness electrical connector from the high pressure Fuel Pump. Detach the intermediate fuel pipe first then disconnect all electrical connectors which link the Fuel Injector wiring harness to the fuel injectors. Unscrew the Fuel Rail bolts before you remove the Fuel Rail while maintaining the fuel injectors inside the cylinder head. When extracting fuel injectors along with the Fuel Rail you should reinstall them. The upper o-ring seal of the Fuel Injector needs to be discarded and the Fuel Rail plastic spacer should be inspected. Remove the spacer if it shows damage. To replace a Fuel Rail it becomes vital to remove both the Fuel Pressure Sensor from the Fuel Rail and the wiring harness for the fuel injectors. Installing the new Fuel Rail requires application of silicon-free engine oil gm p/n 12345610 (Canadian P/N 993193) or equivalent to both the Fuel Rail threads and sealing cone and the sensor. The installation requires fitting the Fuel Pressure Sensor onto the Fuel Rail before tightening it to 33 nm (25 lb ft). After fitting the Fuel Rail, connect the wiring harness to the fuel injectors. A new plastic spacer needs installation together with engine oil lubrication of the new Fuel Injector upper o-ring seal before installing it. Position the Fuel Rail before securing the outer two Fuel Rail bolts hand tight while tightening the rest hand tight as well. Use the correct sequence to tighten Fuel Rail bolts while beginning at 22 nm (16 lb ft) followed by the main torque to the same value. Reconnect the high pressure Fuel Pump using the engine wiring harness electrical connector followed by installation of the Intake Manifold and Fuel Injector insulator. Then put back the intermediate fuel pipe and connect the engine wiring harness electrical connector to the high pressure Fuel Pump. The fuel system completion includes connecting the engine wiring harness electrical connector to the Fuel Injector wiring harness electrical connector while inspecting for leaks using ignition on-off tests followed by installing the low side fuel pressure service port cap and fuel fill cap and air cleaner assembly.