Replacing Fuel Pump Relay In Chevy Hhr: Step-By-Step Guide

If your Chevy HHR engine is stalling or won't start, you may need to replace the fuel pump relay. To do this, you must first disconnect the battery to reduce the chance of a fire. You can then remove the access cover to get to the pump and replace it. If the pump is outside the tank, you will need to disconnect the fuel lines. It is recommended that fuel filters are replaced at the same time as the fuel pump. This can be a dangerous procedure, so unless you are very experienced in auto repair, it is best to leave it to the professionals.

Check if the fuel pump relay is faulty

If you suspect that your Chevy HHR's fuel pump relay is faulty, there are several warning signs and diagnostic tests you can look out for and perform to confirm. Here are some detailed instructions to help you check if the fuel pump relay is faulty:

Warning Signs:

• Engine Cranking but Not Starting: One of the most common signs of a bad fuel pump relay is when your engine cranks but refuses to start. This usually happens because the relay has failed in the open position, preventing voltage from reaching the fuel pump, and as a result, your engine doesn't receive the required fuel to run.
• Fuel Pump Running Continuously: Although rare, there are cases where the fuel pump relay gets stuck in the closed position, causing the fuel pump to run continuously. If you hear the fuel pump running even when the key is out of the ignition, this could be the issue.
• Illuminated Check Engine Light: In some vehicles, the engine computer or powertrain control module (PCM) monitors the fuel pump relay and its circuit. If it detects a problem, it will turn on the check engine light and store a corresponding diagnostic trouble code (DTC) in its memory. However, not all vehicles will illuminate the check engine light specifically for a bad fuel pump relay.

Diagnostic Tests:

• Voltage Test: You can test the voltage at any point after the relay to see if power is getting through. If there's no voltage, it could indicate a faulty fuel pump relay.
• Temporary Relay Swap: An easy way to test the fuel pump relay is to temporarily swap it with another similar relay from the power distribution box, such as the air conditioning compressor relay. If your fuel pump runs with the alternate relay installed, it confirms that your original fuel pump relay needs replacement.
• OBD II Scanner: Using an OBD II scanner, you can check for any relevant diagnostic trouble codes (DTCs) that may be stored in the engine computer's memory. Code P0230 "Fuel Pump Primary Circuit" is one such code that may be related to a faulty fuel pump relay. However, this code is not supported by all makes and models.
• Fuel Pressure Gauge: You can use a fuel pressure gauge to check the fuel pressure in your Chevy HHR's fuel system. A low fuel pressure reading could indicate a faulty fuel pump relay, as it may not be providing sufficient power to the fuel pump.

It's important to note that these symptoms and diagnostic tests may also point to other issues with your vehicle. Therefore, it's recommended to perform a thorough diagnosis before concluding that the fuel pump relay is at fault.

Disconnect the battery

Disconnecting the battery is the first step in replacing the fuel pump relay in a Chevy HHR. This is a crucial safety precaution to reduce the chance of a fire. Here is a detailed, step-by-step guide on how to disconnect the battery:

• Locate the Battery: The battery is located in the rear of the vehicle, near the rear shock tower. It is usually placed on the driver's side of the engine compartment, under a protective cover.
• Gather Necessary Tools: Before starting, ensure you have the appropriate tools for the job. You will need a basic set of automotive tools, including a wrench or socket set to loosen and tighten battery terminals.
• Prepare the Work Area: Working with the electrical system of a vehicle can be dangerous, so it is essential to take the necessary precautions. Park the car on a level surface, engage the parking brake, and ensure the area is well-ventilated. Place a suitable container or drip pan underneath the battery to catch any spilled fluids.
• Disconnect the Negative Terminal: Locate the negative battery terminal, which is usually marked with a "-" sign or a black cover. Using the appropriate size wrench or socket, loosen the nut or bolt that secures the negative cable to the terminal. Do not allow the wrench to touch any other metal parts of the car, as this could create a spark. Once loose, carefully detach the cable from the battery terminal.
• Disconnect the Positive Terminal: Similarly, locate the positive battery terminal, marked with a "+" sign or a red cover. Again, use the correct size wrench or socket to loosen the nut or bolt securing the positive cable. Detach the cable from the battery terminal, being careful not to let the wrench touch any other metal components.
• Secure the Cables: After both cables are disconnected, ensure that the cables do not touch each other or any metal parts of the car. You may need to tie them back or secure them with tape to prevent accidental contact.
• Remove the Battery (If Necessary): Depending on the specific repair or replacement procedure, you may need to remove the battery entirely. If so, carefully lift the battery out of its tray and place it in a safe location, away from sparks or open flames.
• Perform the Repair: With the battery disconnected, you can now proceed with replacing the fuel pump relay or performing other necessary repairs. Ensure you follow the appropriate safety procedures for the specific task at hand.
• Reinstall the Battery (If Removed): Once the repair or replacement is complete, carefully reinstall the battery, if it was removed. Ensure that the battery is securely placed in its tray and that the cables are properly routed.
• Reconnect the Battery Cables: First, reconnect the positive cable to the positive terminal, tightening the nut or bolt securely. Then, reconnect the negative cable to the negative terminal and tighten it as well. Ensure that the cables are not pinched or trapped by any components.

Always exercise extreme caution when working with a vehicle's electrical system and fuel system. If you are unsure about any part of the process, it is best to consult a professional mechanic or seek advice from a trusted source.

Remove the access cover

To remove the access cover, you will first need to disconnect the battery to reduce the chance of a fire. This is an important safety precaution when working with the fuel system.

Next, locate the access cover. For pumps inside the fuel tank, there will usually be an access cover that needs to be removed. This is typically located on the driver's side of the engine compartment, under a cover.

Once you have located the access cover, you can proceed to remove it. This may require unscrewing or unbolting any fasteners or clamps holding it in place. Be sure to place all fasteners in a safe place so they are not lost.

With the access cover removed, you will now have access to the fuel pump and pre-pump filter screen. In some cases, you may need to drain fuel from the tank before proceeding with the fuel pump replacement. Always refer to the vehicle's repair manual for model-specific instructions and take appropriate safety precautions when working with automotive systems.

Replace the pump and pre-pump filter screen

To replace the fuel pump and pre-pump filter screen, you'll first need to disconnect the battery to reduce the risk of fire. If the pump is inside the fuel tank, you'll need to remove the access cover and possibly drain fuel before taking off the access panel. Once the cover is off, you can replace the pump and pre-pump filter screen. If the pump is outside the tank, disconnect the fuel lines, remove the pump, and install the new one.

After replacing the pump, check for any fuel leaks to ensure the problem is solved. It is also recommended to replace the fuel filters and intake screen for in-tank fuel pumps at the same time as the pump.

Check for fuel leaks

It is important to check for fuel leaks in your Chevy HHR, as leaks can be dangerous and cause damage to your vehicle. Fuel leaks can be caused by corroding metal fuel lines, which has been a common issue in some Chevy HHR models.

To check for fuel leaks, start by inspecting the areas around the fuel lines for any signs of leakage. Look for puddles of fuel or a strong odor of gasoline, which could indicate a leak. If you notice any wet spots or stains, this could be a sign of a fuel leak.

Another way to check for fuel leaks is to pay attention to your sense of smell. If you smell gasoline after filling up the tank or while driving, it could be a sign of a fuel leak. It is also important to listen for any unusual noises, such as a hissing sound, which could indicate a leak in the fuel system.

If you suspect a fuel leak, it is important to take your vehicle to a mechanic or a qualified professional for further inspection and repair. Do not ignore the signs of a fuel leak, as it can be dangerous and lead to more serious problems.

Additionally, you can check the EVAP system, as leaks in this system can also cause the check engine light to come on. The EVAP system is responsible for capturing and storing fuel vapors from the fuel tank, and a leak in this system can affect the pressure and trigger the check engine light.

Frequently asked questions