Replacing Fuel Lines In A 2009 Chevy Hhr: Step-By-Step Guide

If you own a 2009 Chevy HHR, you may eventually need to replace the fuel lines due to leaks caused by rust. This is a known issue with these vehicles, and there are a few options for replacement. You can either take it to a mechanic, or attempt to replace the lines yourself using a kit. There are a variety of fuel line kits available for the Chevy HHR, including those made from nylon, stainless steel, and rubber. These kits are designed to be easy to install, and some even come with pre-cut lines that are specific to your vehicle's make and model.

The replacement process: from fuel filter to engine

The replacement process for the fuel lines of a 2009 Chevy HHR involves removing the old lines and installing new ones. Here is a step-by-step guide on how to do it:

Jack up the car: Use a jack to lift the Chevy HHR and place it on jack stands, ensuring the front end is higher. This will provide easier access to the fuel lines.

Disconnect the fuel pump fuse: Locate the underhood fuse block and disconnect the fuel pump fuse. This will release the pressure in the fuel line.

Release fuel tank pressure: Open the fuel tank cap and start the car to release any remaining pressure in the fuel line.

Remove the old fuel lines: Starting from the front of the car, carefully remove the old fuel lines by working towards the rear. Pay close attention to the retaining clips and clamps, as you will need to reuse some of them.

Prepare the new fuel lines: Obtain a full-length nylon fuel supply line kit that includes both the fuel pressure line and the vapour line. Ensure the kit is compatible with your 2009 Chevy HHR.

Install the new fuel lines: Start at the rear of the car and work towards the front. Connect the new lines to the existing fuel fittings on the engine, following the path of the old lines. Use the provided couplers, hose barbs, and quick disconnect fittings to secure the lines. Reuse the OEM quick fitting at the engine end.

Connect the fuel filter: The new fuel line kit should include a drop-down line from the engine. Connect this line to the fuel filter or the fuel line off the tank. Ensure a secure connection to prevent leaks.

Secure the lines: Use the provided zip ties and steel clips to secure the new fuel lines in place. You can attach them to the existing factory clamp locations or use zip ties to secure them to the old lines.

Check for leaks: Once the new fuel lines are installed, carefully inspect all connections for any signs of leaks. If necessary, apply a small amount of clean engine oil to lubricate the O-rings and prevent leaks.

Test the vehicle: Start the engine and check for any unusual noises or issues. Take the vehicle for a test drive to ensure the new fuel lines are functioning properly.

It is important to follow the instructions provided with your specific fuel line kit and take appropriate safety precautions when working with fuel lines and automotive systems.

The fuel supply line: from tank to mid-section

The fuel supply line is an essential component of your Chevy HHR, responsible for delivering fuel from the tank to the engine. If you own a 2009 Chevy HHR and are experiencing fuel leaks or noticing rust on the fuel lines, it may be time to replace them. Here's a detailed guide to help you with the process:

The fuel supply line is a crucial part of your Chevy HHR's fuel system, carrying fuel from the tank to the mid-section of the vehicle. It is important to replace the fuel supply line if it is damaged or leaking to ensure the safe and efficient operation of your vehicle.

To replace the fuel supply line, start by purchasing a replacement fuel line kit that is compatible with your 2009 Chevy HHR. You can find these kits online or at auto parts stores. Make sure to select a kit that includes the necessary components, such as couplers, hose barbs, quick disconnect fittings, zip ties, and safety tags.

Once you have the replacement kit, jack up your Chevy HHR and place it on jack stands with the front end higher. This will give you better access to the fuel lines. Next, disconnect the fuel pump fuse in the underhood fuse block to release the pressure in the fuel line. You can then start your car to ensure that any remaining pressure is released.

Now, you can begin removing the old fuel lines. Start at the front of the vehicle and work your way to the rear, carefully releasing any retaining clips or clamps that hold the lines in place. Take note of the routing of the lines and the location of the fittings, as you will need to install the new lines in the same way.

With the old lines removed, it's time to install the new fuel supply line. Start at the rear of the vehicle and work your way forward. Connect the new line to the fuel tank and route it along the original path, securing it with the provided zip ties and retaining clips. Ensure that all connections are secure and tight to prevent leaks.

Finally, reconnect the fuel pump fuse and start your vehicle to check for any leaks. If you notice any leaks, tighten the connections and inspect the lines for proper installation.

By following these steps, you can confidently replace the fuel supply line on your 2009 Chevy HHR, ensuring a safe and reliable fuel system for your vehicle. Remember to take your time, work in a well-ventilated area, and wear appropriate safety gear when working with automotive fuel systems.

The vent/vapour line: from tank to engine

The vent/vapour line is one of two lines that run from the tank to the engine. The other is the fuel supply line. The vent/vapour line is also known as the EVAP purge line or the evap line.

The replacement vent/vapour line is made of nylon and is designed to replace the original factory steel line, which is prone to rusting. The replacement line is slightly larger than the original, measuring 5/16 or 3/8, compared to the metric fittings on the original line.

To replace the vent/vapour line, jack up the Chevy HHR and place it on jack stands with the front end higher. Disconnect the fuel pump fuse in the underhood fuse block, release the pressure of the fuel line by starting the car and undo the fuel tank cap.

Start by removing the old lines, working from the front of the car to the rear. When installing the new lines, start at the rear and work them into the retaining clips, feeding the lines towards the front of the car.

Take care with the clamps and retaining clips. Clean the fittings with compressed air and wear safety glasses. When installing the new fittings, use a small drop of clean engine oil to lubricate the O-rings.

The vent/vapour line has a smaller 8mm fitting at the EVAP solenoid under the hood, while the other fittings are 10mm. The replacement line is designed to be an easy install and does not require the removal of the original hard lines.

The EVAP purge line: a second line

The second line is the EVAP purge line. This line is responsible for routing vapours from the fuel tank to the EVAP canister, where they are stored until they can be purged into the engine for combustion. The EVAP purge line is typically made of nylon or rubber and can degrade over time due to exposure to fuel and heat. It is recommended to replace this line with a new one if it shows signs of deterioration or leakage.

When replacing the EVAP purge line, it is important to note that the fittings are metric, with an 8mm fitting at the EVAP solenoid under the hood and 10mm fittings at the tank and canister. The replacement line may be slightly different in size, typically 5/16" or 3/8". It is also important to clean the fittings with compressed air and a small amount of clean engine oil to lubricate the O-rings.

Additionally, the EVAP purge line is connected to the intake manifold and the EVAP canister. The EVAP canister is located near the fuel tank, and the purge line runs from the canister to the engine compartment. The EVAP solenoid controls the flow of vapours through the purge line and is also located in the engine compartment.

When replacing the EVAP purge line, it is recommended to jack up the vehicle and place it on jack stands with the front end higher. The fuel pump fuse should be disconnected, and the pressure in the fuel line should be released by starting the car and opening the fuel tank cap. The old lines can then be removed, starting from the front and working towards the rear. The new lines can be installed in the reverse order, starting from the rear and working towards the front, ensuring that the retaining clips are secure.

It is worth noting that the EVAP purge line is part of the evaporative emission control system, which prevents fuel vapours from escaping into the atmosphere. A malfunction in this system can trigger a P0445 OBD-II trouble code, indicating a large leak or no purge flow.

The parts required: braided stainless steel fuel line, couplers, hose barbs, etc

To replace the fuel lines of a 2009 Chevy HHR, you'll need to source the following parts:

Braided Stainless Steel Fuel Line

The fuel line is the tube that carries fuel from the tank to the engine. Braided stainless steel fuel lines are ideal for high-performance applications as they can withstand high pressure and resist heat and abrasion damage. They are available in various sizes, so be sure to select the appropriate length and diameter for your Chevy HHR.

Couplers

Couplers, also known as hose fittings or adaptors, are essential for connecting the fuel lines to the fuel system and other components. They come in various sizes and materials, including brass, aluminium, and stainless steel. Ensure you select couplers that match the diameter of your fuel lines and are compatible with fuel/oil applications.

Hose Barbs

Hose barbs, or barb splicers, are another type of fitting used to connect sections of the fuel line together. They are available in various sizes, so ensure you select the correct diameter to match your fuel line. They typically come with hose clamps to secure the connection and prevent leaks.

Hose Clamps

Hose clamps are used to secure the fuel line to the couplers or hose barbs and prevent leaks. They are typically made of stainless steel and are available in various sizes to match the diameter of your fuel line.

When sourcing parts, it is important to consider the specific requirements of your Chevy HHR, including the flow rate and viscosity of the fuel system. Additionally, always refer to a trusted mechanic or automotive specialist for advice on the correct parts and installation procedures.

Frequently asked questions