Replacing The Fuel Pump In Your Hhr: Step-By-Step Guide

Replacing the fuel pump in a Chevrolet HHR is a complex process that should only be attempted by experienced mechanics or professionals. The fuel pump is responsible for delivering pressurised gasoline to the fuel injectors in a car's engine. The pump is located in the vehicle's gas tank and is powered by a compact electric motor. The pressure and output of the pump are controlled by a regulator. Due to the risk of fire, it is recommended to get a professional to replace the fuel pump. The cost of replacing a fuel pump varies depending on the model year of the Chevrolet HHR, ranging from $669 to $2409.

Disconnect the battery

Disconnecting the battery is the first step in replacing the fuel pump in a Chevrolet HHR. This is a safety precaution to reduce the chance of a fire.

Before disconnecting the battery, you will need to locate the fuel pump fuse. Pull out the fuse and restart the engine to relieve the engine's pressure. Once the engine dies, disconnect the negative battery terminal.

Now you can begin to remove the fuel pump. There are two types of electric fuel pumps in cars. The first type is placed inside the gas tank, and the other is placed beneath the car.

If your pump is under the car, jack up the car and support it with jack stands. Slide under the car and follow the fuel lines toward the fuel tank. Once you have located the pump, unbolt it and let it drop slowly.

If your pump is inside the fuel tank, it is usually under the carpet or back seat. Pop it open to access the pump.

At this point, you can begin to disconnect the fuel lines from the fuel pump. Make sure you have rags and a fire extinguisher nearby, as fuel will leak from the connectors.

Remove access cover

To remove the access cover of your Chevy HHR's fuel pump, you will first need to disconnect the battery to reduce the chance of a fire. Next, locate the fuel pump. If your pump is under the car, jack up the car and support it with jack stands. Slide under the car and follow the fuel lines toward the fuel tank. Once you've located the pump, you can begin to remove the access cover.

If your pump is inside the fuel tank, it is usually under the carpet or back seat. Pop it open to reveal the access cover. In some cases, you will need to drain the fuel before removing the access cover. With the cover off, you will be able to access the fuel pump and pre-pump filter screen.

If your pump is located beneath the car, you will need to disconnect the fuel lines, EVAP system hoses, and electrical connections to the pump before removing the access cover.

It is important to take all necessary precautions when working with the fuel system to prevent fires. Keep a fire extinguisher nearby and have rags ready to catch any fuel leaking from the connectors.

Drain fuel

To drain the fuel from your Chevy HHR, you will need to locate the fuel pump relay and jump the contacts. This will allow you to drain the fuel tank. It is important to exercise caution when working with the fuel system to avoid any potential fire hazards.

Before beginning the process of draining the fuel, it is recommended to disconnect the battery to reduce the risk of fire. Additionally, it is advised to have a fire extinguisher nearby as a safety precaution. Place rags or towels around the fuel connectors to absorb any leaking fuel during the process.

To access the fuel pump, you may need to remove the rear seat and locate the access panel or cover. In some cases, you may need to lower the fuel tank to reach the pump. If you choose to drop the tank, ensure you have a jack or chest support to handle the weight of the tank after draining the fuel.

Once you have accessed the fuel pump, you can proceed with jumping the contacts on the fuel pump relay. This will enable you to drain the fuel tank safely. Refer to a repair manual or seek advice from a professional if you are unsure about the specific steps or connections.

After successfully draining the fuel, be sure to clean any dirt or residue around the fuel pump area. It is important to avoid contaminating the new fuel pump during installation. Additionally, always replace the O-ring and be cautious when handling the connectors.

Disconnect fuel lines

Disconnecting the fuel lines is a crucial step in replacing the fuel pump in a Chevy HHR. Here is a detailed guide on how to do it:

Locate the Fuel Pump: The fuel pump in the Chevy HHR is located inside the fuel tank. In some cases, there may be an access panel above the tank in the passenger compartment that allows you to access the pump without lowering the tank. If there is no access panel, you will need to drain the fuel from the tank and then lower the tank from the vehicle to access the pump.

Prepare the Work Area: Before beginning any work, it is important to take safety precautions. Have a fire extinguisher ready and keep rags or towels nearby to wipe up any fuel leaks or spills. Place a rag or tape over the fuel entry point to prevent any dirt or debris from entering the fuel tank when it is open.

Disconnect the Battery: Disconnect the negative battery terminal to reduce the chance of a fire. This is an important safety precaution when working with the fuel system.

Remove Electrical Connections: Before disconnecting the fuel lines, you will need to remove any electrical connections to the pump. This may include disconnecting wires, connectors, and sensors. Be careful not to cross any wires during this process, as it can affect the fuel level sensor.

Block the Fuel Lines: Have someone ready to block the fuel lines to prevent fuel from leaking out when they are disconnected. This is important to avoid spills and to minimize the risk of fire.

Disconnect the Fuel Lines: Once the electrical connections are removed, you can proceed to disconnect the fuel lines from the fuel pump. Do this slowly and carefully to avoid any leaks.

Lower the Fuel Tank (If Necessary): If you need to lower the fuel tank to access the pump, follow these steps: drain the fuel from the tank, remove any fuel tank straps and fasteners, and then carefully lower the tank from the vehicle. Be sure to check the straps and fasteners for excessive corrosion and replace them if needed.

At this point, you should have access to the fuel pump and the fuel lines should be disconnected. You can now proceed to install the new fuel pump by following the manufacturer's instructions or a qualified mechanic's advice. Remember to exercise caution and refer to safety guidelines when working with automotive fuel systems.

Install new pump

There are two types of electric fuel pumps. The first type is placed inside the gas tank, and the other is placed beneath the car.

If your pump is under the car, jack up the car and support it with jack stands. Slide under the car and follow the fuel lines toward the fuel tank. Once the pump is located, unbolt it and then let it drop slowly. Be sure to have someone ready to block the fuel lines to prevent gas from leaking out.

If your pump is inside the fuel tank, it is usually under the carpet or beneath the back seat. Pop it open to unbolt the pump. Again, be sure to have someone block the fuel lines to prevent gas from leaking out.

Once the old pump is removed, attach any reusable brackets and pick-up screens to the new pump. Then, install the new pump, reconnect the fuel lines, and put everything else back in place. Refill the tank and start the engine to test.

Frequently asked questions