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

If you're looking to replace the fuel pump on your 2007 Chevy HHR, you've come to the right place. This job can cost anywhere from $1,126 to $2,408.70, depending on labour and parts. It's a moderately complicated task best left to professionals, but if you're determined to do it yourself, there are a few things you should know. First, disconnect the battery to reduce the risk of fire. Next, you'll need to access the pump, which is usually located inside the fuel tank. You may need to drain the fuel and remove an access panel or lower the tank from the vehicle. Once you've located the pump, disconnect the fuel lines and electrical connections, and install the new pump. Be sure to check for leaks before starting the engine.

Disconnect the battery and electrical wires

Disconnecting the battery and electrical wires is the first step in replacing the fuel pump in a 2007 Chevy HHR. This is a crucial safety precaution to reduce the chance of a fire.

• Turn off the engine: Before beginning any work on your Chevy HHR, ensure that the engine is turned off and the keys are removed from the ignition.
• Locate the battery: The battery is typically located in the engine bay, under the bonnet of the car. It is usually a large, rectangular black box with two metal terminals, one positive (+) and one negative (-).
• Disconnect the negative terminal first: Loosen the nut or bolt holding the negative battery cable in place with a wrench. Do not allow the wrench to touch both the positive and negative terminals at the same time, as this could result in a short circuit. Once the nut or bolt is loose, carefully disconnect the cable from the battery terminal.
• Secure the cable: Move the cable away from the battery and secure it in a safe place to ensure it does not accidentally touch the battery terminal.
• Disconnect electrical wires: There will be several electrical wires connected to the fuel pump. These wires should be carefully disconnected, ensuring that you know how to properly reconnect them later. Label each wire with tape and a marker, noting its location. This will make it easier to reassemble everything.
• Use caution: Always exercise extreme caution when working with a car's electrical system. Never attempt to work on a car when it is raining or when the engine is hot. Make sure the engine has been off long enough to cool down before proceeding.

Remember, working on a car's fuel system can be dangerous, especially for those who are inexperienced with auto repair. It is always best to consult a qualified mechanic or seek professional assistance if you are unsure about any part of the process.

Remove the fuel lines

To remove the fuel lines from your 2007 Chevy HHR, you will need to first disconnect the battery to reduce the chance of a fire. Next, locate the fuel pump. If your pump is inside the fuel tank, there will usually be an access cover that needs to be removed. In some cases, you will need to drain the fuel before removing the access panel. If your pump is located outside of the tank, you will need to disconnect the fuel lines and remove the pump.

Once you have located the fuel pump, the next step is to disconnect the fuel lines. Make sure you have rags and a fire extinguisher on hand, as you will get some fuel leaking from the connectors. Have someone ready to block the fuel lines to minimise leakage.

After you have disconnected the fuel lines, you can install the new pump. Reconnect the fuel lines and put everything back in place. Refill the tank and start the engine to test.

It is important to note that working with the fuel system is dangerous, and you should take all precautions to avoid starting a fire. If you are not experienced in auto repair, it is recommended to leave this job to a professional.

Install the new pump

To install the new fuel pump, first reconnect the fuel lines to the pump, making sure to block the lines to prevent fuel from leaking out. Then, put everything else back in its place, refill the tank, and start the engine to test for leaks.

If your pump is inside the fuel tank, it is usually under the carpet or beneath the back seat. You will need to pop it open to bolt the pump in place. 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, bolt it in place.

Make sure to replace any reusable brackets and pick-up screens before installing the new pump. Also, if the fuel system uses an in-line external filter, it is often replaced at the same time. All hoses and electrical connections should be re-established.

Finally, add fuel to the tank and run the engine to test for leaks.

Refill the tank

Once you've replaced the fuel pump in your 2007 Chevy HHR, it's important to refill the tank. Here are some detailed, step-by-step instructions to guide you through the process of refilling the tank safely and securely:

Prepare the Vehicle:

Before refilling the fuel tank, ensure that your Chevy HHR is parked on a level surface and that the engine is turned off. It is recommended to let the engine cool down for at least 15 minutes before refilling the tank, as this will reduce the risk of any accidental combustion. Make sure to have a fire extinguisher nearby as an added safety precaution.

Clean the Area:

Inspect the area around the fuel tank filler neck for any dirt, debris, or residue. Use a clean, dry cloth to wipe away any contaminants. This step is crucial to prevent any foreign objects from entering the fuel tank and potentially causing issues with the fuel pump or engine.

Use Correct Fuel Type:

Chevy HHR vehicles typically use unleaded gasoline. It is essential to refer to your owner's manual to confirm the recommended fuel type and octane rating for your specific vehicle. Using the wrong type of fuel can damage the engine and void any warranties.

Remove the gas cap by turning it counterclockwise. Clean the inside of the gas cap and the area around the filler neck with a cloth to remove any dust or debris. Insert the fuel nozzle into the filler neck and begin refueling. When the tank is full, the nozzle will automatically shut off. Do not overfill the tank.

Secure the Gas Cap:

Once refueling is complete, carefully remove the fuel nozzle and replace the gas cap. Ensure that the gas cap is tightened securely by turning it clockwise until you hear a clicking sound. A properly tightened gas cap helps maintain the correct pressure in the fuel tank and prevents fuel evaporation.

Safety Precautions:

Always exercise extreme caution when handling flammable liquids like gasoline. Do not smoke or use any electronic devices while refueling. Avoid any potential sources of ignition, such as sparks or open flames. Ensure that the engine is off and that no one is inside the vehicle during refueling.

Post-Refueling Checks:

After refueling, check the area around the filler neck for any signs of leakage. Wipe the filler neck and the surrounding area with a clean cloth to remove any spilled fuel. Ensure that the gas cap is securely tightened. If you notice any fuel leaks or unusual odors, do not start the engine, and seek professional assistance immediately.

By following these detailed instructions, you can confidently and safely refill the tank of your 2007 Chevy HHR after replacing the fuel pump. Remember always to prioritize safety and refer to your vehicle's owner's manual for any additional information or guidelines specific to your Chevy HHR model.

Test for leaks

Once the fuel pump has been replaced, the engine is run to test for leaks.

Fuel pump leaks can negatively influence fuel consumption and could cause a fire in the engine compartment. They can also result in insufficient fuel pressure, leading to a lack of engine power.

To prevent leakage, fuel pumps need to be tested for leaks during component production at the supplier level. Later in the production process, connections from the fuel pump to the fuel system need to be tested after final assembly.

To test for leaks, the engine should be started and allowed to reach an operating temperature of 140°F (60°C). A leak detector can be used to determine the presence of leaks. A black light can also be used to inspect injectors and fuel lines for signs of leakage.

If a leak is detected, the engine should be turned off immediately.

Frequently asked questions