Replacing Fuel Tank Filler Hose In Hhr: Step-By-Step Guide

If you're smelling fumes around the fuel filler neck area of your Chevy HHR, you may have a leak. Before taking your car to a dealer, you can try replacing the fuel filler neck hose yourself. This can be done by locating the fuel filler neck, checking for any exterior damage, and determining if it is leaking vapours. If the fuel filler neck is damaged or leaking, you can purchase a replacement from an auto parts store or dealership and install it yourself by following online guides. However, always exercise caution when working with fuel systems to avoid any safety hazards.

Locating the fuel filler neck

Visual Inspection:

Begin by visually inspecting the fuel filler neck for any signs of exterior damage. Check the mounting screws inside the fuel door area to ensure they are all present and securely fastened. Verify the condition of the rubber hose and clamp connected to the fuel filler neck. Look for any signs of damage, cracks, or leaks. On some vehicles, you may need to remove a protective cover to access and inspect the rubber hose and clamp.

Leak Inspection:

In addition to visual inspection, it is important to determine if the fuel filler neck is leaking vapors. Modern vehicles are equipped with sensors that detect vapor leaks and illuminate the "check engine" light on the dashboard. Some common error codes related to fuel vapor leaks near the fuel filler neck include P0093, P0094, P0442, and P0455. If you notice these error codes or smell fuel vapors, it is important to address the issue promptly.

Vehicle Preparation:

Before proceeding with any repairs or replacements, it is crucial to prepare your vehicle properly. Park your vehicle on a flat, hard surface and ensure the transmission is in park (for automatics) or in first gear (for manuals). Engage the parking brake to prevent the vehicle from moving. Install a nine-volt battery saver into the cigarette lighter to maintain power to your vehicle's computer and settings during the repair process.

Accessing the Fuel Filler Neck:

Open the vehicle's hood and disconnect the ground cable from the negative post of the battery. This will disable the power to the fuel pump or sending unit. Next, use a floor jack to lift the vehicle at its specified jacking points until the wheels are completely off the ground. Place jack stands under the jacking point locations and lower the vehicle onto them. Refer to your vehicle's owner's manual for the exact jacking points.

Once the vehicle is securely raised, open the fuel door to access the fuel filler neck. Remove the mounting screws or bolts attached to the cutaway, and detach the fuel filler cap cable from the fuel neck. At this point, you should be able to visually inspect the fuel filler neck and its surrounding components for any signs of damage or leaks.

Locating the Fuel Tank:

To gain a better view of the fuel filler neck and its connection to the fuel tank, you will need to locate and access the fuel tank. Go under the vehicle and look for the fuel tank, which is typically located at the rear of the vehicle. You may need to use a transmission jack or a similar tool to support and lower the fuel tank for better access. Remember to take necessary safety precautions when working with fuel and ensure proper ventilation.

By following these steps, you will be able to locate the fuel filler neck and perform a thorough inspection. Remember to refer to vehicle-specific repair manuals or seek assistance from a certified mechanic if you have any doubts or concerns during the process.

Determining if the fuel filler neck is leaking vapours

The fuel filler neck is the component that connects the fuel filler port to the fuel tank, providing a path for the fuel to enter the tank when filling up the vehicle. It is usually made of metal or rubber, and while these materials are durable, they can wear out over time.

A leaking fuel filler neck can cause issues with the vehicle's emissions and can even become a safety hazard if fuel leaks from the vehicle. A leaking fuel filler neck will usually produce a few symptoms that can alert the driver of a potential issue.

Common symptoms of a leaking fuel filler neck

Fuel smell

While a faint fuel smell when filling up the vehicle is normal, if the smell lingers or becomes stronger over time, this could indicate that the fuel filler neck has a small leak.

Check Engine Light comes on

If the computer detects any issue with the vehicle's EVAP system, it will set off the Check Engine Light to notify the driver of the issue. The EVAP system is designed to capture and reuse vapours from the fuel tank and will trigger the Check Engine Light if the fuel tank, neck, or any of the system's hoses develop leaks.

Fuel leaks

If fuel leaks from the side of the vehicle containing the filler neck, especially when the vehicle is being filled, this could indicate a problem with the filler neck. Most filler necks are made of rubber or metal, which can corrode and wear out over time, leading to fuel leaks.

How to determine if the fuel filler neck is leaking vapours

To determine if the fuel filler neck is leaking vapours, follow these steps:

• Park your vehicle on a flat, hard surface and ensure the transmission is in park for automatics or in first gear for manuals.
• Place wheel chocks around the front tires and engage the parking brake to lock the rear tires from moving.
• Open the vehicle's hood and disconnect the battery by taking the ground cable off the battery's negative post, disabling the power to the fuel pump or sending unit.
• Using a floor jack, lift the vehicle at its specified jacking points until the wheels are completely off the ground.
• Place jack stands under the jacking point locations and lower the vehicle onto them. For most modern cars, the jacking points will be on the pinch weld just under the doors along the bottom of the car.
• Open the fuel door to gain access to the fuel filler neck.
• Remove the mounting screws or bolts attached to the cutaway and the fuel filler cap cable from the fuel neck.
• Locate the fuel tank by going under the vehicle.
• Using a transmission jack or similar jack, place it under the fuel tank and loosen and remove the straps to lower the tank slightly.
• Reach up and disconnect the harness from the connector on top of the fuel tank. This is the harness for the fuel pump or sending unit on older vehicles.
• Lower the fuel tank further to access the vent hose attached to the tank. Remove the clamp and small vent hose to allow more clearance.
• Remove the clamp on the rubber hose attaching the fuel filler neck and twist the neck to pull it out of the rubber hose. Guide the neck out of the area and remove it from the vehicle.
• Inspect the rubber hose for any cracks. If cracks are present, the hose must be replaced.
• Clean the harness and connector to the fuel pump or sending unit on the fuel tank using electrical cleaner and a lint-free cloth to remove any moisture and debris.
• Wipe out the rubber hose on the fuel tank with a lint-free cloth and place a new clamp onto the hose.
• Take the new fuel filler neck and twist it into the rubber hose. Put the clamp in place and tighten up the slack, allowing the neck to twist but not the clamp.
• Raise the fuel tank to the vent hose and attach the vent hose using a new clamp. Tighten the clamp until the hose will not twist and turn 1/8 turn.
• Ensure you do not use the old clamps as they will not hold tight and may cause a vapor leak.
• Raise the fuel tank further to align the fuel filler neck with the cutaway and align the mounting holes.
• Lower the fuel tank and tighten the clamp, keeping the neck from moving.
• Raise the fuel tank to the harness and connect the fuel pump or sending unit harness to the tank connector.
• Attach the fuel tank straps and tighten them until they stop. Torque the mounting nuts to specifications on the fuel tank.
• Align the fuel filler neck with the cutaway in the fuel door area and install the mounting screws or bolts to secure it tightly.
• Attach the cable of the fuel filler cap to the neck and screw on the cap until it locks in place.
• Get a transfer tank or portable fuel can and remove the fuel filler cap, emptying the fuel into the fuel filler neck to fill up the tank. Avoid spilling any fuel on the ground or neck area.
• Check for leaks by waiting 15 minutes away from the vehicle and then returning to inspect for leaks. Look under the vehicle for any fuel drops and sniff for any vapours. You can use a combustible gas detector to check for vapour leaks that you cannot smell.
• If there are no leaks, continue with the procedure. If leaks are found, check the connections to ensure they are tight. If adjustments are made, perform another leak inspection before continuing.

Note: If there are any vapour leaks, the vapor sensor will detect the leak and display the engine light when driving the vehicle.

Replacing the fuel filler neck

The fuel filler neck on a Chevy HHR is a solid piece of formed tubular steel that joins the fuel filler inlet and the rubber fuel fill hose on the gas tank. The fuel filler neck is connected to the body inlet cutaway with steel screws and is fitted inside a rubber hose attached to the vehicle’s fuel tank.

Verifying the Fuel Filler Neck Condition

First, locate the fuel filler neck and look for any exterior damage. Check to see if all of the mounting screws are inside the fuel door area. Verify that the rubber hose and clamp are visible and if there is any damage. On some vehicles, you may not be able to check the rubber hose and clamp under the vehicle. There may be a cover that protects the fuel hose from debris, which needs to be removed for inspection.

Next, determine if the fuel filler neck is leaking vapours. If it is, the engine management system will record this. Sensors will sniff for vapours and make the engine light come on when vapours are present. Some common engine light codes related to fuel vapours near the fuel filler neck include P0093, P0094, P0442, and P0455.

Before beginning, park your vehicle on a flat, hard surface. Make sure that the transmission is in park (for automatics) or in 1st gear (for manuals). Place wheel chocks around the front tires and engage the parking brake to lock the rear tires from moving.

Install a nine-volt battery saver into your cigarette lighter to keep your computer live and keep your setting current in the vehicle. If you do not have a nine-volt battery saver, that is okay.

Open the vehicle’s hood and disconnect your battery. Take the ground cable off of the battery’s negative post, disabling the power to the fuel pump or sending unit.

Using a floor jack, lift under the vehicle at its specified jacking points until the wheels are completely off the ground. Place the jack stands under the jacking point locations and lower the vehicle onto the jack stands. For most modern cars, the jacking points for jack stands will be on the pinch weld just under the doors along the bottom of the car.

Open the fuel door to gain access to the fuel filler neck. Remove the mounting screws or bolts attached to the cutaway. Remove the fuel filler cap cable from the fuel neck and place it aside.

Go under the vehicle and locate the fuel tank. Take a transmission jack or similar jack and place it under the fuel tank. Loosen and remove the straps to the fuel tank and lower it a little. Reach up on top of the fuel tank and feel for a harness attached to the tank. This is the harness for the fuel pump or sending unit on older vehicles.

Lower the fuel tank further to reach the vent hose attached to the fuel tank. Remove the clamp and small vent hose to allow more clearance. Vehicles from 1996 and newer have a return fuel charcoal canister attached to the vent hose to collect fuel vapours for emissions.

Remove the fuel filler neck. Take off the clamp on the rubber hose attaching the fuel filler neck and twist the fuel filler neck, pulling it out of the rubber hose. Guide the fuel filler neck out of the area and remove it from the vehicle. If you have to remove the fuel tank for clearance, be sure to transfer any fuel out of the tank prior to transferring the fuel tank. It is best to have the vehicle at a 1/4 tank of fuel or less when removing the fuel filler neck.

Inspect the rubber hose for any cracks. If there are any cracks, the rubber hose must be replaced.

Clean the harness and the connector to the fuel pump or sending unit on the fuel tank. Use electrical cleaner and a lint-free cloth to remove any moisture and debris. While the fuel tank is lowered, it is recommended to remove and replace the one-way breather valve on the tank. If the breather valve on the fuel tank is non-serviceable, then you will need to use a pump to check the valve's condition. If the valve has failed, you will need to replace the fuel tank.

The breather valve on the fuel tank allows fuel vapours to release into the canister but not allow any water or debris into the tank.

Wipe out the rubber hose on the fuel tank with a lint-free cloth. Place a new clamp onto the rubber hose. Take the new fuel filler neck and twist it into the rubber hose. Put the clamp in place and tighten up the slack. Allow the fuel filler neck to twist but not allow the clamp to move.

Raise the fuel tank to the vent hose. Attach the vent hose using a new clamp. Tighten the clamp until the hose will not twist and turn 1/8 turn. Make sure that you do not use the old clamps. They will not hold tight and cause a vapour leak.

Raise the fuel tank all the way up to align the fuel filler neck to the cutaway and align the fuel filler neck mounting holes. Lower the fuel tank and tighten the clamp. Keep the fuel filler neck from moving.

Raise the fuel tank up to the harness. Connect the fuel pump or sending unit harness to the fuel tank connector. Attach the fuel tank straps and tighten them until they stop. Torque the mounting nuts to specifications on the fuel tank. If you do not know the torque value, you can tighten the nuts 1/8 turn more with blue locktite.

Align the fuel filler neck to the cutaway in the fuel door area. Install the mounting screws or bolts into the neck and secure it tight. Attach the cable of the fuel filler cap to the neck and screw on the fuel filler cap until it locks in place.

Checking for Leaks

Get a transfer tank or a portable fuel can. Remove the fuel filler cap and empty the fuel into the fuel filler neck, fueling up the tank. Try not

Checking for leaks

Once you have finished replacing the fuel filler neck, you will need to check for leaks.

Step 1: Get a transfer tank or a portable fuel can

Remove the fuel filler cap and empty the fuel into the fuel filler neck, fuelling up the tank. Try not to drain any fuel onto the ground or neck area.

Step 2: Check for leaks

Wait 15 minutes away from the vehicle, then return to the vehicle and check for leaks. Look under the vehicle for any fuel drops and sniff to see if you can smell any vapours. You can use a combustible gas detector to check for any vapour leaks that you cannot smell.

If there are no leaks, you can continue. However, if you find a leak, check the connections to see if they are tight. If you had to make adjustments, make sure to check for leaks again before continuing.

Note: If there are any vapour leaks, when driving the vehicle, the vapour sensor will pick up the leak and display the engine light.

Returning the vehicle to operating condition

• Open the vehicle’s hood. Reconnect the ground cable back onto the battery’s negative post. Ensure that the connection is good.
• Tighten the battery clamp. Ensure that the connection is good.
• Using a floor jack that is recommended for the weight of the vehicle, lift under the vehicle at its specified jacking points until the wheels are completely off the ground.
• Remove the jack stands and keep them far away from the vehicle.
• Lower the vehicle to where all four wheels are on the ground. Pull out the jack and put it aside.
• Remove the wheel chocks from the rear wheels and put them aside.

Test drive the vehicle

• Drive the vehicle around the block. During the test, go over different bumps, allowing the fuel to slosh around inside the fuel tank.
• Monitor the dash for the fuel level and for any engine light to appear.
• If your engine light comes on after replacing the fuel filler neck, then there may be a further diagnosis of the fuel system needed or a possible electrical issue within the fuel system. If the problem persists, then you should seek out help from a certified mechanic.

Frequently asked questions