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Home › Chevrolet › 2006 › HHR LS, Standard › Repair and Diagnosis › Engine Performance › System › Engine Controls - 2.2L - Introduction (2 Of 2) › Repair Instructions › Fuel Tank Replacement › Installation Procedure

Installation Procedure

  1. If the fuel tank was replaced perform the following steps, install the fuel tank module. Refer to Fuel Pump Module Replacement .
    2. Fig 1: Fuel Tank Electrical Harness
    GM1636804Courtesy of GENERAL MOTORS CORP.
  2. Install and connect the fuel tank electrical harness.
    3. Fig 2: Fuel Tank Vent Pipe
    GM1636697Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank vent pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    4. Fig 3: Fuel Feed Intermediate Pipe
    GM1636696Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel feed intermediate pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    5. Fig 4: Fuel Tank Vent Pipe
    GM1636693Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel tank vent pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 5: Fuel Tank & Straps
    GM1636706Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, place the fuel tank on the suitable jack.
  7. Using the adjustable jack, carefully raise the fuel tank into position.
  8. Position the fuel tank straps.
    9. NOTE: Refer to Fastener Notice .
  9. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft).

  10. Remove adjustable jack from under the fuel tank.
    11. Fig 6: Exhaust Pipe
    GM1631769Courtesy of GENERAL MOTORS CORP.
  11. Raise the exhaust and install the muffler insulators to the underbody hangers.
  12. Install the exhaust pipe insulators to the underbody hangers.
    13. Fig 7: Fuel Tank Electrical Connector
    GM1636801Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel tank electrical connector (1) to the pass thru connector.
    14. Fig 8: Fuel Fill Pipe Hose
    GM1636704Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel fill pipe hose to the fuel tank.
  15. Tighten the fuel fill pipe hose clamp (2) at the fuel tank.

    Tighten:  Tighten the clamp to 4.5 N.m (40 lb in).

  16. Connect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  20. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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