LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2009 >> HHR SS, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.0L - Introduction >> Repair Instructions >> Direct Fuel Injector Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

    Fig 1: View Of Fuel Injector Components
    GM1829979Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW plastic spacer (2) onto the fuel injector(s).
  2. Lubricate a NEW O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  3. Install the NEW O-ring seal (1) onto the fuel injector(s).
    4. Fig 2: View Of Injector Tip & Special Tool EN 48266
    GM1829992Courtesy of GENERAL MOTORS CORP.
  4. From the EN-48266  , position the EN 48266-1 to the injector tip. See Special Tools .
    5. Fig 3: Using Special Tool EN 48266-1
    GM1829994Courtesy of GENERAL MOTORS CORP.
    NOTE: DO NOT lubricate the NEW seal.
  5. Install a NEW seal onto the EN 48266-1.
    6. Fig 4: View Of Special Tool EN 48266-1
    GM1829993Courtesy of GENERAL MOTORS CORP.
  6. Pull the NEW seal by hand over the EN 48266-1 and into the groove in the injector.
  7. Remove the EN 48266-1 from the injector tip.
    8. Fig 5: View Of Injector Tip & EN 48266-2
    GM1829997Courtesy of GENERAL MOTORS CORP.
  8. From the EN-48266  , install the EN 48266-2 to the injector tip. See Special Tools .
    9. Fig 6: View Of Special Tool EN 48266-2
    GM1829998Courtesy of GENERAL MOTORS CORP.
  9. Using the EN 48266-2, re-size the seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.
  10. Remove the EN 48266-2.
    11. Fig 7: View Of Direct Fuel Injectors
    GM1830014Courtesy of GENERAL MOTORS CORP.
  11. Install the direct fuel injectors to the cylinder head.
    12. Fig 8: Identifying Direct Fuel Injector Hold Down Clamps
    GM1829978Courtesy of GENERAL MOTORS CORP.
  12. Install the NEW direct fuel injector hold down clamps.
    13. Fig 9: Identifying Fuel Rail & Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  13. Place the fuel rail (2) into position.
  14. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
  15. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    16. Fig 10: Identifying Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  16. Tighten the fuel rail bolts in the sequence shown.

    Tighten: 

    • Tighten the bolts a first pass to 22 N.m (16 lb ft).
    • Tighten the bolts a final pass to 22 N.m (16 lb ft).

  17. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    18. Fig 11: View Of Engine Wiring Harness & High Pressure Fuel Pump
    GM2035275Courtesy of GENERAL MOTORS CORP.
  18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  19. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
    20. Fig 12: View Of Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel injector insulator.
    21. Fig 13: Identifying Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM2035304Courtesy of GENERAL MOTORS CORP.
  21. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  22. Inspect for 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.
  23. Install the low side fuel pressure service port cap.
  24. Tighten the fuel fill cap.
  25. Install the intake manifold assembly. Refer to Intake Manifold Replacement .
scientia non olet · About LEMON Manuals