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Home >> Chevrolet >> 2010 >> HHR SS, Standard >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.0L - Repair Instructions >> Repair Instructions >> Direct Fuel Injector Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: Identifying Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM2035304Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  2. Remove the intake manifold assembly. Refer to Intake Manifold Replacement .
    3. Fig 2: Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel injector insulator.
    4. Fig 3: View Of Engine Wiring Harness & High Pressure Fuel Pump
    GM2035275Courtesy of GENERAL MOTORS CORP.
  4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (High Pressure Side)  or Fuel Pressure Relief (Without CH 48027)  or Fuel Pressure Relief (With CH 48027) .
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
  7. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    8. Fig 4: Fuel Rail Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  9. Remove the fuel rail bolts (1).
    10. NOTE: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.
  10. Carefully remove the fuel rail (2).
    11. Fig 5: Direct Fuel Injector Hold Down Clamps
    GM1829978Courtesy of GENERAL MOTORS CORP.
  11. Remove and discard the direct fuel injector hold down clamps.
    12. Fig 6: Direct Fuel Injectors
    GM1830014Courtesy of GENERAL MOTORS CORP.
  12. Remove the direct fuel injectors.
    13. Fig 7: Removing Stuck Fuel Injector
    GM1769952Courtesy of GENERAL MOTORS CORP.
    NOTE: A fuel injector may remain stuck in the cylinder head. If this occurs, complete the following steps:
    1. Remove the fuel injector hold-down clamp before removing the fuel injector.
      NOTE: Use the injector remover and slide hammer to pull the fuel injector straight out along the fuel injector axis. DO NOT tilt or twist the fuel injector during this process.
    2. Use J-37281-A:  injector remover, and J-2619-01:  hammer to remove the fuel injector.
    3. Once injectors have been removed it will be necessary to clean and rebuild all the injectors. Refer to Fuel Rail and Injectors Cleaning and Inspection .
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