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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 >> Fuel Injection Fuel Rail Assembly 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. 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) .
  2. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  3. Remove the intake manifold. Refer to Intake Manifold Replacement .
    4. Fig 2: Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  4. Remove the fuel injector insulator.
    5. Fig 3: High Pressure Fuel Pump Connector & Clip
    GM1826282Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the intermediate fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    7. Fig 4: Fuel Rail Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  8. Remove the fuel rail bolts (1).
    9. NOTE: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.
    NOTE: A fuel injector may remain stuck in the cylinder head. If this occurs, complete the following steps:
  9. Carefully remove the fuel rail (2).
    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 .
    10. Fig 5: Fuel Rail Fuel Pressure Sensor
    GM1829977Courtesy of GENERAL MOTORS CORP.
    NOTE: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.
  10. If replacing the fuel rail, remove the fuel injection fuel rail fuel pressure sensor.
  11. Remove the fuel injector wiring harness.
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