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Home >> Chevrolet >> 2011 >> HHR LS, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.2L Or 2.4L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Fuel Tank Module, Vent Pipes, Fuel Feed Intermediate Pipe And Electrical Harness
    GM2442971Courtesy of GENERAL MOTORS COMPANY
  1. If the fuel tank was replaced, perform the following steps. Install the fuel tank module (4). Refer to Fuel Pump Module Replacement .
  2. Install and connect the fuel tank electrical harness (1).
  3. Install the fuel tank vent pipes (3, 5). Refer to Plastic Collar Quick Connect Fitting Service .
  4. Install the fuel feed intermediate pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 2: Fuel Tank Straps And Bolts
    GM2442975Courtesy of GENERAL MOTORS COMPANY
  5. With the aid of an assistant, place the fuel tank (3) on a suitable jack.
  6. Using the adjustable jack, carefully raise the fuel tank into position.
  7. Position the fuel tank straps (2).
    8. CAUTION:

    Refer to Fastener Caution .

  8. Install the fuel tank strap bolts (1) and tighten to 45 N.m (33 lb ft).
    9. Fig 3: Muffler Insulators
    GM2442978Courtesy of GENERAL MOTORS COMPANY
  9. Raise the exhaust and install the muffler insulators (1) to the underbody hangers.
    10. Fig 4: Exhaust Pipe Insulators
    GM2442984Courtesy of GENERAL MOTORS COMPANY
  10. Install the exhaust pipe insulators (1) to the underbody hangers.
    11. Fig 5: Fuel Tank Electrical Connector
    GM2442991Courtesy of GENERAL MOTORS COMPANY
  11. Connect the fuel tank electrical connector (1) to the pass through connector.
    12. Fig 6: Fuel Tank Vent Pipe Quick Connect Fittings, Hose And Clamp
    GM2442966Courtesy of GENERAL MOTORS COMPANY
  12. Install the fuel fill pipe hose (4) to the fuel tank.
  13. Tighten the fuel fill pipe hose clamp (3) at the fuel tank to 4.5 N.m (40 lb in).
  14. Connect the fuel tank vent pipe quick connect fittings (1, 2). Refer to Plastic Collar Quick Connect Fitting Service .
  15. Lower the vehicle.
  16. Refill the fuel tank.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  18. 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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