The National Highway Traffic Safety Administration has launched an investigation after receiving numerous complaints regarding fuel leaks in the Chevrolet Cobalt and HHR compact cars.
According to The Detroit Free Press, NHTSA says it has received 208 complaints from owners of the Cobalt and HHR over fuel leaks. Of these, 39 complained of fuel leaking out from a line located near the left rear well. The safety watchdog claims the leaks are caused by corroding metal fuel lines.
In a statement issued to the Free Press, GM spokesman Dan Flores said the automaker has “been in discussion with NHTSA on this matter and will continue to cooperate with NHTSA in its investigation.”
The government has not yet tied any crashes, fire or injuries to the purported fuel leaks. NHTSA reps also told the Free Press they would investigate any potential safety issues that may stem from the problem and noted that investigations like these can lead to recalls.
The agency’s probe involves 614,000 Cobalt and HHR models. Cobalt models affected are from the 2008 to 2010 model years, while the HHRs are from 2008 and 2009. Searching these vehicles on NHTSA’s online database turns up a number of complaints pertaining to this same fuel leak issue.
“The gas line is rusted and leaking,” one owner of a 2009 Chevrolet HHR said. “There is a strong odor of gasoline at the rear drivers side tire of my car. It leaves fuel on my driveway.”
One complaint said the location of the gas lines, which are located within an insulation heat shield near the exhaust pipe/muffler, is the reason behind the corrosion. They also said GM had them come in to confirm the corrosion problem – suggesting the issue was previously on the automaker’s radar.
“Gas line corrosion problem (due) to muffler right under gas lines and gas line up in pocket where heat and moisture cause early corrosion (poor design),” the complainant, who owns a 2008 Chevrolet Cobalt, wrote. “GM had me go to a dealership and confirm corrosion problem.”
It is not clear when the findings from NHTSA’s investigation will be released.
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Comments
So this is just so stupid IMO. Takes me back to the fact that you just can’t engineer out the stupid. These cars (of the newest models) are now going on 11 years old! This is certainly pertaining to cars sold in the rust-belt where they use salt/brine on the roads so drivers can be on the roads during conditions with snow and ice. I know. I grew up in NW Illinois where this is the norm. FACT: cars will rust out in those states. You can’t stop it, only slow it down. So when these people who feel their 10+ year old car driven on the salted roads should not have rust issues, it just makes me laugh! What the heck do they expect? Do these same people feel that a car should never deteriorate? Even in states that boarder the oceans, you can still get rust from the moist salt air. Florida is worse here than California due to the higher humidity. Why are these people not just having those bad parts replaced? Now there’s a novel idea!
Just like the GM trucks side saddle fuel tanks from back in the 70’s where GM was forced to recall and fix those trucks. Even though the trucks met and exceeded all federal regulations in place at that time, GM had to “fix” the problem years later. How exactly are any companies supposed to predict future regulations and design for those rules not even in place yet? Just plain stupid because consumers want everything for nothing and want it to last beyond reasonable times while passing future regulations.
How come this is an issue with primarily Cobalt and similar cars? I live in Ohio and have a 2009 Cobalt–SAME ISSUE. Had someone patch up my fuel lines. Same guy has said that he’s seen more than a dozen of these cars with the exact same issue. Why do they rust primarily in that one spot (behind the rear wheel)? Think about that.
I have had a half dozen cars in the last 25 years and the Cobalt is the only one where I’ve had an issue with fuel lines rusting out.
There is a design flaw where the gas lines are located near the muffler and with condensation from the muffler it ends up rusting out the lines and causing Dangerous leaks from the gas lines with the Colbalt which has been found with this car.The Pontiac G5 as well as the G6 have the same design flaw issues I have experienced and have replaced the fuel lines out of pocket with the G5 which is not covered by a recall. Contact the National Highway Administration if this issue occurs in a vehicles that experiences this problem, the more complaints they receive will then force GM to recall your vehicle. If you experience this problem the more complaints launched the faster these vehicles will be safer for the consumer and the public. The consumer of these vehicles should not have to absorb the cost of repair for something that GM should recall if they value their customers continued business as well as the safety of you and your family that trust the safety when they turn the key!
You are right
Cars don’t last forever
There’s a 3 yr bumper to bumper warranty
Drivetrains 5 yr
Computers 8 yrs
After that replace the parts yourself
I have a 2002 S10 and a 1995 Jeep Wrangler. They have rust but the fuel lines dont leak. Just my HHR
I am glad they are finally doing this. I grew up in the midwest, so I understand snow, salt and its effects on vehicles. However, my cobalt has been a texas and arizona car. Despite our distance from the known corrosive elements, I still had to pay out of pocket to replace my fuel lines.
This corrosion issue still effects vehicles outside of tbe rust belt.
same problem,same place,cobalt 2010,quebec,canada.
Please just put these POS out to pasture, they were both a mistake on GM’s part.
They have been out to pasture; the Cobalt stopped in 2010 and the HHR in 2011.
Mine is a 2010 in Canada = Salt
44,500 kms
Runs perfectly
Zero problems
Except the original alloy wheels corroded and wouldn’t hold air
That was extremely annoying
Lol
Just paid $963 to have both lines replaced plus a fuel filter for good measure on our beloved and very well maintained 2005 Cobalt LS. Happened in the exact same spot just before the driver’s side rear tire. Maybe GM would be nice and refund that hard earned money back for a poor design?🤔 One can wish!
I replaced the fuel lines on my 2007 Cobalt a couple of years ago because of corrosion; perhaps this is a problem that extends to earlier years.
Had to have my dealer maintained 2009 HHR in for the fuel line leaking/ rust thru. Almost a $1000 later its fixed but have to wonder about the brake lines. How much more would it have added to the cost of the car for stainless?
can’t even drive my car because of this and they are taking their time to investigate
I work at a used car lot and we get a lot of HHR’s because they are popular.4 out of 5 of them have had leaks in front of rear drivers side tire.Definitly a flaw in the design and material used for these gas lines.
i have a 2009 cobalt lt 56000 miles runs great well maintained ,kept in garage since it was bought: and out of nowhere i smell gas ,and see puddles behind drivers rear door .more than 1100 dolars at dealership for two lines and a fuel filter,with the problem in the exact same place as others regardless of environment and year of car these should havebeen takin care ,i never read or recieved any news concerning these fuel leaks and hopefully they will correct these before someone dies.i will be on the lookout for a reimbursement form.
My 08 colbolt is leaking gas from the same spot behind drivers door
I took my car in for an oil change and the mechanic brought me back to show me my car had a fuel line leak. I just paid 800.00 to have my fuel line replaced on my 2008 Chevy HHR. I thought $800.00 was far too much, but given the severity and potential for disaster, I was afraid to drive it and reluctantly agreed to pay this price. Did I just get ripped off or is this in the ballpark? Hoping for a recall and maybe a reimbursement from Chevy. This was the result of a defectively designed car! But can someone tell me if I paid way too much money? I will at least feel better about this if I know I wasn’t ripped off. Thanks much.
You got a better deal than I did!! $963.00 for a 2005 2dr Cobalt…..this should solely fall on the manufacturer and anyone affected by this defect should be reimbursed in my opinion.
Paying $1000 for a dealer to repair fuel line leak. 2011 Chevy HHR. Same place as everyone else. Hoping they have a recall for this. It is certainly a dangerous problem. It was leaking visible gas.
I have a Chevy HHR 2007 I had the same problem corrosion of the fuel lines and just had it fixed by the dealer and I have my receipt for it saying it’s the corrosion of the fuel lines that you have put on my vehicle
I was told by a mechanic 2 days ago, that he is surprised I haven’t blown up by now. My kids ride in the back and started complaint of gasoline. I can’t afford that.
I own a 2011 Chevy hhr ,just parked it off my hot top drive way because of fuel leak over left wheel fuel line ,why would Chevy use such crappy fuel line material and poor location ?
Does anyone know what the status of the review by NHTSA is? I have $800 invested in a part that should never rust through. Besides expensive, the leak is right by the muffler. Talk about a ticking time-bomb! (2009 HHR)
I have no idea but I did submit a complaint on their site. I have a 2009 Cobalt and I just got new fuel lines put in. Perhaps if more people who have experienced this submit complaints it’ll prod them into action.
I am so annoyed with this issue of my fuel lines leaking. My HHR is a 2006, and has 89,000 miles on it, and would still have a lot of life left in it, if it were not for this issue, that I CANNOT afford to get fixed. Why isn’t there a recall on this issue. Now my car is just sitting in my driveway rotting because of poor design, and its paid for!!! Who can I call and blast over this nonsense??
I got my fuel lines (and filter) replaced for under $400. Scout around and see if you can find something in your price range–and keep the receipt. Dealership will rob you blind.
Yes, I’d never go to a dealership. Thanks for the reply.
I think it should be all HHR that has the problem with the left wheel corrosion, not go by vin numbers or year. My 2011 has this problem and is costing $800.00 to get it fixed which I live on a small social security check but that is only way to get around. How sad they cant do that on ALL HHR VEHICLES
Are you having a dealer replace them? I would find a mechanic who could do it for half that. I paid under $400 and got my lines and filter replaced. They told me these lines should outlast my car!
If they replaced it with the same OEM fuel line that came with the car, then it’s going to have the same issue over time. They didn’t fix the problem. I went with a nylon tube solution from the tank to the good section starting under the drivers seat going forward. So, in the area where the issue is, the nylon tube will certainly not corrode over time.
I own a 2010 Chevy Colbot, with only 82,000 km. Fuel line leaking and corroded. Very disappointed. Just cost me $900.00.
just had fuel line leak near front of drivers rear tire and muffler doing run around
notice strong smell of gas but then i just used engine cleaner and check leaks under car and it was water and older others leaks from before
then check engine light was on then off and i put in 85 corn oil gas in
had been running car on low amt of fill tank–put in fuel ejector cleaner
and also turn ignition over and took more than couple times —about 5x and scratched alternator
finally saw and felt dripping gas on pavement so went to GMC dealer and looked under to see rusting out about 3 inched on both lines
got estimate of unexpected 1k
bad time on my bank acct
need GM hhr recall info
Please include the 2011 Chevrolet HHR in your investigation. I am having the exact same problem with my 2011 Chevrolet HHR. I was driving it to the store. When I parked, there was an intense odor of gas. I looked around and followed the smell to the exact spot described. Rear driver’s side, in the vicinity of the front of the rear tire. This is extremely unsafe and as I’ve been looking into this, there are countless others who also own the 2011 Chevrolet HHR and are having the exact same problem. Please let all of us know if there is a recall for this extremely dangerous problem on the 2011 model. Thank you.
It’s now July, 2021
My little 2008 HHR is sitting in my driveway rotting away also. I have been on disability for 3 years.
I purchased the little car because I’ve always been a Chevy driver and thought it would be a reliable car.
I do not have $1000 to replace a problem with the fuel lines that should have been recalled.
I am very disappointed in GM.
Shame on you.
I do not have a $1,000 to repair a problem that GM has known about for a while now.
They should be held accountable for their actions.
My 2006 Chevy cobalt sat in the hot sun and had the fuel leak so I was told Chevrolet would fix it under the special campaign for the problem…. after having it towed to a dealer they fixed the exact problem in the recall then charged me almost a $1,000.00 to fix it . Of course, it being a Chevy dealer the labor was more than the parts! Plus, they supposedly did a multi-point inspection & that was a lie! The other things l know are wrong with my car they made all green so they really charged me for it & never really did it! I used to love chevys and only would drive them but, the way they are going about these cobalt problems make me think twice!
I have a 2010 hhr with only 49950 mi on it. I smelled gas and saw a leak under driver side back door in front of back tire. I could see corrosion of fuel line at block where rubber line meets metal connection. Will have mechanic fix leak.
If you take it to a dealer, be prepared for $750 – $800 repair bill. This is wrong in so many ways. Apparently, not enough cars or houses have burned to the ground to get serious attention from GM or NHSTA.
GM will take care of your Cobalt problem no matter where you live(06 & 07s). I know because they just did it for me. Your local Chevy dealer probably will charge you but, GM reimburses the cost plus labor. There is a special warranty for the fuel leaks only if it’s the module, any other thing that accuses from the leak is not included.
Good luck, just go on line & find GM, give them a call.lve done it & was refunded over 1/2 of my cost.
Just found out my fuel line is leaking on my 2008 chevy hhr….
I replaced the fuel line in my 2008 Chevy Colbalt to the tune of $750. It was leaking from the driver’s side rear wheel and if anyone ever threw a cigarette out the window, I would have ended up in a ball of fire. So dangerous. I understand the car is old but for the manufacturer to be aware of this issue and not put out a recall is so negligent!
I’ve just been through this. Maybe 2 months ago I began to smell fuel. Then last month I began to see the dripping by the rear driver side wheel for a few minutes after turning the car off. Then I found the issue described here and by lots of other HHR/Cobalt owners online with the identical issue.
I had set up an appointment to bring my 2011 HHR (117,000 miles) to the local Chevy dealer that I trust(ed) for service. A few days before the appointment I called to get an estimate. They said they would not provide an estimate without paying $175 for diagnostic to determine the problem. I said I know what the problem is, I want you to replace the fuel line, simply tell me how much you charge to replace the fuel line. They refused without paying the $175 for diagnostic first. I told them to cancel the appointment they just lost a loyal customer.
I located a few repair kits online. This alone is an indication of how pervasive the issue is – that there are companies selling repair kits for it! The one I settled on due to the universal excellent reviews was from Inline Tubing (part NFR0001) which is about $80 and includes fuel and vapor line replacements from the tank with enough tubing to reach under the drivers seat. The vapor line is the metal line running adjacent to the fuel line and likewise has corrosion similar to the fuel line for the same reason. The kit includes compression fittings to attach the new lines to the good section of the existing ones and at the other end, has a quick connect for the vapor line (same as existing) and for the fuel line a compatible metal piece that inserts into the existing quick connect. It cost me probably an additional $40 for other items needed to complete the job. Note, I am not the most mechanically inclined individual around, and I was able to do this DIY job. The kit is easy to understand, and the instructions are just a few easy steps which they provide on a single page.
I just let my car idle on the driveway for about 10 minutes, then took it for a short drive, and I am thankful this was an economical solution to help me keep my HHR going.
Don’t bring your HHR/Cobalt to Chevy or a garage that’s going to charge you an arm and a leg to replace the entire fuel line. Pick up one of these kits and either do it yourself, or bring it to a local garage and let them do it – it may take one hour of their time (it took me 6 or 7 hours, but I was extra cautious with everything).
I agree. I ordered an aftermarket stainless steel fuel line kit from Rock Auto for around $150 and, with the help from my brothers, knocked it out in an afternoon. It’s a fairly simple fix. It goes to show that if you’re able to fix it yourself, that’s the way to go for the cost savings and the satisfaction of a job well done.
Will be replacing a second fuel line on my 2011 hhr and she has over 219K on her. soon as I get my refund will get it fixed. GM should refund our money
It happens in the G5 Pontiac’s as well, it’s not only that you have to eat the cost @$1,300 and I also understand that cars wear out but mine is a 2008 with 33,000 miles on it well taken care of. My main concern is there should be a recall on these vehicles I shouldn’t be replacing any gas lines period! It is a safety issue the gas smell was so strong it came through the front of my house where there is an attached garage and a small child sleeping in it. The smell was overpowering luckily my child was OK but if he would have been in there longer than a nap and this happened overnight it may have been a different outcome, not to mention it could have exploded with any spark while driving or parked! My dam house could have went up in flames! Lousy design agreed but by not recalling these vehicles is dangerous and irresponsible! I Will never purchase another GM vehicle with the lack of concern expressed when I launched a complaint of this safety issue! Buyer beware
My 2005 HHR is now sitting in my driveway and has been for about 2 years because of a fuel line leak. I could not afford to take it to a dealer so o hired someone who put new fuel line connections on with compression fittings, amd left my fuel line dangling so I could see it looking underneath from my house window. It’s now tied up with a zip tie. I am afraid yo drive it. Mine has 89000 .miles. Tue manufactures need to be made to fix these issues, period.
Same problem fuel line leak on 2008 Cobalt driver side left rear by back door.
Been a certified mechanic for over 25 years. This fuel line design is guaranteed for failure. That wrapping of steel lines just traps moisture & the road salt is going to speed up the deterioration. Why didn’t they route fuel lines on other side, opposite of exhaust?
I inherited a 2006 Chevy HHR from my Dad who passed away with only 80,000 miles. The car came from PA and has some rust but great car with full dealership receipts from new. I ran the car the other day and smelled gas immediately. As I attempted to find the source, there was a puddle of fuel about 3 feet in diameter underneath the vehicle and it was pouring directly on the exhaust on the drivers side rear area. I quickly shut off the car and rolled it out into the driveway. It stopped as soon as the car was shut off because the fuel pump stopped pressurizing the system. The fuel lines are rusted. Probably one of the most frightening experiences I’ve had. Thank God I wasn’t driving it at the time, would have been a CarBBQ. Guess I’m replacing fuel lines. Please be sure to inspect your vehicle, this is not cool!
Same thing happened to me on 2008 cobalt I purchased in 2009 had to replace factory fuel lines.
These vehicles should have been recalled. .
Fire hazard there have been affected by same problem.