Chevrolet HHR And Cobalt Investigated Over Fuel Leak Concerns
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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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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?