2008 Chevrolet HHR fuel/propulsion system problems

“FUEL LINE LEAKING IN TWO PLACES, IN THE REAR AND IN THE FRONT. COMPLETELY RUSTED OUT. MY CAR ONLY HAS 60,800 MILES ON IT. TYPE OF CAR IS A 2008 CHEVY HHR LT 2.4. GAS IS LEAKING ON THE GROUND AND A STRONG SMELL OF GAS IS EMITTED FROM THE CAR. THIS IS VERY DANGEROUS BECAUSE THE CAR COULD CATCH FIRE. I DID NOT THINK THIS WOULD HAPPEN TO MY CAR WITH SO FEW MILES ON THE CAR. I DID NOT KNOW THERE WAS A PROBLEM AND DROVE THE CAR 130 MILES AWAY FROM HOME TO MY DAD'S FUNERAL. THEN I HAD TO DRIVE IT BACK BECAUSE TH E TOW WOULD HAVE BEEN $700. THE MECHANIC WHO INSPECTED THE CAR. BUDDY LLOYD'S LAKEVIEW AUTOMOTIVE AT 4757 SANG RUN ROAD IN MCENRY, MD 21541, SAID IT WOULD COST ABOUT $2,000 TO FIX BECAUSE OF THE EXTENT OF THE CORROSION AND THE CHAEP MATERIALS USED. IN ADDITION, THE FUEL LINES ARE LOCATED UNDERNEATH OTHER MAJOR PARTS AND WOULD HAVE TO BE TAKEN OFF TO GET TO THE FUEL LINES. THE MECHANIC SAID AT ANY MOMENT IF I HIT A BUMP THAT THE GAS COULD EMPTY THE TANK AND POSSIBLY CATCH FIRE!”

“2008 HHR Chevy LS 4D. Within 10 months of purchasing this car (October, 2017) the smell of gasoline became so strong I took it to the local mechanic. The fuel line had completely rusted out. I was told it could have caught fire! Cost of replacement was $420.00. A huge financial burden for a senior citizen. I have original bill for this amount and receipt of payment.”

“Purchased vehicle in Sep 2021. After 4 months of purchase, muffler became loose from exhaust after hitting a pothole on highway and, having a mechanical background, I repaired the exhaust by placing a solid stainless steel exhaust sleeve around the weak area and tac welding it. Within a month, I began to smell a rich fuel odor after every trip. I jacked up vehicle and found a fuel leak within insulated area just left of exhaust. I also located another small exhaust leak and repaired it as best as possible with an exhaust wrap, then took it to an exhaust repair shop. I was told fuel leak had to be repaired before exhaust repairs could be done. Mechanic said HHRs we're well known for fuel line corrosion due to poor design and eventually leaking. He said he has turned away many HHRs and Cobalts for this problem over the last 2-3 years.”

“Fuel tank assembly developed a fuel leak at or around its integrated tank vents creating a strong fuel smell inside and outside the vehicle. THIS IS NOT A RUSTED FUEL LINE PROBLEM. This poses a fire hazard if the vehicle were to come into contact with any spark or flames. This also poses a health hazard from exposure to toxic fumes inside and outside the vehicle. This condition did not trigger any warning messages from the onboard vehicle computer. The seal between the tank vents and fuel tank is made by the manufacturer and is unserviceable. I attempted to seal the leaks with adhesive but was unsuccessful. I then purchased a used replacement fuel tank from an auto recycler and discovered it also has this issue. I believe this to be a design defect that will lead to an unsafe condition in these vehicles. I can make these components available for inspection. I have not had the issue inspected by any other parties as that would involve further costs.”

“Around 6 months ago I started to notice a fuel smell and upon inspection at the local shop it was diagnosed that my fuel line had rusted through and they informed me there are other cases of this exact issue on the Chevrolet hhr and cobalt vehicles with this engine and fuel setup it has started to leak into the exhaust but has not caught fire.”

“I noticed a strong odor of gasoline and took the HHR to my local mechanic. He diagnosed it as a rusted fuel line caused by the proximity of a heat shield that traps water.. He was able to repir it by splicing in a section of the line. A bout a yer later the line was leaking again and this time there is not enough line left to splice that isn;t rusted. Obviously this is a danger ranging from leaking gasoline hitting a hot exhaust to a passerby discarding a lit cigarette near the leak and blowing themselves and my car to Kingdome Come. A Check engine light comes on periodically, but is only partially indicative of the gas leak as a possibility. This is a safety issue for both the owner and anyone who might happen by with a lit object”