IllustrationFUEL LINE HAS RUSTED AND STARTED LEAKING FUEL JUST IN FRONT OF DRIVERS REAR TIRE. NOTICED ONCE VECHILE WAS PARK. I SAW A PUDDLE AND SMELT THE AROMA OF FUEL.
2008 Chevrolet Hhr
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2008 Chevrolet Hhr do not stand out strongly from the model-year median of 565.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Hhr years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
740–25K
7125–50K
9750–75K
11175–100K
110100–150K
36150K+
499 reports with mileage · 117 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 297 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 108 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel/propulsion System. Review the 71 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
30 crash reports6 fire reports21 injury reports
Fuel/propulsion System complaints
71 reportsFUEL LINES HAVE RUSTED. ENGINE LIGHT CAME ON. CAR IS NOW PARKED SAFELY. PENDING REPAIR. INFERIOR MATERIALS FROM CHEVROLET ON THIS CAR. MANY ON CHEVY BLOG WITH THE SAME PROBLEM.
TL* THE CONTACT OWNS A 2008 CHEVROLET HHR. THE CONTACT STATED WHEN THE VEHICLE WAS PARKED IN THE GARAGE THE VEHICLE EMITTED A FUEL ODOR. THE CONTACT INSPECTED THE VEHICLE AND FOUND THE FUEL LINES THAT ARE LOCATED AT THE DRIVER'S SIDE FRONT WHEEL CORRODED DUE TO WATER INTRUSION WHICH PENETRATED THE FUEL LINE RUBBER MOUNT AND META…
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TL* THE CONTACT OWNS A 2008 CHEVROLET HHR. THE CONTACT STATED WHEN THE VEHICLE WAS PARKED IN THE GARAGE THE VEHICLE EMITTED A FUEL ODOR. THE CONTACT INSPECTED THE VEHICLE AND FOUND THE FUEL LINES THAT ARE LOCATED AT THE DRIVER'S SIDE FRONT WHEEL CORRODED DUE TO WATER INTRUSION WHICH PENETRATED THE FUEL LINE RUBBER MOUNT AND METAL COVER. THE CONTACT REPAIRED THE VEHICLE HIMSELF. THE CONTACT REPLACED THE CORRODED FUEL LINES WERE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.
WHEN I TURNED OFF MY CAR RECENTLY, I COULD SMELL GASOLINE. I COULD ALSO SMELL IT WHEN THE AIR CONDITIONING WAS ON. I TOOK MY HHR TO SWEENYBUICK/GMC, AND THEY POINTED OUT THAT TWO FUEL LINES WERE RUSTED THROUGH AND I WAS DRIVING MY CAR UNDER DANGEROUS CIRCUMSTANCES...SOME OF THE GASOLINE WAS LEAKING CLOSE TO THE MUFFLER. MY SERVI…
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WHEN I TURNED OFF MY CAR RECENTLY, I COULD SMELL GASOLINE. I COULD ALSO SMELL IT WHEN THE AIR CONDITIONING WAS ON. I TOOK MY HHR TO SWEENYBUICK/GMC, AND THEY POINTED OUT THAT TWO FUEL LINES WERE RUSTED THROUGH AND I WAS DRIVING MY CAR UNDER DANGEROUS CIRCUMSTANCES...SOME OF THE GASOLINE WAS LEAKING CLOSE TO THE MUFFLER. MY SERVICE AGENT SAID A FIRE COULD HAVE EASILY STARTED. THE MECHANIC REPLACED MY FUEL LINES, AND THEN TOLD ME THAT HE HAS HAD TO REPLACE FUEL LINES IN OTHER CHEVY HHR'S AND CHEVY COLBALTS. AT NO TIME HAS GM EVER NOTIFIED ME THAT MY FUEL LINES CAN RUST THROUGH, AND THAT OTHER CARS HAVE HAD THE SAME ISSUE: HHR OR COBALT. HOWEVER, THIS DANGEROUS RUSTING HAS OCCURRED IN OTHERS. I WENT ONLINE AND FOUND OUT THAT OTHERS HAVE EXPERIENCED RUSTED FUEL LINES, AND SOME HAVE ATTEMPTED TO REPLACE THE LINES THEMSELVES. A RECALL SHOULD HAVE BEEN ISSUED. HOPEFULLY NO ONE WILL DIE IN A TRAGIC FIRE CAUSED BY GAS LEAKS. I COULD SMELL THE GASOLINE BOTH WHEN DRIVING (ESPECIALLY WITH THE AIR CONDITIONING ON, AND WHEN USING THE KEY TO TURN THE CAR OFF. HOWEVER, WHEN LOOKING UNDERNEATH THE CAR, I DID NOT DETECT GAS LEAKING FROM UNDERNEATH, AND I BELIEVE THIS WAS A SLOW LEAK, BECAUSE MY GAS GAUGE DID NOT SHOW A DRAMATIC LOSS OF GAS. WHEN I CALLED CHEVROLET CUSTOMER SUPPORT THEY REPORTED IT WAS A KNOWN ISSUE BUT NO RECALL HAD BEEN ISSUED.
MY 2008 HHR PANEL LS HAS A FUEL LEAK AND IT IS LOCATED ON THE DRIVER SIDE JUST IN FRONT OF THE REAR LEFT CAR. AFTER INVESTIGATION I BELIEVE IT IS RUSTED. I UNDERSTAND CHEVY PUT A SLEEVE AROUND THE FUEL LINE FOR WHATEVER REASON AND LIVING UP NORTH IT HAS TRAPPED WATER AND RUSTED. THE FUEL LINE IS NEAR THE EXHAUST AND I FEAR IT…
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MY 2008 HHR PANEL LS HAS A FUEL LEAK AND IT IS LOCATED ON THE DRIVER SIDE JUST IN FRONT OF THE REAR LEFT CAR. AFTER INVESTIGATION I BELIEVE IT IS RUSTED. I UNDERSTAND CHEVY PUT A SLEEVE AROUND THE FUEL LINE FOR WHATEVER REASON AND LIVING UP NORTH IT HAS TRAPPED WATER AND RUSTED. THE FUEL LINE IS NEAR THE EXHAUST AND I FEAR IT MIGHT IGNITE OR POSSIBLY TRAP MYSELF OR A DRIVE IN A FLAMING VEHICLE. CAN YOU TELL ME IF THIS PROBLEM IS ONGOING AND HAS BEEN RECALLED.
I PUT MY 2008 HHR IN THE SHOP FOR A BRAKE ISSUE AND MENTIONED TO MY MECHANIC THAT I SMELLED A FAINT SMELL OF GASOLINE TO CHECK IT OUT. HE CALLED LATER AND TOLD ME THE BRAKES WERE A MINOR ISSUE BUT THE GAS SMELL WAS THE MAJOR ISSUE. THE GAS LINE WAS RUSTED OUT IN MORE THAN ONE PLACE AND I WAS LEAKING GAS ALL THIS TIME. MY STORY…
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I PUT MY 2008 HHR IN THE SHOP FOR A BRAKE ISSUE AND MENTIONED TO MY MECHANIC THAT I SMELLED A FAINT SMELL OF GASOLINE TO CHECK IT OUT. HE CALLED LATER AND TOLD ME THE BRAKES WERE A MINOR ISSUE BUT THE GAS SMELL WAS THE MAJOR ISSUE. THE GAS LINE WAS RUSTED OUT IN MORE THAN ONE PLACE AND I WAS LEAKING GAS ALL THIS TIME. MY STORY ABOUT THE GAS LINE IS ALMOST WORD FOR WORD THE SAME AS A PRIOR COMPLAINT ON THIS SITE. THIS IS A HIGHLY DANGEROUS ISSUE AND APPARENTLY NOT AN ISOLATED ONE. $ 1000.00 IN REPAIR BUT MY SAFETY AS WELL AS MY FAMILY'S IS AT STAKE. MY MECHANIC RECOMMENDED THAT I NOT GET INTO THIS CAR UNTIL THIS REPAIR WAS MADE. IMAGINE MY SURPRISE WHEN I READ SOMEONE ELSE HAD THE EXACT SAME PROBLEM ON THE SAME TYPE CAR.
FUEL LINES RUSTED AND LEAKING. LEAK LOCATED ON DRIVERS SIDE JUST BEFORE REAR TIRE. UPON EXAMINATION IT APPEARS THAT THE TWO FUEL LINES ARE WRAPPED WITH INSULATION OF SOME SORT DUE TO THE LINES PROXIMITY TO THE EXHAUST. THIS INSULATION HAS BEEN TRAPPING MOISTURE FOR YEARS CAUSING THE OXIDATION OF NON STAINLESS STEEL FUEL LINES. …
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FUEL LINES RUSTED AND LEAKING. LEAK LOCATED ON DRIVERS SIDE JUST BEFORE REAR TIRE. UPON EXAMINATION IT APPEARS THAT THE TWO FUEL LINES ARE WRAPPED WITH INSULATION OF SOME SORT DUE TO THE LINES PROXIMITY TO THE EXHAUST. THIS INSULATION HAS BEEN TRAPPING MOISTURE FOR YEARS CAUSING THE OXIDATION OF NON STAINLESS STEEL FUEL LINES. THIS DANGEROUS CONDITION WAS NOTICED WHILE THE VEHICLE WAS STOPPED. I HAVE TAKEN THE VEHICLE TO A MECHANIC AND HAVE BEEN TOLD THAT THE LINES MUST BE REPLACED WHICH WILL COST APPROX 650 DOLLARS. THE MECHANIC INFORMED ME THAT HE IS FAMILIAR WITH THIS COMMON SAFETY HAZARD ATTACHED TO THIS MODEL. I ALSO HAVE NOW READ OTHER COMPLAINTS REGARDING THIS DANGEROUS PROBLEM. I STRONGLY SUGGEST THAT THE NHTSA USE ITS CONSIDERABLE INFLUENCE WITH THE MANUFACTURER OF THIS VEHICLE TO ENACT A SAFETY RECALL FOR THIS HAZARD ON THIS MODEL AND ALL VEHICLES THAT MAY HAVE THIS DEFECT. THIS SAFETY VIOLATION HAS BEEN REPORTED TO YOUR ORGANIZATION, TO CHEVROLET DEALERSHIPS AND TO GENERAL MOTORS' CHEVROLET DIVISION FOR YEARS AND THOSE NOTIFICATIONS HAVE ALL BEEN IGNORED. WILL IT TAKE MULTIPLE HORRENDOUS TRAGEDIES BEFORE SOMEBODY DOES THE RIGHT THING. DOES AN AMERICAN CAR COMPANY NEED ANOTHER FORD PINTO-LIKE (AKA "PINTORCH") NEGATIVE PUBLICITY CAMPAIGN ON ITS HANDS?I I CANNOT FATHOM WHY A COMPANY THAT ISSUED A RECALL FOR A PLASTIC LATCH FOR A DASHBOARD DOOR AND HAS SCOFFED AT FOLKS FOR NOTIFYING THEM OF THIS VERY PREVENTABLE SAFETY HAZARD.
FUEL LINE LEAKING, NEAR FUEL TANK UNDER HEAT SHIELD, BETWEEN EXHAUST PIPE AND BODY PART. THE VEHICLE WAS PARKED.IT APPEARS THAT THE EXHAUST HAD REPEATEDLY SMASHED THE FUEL LINE, OVERTIME.
TAKATA RECALL. MY 2008 HHR IS LEAKING GAS FROM THE FUEL LINE BY MY REAR DRIVERS SIDE TIRE. THE LEAK STARTS WHEN I START MY CAR AND ENDS WITHIN 30 MINUTES OF THE CAR ENGINE BEING TURNED OFF.
I WAS TOLD BY A NEIGHBOR THAT FUEL WAS LEAKING FROM THE REAR BOTTOM OF THE CAR. I CAME HOME AND LOOKED UNDER THE CAR AND SAW THAT FUEL WAS LEAKING FROM THE GAS LINE NEXT TO THE MUFFLER.THE VEHICLE IS NOW PARKED IN THE DRIVEWAY.
Official recalls
414V171000 · Electrical System:ignition
Apr 10, 2014
General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.
Consequence & remedy
Consequence: If the key can be removed from the ignition when the ignition is not in the "off" position, the vehicle could roll away: (a) for an automatic transmission, if the transmission is not in the "Park" position; or (b) for a manual transmission, if the parking brake is not engaged and the transmission is not in the "Reverse" position. This potential for rollaway increases the risk for a crash and occupant or pedestrian injuries.
Remedy: General Motors will notify owners, and for vehicles that were built with the defective ignition cylinder and have not previously had the ignition cylinder replaced with the redesigned part, dealers will replace the ignition cylinder and cut and, if necessary, re-learn two ignition/door keys for each vehicle. For vehicles that were built with the redesigned ignition cylinder or had the ignition cylinder replaced with the redesigned part, dealers will cut and, if necessary, re-learn two ignition/door keys for each vehicle. The recall began on April 18, 2014. Chevrolet owners may contact General Motors at 1-800-222-1020, Pontiac owners at 1-800-762-2737, and Saturn owners at 1-800-553-6000. General Motors' number for this recall is 14113 for the ignition lock cylinder and key replacement, and 14133 for only key replacements. Note: Until a vehicle has been remedied, owners and operators are advised that when exiting, to be sure that the vehicle is in "Park," or in the case of a manual transmission, that the vehicle is in the "Reverse" position and the parking brake is engaged.
14V047000 · Air Bags; Electrical System:ignition:switch
Feb 10, 2014
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence & remedy
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Additional source detail variants (2)
Air Bags
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Electrical System:ignition:switch
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
08V444000 · Latches/locks/linkages:doors:latch
Sep 3, 2008
GM IS RECALLING 296,422 MY 2006-2008 CHEVROLET HHR VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 201, 'OCCUPANT PROTECTION IN INTERIOR IMPACT." THE DOOR ON THE STORAGE BIN IN THE TOP CENTER OF THE INSTRUMENT PANEL FAILED TO REMAIN CLOSED AS REQUIRED.
Consequence & remedy
Consequence: THIS STANDARD SPECIFIES PERFORMANCE REQUIREMENTS TO PROVIDE HEAD IMPACT PROTECTION FOR OCCUPANTS.
Remedy: A REDESIGNED LATCH WILL BE MADE AVAILABLE. THE RECALL BEGAN ON DECEMBER 23, 2008. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, OR THROUGH THEIR WEBSITE AT <A HREF=HTTP://WWW.GMOWNERCENTER.COM>HTTP://WWW.GMOWNERCENTER.COM</A> .
08V046000 · Air Bags
Jan 30, 2008
GM IS RECALLING 181,516 MY 2006-2008 CHEVROLET HHR VEHICLES NOT EQUIPPED WITH OPTIONAL ROOF RAIL AIR BAGS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 201, 'OCCUPANT PROTECTION IN INTERIOR IMPACT.' IN TESTS, ONE OF THE UPPER INTERIOR OCCUPANT PROTECTION TEST POINTS EXCEEDED THE STANDARD'S REQUIREMENT.
Consequence & remedy
Consequence: THIS STANDARD SPECIFIES PERFORMANCE REQUIREMENTS TO PROVIDE HEAD IMPACT PROTECTION FOR OCCUPANTS.
Remedy: DEALERS WILL INSTALL AN ENERGY-ABSORBING PLASTIC PIECE TO THE HEADLINER TRIM. THE RECALL BEGAN ON APRIL 2, 2008. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 OR THROUGH THEIR WEBSITE AT <A HREF=HTTP://WWW.GMOWNERCENTER.COM>HTTP://WWW.GMOWNERCENTER.COM</A> .
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE20011 · Fuel Line Leak
Opened Jul 5, 2020 · Closed Aug 17, 2023
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Other:delivery:hoses, Lines/piping, And Fittings; Fuel/propulsion System
On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. The agency reserves the right to take additional action if warranted by new circumstances.Review the ODI reports cited above at nhtsa.gov under the attached identification numbers.
Additional source detail variants (3)
Fuel/propulsion System
On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. The agency reserves the right to take additional action if warranted by new circumstances.Review the ODI reports cited above at nhtsa.gov under the attached identification numbers.
Fuel System, Gasoline
On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. The agency reserves the right to take additional action if warranted by new circumstances.Review the ODI reports cited above at nhtsa.gov under the attached identification numbers.
Fuel System, Other:delivery:hoses, Lines/piping, And Fittings
On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. The agency reserves the right to take additional action if warranted by new circumstances.Review the ODI reports cited above at nhtsa.gov under the attached identification numbers.