2006 Chevrolet HHR: fuel pump failure

Filed Sep 10, 2019 · Fuel system · 96,000 miles · HI

Fuel lines leading between the fuel pump and engine have rusted severely and have caused a puncture fuel line which leaks fuel.

Filed May 22, 2018 · Fuel system · 178,000 miles · MO

The chevy hhr was built with steel fuel lines running from the fuel pump outside the fuel tank across the front of the tank to the drivers side of the vehicle where they turn and run just above the exhaust pipe. To prevent heat buildup the fuel lines are wrapped with an insulating tape of some sort. This tape loosens over time and allows water to accumulate within the wrapping of the fuel lines. This causes the fuel lines to rust to the point of failure wherein the fuel then leaks out very near or onto the exhaust pipe. This is a fire hazard and could result in the injury or death of any occupants of the vehicle in the event of a fire or explosion of the fuel tank. Although this is a problem with the design of the hhr, chevrolet has yet to do anything about it. I was told by my local dealer that the entire fuel line system from the tank to the engine would need to be replaced at an estimated cost of $1000. I discovered this when I parked my hhr in the driveway and smelled fuel. My vehicle is leaking fuel and is not safe to drive. I own 2 hhrs, a 2006 ls, and a 2009 ss, and am now looking at a $2000 expense just to make them safe to drive. This should be the responsibility of chevrolet, not every owner of a hhr.

Filed Oct 27, 2017 · Fuel system · 152,800 miles · OH

Both the fuel line (tank to engine compartment) and the return line (part of the egr system) have rusted and are leaking fuel. The rust on both lines extends from just in front of the rear wheel (on the driver's side) to within about 6 inches of the fuel tank. The lines leak when pressurized, I.e., when fuel is pushed through them by the vehicle's electric fuel pump, and they seep gasoline after the vehicle is shut off. The smell of gasoline permeates the passenger compartment when stopped, and the engine is running, as at a traffic signal. The vehicle leaves a thin puddle of fuel, about 6" in diameter, beneath the car when parked. The leak is quite near the exhaust system, as well. The vehicle has approximately 152,800 miles. I am the original owner, having purchased it from robinson chevrolet, in wheeling, wv on july 1, 2007. I am very reluctant to drive the car, because of the fire hazard that it presents. Fortunately, my wife and I have another vehicle that we can share, at least until the fuel leakage situation is resolved on the hhr. I did not have an opportunity to photograph the rusted lines while the car was on a lift, but I did shoot a photo of the lines with my mobile phone. The photo is of the area just forward of the driver's side rear wheel. (see uploaded photo.) it's not the best image of the problem, but it is the best that I could do with the car in my driveway.

Filed Jul 31, 2016 · IN

Fuel line is leaking when fuel pump is running. Not the only car have cobalt that was having the same problem.

Filed Mar 14, 2014 · Electrical, Fuel system · 106,000 miles · OK

Tl* the contact owns a 2006 chevrolet hhr. The contact stated that while driving approximately 55 MPH, the engine stalled without warning. The engine failed to restart and the vehicle was towed to an authorized dealer where the rear fuse box and fuel pump were replaced. The failure persisted after the repair. The vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 106,000.

Filed Sep 26, 2008 · Fuel system · OR · fire · 1 injury

On or about 30aug08 al line to the fuel pump on my 2006 chevy hhr leaked causing the car to catch on fire. Prior to this incident, the vehicle had been taken to the dealer for warranty work 7 times. To correct other issues. I am writing because I was charged for the repair. It took 30 days to get the part, and general motors sent a representative to the dealership who took over 300 pictures of the car.