Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2009 Chevrolet HHR owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2009 Chevrolet HHR. The contact while driving at an undisclosed speed, noticed a strong fuel odor. The contact stated that upon parking and exiting the vehicle, there was fire underneath the rear driver's side, where the fuel tank was located. The contact was able to extinguish the fire with a fire extinguisher. There was no injury sustained. The contact then noticed a trail of fuel on the floor. The contact became aware that fuel had leaked while driving. The vehicle was towed to an independent mechanic, where it was diagnosed that the fuel line was corroded and needed to be replaced due to a wrong design. The contact stated that the fuel line was designed over the muffler, which caused water intrusion and corrosion. The vehicle was then towed to the dealer, where the fuel line was replaced. The vehicle was repaired. …
The contact owns a 2009 Chevrolet HHR. The contact stated while starting the vehicle, the rear of the vehicle started burning. The contact was able to stop the fire and the contact noticed that the gasoline was leaking onto the ground under the vehicle. No one was injured and no police report was filed. The vehicle was diagnosed by an independent mechanic and the mechanic stated that the fitting to the gasoline trunk was damaged causing the gasoline to leak. The vehicle was repaired. The manufacturer was contacted, and the manufacturer did not provide any assistance. The failure mileage was 28,000
The contact owns a 2009 Chevrolet HHR. The contact stated that while the vehicle was parked, and while driving the vehicle, there was a strong fuel odor coming from the vehicle. Additionally, the contact noticed that the vehicle was experiencing excessive fuel consumption. The contact also noticed that fuel had leaked onto the ground. The contact stated that upon inspecting the vehicle, the contact noticed that fuel was leaking from the driver's side rear wheel well, where the fuel tank was located. The contact related the failure NHTSA Action Number: PE20011(Fuel System, Other, Fuel/Propulsion System, Fuel System, Gasoline). The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not notified of the failure. The failure mileage was approximately 110,000.
The contact owns a 2009 Chevrolet HHR. The contact stated while the vehicle was parked, he noticed fuel leaking from the rear driver's side of the vehicle. The vehicle was not taken to a dealer or independent mechanic for diagnosis or repairs. A Chevrolet dealer was contacted and confirmed that the VIN was not included in a recall. The contact stated that he was able to look under the vehicle and found that the fuel line was corroded. The contact was relating the failure to an unknown recall for a fuel line that was issued for similar Chevrolet HHR vehicle. The manufacturer was not notified of the failure. The approximate failure mileage was 52,000.
The contact owns a 2009 Chevrolet HHR. The contact stated that there was a fuel leak near the driver's side rear door. The contact stated that the TPMS, ESC, and check engine warning lights were illuminated. The contact researched online and determined that the failure was related to NHTSA Action Number: PE20011 (FUEL SYSTEM, OTHER, FUEL/PROPULSION SYSTEM, FUEL SYSTEM, GASOLINE). The contact called the local dealer and was informed there were no recalls on the VIN. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 136,440.
The contact owns a 2009 Chevrolet HHR. The contact stated upon parking and exiting the vehicle, she smelled a strong gasoline odor on the driver's side of the vehicle. There was no warning light illuminated. The contact stated that the failure persisted. The vehicle was taken to the dealer where it was diagnosed that the fuel line needed to be replaced. However, the parts were not available. The vehicle was not repaired. The contact referenced NHTSA Action Number: PE20011. The manufacturer was not notified of the failure. The failure mileage was approximately 111,800.
The contact owns a 2009 Chevrolet HHR. The contact stated that while attempting to start the vehicle, the vehicle would not immediately start. The contact later noticed a fuel odor inside the vehicle. The contact discovered a fuel leak coming from the rear driver's side of the vehicle. The cause of the failure was not determined. The local dealer was notified of the failure. The manufacturer was not notified of the failure. The failure mileage was 125,000.
The contact owns a 2009 Chevrolet HHR. The contact noticed that there was a leak coming from the rear driver's side of the vehicle. Additionally, there was a fuel odor coming from the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that there was a rusted fuel line. The dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 103,900.
I have a 2009 Chevy HHR with only 62k miles. Recently while driving out of town there was a strong gas odor in the car all the way home. We had also parked the car in a relatives attached garage leaving a gas odor. When parked at home a puddle of gasoline formed under the car. The fuel leak was from corroded fuel lines on the driver side in front of the rear tire. Upon inspection both supply and return fuel lines were corroded in an approximate 5 foot span. This fuel leak put us at risk of fire and also the entire garage/house where the car was parked. I contacted General Motors about the problem and was told to take it to a dealer for service. I asked General Motors for assistance in the cost and they said it would require a diagnostic by the dealership. I contacted the dealership and was told I would get no assistance per General Motors PET equation.
Gas/Fuel line leaking at LR door area, not noticed until gas smell. Poor design, wrapping fuel line in insulation near exhaust collects salt and water causing lines to rust, dripping raw gas. A safety hazard, a spark or cigarette butt could have caused a major fire, not only to the vehicle but surrounding vehicles and or property. A Chevrolet HHR is the same platform as a Chevrolet Cobalt and a Saturn Ion, all have the same safety-related issue. I contacted a local Chevrolet dealer they were unable to repair for 4 days, and would not cover needed repairs under a recall or warranty. Imagine leaking gas puddle under the vehicle in a parking lot with children and people walking nearby, fireworks! A recall is desperately needed ASAP!
NHTSA investigations
Fuel Line Leak
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).
Fuel System complaints in other HHR years
Frequently asked questions
How common are fuel system problems on the 2009 Chevrolet HHR?
NHTSA has 84 complaints about the fuel & propulsion system of the 2009 Chevrolet HHR, 17% of the model year's 508 complaints. The component named most often is delivery › hoses, lines/piping, and fittings (4 mentions).
Is there a recall for 2009 Chevrolet HHR fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2009 Chevrolet HHR, though it has 4 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2009 Chevrolet HHR fuel system problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.