In this forum, there is thread about fuel lines leaking on the HHR due to rust. The thread is closed, so I hope no one minds that I'll add something as a new thread.


Some months ago, the United States National Highway Traffic Administration (NHTSA) contacted me inquiring about a fuel line leak in my 2006 HHR. My only guess as to how they knew mine leaked is that perhaps the repair shop was diligent enough to report this. The investigator said they have had complaints and reports of fires, including a woman whose child was in the car when it caught fire. The pictures he sent showed a totally destroyed car. I was lucky. I was at home and, when the fire started, was able to shove the car out of the way of the flaming driveway and put the car's fire out with an extinguisher.


The investigator said they are pursuing these cases and trying to force GM into a recall &/or compensation if the repair has already been completed (with much resistance from GM). Their investigatior, as well as the repairing mechanic, said there is a spot near the rear where salt & water build up. When the line rusts, it sprays gasoline on the hot exhaust. He's subsequently contacted me a few times to update that they are still fighting GM.


If you have had a rusted fuel line, fire or not- United States resident or not, 2006 or not, please file a report with NHTSA at NHTSA.gov. The "Report A Problem" link is on the right side of the page.


Regarding the repair; the servicing facility specializes in custom brake & fuel lines. GM owners know them well. They even re-route lines when posswible to protect the metal better. He's saved me lots of money on my current Sierra and past trucks & cars. (They always break either when I'm super busy or in cold winter, thus the need for a shop.) Before looking at the car, the owner of the small facility knew where it rusted and asked if there was a fire, so this must be a common problem in the Detroit area if this small shop sees them. Unfortunately, he said because they will rust again, for liability insurance, they only will use GM parts instead of his premium, stainless lines. Fortunately, their mechanics knew how to install factory lines without removing the car's body (what 2 GM dealers told me must be done.)


Please don't hesitate to contact NHTSA, even if you no longer own the car or don't live in the US. It may help you get compensation.

 

Federal government agencies don't send unsolicited letters or emails. We had a member that had his ox gored and was publishing almost identical claims. Probably why that thread is closed.
Not saying "don't report", just skeptical of receiving unsolicited mail from the government.

 

Thank you!

 

2007 here. I replaced these lines. I located newly installed lines on a junkyard special and invested about ten bucks in them. Note they are the same lines found on Cobalts.

I installed them with the car raised on a jack, it takes a little wobble and a second person is very helpful to guide them into position, especially at the front of the car.

Here's why they rust: there is a fiber jacket with an aluminum coating that protects the lines where they are nearest the exhaust, a heat shield, and that fiber holds much and moisture. (edit: fiber heat shield is located just ahead of driver's side right rear tire, under the car)

I omitted it on my repair.


I have a further modification: Not yet complete, but I have some heat shrink tubing I would like to slide down the line in several short chunks. I would like install the heat shrink as isolators at each and every point where the lines make contact with any and every clip and guide that secures them to the body. the lines can also corrode here. This includes a long section completely isolating the foot long angled protector to the rear, and beneath the area where fibrous heat shielding should be reinstalled. I would also add dielectric grease coating OR glue gun under the heat shrink prior to shrinking to prevent corrosion by trapping moisture out.

 

The usual spot is in front of the driver rear wheel where salt gets suck under the holder thingy.

 

2006 here, when my lines leaked earlier this summer, I used the nylon replacement kit sold for that purpose. No problems since, and no fires.

 

I’ve used stainless steel and nylon lines , both without the insulation, no problems, I do have some DEI heat shielding to install, but haven’t yet.

 

Mine just leaked, smelled gas, then saw a wet spot under the car.

Yep rotted by the rear , driver side rear tire,

Asked a local shop to repair, they just put a rubber line with 2 clamps. Not what I really wanted, but it was at a bad time for me to do it.