Rusted Fuel Line
 

Noticed fuel smell from rear drivers side the other day. Put the car up on the ramps. One of the 2 fuel lines (the top one) is rusted and leaking. The line runs right along the rocker panel and the rusted spot is right in front of the rear tire. Guess the midwest winters have not been kind to my car. Anyone else with this issue? This appears to be a problem with the Saturn Ions of the same vintage. Can it be patched by removing the rusted section or will the whole line have to be replaced? Thanks for any advice

If there is only a small spot in the line you can rear the line with a compression fitting. If the line has mutable bad places in it I would look into replacing the complete line. If the problem is close to the end you may be able to find a repair end at your local part store.

Lucky: Thanks for the advice... I will look into those options.

Snoop- once repaired, perhaps some type of undercoating or paint over the gas lines (& maybe brake lines) might be worthwhile to prevent future rust-outs..

Just sayin'..

Thanks Sleeper-good advice

What size lines are needed to make this repair?

I'm not sure. I'm guessing 5/16.

From the othe thread you asked in, from Grizzly Old Man



The fuel line is 3/8" the return line is 1/4" When mine rusted out I used fuel injection rated hose to replace the rusted bit. If you use the rubber hose be sure to get fuel injection rated hose clamps. The regular screw clamps even if they are stainless steel will fail because the hose is under pressure.

I couldn't remember for sure.

So it is 3/8 fuel line our hhr's don't use a fuel return line because the fuel regulator is in the tank. (Except ss model)

the 1/4 inch line is a fuel vapor line but I would repair it the same as a fuel line using fuel injection rated hose.

If repairing with hose I use a double flare tool to both ends of the metal fuel line to give the hose something to grab onto.

I just had the same thing happen to my 2008 HHR, and the tech at the dealership said that they are seeing about 3 of these show up a month. Cobalt's and HHR's

Just a note, If this happens when your car is in an attached garage, be carful with the fumes.

fuel line size plz
 

My 07 HHR 2.4 LT fuel line is rusted out now too.
What is the size id od of the fuel line please. Mine looks like 3/8 od.
Thanks in advance.

The sizes are mentioned in some of the previous posts in this thread.

My fuel and vapour lines are both 3/8 or 10mm

I just had the shop make new nylon lines for mine... They used 3/8 inch line.

Do you have pictures?
I did find this video:

No pictures... I haven't been under the car since this was done. Rarely am I under a car and have a camera.

What they used is a nylon tubing made for fuel lines (I don't know a brand) that they have the tools to heat and properly form the bends matching the original lines and use the original hangers. (no zip tied hose strapped somewhere to the frame) Basically it's like the nylon pre-formed kits, but they make it themselves in house.

It's central Ohio, they do a lot of this stuff...

The shop didn't patch mine, though. They went new from tank to engine and did the vapor line too. (my request to replace all) They had to add the insulation where it runs close to the exhaust in the rear, like the factory line was.

Evidently, all of the connectors are available from any store that stocks Dorman products.

I had mine fixed about a year ago and somewhere on this board it was suggested that we call gm and report that this was a problem. I also read that we should notify the national transportation safety board and let them know so that maybe this will be part of a recall.

#Met00
 

Rusted out fuel line that was wrapped in fiberglass. $650 Repair. NTSB needs to look at this.

Look at what?

"Wrapped in fiberglass"? Not from the factory!

Sounds like a huge rip-off for a $25 repair.

Agreed, wife has a POS Saturn that the fuel lines were rusted as well. HHR is not immune to this. If you live and drive a car in an area were they use salt in the winter expect this to happen.

x2, plus it is an 11 year old vehicle.

It's not a matter of if the fuel lines will leak, it's when. They corrode from the outside from road salt and dirt holding moisture around the clamps and the inside from the alcohol in the fuel. GM claims it only happens in northern states but NHTSA has reports of vehicles sold new in Phoenix Arizona that never left the state that corroded. They needed to be made of stainless steel or a plastic. You can repair it yourself with hose rated to handle 60 psi fuel pressure. Most repair shops will only replace the lines with factory or aftermarket lines because of liability concerns. The factory lines are expensive. Lines to Go has the sets for under $200. They sell thousands of them. https://www.linestogo.com/hhr-fuel-lines/

https://www.rockauto.com/en/moreinfo...432001&jsn=446


for the HHR.......

UGGG on the Fuel Lines
 

I just replaced my 09's with single oem front to back metal type set from Inline Tube. Everyone... it's a good thing I have a lift and "A Guy" to help me with the installation. Turned out great but a chore. 6 hrs. for the two of us. The insulation and brackets are the culprits.