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.

 

843de reported that he heard from reliable sources new upgraded parts will be available soon.

 

It appears I now have the dreaded rusty fuel line leak and plan to replace the entire line assuming I can find replacement. After scanning all the discussions on fixing the problem, I haven't seen anybody mention how difficult it is or is not to replace the line. I assume the line has the typical high-pressure fitting on each end, but I'm more concerned about access to those fittings and how the line snakes its way from the tank to the engine. Anybody?

 

Mitchell seems to think it is so generic that they don't even mention it.
Same with AllData.

Or, maybe they just hid it better than other things.

 

Can anyone here tell me how long it takes to replace fuel line? I have a 2009 hhr ss.

 

Not a tough job. Just tedious. I took me longer to cut out the old than connecting the new on my 2009 SS. There were a few things I encountered with the replacement lines and instructions:

- It would be better if the couplers on the fuel line and the vapor return line were offset more than they are. They tend to interfere with each other and make it difficult to secure to the brackets and tighten, especially the last section at the rear of the car where the lines wrap around the exhaust pipe.
- The original nylon vapor return line needs to be cut near where it's bonded to the steel line, not near the connector on top of the engine.
- The braided high-pressure fuel line is a little too long. It works, but I had to loop it around to connect.

FWIW, Here are photos of the original lines I cut out and the replacement lines.

 

Just to correct terminology: The fuel system is return less. The other line is EVAP.

The fuel pressure is dynamically regulated according to demand.

 

If your fuel lines rusted, report it here;
https://www-odi.nhtsa.dot.gov/VehicleComplaint/

 

Why? It is normal wear and tear. We are not talking about manufacturing defects. Has anyone been injured? Is it a pervasive safety issue caused by manufacturing errors?

Metal exposed to the chemicals that some states use on roadways in the winter tends to corrode. Probably get more done by suing your state highway department, or whoever authorizes the chemicals on the roadways. I know my state switched chemicals for that reason.

If it makes you happy then do it.

 

Up here rusty fuel and brake lines are due to the road salt in winter, it’s the owners responsibility to address that issue by rustproofing the car.