This service bulletin provides information on the cold start control system in DI engines to reduce cold start emissions and improve fuel economy.
full bulletin at NHTSA ↗2008 Chevrolet HHR fuel system problems
moderate 14 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
14
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 14 fuel system complaints filed for the 2008 Chevrolet HHR, here's the actual mileage breakdown — failures cluster heaviest at 150,000+ mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Among the 6 model years of Chevrolet HHR in our records for fuel system problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
full bulletin at NHTSA ↗This bulletin provides information on the TOP TIER Detergent Gasoline Licensed Brands and the TOP TIER Diesel Fuel Licensed Brands that are recommended for use in all GM vehicles and the TOP TIER FUELS website URL.
full bulletin at NHTSA ↗This service bulletin provides the technician with additional information on fuels, fuel additives and fuel management.
full bulletin at NHTSA ↗This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Fuel leaks on 2008 HHRs cluster around rusty fuel lines near the rear driver's side wheel and fuel pump corrosion. Most failures occur between 100,000 and 180,000 miles, though one appeared at just 6,000 miles. Owners describe fuel odors—both inside the cabin and outside—followed by visible drips or puddles under the vehicle. One owner discovered fuel pulsating from a steel line corroded completely through where it sat in a plastic retainer; he noted the retainer traps road salt and holds moisture, while brake lines in the same area remained unaffected. Another found a fuel line wrapped in heat-shrink tape that had corroded, suggesting moisture became trapped under the tape. A third reported a fiberglass mat heat barrier soaked in fuel rubbing against the exhaust, a fire risk. One pump assembly simply corroded severely and leaked; one early tank failure persisted even after tank replacement. No owner reported warning lights for most failures. Dealers and independent mechanics diagnose the problem and replace fuel lines or pumps; GM declined warranty help on one high-mileage vehicle, citing 8 years and 170,000 miles as beyond expected lifespan. No recall or technical service bulletin appeared in any narrative.
Same Chevrolet HHR fuel system reports on nearby years: 2009
Failure modes owners describe
Fuel line rust and perforation
Fuel lines, particularly those routed along the undercarriage near the rear driver's side, rust through and develop holes or complete breaches, causing fuel leaks. The problem appears tied to design—plastic line retainers trap road salt and moisture, and some fuel lines lack protective coating compared to brake lines in the same areas. Heat-shrink tape wrapping also appears to trap moisture and contribute to rust.
When: Between 68,900 and 199,000 miles; most commonly reported 103,000–178,000 miles; one early failure at 6,000 miles
Symptoms owners cite: Fuel odor inside and outside the vehicle; Visible fuel leaks or puddles under the rear driver's side wheel well area; Pulsating fuel flow from compromised fuel line; Wet spots on pavement or ground beneath vehicle
Repairs/costs cited: Fuel line replacement required; some owners cite costs implicitly through independent mechanic visits; one owner noted temporary replacement part used pending permanent part availability
Recalls/TSBs owners mention: GM declined warranty coverage on complaint #1, citing vehicle age (8 years) and mileage (170,000 miles) as beyond expected service life; manufacturer advised dealer diagnosis but provided no recall or technical service bulletin citations in narratives
Fuel pump corrosion
Fuel pump assembly becomes severely corroded, resulting in fuel leakage from the pump area and contamination of the fuel system.
When: Approximately 125,000 miles
Symptoms owners cite: Fuel leak from fuel pump area; Fuel on ground underneath vehicle
Repairs/costs cited: Fuel pump replacement performed by independent mechanic
Fuel tank leak
Fuel leaks from the fuel tank itself, not stemming from line connections or pump corrosion.
When: Approximately 6,000 miles (early failure)
Symptoms owners cite: Fuel odor; Fuel leak from tank area
Repairs/costs cited: Fuel tank replacement performed; failure persisted after replacement, suggesting possible secondary issue
Recalls/TSBs owners mention: Manufacturer contacted but provided no assistance
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The contact owns a 2008 Chevrolet HHR. The contact stated that after starting the vehicle, the contact became aware of a fuel leak nearby the rear driver’s side wheel. There were no warning lights illuminated. The contact towed the vehicle to an independent mechanic who diagnosed that the fuel line had completely rusted due to being wrapped in heat-reliant tape. The contact was informed that the…
Had fuel system trouble with your 2008 Chevrolet HHR?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2008 Chevrolet HHR?
It's a documented issue but not catastrophic. 14 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 13 complaints that reported odometer mileage, most fuel system failures cluster between 103,000 and 170,000 miles, with the median around 125,000. A quarter of owners report trouble before 103,000; a quarter make it past 170,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2008/Chevrolet/HHR.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.