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 ↗2009 Chevrolet HHR fuel system problems
severe 16 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
16
Recalls
0
Avg fix
$1,200
2fires
What stands out
Of the 6 model years of Chevrolet HHR we track for fuel system problems, this one carries the most owner complaints on file — 16.
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
Owners report fuel line corrosion and leakage as the dominant complaint, with roughly two-thirds of narratives describing fuel leaks at the rear driver's side, typically near the fuel tank, starting between 28,000 and 75,000 miles and continuing through 200,000 miles. Leaks produce strong fuel odor, wet the ground and driveways, and in two cases, caused fires during startup or immediately after parking. One owner who took his leaking vehicle to an independent mechanic was told the fuel line was designed over the muffler, allowing water intrusion and accelerating corrosion.
Separate complaints describe a gas pedal assembly defect where backwards-mounted steel sweepers wear the carbon potentiometer track inside the pedal, causing erratic throttle response, engine power reduction warnings, and eventual failure to start. A one-owner electronics technician disassembled his pedal and confirmed the design flaw.
One early-purchase complaint reports a lean-fuel mixture causing check engine lights and stalling despite dealer computer reset and fuel additive treatment, with the owner unable to get warranty service.
Multiple owners cite NHTSA recall PE20011, but dealers confirmed several VINs were not included. Manufacturer assistance and warranty coverage were inconsistently offered or denied across these complaints.
Same Chevrolet HHR fuel system reports on nearby years: 2008
Failure modes owners describe
Corroded fuel line
Fuel line corrodes and leaks, typically at the rear driver's side near the fuel tank. One narrative notes the design routing fuel line over the muffler causes water intrusion accelerating corrosion.
When: 28,000 to 210,000 miles; earliest reports under 75,000 miles common
Symptoms owners cite: Strong fuel odor from vehicle or near rear driver's side; Fuel leaking onto ground, driveway, or inside vehicle; Excessive fuel consumption reported in one case; Visible rust on fuel line upon inspection
Repairs/costs cited: Fuel line replacement required. One dealer stated replacement parts were not available. One owner discovered online repair kit but manufacturer stated warranty would be voided if used.
Recalls/TSBs owners mention: One recall action PE20011 referenced by multiple owners, but several found their specific VINs were not included. Manufacturer provided no assistance in at least two documented cases. No recalls applied to several vehicles despite similar failures.
Fuel tank fitting failure
Fuel tank fitting becomes damaged, causing gasoline to leak from the tank.
When: 28,000 miles reported
Symptoms owners cite: Fire at rear of vehicle during startup; Gasoline pooling and leaking onto ground beneath vehicle
Repairs/costs cited: Fitting repair completed by independent mechanic.
Recalls/TSBs owners mention: Manufacturer contacted but did not provide assistance
Throttle body and accelerator pedal sensor malfunction
Gas pedal position sensor and throttle body report incorrect readings, limiting engine power. Owner with electronics background determined accelerator pedal assembly had backwards-mounted steel sweepers scraping carbon off the potentiometer resistor track.
When: Failure progressive, eventually preventing engine start
Symptoms owners cite: Engine sluggish, not responding to throttle input; Engine power reduced warning on instrument cluster; Eventual complete loss of power and inability to start
Codes mentioned: Wrong readings on throttle body, Wrong gas pedal position
Repairs/costs cited: Throttle body replacement ($400) did not resolve issue; accelerator pedal replacement ($90) fixed problem. Root cause: backwards-assembled steel sweepers (part 807819) inside gas pedal assembly (GM part 20757615, HELLA brand, dated 08/24) wore carbon off potentiometer resistor.
Lean fuel mixture and engine stalling
Engine running lean causes check engine light and power loss. Fuel additive treatment did not resolve issue.
When: Within 150 miles of purchase on used vehicle with factory warranty still active
Symptoms owners cite: Check engine light illuminated; Engine stalling and losing power; Fuel running lean per dealer diagnosis
Codes mentioned: Fuel running lean
Repairs/costs cited: Dealer reset computer and recommended fuel additive; problem persisted. Vehicle still under factory warranty but owner unable to obtain service support.
Synthesized from 16 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had fuel system trouble with your 2009 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 2009 Chevrolet HHR?
It's a meaningful issue. 16 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Across the 14 complaints that reported odometer mileage, most fuel system failures cluster between 52,000 and 121,499 miles, with the median around 110,000. A quarter of owners report trouble before 52,000; a quarter make it past 121,499. 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/2009/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.