2006-2011 Chevrolet HHR Problems: 11 Known Issues

Every 2006-2011 HHR is covered by GM's ignition switch recall (2008-2011 models were added because faulty replacement switches may have been installed during repairs). A heavy keyring or rough road conditions can shift the ignition from "Run" to "Accessory," shutting off the engine and disabling the airbags, power steering, and power brakes while driving. The GM victim compensation fund's final report counted 124 deaths and 275 injuries related to this defect across all affected GM vehicles. The defect is identical to the Cobalt ignition switch issue.

The HHR was part of GM's massive ignition switch recall. The switch is not robust enough, so a heavy key chain or a bump from the driver's knee can jostle the key out of the 'run' position, shutting off the engine and cutting power to steering, brakes and airbags. With the engine off, airbags will not deploy in a crash. This defect was tied to dozens of deaths and led to recall campaign 14V047 (2006-2007 HHR, expanded to 2008-2011 HHRs that may have received a defective switch as a service part) and the separate 14V171 ignition-key-removal recall covering 2006-2011.

The HHR has a documented issue with fuel line corrosion, particularly in rust belt states. The fuel line corrodes just forward of the driver-side rear wheel, developing leaks that create a fire hazard. Road salt and debris accelerate the corrosion. The issue is most commonly seen on vehicles in the northeastern and midwestern United States where road salt is used heavily in winter.

HHR owners frequently report the fuel gauge reading incorrectly or bouncing around unpredictably while driving, sometimes stuck on empty or full. The cause is the fuel level sensor inside the tank: the contact fingers that slide across the resistor card wear out or get fouled by fuel deposits, sending an erratic signal to the gauge. Bad readings can also coincide with ABS/traction warnings due to shared wiring or BCM issues.

The HHR uses an electric power steering system that is prone to sudden failure, particularly on 2006-2008 models. The power steering can quit mid-drive with no warning, making the vehicle extremely difficult to steer. The 2007 model alone has 726 NHTSA complaints, 424 of them involving the steering system and 15 of those reporting a crash. The EPS module failure is the most dangerous of the HHR's common problems.

The 2.2L (L61) and 2.4L (LE5) Ecotec four-cylinders are prone to timing chain wear caused by failing plastic guides and weak tensioners, often aggravated by extended oil-change intervals or low oil. Because the engine is an interference design, a stretched chain that jumps time can let pistons strike valves and destroy the engine. The telltale sign is a rattling or scraping noise from the passenger side of the engine, especially on cold start, frequently accompanied by code P0008/P0017 for cam-to-crank correlation.

General Motors recalled 2009 Chevrolet HHR models under NHTSA campaign 09V073000 because the transmission shift cable adjustment clip may not be fully engaged. With the clip unseated, what the shift lever indicates and what gear the transmission has actually selected can differ. The two consequences NHTSA describes for an HHR owner are being unable to restart the vehicle, and the vehicle rolling away after the driver has already gotten out — with no warning beforehand. The recall cites noncompliance with FMVSS 102 and FMVSS 114. The 276,729-vehicle figure is the total for the entire campaign, which spans several 2009 GM models, not the HHR alone.

The HHR's electric power steering motor can fail intermittently or completely, causing the steering to suddenly become very heavy while driving. Owners report the EPS shutting off under any condition, after which the wheel is extremely hard to turn until the engine is shut off and restarted to reset the system. GM recall 14V153 covered the 2009-2010 non-turbo cars and replaced the EPS motor, and a GM bulletin extended free EPS motor replacement (lifetime) to many 2006-2009 non-turbo HHRs; turbo models were excluded despite similar complaints.

The HHR uses GM's PASS-Key III+ theft-deterrent system, which reads a transponder chip in the ignition key, and a damaged key transponder or a fault in the reader circuit commonly triggers a false theft condition. The 'Service Theft Deterrent System' message appears, the security light flashes, and the engine cranks but will not start (or will not crank), often intermittently. A damaged key transponder, a weak battery, or poor grounds/connections are the usual culprits.

A very common HHR HVAC fault: the blower fan stops working on low and medium speeds and only runs on High (which bypasses the resistor). The root cause is a failed blower motor resistor, frequently accelerated by a design flaw where the butyl sealant patch under the passenger-side cowl dries out and lets rainwater leak onto the blower motor and resistor. The wiring connector can melt as well, causing repeat failures.

The HHR's interior door handles are cheap chrome-plated plastic that crack and snap off during normal use, leaving the door unable to be opened from inside. CarComplaints logged 23 reports for the 2006 model alone, at an average of ~94,600 miles. GM never recalled the handles; dealers historically quoted replacing the entire inner door panel (often $300-$500), though the handle alone can be replaced far more cheaply with aftermarket parts.