Notes: The 2006 Cobalt continued to carry the torch first lit by the 2005 model year. To be clear, that torch is burning bright with widespread power steering issues, electrical curiosities and a dangerous ignition switch defect which led to a massive recall by GM. This isn’t a great torch to carry.

The 2006 added it’s own special flare with gas leaks due to cracks in the “return portion of the modular reservoir assembly.” A recall of 2006 Cobalts was issued to fix the problem, but only to vehicles sold in or current registered in Arizona and Nevada, leaving other owners to pay for repairs themselves.

Between this car stalling while driving, giving owners fits with power steering failure and having it be a potential tinderbox because of gas leaks, we felt we had no other option than to award it our “Avoid Like the Plague” badge.


really awful
Crashes / Fires:
1 / 2
Injuries / Deaths:
1 / 0
Average Mileage:
81,883 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2006 Chevrolet Cobalt fuel system problems

fuel system problem

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2006 Chevrolet Cobalt Owner Comments (Page 7 of 10)

« Read the previous 20 complaints

problem #71

Sep 102012


  • 214,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact stated that the vehicle was leaking gasoline. The contact was informed of a recall for NHTSA campaign id number: 09V419000 (fuel system, gasoline: Delivery: Fuel pump). The vehicle was taken to a dealer for repair but after contacting the manufacturer he was informed his mileage was too high and the recall would not be honored. The vehicle was not repaired. The failure and current mileage was 214,000.

- Maryland Heights, MO, USA

problem #70

Oct 012012

Cobalt 4-cyl

  • 100,000 miles
My car has a large amount of fuel smell which I saw was a recall in some states but not mine. Is ther anything I can do.

- Mason, OH, USA

problem #69

Oct 012012

Cobalt 4-cyl

  • 184,000 miles
Strong fuel smell while driving and when vehicle not running. Fuel leak from gas tank area. GM recall will not cover because they say it was a "goodwill" recall and put mileage limitations. GM wants me to pay dealership for an "official" diagnosis and they "might" help me. Sounds like a gimmick to get more money for the dealership. They know I am over the mileage limitations so why pay the extra money for an official diagnosis" rip off, they know this is a problem. When someone blows up maybe they will repair then?"

- Flowery Branch, GA, USA

problem #68

Oct 052012


  • 51,476 miles


I took my 2006 Chevy ss Cobalt into the dealership because there was a strong gas smell coming from the car. I was told there was a recall on this model of car for the fuel system, gasoline: Delivery : fuel pump but only if I lived in Arizona or Nevada. I also looked up a few different forums online for this problem and there were many others that did not live in the states listed that had this same problem. There seems to be a problem in other regions on the recall that aren't being addressed that could cause some serious issues.

- Evans , CO, USA

problem #67

Oct 052012

Cobalt 4-cyl

  • 125,000 miles
Car smells of unburned fuel very strong when driving.

- Stockton, CA, USA

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problem #66

Sep 222012

Cobalt 4-cyl

  • 130,000 miles
Could smell gas every time that I got out of car. Was told that it was not covered under the recall because it was over the 120,000 miles that they allowed. So, I had to pay for it myself. Who in their right mind would make a fuel pump and sending unit out of plastic. Connection points should be steel.

- Dayton , TX, USA

problem #65

Jul 282011

Cobalt 4-cyl

  • miles


I was under my car inspecting it for a leak from spots I saw on the drive way. I found out the hard way it was a fuel leak near the gas tank when it decided to catch on fire with me underneath the car. I was not injured but the car was a total loss. I had previously asked the dealer to do any recall work needed when my power steering pump had gone bad. They told me the power steering pump was the only recall issued for my vehicle. I found out now, over a year later that some were recalled for a fuel line problem like this, and mine has a VIN that matches the recall, but since mine was not sold in a state covered my vehicle was not covered by the recall. Would have been nice to know before crawling under the car.

- Charlottesville, VA, USA

problem #64

Sep 032012


  • 95,000 miles
The contact owns a 2006 Chevrolet Cobalt. While parked, the contact noticed a strong fuel smell. The contact inspected the vehicle and discovered fuel leaking from the top of the fuel tank. The vehicle was taken to the dealer for diagnostic testing. The technician stated the fuel pump module would have to be replaced. There was a recall under NHTSA campaign id number: 09V419000 (fuel system, gasoline:delivery:fuel pump) that may have been related to the failure. The manufacturer was made aware of the failure and stated that the VIN was not included in the recall. The vehicle was not repaired. The approximate failure mileage was 95,000.

- Commerce City, CO, USA

problem #63

Aug 062012

Cobalt 4-cyl

  • 114,000 miles
Cracked inlet on fuel module, leaked gas.

- N. Little Rock, AR, USA

problem #62

Nov 082011

Cobalt 4-cyl

  • 149,366 miles
My car smelled like gasoline and I took it to the dealership because upon research I realized that there was a recall on this car for this same issue. After the issue was diagnosed to be a fuel leakage, GM was contacted by rosner Chevy and I was advised that the repairs to my car would not be paid for by GM. I contacted GM and I was told my car had too many miles and therefore they would not honor the recall. I was forced to pay $578.36, in order to get my car repaired.

- Palm Bay, FL, USA

problem #61

Sep 252012


  • 85,500 miles


TL * the contact owns a 2006 Chevrolet Cobalt. The contact stated that gasoline fuel fumes were emitted into the vehicle cabin. The vehicle was not taken to the dealer. The manufacturer was not made aware of the failure. The vehicle was not repaired. The VIN was not available. The failure mileage was 85,500 and the current mileage was 86,072.

- Bolivar, MO, USA

problem #60

Aug 012012


  • 62,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that while parked the smell of fuel emitted inside of the vehicle. The vehicle was taken to a private mechanic. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 62,000 and the current mileage was 65,000.

- Mahanoy, PA, USA

problem #59

Aug 272012

Cobalt 4-cyl

  • 73,256 miles
NHTSA, I'm responding to an article that I read on cnn regarding fuel pump pressure line for 2007 Chevy Cobalt. My vehicle is a 2006 Chevy Cobalt that on 08/28/2012 had to replace the fuel pump pressure line that is currently being recalled by GMC for 2007 to 2009 Chevy Cobalt. I would like for the 2006 Chevy Cobalt be placed on recall list so I can be refunded the 695 dollars I had to pay for my fuel pump pressure line to be replaced. I' M sure there are more 2006 Chevy Cobalt owners that have experience the same fuel pump problem.

- Torrance, CA, USA

problem #58

Jul 142012

Cobalt 4-cyl

  • 61,000 miles
Car has strong smell of fuel both when operating and afterwards. Gas odors also enter car when interior fan is running.

- Broadview Heights, OH, USA

problem #57

Aug 272012

Cobalt 4-cyl

  • 105,300 miles
I noticed the car emitting a gas smell which consistently got worse over the week. I took it in to have it checked and discovered that the entire fuel pump had to be replaced because part of it was leaking gas. The mechanic explained that the fuel pump is above the gas tank, and they had to take it all apart to even look at it. I discovered that a recall was in place (GM recall no. 090226), but only in certain states (not mine). I'm no mechanic, but the actual mechanic said that the recall description matched the problem this car is facing. He also mentioned that because he had to take it all apart this problem was probably not from everyday wear and tear. I hadn't noticed any leaks until after I got it checked, and now it is leaking all over the place. I am curious as to why the recall is only in certain states. Is the weather a factor" did only certain cars get this faulty part" if it is known that the part is subpar, let's get all states on board.

- Fitchburg, MA, USA

problem #56

Sep 202012

Cobalt 4-cyl

  • 132,384 miles
Gas mileage had significant decrease on highway trips. After driving >50 miles and parking car in garage, garage would smell horribly of gasoline. Upon initial investigation, gasoline was leaking from the top-end of the fuel tank in the area of the plastic supply and return lines via the fuel pump. Significant amount of leakage found on car under body. Symptoms match NHTSA campaign id number: 09V419000. Car was taken to tom gill Chevrolet for repair work where it was diagnosed to replace fuel pump assembly due to a cracked fuel supply/return line on fuel pump modular. Upon discussing with dealership, it as indicated this item was under recall but is region specific. Dealership made comments that it was regional due to cost of repair. This car was manufactured with the same components as the cars recalled in New Mexico, Mississippi, California, etc. It is unacceptable for the consume to bear cost of replacement due to region when it is a common problem with the Cobalt platform.

- Independence, KY, USA

problem #55

Sep 102012


  • 129,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that while driving at various speeds fuel fumes were emitted into the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the fuel module cracked and caused the fuel to leak. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure and current mileage was 129,000.

- Lilbourn, MO, USA

problem #54

Sep 122012

Cobalt 4-cyl

  • 84,000 miles
The plastic supply and return port on the modular reservoir assembly is crack, causing fuel to leak. This is exactly the same as current NHTSA campaign id 09V419000. However, GM told me that my VIN is no covered under this recall. The recall should be extended to the rest of the country, instead just certain states. Luckily, I caught this issue before a car fire occurred.

- Willowick, OH, USA

problem #53

Sep 072012

Cobalt 4-cyl

  • 119,613 miles
Started smelling an odor of gas, very strong. Started making me nauseated and gave me a headache. By the time I made it home I notice that my car used a lot of gas. My brother looked at it and says the gas is leaking and it is on top of the gas tank.

- Fitzgerald, GA, USA

problem #52

Jul 282012

Cobalt 4-cyl

  • 90,400 miles
The fuel pump was leaking fuel from the top of the pump and had to be replaced. This was a safety hazard because fuel was leaking on to the ground. This is the same issue other 2006 Cobalt's were recalled for in other states, recall # 09V419000. My car was not purchased or registered in those states but it still experienced this problem. I want to be reimbursed by the manufacture for the repairs.

- Blacklick, OH, USA

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