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:
81,956 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 9 of 10)

« Read the previous 20 complaints

problem #32

Jul 272012


  • 55,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact confirmed that after exiting the vehicle the smell of fuel emitted from the tank. The vehicle was taken to a private mechanic. The mechanic confirmed the fuel pump module needed to be replaced. The manufacturer was contacted and they confirmed the VIN failed to qualify for a recall under : 09V419000 (fuel system, gasoline:delivery:fuel pump). The vehicle was not repaired. The failure and current mileages were 55,000.

- Pottstown, PA, USA

problem #31

Aug 082012


  • miles
The plastic supply on the modular reservoir assembly has cracked on my 2006 Cobalt. Fuel is leaking from the area. The crack is causing gas to leak to the ground. My mechanic has said this could lead to my vehicle catching on fire. It appears that Cobalts in other areas of the country have been recalled for this same issue. I'm wondering why all Cobalts have not been recalled as I have heard/seen many other '06 Cobalt owners in others states are having the same issues.

- Lenexa, KS, USA

problem #30

Aug 082012

Cobalt 4-cyl

  • Automatic transmission
  • 75,000 miles
The contact owns 2006 Chevrolet Cobalt. The contact stated that fuel fumes were emitted into the vehicle. The contact mentioned that after inspecting the vehicle he determined that the fuel sending unit was defective. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure and the current mileage was 75,000. Updated 01/05/13 the consumer stated the defective fuel pump sending unit was replaced. The plastic lines were defective and started to leak.

- Seaford , NY, USA

problem #29

Jul 112012


  • 80,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact stated that an overpowering odor of fuel was entering the vehicle. In addition, the contact was able to locate fuel leaking into the vehicle. The vehicle was taken to the dealer for diagnosis. The dealer stated that they had to replace the fuel pump. The vehicle was not repaired. The manufacturer was not contacted. The failure mileage was 80,000 and the current mileage was 90,000.

- Floyds Knobs , IN, USA

problem #28

Aug 082012

Cobalt 4-cyl

  • 77,000 miles
I started noticing a smell of fuel from my vehicle but did not see a leak. I took the vehicle to my local mechanic who noticed a leak, they were then able to verify that the plastic fuel line piece was broken which means the fuel pump needs to be replaced. I went online and noticed a recall on the 2006 Chevy Cobalt because of fuel pump issues. In a GM recall bulletin I located online dated Jan. 2010 bulletin # 09226, stated that the vehicles affected had VIN # with the last 8 digits between 67600011 and 67887442. My vehicle's VIN number falls between those two numbers but according to a Chevrolet customer service agent, who acknowledged the recall on the faulty part, my VIN # is not valid for the recall. I took it to my local mechanic to get fixed because it is a safety issue if nothing else. I am writing you because I believe that Chevrolet should be financially responsible for this repair especially because they acknowledge that they have had issues with the fuel pumps on the 2006 Chevrolet Cobalts. Any help you could provide in this matter would be greatly appreciated.

- Wilmington, DE, USA

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problem #27

Jul 162012

Cobalt 4-cyl

  • 138,000 miles
I have had issues with my fuel pump. The smell of gas and some slight leaking from underneath the car near fuel tank. Car hesitates sometime and stumbles like it wants to stall. My air fuel ratios are all over the place as well as my short term and long term fuel trim. Which indicates that the fuel pressure is not correct or constant. This could be a leak. However there are recalls out for this problem that falls under my VIN number but not my state. I think that since my VIN number falls under the correct recalled VIN numbers and I am having the same issues that it should be fixed for free and not have it limited by states if im showing the same signs and problems.

- Shillington, PA, USA

problem #26

Jul 312012


  • 150,000 miles


The contact owns a 2006 Chevrolet Cobalt. The contact stated that there was fuel leak and gasoline fumes were inside vehicle. The gasoline fuel had also leaked onto the interior floorboard of the vehicle. The vehicle was not taken to a dealer or a repair shop for inspection or repairs. The manufacturer was made aware of failure but no further assistance was provided to the contact. The contact referenced NHTSA campaign id number: 09V419000 (fuel system, gasoline:delivery:fuel pump) however the VIN was not included in the recall campaign. The approximate current and failure mileage was 150,000.

- Taylor, TX, USA

problem #25

Aug 032012


  • 99,020 miles
My car started smelling like gasoline, and I couldn't figure out why. The smell was inside and outside of the car. This didn't start till the temperature here in va was over 100 degrees. I was told could of been that my gas cap was not venting properly. The gas smell became so intense outside and inside the car even after I replaced the gas cap. I have received prices of $650 to over $1000 to have the defective fuel pump replaced (all one unit) according to the repair shops. I think that we elect officials to office and they should make GM fix the defective items (especially since they know about the recall) in all states before someone gets killed...oh yea that's right they got a bail out---we are just your average joes buying vehicles from them putting monies in their pockets and they wont fix what is a defective part that can and will eventually kill someone when their car catches on fire.

- Williamsburg, VA, USA

problem #24

Jul 232012


  • 17,117 miles
The contact owns a 2006 Chevrolet Cobalt. While parked, the contact noticed an overpowering gasoline fuel smell. The vehicle was taken to an independent mechanic for diagnostics where the mechanic advised that the sending unit was fractured and would have to be replaced. The contact referenced NHTSA campaign id number: 09V419000 (fuel system, gasoline:delivery:fuel pump) that but was advised by the manufacturer that the VIN was not included in the recall campaign. The vehicle was repaired. The approximate failure mileage was 17,117.

- Islip, NY, USA

problem #23

Aug 012012


  • 106,000 miles
I own a 2006 Chevy Cobalt. I seen that there was a recall for the fuel pump module recall # 090226. The recall was a few yrs ago before I owed my car, but I have smelled fuel and now its leaking fuel underneth my car. When I seen the recall I went to Chevrolet and they said because my car was involved in an accident a few yrs ago that they wont honor the recall. I dont understand that.. just because it was in an accident doesnt mean that the gas leak isnt because of there mistake when making my car!! it forsure isnt from an accident yrs before, the car has been fine after. Im not sure if theres anything you can do to help me out or anyway I can have them honor the recall and fix my car like it says they will fix free of charge in recall, but its dangerous to drive this way and can catch on fire, like I said it was there mistake when making car, and they want me to pay to fix it. I cant afford to.. I just think they find any excuss they can to get out of admitting to fault. Please if you have any suggestions for me let me know. Thanks.

- Dickson, TN, USA

problem #22

Aug 012012


  • miles


My 2006 Chevrolet Cobalt has a safety recall that regarding the fuel pump module but Chevy is only replacing the fuel pump for certain VIN numbers, mine is not included and I am having the same problem of smelling gas when the car is in park and my car is beginning to leak fuel. Obviously this problem is more widespread then Chevy is willing to recognize and I don't feel it is fair that I should have to pay the have the fuel pump replaced when GM/Chevrolet obviously knows the part is defective.

- Enola , PA, USA

problem #21

Jul 302012

Cobalt 4-cyl

  • 77,000 miles
There has been recalls on the Chevy Cobalt in other states for the fuel pump. Due to heat the fuel pump cracks and leaks fuel which could cause fire or explosion. We live in West Virginia and have had high temperatures and our cars fuel pump cracked causing car to stall and gas leaking around area. Because we don't live in one of the states that it was recalled in they will not fix our car. It is a defective part that can cause injury or death and to my understanding the ones they recall they fix with the same plastic that will crack again. Shouldn't a recall be for all Cobalts if all the Cobalts are doing this or a warning label that says only buy the car if you live in a cold or cool climate. I can't see how Chevy is getting away with this let alone fixing the problem with the same part!

- Idamay, WV, USA

problem #20

Jul 262012

Cobalt 4-cyl

  • 68,590 miles
The vehicle developed a gas leak due to a faulty fuel module, gas is leaking from that part. There is a recall on that vehicle. The vehicle make, model, year and VIN# match up, I've been told by one dealership that it was covered under the recall and by another dealership that it was not covered. I was told that it won't be covered because the vehicle is not from a particular state where the recall covers the problem. It has been almost a week of trying to get answers from GM to find out why the recall doesn't cover the problem just because it's not from other states, (AZ, ca, fl) are just a few of the states that have the recall on the same vehicle, same defective part, where the recall covers. The cost to fix the problem is well over $600 for a problem that GM is well aware of but are so far unwilling to take responsibility for their defective part.

- York , PA, USA

problem #19

Jul 162012


  • 44,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that gasoline fuel fumes were prominent both inside and outside of the vehicle. The contact also observed fuel dripping rom the vehicle and onto the ground. The vehicle was driven to a mechanic and after inspection, he informed the contact that the fuel was coming from a module that was connected to the fuel tank and lines. The dealer was notified of the issue who advised the contact that the vehicle was not included in NHTSA campaign id number: 09V419000(fuel system, gasoline: Delivery: Fuel pump). The vehicle was not repaired. The manufacturer was also notified who confirmed that the contact's VIN was not included in the recall and offered no further assistance. The failure mileage was 44,000.

- Owings Mills , MD, USA

problem #18

Jul 292012


  • 72,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that fuel was leaking from underneath the vehicle. The manufacturer was notified and the contact was informed that his vehicle was not registered in one of the states included in the recall associated with NHTSA campaign id number 09V419000 (fuel system, gasoline:delivery:fuel pump). The vehicle was not repaired. The failure mileage was 72,000.

- Springfield, IL, USA

problem #17

Jul 012012

Cobalt 4-cyl

  • miles
There is a constant, none ending smell if gasoline inside/outside of my vehicle. The smell is terribly strong. It's the strongest on the passenger side.

- Chicago , IL, USA

problem #16

Jul 202012

Cobalt 4-cyl

  • 60,000 miles
I started smelling a gas odor after parking my vehicle then saw gas on the ground under vehicle. I had a mechanic look at it. He said it was the plastic supply or return port on the module reservoir assembly. It was cracked. Then I found out there was a recall for this but only in certain states. I don't live in those states, I live in Pennsylvania. I don't understand why the recall isn't in all states - a defective part is a defective part no matter what state it is in. This is a fire hazard or an explosion waiting to happen.

- Quarryville, PA, USA

problem #15

Jul 022012


  • 99,999 miles
There is currently a recall on this make, model and year in the states of Arizona and Nevada for fuel tank problems (NHTSA campaign id: 09V419000). I live in Missouri where my car was issued and am currently experiencing the same problems to my car due to the extreme heat in the area. I think that all cars that fall within the make, model and year should be recalled in the midwest due to the extreme heat we've experienced.

- Festus, MO, USA

problem #14

Jul 152012


  • 103,000 miles
The contact owns a 2006 Chevrolet Cobalt. The contact stated that he smelled gasoline from inside vehicle. The vehicle was not taken to dealer or a repair shop for inspection. The manufacturer was made aware of the issue however no further assistance was provided. The current mileage and failure mileage was 103,000.

- Hot Springs, AR, USA

problem #13

Jul 122012

Cobalt 4-cyl

  • 99,433 miles
A noticeable gas odor upon entering and exiting the car was noticed. The vehicle was inspected by a certified GM service technician. Upon inspection & review of recalls, it was discovered the issue was directly related to special coverage adjustment #09275A issued March 2010 & a product safety recall #09226B issued May 9, 2012. However, the state of ownership or registration does not fall into the list of states indicated on the recall. The technician indicated the states listed are hot, more southern states than the state of Missouri where the car is currently registered. However, much of the midwest has seen much higher than normal temperatures during the last 30-45 days...temps in the 100 plus range. The VIN also falls within the range listed on the recall notice. GM was notified to ask if they would honor the repair but indicated the bulletins are issued by the government & if the care registration or ownership does not fall within the limits set, coverage is not provided. Wouldn't GM rather cover a minor repair bill than to be sued for hundreds of thousands of dollars when my house burns down due to this problem?? it doesn't make sense to me that although I have the same problem as listed in the recall due to high-temperature weather, and my car falls within the VIN #S listed as well as year, make & model, that because I don't live in a more southern state, I am forced to pay for a repair that shouldn't be needed in the first place if the car was manufactured correctly. If it is a problem directly related to the original findings, it shouldn't matter what state I live in. I'm disappointed in not only my government but GM for not honoring this repair issue and would request a review. Technician indicated numerous cars in this area have been brought in with this same problem.

- Altenburg, MO, USA

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