2006 Chevrolet Cobalt Fuel system Problems

The contact’s wife owns a 2006 Chevrolet Cobalt. The contact stated there was an abnormal fuel odor inside the cabin of the vehicle. While exiting the vehicle, the contact became aware that there was an oil leak underneath the rear end of the vehicle, and the fuel odor was more evident. There were no warning lights illuminated. The vehicle was jerking while accelerating and while driving from being stationary. The vehicle was not taken to the dealer to be diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was unknown.

NHTSA ID

11676098

Incident

Jul 23, 2025

The fuel tank has an evap leak that somehow breaks on top the tank so it leaks the gas vapors and could potentially start a fire but the part that breaks is a non serviceable part so it can’t be fixed without purchasing a whole new gas tank that isn’t cheap. My other concern is the infamous grounding issue with the wires on the ground g105 I believe right next to oil filter that grounds the transmission and engine control modules well it shorts at times when driving and suddenly your car dies while driving how scary it could cause a wreak and kill somebody it’s a very scary issue that constantly comes back even after trying to re ground it needs to be recalled and fixed it’s going to kill somebody and it’s a well known issue for this make and model that should have already gotten attention to be resolved.

NHTSA ID

11673114

Incident

Jul 13, 2025

strong smell of fuel affraid to drive the igntion get stuck and locks so you cant turn the car on

NHTSA ID

11573304

Incident

Feb 22, 2024

The vehicle is leaking from the fuel tank

NHTSA ID

11533375

Incident

Jul 17, 2023

Fuel line rusted, leaking under car. Smell gas in cabin.

NHTSA ID

11527970

Incident

Jan 1, 2023

The contact owns a 2006 Chevrolet Cobalt. The contact became aware that fuel had been puddling underneath the vehicle. The contact had previously noticed an abnormal gasoline odor inside the cabin of the vehicle. The contact stated no warning light was illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle had not been diagnosed or repaired. The manufacturer had been informed of the failure. The contact researched online and determined that the failure was related to NHTSA Campaign Number: 09V419000 (Fuel System, Gasoline). The failure mileage was approximately 59,410.

NHTSA ID

11519846

Incident

Jan 13, 2023

Mileage

59,410 mi

Fuel leaking due to corrosion of fuel lines located near driver side rear wheel.

NHTSA ID

11506124

Incident

Feb 3, 2023

Before I get into all of it there has never been an accident not yet at least. I do everything I can to try an stop that from happening, (but accidents do happen) only because I know my car could kill on me so I’m extra careful. 1) After I get gas I’m my car the car won’t start right away. I have to restart it a couple times an step in the gas an rev up wasting the gas I just put in to get it to start. 2) When I stop an start to pull out of somewhere on to a main road the car will just die on me so I’m stuck pulling out in traffic trying to get my car to start again. It’s when I come to a stop an pull out it just kills on me. So I have to make sure no one else is coming an I have enough time to be able to restart it otherwise I’m worried when I pull out of anywhere or stop an go that another car will smack into me because my car just died on me in the middle of the road/ pulling out an crossing lanes. SUPER SCARY! 3) Let get into the next issue so anytime I run my ac my car starts to do this jumping thing like it wants to kill on me not to mention it has killed on me with the ac on (I live in Louisiana an it’s too hot not to have ac plus I have 3 kids) what’s sad is the ac works fine but if you want the car to maybe not die then turn it off an you have a better chance of it not killing off on you but not always a guarantee. So ill run it for second to try an cool down so I’m not drenched in sweat but I have no other choice to turn it off so the car doesn’t just die on me. This refers back to the 2nd problem I make sure it’s off anytime I pull out of anywhere thinking that would help it from killing on me while trying to get out of anywhere but it doesn’t but I can tell you If the ac is on when I pull out when I start to go it dies right as I’m in the middle of the road every time never fails. Mechanics have replaced parts trying to fix the issue, but it still happens I can’t keep buying/fixing things for nada, ongoing problems since buying.

NHTSA ID

11477531

Incident

Aug 5, 2020

Fuel line leaking similar to the recall on 2008-10 Cobalts -- gas puddles or drips from leaking fuel lines near the left rear wheel well, near the exhaust pipe and muffler. The leak is caused by corrosion of the metal fuel lines that are secured to the body of the car by plastic blocks.

NHTSA ID

11476868

Incident

Jul 29, 2022

The contact owns a 2006 Chevrolet Cobalt. The contact stated while standing outside the vehicle a fuel odor was detected. The contact also stated that while driving, there was a fuel odor detected inside the vehicle. The vehicle was not taken to the dealer or independent mechanic to be diagnosed or repaired. The dealer was contacted and the contact was awaiting an appointment. The contact was also informed that the VIN was not under recall. The manufacturer was contacted and made aware of the issue. The manufacturer informed the contact of a fuel pump module replacement coverage under Manufacturer Communication Number: 09275. Future Chevrolet (4811 Madison Ave, Sacramento, CA 95841) was contacted and the contact was still awaiting a callback. The contact related the failure to NHTSA Campaign Number: 09V419000 (Fuel System, Gasoline) however, the VIN was not included. The approximate failure mileage was 69,817.

NHTSA ID

11459710

Incident

Mar 26, 2022

Mileage

69,817 mi

My 2006 Chevy Cobalt has a fuel leak which was recently a recall. I have been told by several dealerships that it will not be repaired for free. How can this be? I didn't know recalls expired. It's a safety issue and the manufacturer's responsibility. Please advise me on next steps.

NHTSA ID

11442074

Incident

Jan 30, 2021

Last year or so, even before than, I noticed suddle fuel odor smell & noticed few drops by left rear wheel area...it has progressingly gotten worse and now puddles and smells of fuel constantly...all which I traced back to fuel lines by rear exhaust heat shield area where it's very rusty, inline elsewhere around car area...seems to be bad design and or manufacturing issue...also very common I noticed with cobalt saturn Pontiac models sharing same design & platform.. Very dangerous and needs to be corrected by gm!

NHTSA ID

11438813

Incident

Oct 31, 2021

My headlight an blinker quit working new bulbs an all new wiring it it still will not work My trunk button also just stopped working an the fuse is not blown. I even replaced it just to make sure still nothing. Door panel clips won’t stay in bought new ones same thing so now my handle is coming apart an my door doesn’t want to shut bc it thinks I’m still holding the handle.. Fuel everytime I get gas I have to crank my car a few times and press on the gas before I can get it to go otherwise it just dies on me I’ve had it looked at they said it was something about how my car does not know when to stop releasing air I think. My blinkers don’t turn off unless I do it manually. The seals on my door is no good anytime it rains it’s coming inside of my car an since the door panel won’t stay on it’s coming straight into my car

NHTSA ID

11438524

Incident

Oct 28, 2021

I began noticing a slight drop in fuel mileage at first. Started smelling fuel while parked and only getting 200 miles to a tank. Noticed the supply and return fuel lines where damp. Dropped the tank and the fuel lines at the pump were cracked a little. I temporarily fixed thos with jb weld but dont expect it to last.

NHTSA ID

11437900

Incident

Oct 18, 2021

Fuel lines are rusted where the heat tape is around them by the exhaust. This has caused them to rust and no is leaking fuel. I am worried that it's going to catch fire. This is my daughter's car and is a very poor design.

NHTSA ID

11422488

Incident

Jun 25, 2021

The contact owns a 2006 Chevrolet Cobalt. The contact stated that after turning off the vehicle, there was an abnormal fuel odor coming from the vehicle. Upon inspection, the contact discovered severe corrosion on the rear driver’s side undercarriage of the vehicle. Due to the rust, the fuel lines started leaking. The local dealer was contacted and informed the contact that the Vin was not under recall. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 126,000.

NHTSA ID

11420860

Incident

May 24, 2021

Mileage

126,000 mi

There is a recall for some vin numbers on the 2006 Chevy cobalt (recall # 09V419000). My vin number was not included but the exact recalled part was also defective on my car. I wanted to let you know because there are probably several more vins that should be included in this recall, as my car is proof of that.

NHTSA ID

11418550

Incident

May 17, 2021

HAD TO CHANGE MY FUEL PUMP DUE TO A CRACK ON IT. MY KEY GETS STUCK IN THE IGNITION SWITCH IN ORDER TO TAKE IT OUT I HAVE TO PUSH A BUTTON UNDER THE STEERING WHEEL. I TO CHANGE MY STEERING SHAFT BECAUSE IT DOES A CLACKING NOISE.

NHTSA ID

11413628

Incident

Feb 14, 2021

TL* THE CONTACT OWNS A 2006 CHEVROLET COBALT. THE CONTACT STATED WHILE THE VEHICLE WAS STATIONARY, HE STARTED TO SMELL A FUEL ODOR. THE CONTACT STATED NO WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO INDEPENDENT MECHANIC AND THE CONTACT WAS INFORMED THAT THE FUEL PUMP NEEDED TO BE REPLACED. A DEALER WAS NOT CONTACTED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER HAD BEEN INFORMED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V419000 (FUEL SYSTEM, GASOLINE). THE FAILURE MILEAGE WAS APPROXIMATELY 94,000.

NHTSA ID

11405035

Incident

Dec 1, 2020

Mileage

94,000 mi

FUEL LINE LEAK BY LEFT REAR WHEEL WELL. HEAT SHIELD SEEMS TO CAPTURE MOISTURE AND HAS RUSTED LINE BY CLIP. RESULTS IN FUEL LEAK BY EXHAUST SYSTEM.

NHTSA ID

11402795

Incident

Mar 12, 2021

Mileage

80,000 mi

WHILE DRIVING ON EXPRESSWAY, CAR WENT DEAD> HAD TO MAKE AN EMERGENCY STOP. POWER STEERING WENT OUT, BUT AFTER RESTARTING THE CAR IT WAS OK. IT KEEPS HAPPENING OFF AND ON- ON OCCASIONS. I KEPT SMELLING GAS, TOOK IT TO CAR REPAIR SHOP WAS TOLD I COULD NOT DRIVE THE VEHICLE, WAS TOLD THE GAS TANK HAD TO BE REPLACED OR WHATEVER THE PART INSIDE THE GAS TANK. NOTE: WHEN THE POWER STEERING PROBLEM ARRIVED I WAS LEAVING GOING TO WORK. I STARTED THE CAR BUT THE STEERING WAS HARD TO TURN SO I PULLED BACK INTO PARKING SPACE AND TURNED OFF THE ENGINE. I RESTARTED AFTER A FEW MINUTES-WAS ABLE TO STEER OK. UPON SMELLING GAS THIS WENT ON FOR SERVAL DAYS. I THOUGHT IT WAS FUMES FROM OTHER CARS. I WOULD SMELL GAS WHILE DRIVING IT. ONE DAY AS I PULLED UP TO WORK I GOT OUT OF THE CAR AND NOTICED SOMETHING WET NEXT TO MY FRONT TIRE. I COULD SMELL GAS FUMES. I TOOK IT TO REPAIR SHOP THE NEXT DAY. SHOP TOLD ME THE CAR COULD HAVE CAUGHT ON FIRE.

NHTSA ID

11390483

Incident

Dec 21, 2018

Mileage

100,000 mi

THE COMPANY WRAPPED A HEAT SHIELD FIBER AROUND A BARE METAL FUEL LINE CAUSING PREMATURE FAILURE OF THE LINE IN THAT SPECIFIC LOCATION DUE TO RUST FROM THE TRAPPED MOISTURE. THE FUEL LINE BURSTS CAUSING A STEADY FLOW OF GASOLINE TO POUR FROM BENEATH THE VEHICLE CAUSING AN EXTREMELY HAZARDOUS SITUATION. THE CAR CONTINUES TO FUNCTION, LEAVING A TRAIL OF GASOLINE EVERYWHERE YOU GO. THE HEAT WRAP DOES NOT APPEAR TO AFFECT THE BRAKE LINE DUE TO IT'S BLACK COATING. THE FUEL LINES SHOULD ALSO BE PROTECTED IN THIS AREA.

NHTSA ID

11389666

Incident

Jan 16, 2021

Mileage

149,897 mi

VERY STRONG FUEL SMELL STARTED OCCURRING THAT WAS NOTICEABLE EVEN AFTER LONG PERIODS AFTER PARKING. UPON FURTHER INVESTIGATION A FUEL LEAK WAS DISCOVERED ON THE OUTLET OF THE FUEL PUMP WHICH IS INTEGRAL TO THE FUEL TANK. IT APPEARS THERE IS A CRACK OR SOME SORT OF DEFECT CAUSING THE EXTERIOR PIECE ON THAT FUEL PUMP TO FAIL. VEHICLE ONLY HAS 64,300 MILES ON IT.

NHTSA ID

11382773

Incident

Dec 1, 2020

Mileage

64,300 mi

MY VEHICLE, A 2006 CHEVY COBALT LT, LIKE MANY OTHER CHEVY COBALTS I'VE FOUND IN MY RESEARCH, HAS A FUEL LEAK IN THE REAR DRIVER SIDE. I HAVE NOT PINPOINTED THE EXACT LEAK LOCATION BUT I HAVE A PICTURE DISPLAYING THE FUEL LINE COVERED IN WHAT SEEMS LIKE AN ALUMINUM FOIL TO KEEP THE LINES FROM HEATING UP. CLEARLY THIS DOESN'T WORK. THIS IS A COMMON ISSUE AND I BELIEVE IT NEEDS TO BE ADDRESSED.

NHTSA ID

11374645

Incident

Nov 5, 2020

Mileage

80,000 mi

PLASTIC FUEL TANK CRACKED AND FUEL IS DRIPPING FROM VEHICLE IMPOSING A POTENTIAL FIRE AND HAZARD.

NHTSA ID

11374164

Incident

Nov 11, 2020

Mileage

133,000 mi