2009 Chevrolet Cobalt

On July 5, 2020, the Office of Defects Investigations (ODI) opened PE20-011 to investigate instances of metal fuel lines under the vehicle corroding and leaking fuel in model year (MY) 2008 through 2010 Chevrolet Cobalt and 2008 through 2009 Chevrolet HHR passenger cars manufactured by General Motors (GM). The metal fuel lines are corroding and leaking fuel in the area between the front and rear wheels on the driver's side of the vehicle before the muffler. Most consumers allege a fuel odor and/or an observable fuel leak that alerts them to the condition.The subject metal fuel lines have a protective AGE coating and, in the vicinity of the left rear wheel, are further wrapped in a foil heat shield. The AGE coating consists of an annealed zinc aluminum alloy metal coating with extended corrosion protection paint. Under certain conditions, water and corrosive road deicing agents may enter a crevice between the heat shield and the AGE coating. With extended environmental exposure in high corrosive environments, the AGE coating can degrade. If it degrades enough, the base metal lines may begin to corrode beneath the heat shield.Corrosion to the fuel lines may eventually cause a perforation to develop in the line, allowing fuel vapors to escape from between the line and the heat shield, emitting a fuel odor that will be detectable to the vehicle operator. If the corrosion progresses, fuel may begin to weep from the line. Further metal degradation due to corrosion could create a drip or a mist of fuel. If this occurs, vehicle owners may see drips, spots, or puddles on the ground near the rear portion of the vehicle, primarily along the driver's side rear wheel.The majority of allegations (85%) were reported for vehicles that are operated in the salt belt region of the United States. This area includes states in the Northeast, mid-Atlantic, and Midwest regions. Additionally, the average failure mileage in the subject vehicles is approximately 111,000 across all data sources.Considering the low manufacturer complaint/warranty rates of fuel line replacement, the fact that the majority of failures are concentrated in salt belt states, high failure mileages, as well as the field exposure time for the subject vehicles, and the highly detectable and progressive nature of this failure over time, the potential safety consequences of this issue are very low. To date, there have been no reported crashes, injuries, or fatalities related to this issue. There are two reported fires in ODI data and no reported fires in GM data. Both ODI reported fires were minor, occurred after the vehicle was parked, and were extinguished utilizing fire extinguishers.In view of the progressive failure occurring at high mileages, the age of the subject vehicles, the high detectability of the leak, and the majority of failures occurred in salt belt states, this Preliminary Evaluation is closed. The agency reserves the right to take additional action if warranted by new circumstances.Review the ODI reports cited above at nhtsa.gov under the attached identification numbers.

On November 18, 2010, NHTSA's Recall Management Division (RMD) opened an audit query (AQ10-001) to investigate recall remedy completion by rental car companies on safety recall campaigns.It was expected to provide the agency an indication of how completely and how quickly rental car fleets perform necessary recall-related remedies on the vehicles owned and then rented/leased for use on the roadways.RMD queried three (3) major motor vehicle manufacturers (Ford, Chrysler, and General Motors) and requested data regarding completion figures for fifteen (15) discreet safety recalls.Analysis of this data demonstrated that rental car recalls completion was neither complete nor consistent.The rental car companies representing the largest market share in the industry were then queried as to their respective policies for the rental, lease, and sale of vehicles with open recalls.The data and responses from the manufacturers and the rental car companies can be found in the document repository by accessing the ?Associated Documents link above.In December 2015, Congress enacted the Fixing America's Surface Transportation (FAST) Act.One section of the Act prohibits rental car companies from renting, leasing, or selling motor vehicles subject to open safety recalls.With the passage of the FAST Act and its prohibition, there is no continuing need for the agency to investigate rental car recall completions.Accordingly, this investigation is closed.The agency reserves the right to open any future investigations, including audits of individual recalls, or groups of recalls, or rental car companies, to examine more closely safety recalls performance and completion issues in this area.

In a March 1, 2010 letter, General Motors Corporation (GM) provided a defect information report to NHTSA regarding a problem that could result in sudden loss of power steering assist in certain model year (MY) 2005 through 2010 Chevrolet Cobalt and MY 2007 through 2010 Pontiac G5 vehicles equipped with electric power steering (EPS).The letter indicates that the loss of steering assist could occur at any time while driving and that, once assist is lost, a message is displayed on the Driver Information Center (DIC) and a chime sounds to inform the driver.The letter further states that steering control is maintained in manual mode, but would require greater driver effort at low vehicle speeds.In the next ignition cycle, power assist is typically regained and the DIC message is no longer displayed.GM's letter identifies the root cause of the EPS failure as the EPS motor and indicates that production of a new motor started in December 2009.GM's recall repair procedure instructs dealers to replace the EPS motor in all recalled vehicles. ODI's analysis of all information available related to sudden loss of EPS assist while driving in the MY 2005 through 2009 Chevrolet Cobalt vehicles shows current complaint and warranty rates of 323/100,000 vehicles and 0.4% respectively.In response to ODI's request for information, GM identified 81 complaints where a crash was claimed that may be related to loss of EPS assist.ODI's analysis of all crash claims was based on verifiable factors such as; whether a loss of EPS was indicated at the time of the crash by a chime or malfunction indicator lamp or if a EPS related component malfunction was identified after the crash occurred.With this method ODI identified 36 possible crashes related to EPS failure.GM assessed crash claims based on the available facts and excluded crash claims that indicated that the vehicle was travelling at speeds in the range of 30 mph or greater.GM said that it believes if power assist is lost while a vehicle is moving at speeds in the range of 30 mph or greater there is a small difference in steering efforts perceived in subjective evaluations at those speeds and it is unlikely to lead to loss of vehicle control. Based on GM's safety recall, this investigation is closed.

The contact owns a 2009 Chevrolet Cobalt. The contact stated that the vehicle was taken to an independent mechanic for repair; however, the mechanic found a fuel leak and an abnormal gasoline odor. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 17,311.

NHTSA ID

11728020

Incident

Mar 23, 2026

Mileage

17,311 mi

The contact owns a 2009 Chevrolet Cobalt. The contact stated that while driving at an undisclosed speed, the steering wheel failed to turn in the intended direction. In addition, the power steering failure warning light was illuminated. The vehicle was turned off. The contact stated that while attempting to restart the vehicle, the vehicle was started, and the power steering failure warning light was off. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact referenced an unknown recall with a similar failure description; however, the VIN was not included. The manufacturer was not made aware of the failure. The failure mileage was 154,824.

NHTSA ID

11694845

Incident

Oct 18, 2025

Mileage

154,824 mi

Steering went out while driving

NHTSA ID

11647813

Incident

Feb 25, 2025

The air bag never deployed I bought car in 2018 from original owner with car only having 33,000 miles on it and still under warranty til car had 100,000 miles and I hit a deer head on 2 months after getting car which bought in may of 2018 hit the deer in July 2018 . The deer was hit with the front passenger side it broke my headlight n messed my hood up and smashed in the grill little and my air bags never deployed I hit deer at 50 mph , after that had happened I took it in to Chevy dealership and had them look at car cause I told them I hit that deer and air bag never deployed and that my air bag light came on once in awhile and said service air bag . The dealership said they do that sometimes and did something to make light go off that was it my air vag light still comes on and says service air bag . Also ignition switch and fuel smell foul coming from car a lot and is as I speak . My reduce engine power light comes on a lot and have no power to gas pedal n car won’t stay running . I have try to get two recalls fixed back in 2-21 I was having problems with my car back then too special reach called me in Jan of 2021 and told me that there were two recalls on my car ignition switch and fuel module so I informed dealership when I took my car in That next month in feb 21 told them I was informed on 2 active recalls on my car . When they were done with my car later that day I asked them if they fixed the recalls they said no cause it was map sensor so I then made an appt to get recalls fixed when I got there for the recalls to be fixed one of the technicians told me it shows that they were done . I called Chevy and complained about the issue I just had and never had recalls fixed but they must of put it in computer they fixed them So I’ve been really upset that I been trying to get past recalls fixed that are on my car and I get run around and told there isn’t any I know about a past recall on shift selnoid low circuit too that was a past recal

NHTSA ID

11631947

Incident

Feb 20, 2021

The contact owns a 2009 Chevrolet Cobalt. The contact stated that while driving 55 MPH, the contact struck a deer. The air bags did not deploy. Additionally, while driving at slow speeds, the vehicle lost motive power. The contact restarted the vehicle. There was an abnormal sulfur and fuel odor detected. The air bag warning light was illuminated. The vehicle was taken to the local dealer, where it was diagnosed that the MAP sensor needed to be reset. The mechanic reset the air bag light. The mechanic was unable to determine the cause of the air bag failure. The vehicle was repaired, but the failure recurred. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 33,000.

NHTSA ID

11628768

Incident

Jan 1, 2021

Mileage

33,000 mi

There is a leak in the fuel lines that is just awful. Constant while driving Many others have experienced as well. Leaves huge puddles of gas

NHTSA ID

11609896

Incident

Aug 21, 2024

OEM headlights had become dim and one could no longer be aimed, so I ordered these replacements through Amazon. I paid $92 to have them installed, and the mechanic let me know that the high beams could not be activated, except by holding the turn signal, making it dangerous to steer. In addition, when the headlights are on they create so much RF, the radio no longer gets most AM or FM stations. The mechanic confirmed, they are wired incorrectly, but did not wish to attempt to rewire them.

NHTSA ID

11591166

Incident

May 28, 2024

The contact owns a 2009 Chevrolet Cobalt. The contact stated while attempting to start the vehicle, the vehicle failed to start and was jumpstarted; however, the auto theft warning light illuminated, and the key could not be removed from the ignition. The contact was able to drive the vehicle however, the locks failed to lock the doors, and there was a clicking sound when the windows failed to roll up or down. The contact stated that after refueling the vehicle, the vehicle was consuming an excessive amount of fuel. The contact stated that the tank was full however, the next day the fuel tank was empty. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 161,595.

NHTSA ID

11585314

Incident

Apr 1, 2024

Mileage

161,595 mi

New Vehicle Monitoring Programs Section in IVH

This Preliminary Information communication provides information to the technician about vehicles that have an intermittent no crank, no start, or start stall concern with the security light coming on. Technician may find Diagnostic Trouble Codes B3055, B3060, B3935, C0750, C0755, C0760, C0765, and/or C0775.

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.