Lately at the dealership we have seen another rash of problems on the Chevorlet Cobalt and Saturn Ion vehicles. These are basically the same car, just different nameplates. What the customers are complaining about is a fuel leak at the fuel tank area, or a strong smell of gasoline coming from under the car. The problem they are experiencing is a common issue on some of these vehicles.
The fuel pump on these cars is located inside the gas tank. and is sealed with a large rubber gasket and a locking ring to hold it in place. What is happening is that the top of the fuel pump assembly is losing it’s seal around the opening and fuel is escaping from around the lock ring when the tank is full or the fuel sloshes upward during turns, acceleration, bumps, etc. Another problem on some of these cars is the fuel is actually making it’s way through the wiring connector or holes for the fuel lines. This obviously is NOT supposed to happen and can be a very dangerous problem. Fires, explosions, and personal harm can come about if this problem is not corrected.
Luckily, General Motors knows about this issue and has come out with a product safety recall to correct this problem. An entire new design fuel pump module assembly will be installed free of charge to the customer. This new design has been corrected and will not leak any fuel.
To replace the fuel pump module is a bit involved, but not an entirely hard job. The fuel tank has to be removed from the car to access the fuel pump area and replace it. This is best done when the tank is at or near empty. Lifting a completely full gas tank is NOT something we mechanics are fond of doing, so do us a favor and run as much gas out of your vehicle before bringing it in!
Once the tank is removed, it is a fairly simple process of changing over the pump. You have to remove the lock ring, then the pump assembly can be taken out. The fuel level sensor has to be changed over to the new pump, and then with a new gasket, the new pump assembly is reinstalled into the gas tank and sealed with the lock ring. Installation of the gas tank back into the car, fuel line attachments, wiring connector attachments, fuel filler hose, etc…and it’s all done. A quick start up after repairs are made will double check to make sure no leaks are found. All in all, a pretty straight forward procedure.
If you have a Chevrolet Cobalt, Saturn Ion, or Pontiac G5…you may want to check with your local GM dealership to see if your vehicle is covered or needs this repair done. If you’ve noticed fuel on the ground or smell gasoline, get it taken care of as soon as possible!
Below are a couple pictures of a job that was just done today on a Saturn Ion. You can see on the fuel tank how the leakage has run down the sides. This will give you an idea of actually how much gas can leak out of the top! And in the fuel pump picture, some descriptions are given to show where the leaks occur.
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111 Comments on "Fuel Leak Recall On Chevrolet Cobalt And Saturn Ion"
Hi,have a 2008 Chevy colbalt leaking fuel,in from St. Louis mo,can anyone direct me to whom I should call,I’ve read the threads,but if anyone can tell me that has been through this,,thx Stephen email@example.com
I just had the fuel line replaced on my Cobalt 2007..Can I get a refund?
Just some poss help for anyone having the gas leak issue on the Chevy cobalt (gas leak in Front ofvrear driver side tire there is a SPECIAL COVERAGE for it . I hope this Help’s someone. The special coverage # is 12191 just take to GM dealer.
Does the fuel tank recall expire on the 2007 cobalt? Just bought it for my son and sure enough fuel leaking from rear of tank.
I also have a gas leak showing under rear driver side door.this is on a 2010 Chevy cobalt LS. I haven’t saw a recall for this model year yet. Has anybody else had this problem.
Yes I am having same issue
ANY GM DEALER WILL REPLACE FUEL MODULAR WITHOUT COST. LIFETIME WARRANTY NOT RECALL. CAN GET FIXED NOW.
This is incorrect. GM will only replace the fuel pump if they have previously replaced it or if it is under a recall.
Yup just had two lines replaced today. Did your smell strong of gas afterwards? I brought it to shop had it fixed today but my car still smells of gas bad
My 2006 cobalt is leaking fuel from the fuel line. I was told there is no recall for my car!!
I have a 2007 Cobalt that is having the exact same issues. And also, I don’t smell gas in the car but once I’ve parked an am exiting my car, I get the gas smell.
Is the 2003 Saturn ION 3 covered under this recall?
Noticed a gas smell and my 2006 Cobalt SS had to crank a while before starting. Took it to the dealer, they checked and found that it qualifies for replacement tank and pump under program. Hopefully will get the car back next Tue. Only have 70K on this car, will be glad to get this fixed.
I have a 2006 Saturn Ion. I just paid $700.00 to get my fuel lines replaced. My daughter has a 2007 Saturn Ion, she had a recall and they fixed her fuel lines for free due to a recall. My question is, Is GM going to do a recall for 2006 for the same problem? This is right at the Christmas season and it took a chunk of my holiday savings to get my car fixed.
2007 chevy cobalt with a bad fuel smell. I took it to the dealer and was given an 800.00 estimate to replace the fuel lines. This is an obvious manufacturing defect yet only the tank and pump have been recalled.
I agree! Chevy has found there way out of this one. It is the leaking of gas lines and unsealed fuel pressure regulator that should have been recalled! Dealer just refused to replace my fuel lines and quoted me $1200. I’m going to get a mechanic to cut out the bad part and attach a new piece of line. Hope that works…
I have a 2009 Chevy Cobalt that I just got from a used dealer and it smells like gasoline bad when I’m driving and when it’s just sitting in the driveway from the VIN it’s saying there is no recalls on it but I disagree cause it stinks bad what should I do?
Is it running out onto the ground on the driver side near the rear left tire? If so, mine was doing the same thing. Thought it was having starting problems but seen it gushing out onto the ground. Left it at my mechanic’s garage where we discovered it.
most likely one or both lines are rusted through in the area just in front of the driver’s side rear wheel housing. you;ll see the lines are wrappedd with a heat shield in that location. Most likely leaking fuel inside the heat shield area. I just replaced both lines on my 2007 last weekend. Had that smell of gas for a few months. Bought stainlesss steel replacements through rock auto for $142.00.
I had 2007 Cobalt fix in 2015 for a gas leak it was cover under a recall. But now It is leaking again. Will this be cover again?
just got off phone with a GM Rep. my 06 saturn ion has the same gas smell. They will cover fuel pump, gas tank , and 2 little plastic lines on top of the tank. NOT the actual metal fuel lines that run from the tank to the engine. The dealer said the fuel lines are rusty and leaking and can repair them for a additional $850.00 .
It was the fuel line that had a crack in it. $615 ouch. This is robbery.
I live in Richmond, Ind the dealership is wetzel GM. They are looking at it now
I’m have a fuel leak on my 2009 cobalt right now. I called the locate GM dealer they check to see if a recall is out there. And NO it’s not.
i have the same problem
Just got my 2006 Chevy Cobalt back from dealer today, with the fuel pump/tank/pipe replaced free of charge. When I drove the car into the dealer service, they instantly told me that was a recall by the fuel smell, no hassle. I am in Beaverton OR.
Am I covered in Louisiana my cobolt has a very bad gas leak soon as I start pumping a lot of gas is pouring out from under my car
am I covered under this recall in Missouri I hv recently had a gas smell comming from my car and is leakin around gas tank
does this recall about fuel leaks extend to Missouri
I just had my 2008 cobalt gas tank and pump replaced in Union Mo. It would have been over 1,000 to fix got it done free.
I hv a chevy cobolt and started smelling gas and hving problems w it starting tje first try am I covered by the recall in Missouri
So there are so many complaints about leaking fuel,gm acknowledged that it is dangerous and could cause a fire yet so many of the leaks are the fuel lines at the top of the tank were the fuel pump module is and the recall does not cover this.my 2008 had a strong gas odor and leaking at the top of the tank and just like everyone else I take it in pay the diagnostic fee and told it’s the line and for $900.00 we can fix it. That’s terrible gm how many complaints there are on this and yet no concern from you.I really have been let down by gm over the last 5 years. all 3 of my gm vehicles I own have a recall right now and yet the fuel line witch I feel is more of a issue than any of the rest is not one of them. Sorry that I feel let down by you and being dedicated to your products over the last 29 years I really am surprised by all the recent problems I have had.it would be great to hear why you show no concern to fix this problem.so they send my wife driving away with fuel leaking but not before collecting the diagnostics fee of course.
same thing with me I live in Michigan…I have this gas smell, couple days later got worse know over $600.00 to replace the rusted fuel lines that are now leaking…Think recall should be for all Pontiac G5 2008 no matter what state I’m on disability and it is a struggle drop this amount of money on a issue GM has been aware of …I am disappointed in the way they lack to take care of issues from get go..
Did you go to a GM dealership? There are silent recalls and this might be one of them. Otherwise, call GM head office and if you don’t get a satisfactory response, ask to file a complaint. File a complaint online at BBB if you don’t have any luck at the dealership. You could also take this issue to a consumer helpline or the media if GM won’t help. Basically, keep complaining until you get them to fix it. You can also file a complaint with any government consumer departments. Just be very persistent.
I did call GM ran vin number said not covered and yes filed a complaint
how do you file a complaint
My moms car is Saturn ion and she got the recall part in mail on gas tank but it’s a revolution will they fix it ???
2008 Cobalt in KY not included in recall. (wrong state)Had gas smell on shutting engine down..Lost fuel pressure causing car to hesitate when cranked cold. Visual moisture and strong gas smell on top of fuel tank.
Called GM they scheduled a diagnostic check at dealership. Instructed if the fuel pump defect was the same part included in the recall it would be covered under ( special service bulletin) Dearlership confirmed the defect was the same and everything would be covered. Dealership technician said I would have to wait until they got the part to make the repair. Unfortunately the “special service” did not cover replacement vehicle. Here I am fourty miles from home and they tell me I can’t drive the car because it is unsafe.
After a loud conversation with the dealer GM they gave me a new car to drive home until my car was serviced. Last thing they wanted was an irate Grand mother in their showroom…Do the research! Call the manufacturer before going to the dealer…No letters when out
I had the same problem. My 2006 Cobalt was having problems starting, occasional rough idle and a smell of fuel when exiting the car. During an oil change I had my regular serviceman look into it. He checked the fuel pressure and found it was low. He lifted the vehicle to check for leaks and found fuel leakage coming from the top of the fuel tank. While deciding what do to I checked for recalls. I found a recall by GM dated October 29th, 2009 for the Fuel Pump Module. Recall #090226. There are special coverages for certain states. Called my local dealer who was also able to find the recall. They wanted me to set and appointment to have it diagnosed. I recognized it was just another way to soak my hard earned dollars out of me so I told them no. I told them I did not need “symptoms” or need to wait for a problem with a safety recall and therefore it did not need to be diagnosed. I told them to order the necessary parts and set an appointment to perform the recall repair. They argued but relented. If they find a leaking fuel line then oh well, I’ll pay for the additional repairs. When all is said and done the recall will be performed, any leaks fixed, and my vehicle will be safe to drive. I hope this helps and good luck.
I live in memphis tn i have a 2007 chevy cobalt I’ve been smelling gas for a while i remember receiving something in the mail but not a recall i hope they fix this problem free cause its there defective parts and they are aware of these gas leak issues im so scared i dont know what to fo or who to talk to
This just happen to me and it’s not a recall by Vin number its a special recall and is covered in every state..I live in ny
Joanne, I need to know what to do, my 2010 Chevy Cobalt isn’t covered under the recall, but gasoline starting spewing everywhere today.
Call GM Corporate and get them to cover it. My dealer said they wouldn’t but I called GM customer service and it was fixed for free.
How did you get it covered
My 08 cobalt hs recently started smelling lke gas. I have read there is a recall for fuel leaks, but not in the state of Ohio.The only warranty I have left is the emissions warranty. My question is this…..will the emiisions warranty cover this or will the recall be valid in the state of Ohio. This is NOT an expense that I can afford.
I live in Toledo,Ohio and I own a 2007 Chevy Cobalt LS I just got my car back a week ago from having this problem. My local GM dealer fixed it free of charge!! It was a $1500 job and it tool a day for them to fix it. So cars in Ohio are affected too!! You need to get it done asap!! Driving your car with this problem you are at high risk of your car could catch fire!! Not trying to scare you but this is an extremely dangerous recall on these cars!! And you will need the fuel filter replaced on the car also!#
It’s not a Vin number recall it’s a special recall I live in ny and it’s covered .at first they said no but as she checked it is
I will let u know I am the owner of a 2008 yellow Chevy cobalt. I was experiencing the smell of gas the steering wheel tightening and popping and our account quit working I’m not sure what that meant. As of tonight 710 pm Muncie Indiana time I was driving down the road and heard a loud pop and I pulled over to see a lady motioning for me to get the heck out of my car! I got out just in time. 20 seconds later the front of my car was engulfed in flames. I was so scared!
are the fuel lines included in the recall have a 2006 was told everything included but fuelines they are corroded and rusted thru…please advise
Yes fuel lines are included it’s part of the gas tank!! I just got my 2007 Chevy Cobalt fixed for this problem!! And you will need the fuel filter replaced on the car also!!
When we got a hold of GM they told us it definitely sounded like the recall problem with this being said we set up a appointment with Dave White our local dealership, but when they looked at it they said it wasn’t a recall problem so we had to pay a tow truck to bring it home. The next day a representative from GM said Dave White was wrong and she had a tow truck take it back to them. Well Dave White’s employee called and said there was nothing they could do that it wasn’t the recall, I talked to the manager and of course told him who I talked to from GM, well I told him and then got another call from GM this happen to be a man at this time and he agreed with Dave White and they said it would cost over $800 to be fixed, needless to say we don’t have $800. 00 so we had to pay for the tow truck to bring the car back home and it’s just sitting here because we’re afraid to drive it because it could catch fire and someone could be killed or at least hurt seriously. This happened last summer and we’re on a fixed income so God only knows if will ever get it fixed. I love my car and I want it fixed. Thank God we have another vehicle I don’t know what to do! !
If you need to use my name Elizabeth Gallagher and my make of car is a 2007 Chevy Cobalt LS, that they just recently fixed for the gas tank, it was fixed by them free of charge!! So your car should be allowed this problem fixed by GM for free also!! And get the fuel filter replaced on the car also!! Good Luck.
Who did you call and could please call me (234-855-0203
Thanks Ted I live in Youngstown, Ohio
Take it to George Ballas on Central Ave. I just got my 2007 Chevy Cobalt fixed for this problem a week or so ago!! They fixed it free of charge for me!! It is a $1500 job and it will take a day or so to install it!! And you will need the fuel filter replaced on the car also.
Hi . I have the same problem with my car and found a solution. I am in CT 06033 .call me and I will talk you tru it mobile 6318753352