Tank Assembly Problems of Chevrolet Cobalt - part 1

Chevrolet Cobalt owners have reported 38 problems related to tank assembly (under the gasoline fuel system category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Chevrolet Cobalt based on all problems reported for the Cobalt.

1 Tank Assembly problem of the 2010 Chevrolet Cobalt

Failure Date: 07/01/2020

Tl the contact owns a 2010 Chevrolet Cobalt. The contact stated that the odor of fuel was present while operating the vehicle. Upon inspection, it was discovered that fuel had leaked from the sub frame near the front of the driver's side rear wheel. In addition, while driving, the check engine light remained illuminated. The cause of the failures were not determined. The local dealer and manufacturer were not notified of the failure. The failure mileage was 237,000.

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2 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 08/09/2018

The contact owns a 2007 Chevrolet Cobalt. The contact stated that a fuel odor was present from underneath the vehicle. The contact looked under the vehicle and found fuel leaking from the fuel tank. There were no warning indicators illuminated. The dealer (fisher Chevrolet GMC Buick, 775 e 32nd st, yuma, az 85365) was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and stated that there were no open recalls under the VIN. The failure mileage was 89,000.

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3 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 04/01/2014

2007 Chevrolet Cobalt. Consumer writes in regards to ignition switch recall. The consumer stated the current actions being taken to remedy the situation were inadequate at best. The consumer did not feel safe driving the vehicle. Also, the gas tank had to be replaced due to a leak caused by a defective seal, that was recalled. The consumer had the seal replaced, prior to the recall. However she was denied reimbursement, because the work was not performed at a gm dealership. The blower motor was replaced multiple times, due to it causing a leak on the passenger side of the vehicle.

4 Tank Assembly problem of the 2005 Chevrolet Cobalt

Failure Date: 12/02/2013

The contact owns a 2005 Chevrolet Cobalt. The contact stated that after fuel was placed in the vehicle and it was parked in the garage, the contact smelled fuel outside of the vehicle. An independent mechanic stated that a crack was present in the fuel tank. The fuel tank was replaced and the failure was remedied. The manufacturer was notified. The failure mileage was 65,000.

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5 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 09/04/2013

The contact owns a 2007 Chevrolet Cobalt. The contact stated that there was a crack located at the seal of the fuel tank. The manufacturer was not made aware of the failure. The failure mileage was 60,791.

6 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 10/01/2012

2007 Chevrolet Cobalt. Consumer writes in regards to fuel pump recall notice. The consumer stated he had trouble starting the vehicle. He took the vehicle to the dealer, where they informed him, the fuel pump had no pressure. The consumer then took the vehicle to a repair shop, where they discovered a problem with the gas tank, which was leaking. The leak was where the fuel pump was connected to the gas tank. The consumer notified Chevrolet and they denied there was a problem with the gas tank. A month later, the consumer received a recall, regarding a problem with the fuel pump.

7 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 08/01/2012

2007 Chevrolet Cobalt. Consumer writes in regards to gas tank splitting at seams.

8 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 07/02/2012

The contact owns a 2007 Chevrolet Cobalt. The driver noticed fuel leaking from under the vehicle. The vehicle was taken to the dealer for diagnostics where the technician stated that the fuel tank had separated at the seam and would have to be replaced. The vehicle was repaired at a cost of $ 1,182. 15. . The approximate failure mileage was 70,000. Updated 7/30/12.

9 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 04/13/2012

The contact owns a 2007 Chevrolet Cobalt. The contact stated that after taking her vehicle in for routine maintenance, she was informed that the fuel tank was leaking. The vehicle had not been repaired. The manufacturer was not notified. The failure mileage was approximately 106,900.

10 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 04/09/2012

The interior of the vehicle had a strong fuel odor. The Chevrolet dealership diagnosed a leaking fuel module and had to replace the gas tank, fuel module, and fuel pipe. While this defect is known to occur on some 2007 Cobalts, gm states that my VIN number is not part of the current known defect. The leaking fuel module recall should be expanded to include all 2007 Cobalts.

11 Tank Assembly problem of the 2008 Chevrolet Cobalt

Failure Date: 03/02/2012

2008 chevy Cobalt with a fuel tank leak. This is an obvious safety issue and a recall was issued for 2007 Cobalts. Ntsha needs to be proactive with gm to correct this problem on subsequent years of the Cobalt.

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12 Tank Assembly problem of the 2008 Chevrolet Cobalt

Failure Date: 01/25/2012

Began smelling a faint gas odor in Jan. 2012 while sitting at stoplight coming from my 2008 chevy Cobalt. Odor has since grown stronger and my mpg's have gone from around 30-32 mpg to 26 mpg on last full tank of gas. This seems to be a common problem with 2008 Cobalts. There was a recall I have come across in my research for years 2005-2007 and problem seems to be of similar nature, but only in certain states, my car was purchased in texas but currently resides in oklahoma and I believe it was kept in another state by previous owner. I feel as though this should be looked into by gm and corrected on their side of the deal.

13 Tank Assembly problem of the 2008 Chevrolet Cobalt

Failure Date: 12/15/2011

I started smelling fuel in the passenger compartment and it has gotten worse. People complain about the fuel odor when they walk by. I have recently been informed by my mechanic that it is fuel leakage at the top of the tank. I have found the recall issues for the 2006 and 2007 Cobalts and I believe the 2008 should be included. My car is currently registered in TX, but it is a CA vehicle. Overwhelming odor inside and outside of vehicle. Extreme fire danger!!!!!.

14 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 12/09/2011

The vehicle was brought in for a recall to replace fuel module for fuel odor? well the module was replaced with the new module kit(3. 107). Before this replacement we had no problems with the car and fuel odor/fuel gauge. Now that we had the recall down there is a strong fuel odor and the gas gauge will read full at times and when the car is shut off and turned back on after driver . 7 miles the gauge will say its only got a 1/4 tank of gas and we switch the car on and off a few times and it will finally go back to full but after driving it about 3 miles the gauge will go back down to a 1/4 tank and we have to stop and cycle the key on and off at least 4 times for it to give a somewhat accurate reading but after driving a couple miles the gauge will go to empty. Even when the tank is empty the gauge will say there's a half tank of gas, I have even got stuck multiple times thinking there was gas in the car. Anyway point being that this module kit 3. 107 gave me all the symptoms of why it was being recalled and messed up my fuel gauge and the dealer refuses to fix it as warranty so because the fuel gauge isn't part of the recall. So I further investigated on multiple online forums and it seems everyone that gets this recall down has had major problems with the fuel gauge and a fuel odor they didn't have before the recall. So im hoping the NHTSA will further investigate this issue, this could be a huge safety issue running out of gas in the middle of the road/highway/dark long dirt roads with no gas stations for miles. So please read this and check your Cobalt by cycling the ignition and you will see after module replacement the fuel gauge is erratic/gas odor is now present. Chevys cheap recall is just not cutting it and they need to look into recalling the fuel level sensor with the module cause this problem seems like it happens to every Cobalt I have seen with this recall.

15 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 11/23/2011

The contact owns a 2007 Chevrolet Cobalt. The contact stated that fuel fumes were emitted into the vehicle. The contact mentioned that after inspecting the vehicle he noticed that fuel was leaking out of the fuel tank. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure who advised that they would contact him at a later date. The vehicle was not repaired. The VIN was not available. The failure mileage was 110,000 and the current mileage was 116,000.

16 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 11/08/2011

I have a fuel leak in the upper part of my gas tank.

17 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 09/26/2011

The contact owns 2007 Chevrolet Cobalt. The contact stated there was a fuel leak in the fuel tank and gasoline fumes coming from the inside of the vehicle. The vehicle was taken to the dealer who stated there were no recalls and they did not see any fuel leaks. The manufacturer was notified and stated the mechanic also did not see any fuel leak and offered no other assistance. The failure mileage was 51,174.

18 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 09/23/2011

Very strong gasolene odor when vehicle is running or after stopping. Fuel dripping from gas tank onto ground underneath.

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19 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 09/08/2011

Was driving my car and when I got home I smelled gas when I got out. So I got up underneath and smelled it even stronger. I took my car in to get an oil change and had them look for a gas leak. There is a gas leak coming from somewhere around my gas tank. This smell has gotten worse. This is dangerous to be driving around my car with such a problem. There have been other people reporting the issue as well. This is a safety issue that gm needs to recall everywhere not just certain states. I am a single mother and my son doesn't need to be smelling that every day when he's in my car. I do not have the money for repairs but this is something that I did not do. The car has a clean title and I have never hit anything hard to cause a leak from the top of the gas tank.

20 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 08/02/2011

Fuel leak around the top of fuel tank. Strong fuel smell in garage could have caught house on fire if ignited by a spark or other source.

21 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 07/18/2011

I have a 2006 Chevrolet Cobalt ss 2. 0l that just recently started to leak gas really bad about a month ago. There is already a recall for 69,139 Cobalts for this issue and the NHTSA campaign id number is 09v419000. My car is currently registered in arizona and was previously registered in nevada, the summary of the recall clearly states that "general motors is recalling certain model year 2006 Chevrolet Cobalt and Saturn ion vehicles originally sold in or currently registered in the states of arizona and nevada". My car is an 2006 model and was registered in both of those states, so I feel like there was a mistake that was made on gm's part while doing research on this recall and there are still vehicles out there like mine that have this issue. This has been a big inconvenience for me as I cannot even start my car without gasoline pouring out from the gas tank area and fear of my car igniting on fire. I just contacted general motors today and they told me that there was nothing that they could do to help so I'm hoping someone will read this here and get word out so that no one is seriously injured or killed. I appreciate your time!!.

22 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 07/10/2011

Strong smell of gas when im driving the car in and outside. The car has trouble starting,I had it checked and was told there was a fuel leak. Called gm and was told even though their was a special coverage for my state they would not fix the leak. This is a dangerous leak due to a faulty plastic part. I hope my family doesnt die from inhaling fumes or blow up. Kinda makes you think its another pinto exploding gas tank deal. I guess they wont do anything until someone dies. I have had many problems with this car starting a week after I bought it new. Knocking when the engine starts,using oil now,airbags not working ,small electrical things keep going wrong. When I take it in im told they cant reproduce the problems.

23 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 07/09/2011

Fuel leak around the top of fuel tank. Fuel smell. . . .

24 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 06/11/2011

24,866 mile fuel tank defect. Crack in the tank close to the filler neck. No impact , no collision. Supplier defect.

25 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 06/08/2011

I smelled a strong gas odor and the minutes later half of my gas was leaking out onto the parking lot with gas so high it is expensive took it to the dealership said I had a crack in my filler neck of the fuel tank and that it would be $1150 to get it fixed.

26 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 04/20/2011

2007 chevy Cobalt leaking fuel from fuel tank. Know problem, gm issued recall in several states. Called dealership, was advised vehicle was not recalled in indiana. Offered to sell replacement tank at cost of $1200.

27 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 03/01/2011

The contact owns a 2007 Chevrolet Cobalt. The contact stated that she smelled a strong gasoline odor. After a few months of inhaling the fumes she was hospitalized and given antibiotics. The vehicle was inspected by an independent mechanic who advised her that the fuel tank assembly needed to be replaced. The vehicle was repaired for the fuel tank assembly. The manufacturer was contacted and advised her that only certain states were included in a recall, which did not include her state. The failure mileage was unknown and the current mileage was 90,000. The VIN was unavailable.

28 Tank Assembly problem of the 2009 Chevrolet Cobalt

Failure Date: 12/24/2010

The contact owns a 2009 Chevrolet Cobalt. The vehicle was parked when the contact began to smell fuel fumes. The vehicle was taken to an independent repair shop where the contact was informed the fuel tank was leaking. The vehicle was not repaired. The failure and current mileages were 43,000.

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29 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 09/30/2010

Smell gasoline coming from the rear of the vehicle. Looked under rear of vehicle and can see gas dripping from the top of the gas tanks fuel module. Recall only covers certain vehicles with the same problem! fumes could ignite anytime. Dealeship will not repair on recall due to VIN not falling between the numbers.

30 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 09/15/2010

The contact owns a 2006 Chevrolet Cobalt. The contact stated that the vehicle was taken to a local repair facility for a routine oil change when the contact was informed that there was an abnormally strong gasoline fuel odor emitting from the vehicle. The mechanic discovered a fuel leak and performed a diagnostic. The mechanic advised the contact that the fuel sending unit was fractured at the top of the fuel tank. The vehicle was repaired. The failure and current mileage was 60,000. Updated 01/04/lj the consumer stated the same problem he experienced a recall was issued. However, his VIN was not included. Updated 01/10/jb.

31 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 11/01/2009

One day my wife walked past the car & smelled gas. I tracked down the smell to the top of the gas tank. I removed the gas tank to find the fuel supply port leaking gas. I have yet to take care of it.

32 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 10/11/2009

The contact owns a 2006 Chevrolet Cobalt. The fuel tank has developed cracks. A technician from the dealer stated that they would have to perform a smoke tank test at an expense of $112. 00. And then dropped the tank to see where the fuel leak was coming from. If the fuel tank has to be replaced it will cost $900. The Chevrolet manufacturer advised him to have the diagnostic test, and afterward they may provide a discount to replace the fuel tank. The failure mileage was 108,000. The VIN number was unavailable.

33 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 10/08/2009

Gas fumes smell while in car and outside of car. Gas puddling under car. Had service done to car to find cause. No leak in/on gas tank, may be evac system or system that pressurized gas. Possible blockage and afraid of driving car due to it ending up in flames. Called gm to see if there is a recall, was told no recall on my VIN# but found out on internet through autoblog that gm has plans on a recall but doesn't state when owner's will be notified or whether or not my car will be part of that recall. I have noticed a lot of people that own 2006 Cobalts are having a lot of fuel problems.

34 Tank Assembly problem of the 2007 Chevrolet Cobalt

Failure Date: 09/20/2009

2007 Chevrolet Cobalt with 68000 miles on it has fuel leaking from top of tank. Mechanic and parts house say this is very common for this vehicle. This seems to be a real safety issue that I and others believe should warrant a recall.

35 Tank Assembly problem of the 2006 Chevrolet Cobalt

Failure Date: 09/20/2009

The contact owns a 2006 Chevrolet Cobalt. The contact stated that two gallons of fuel leaked from the fuel tank. Fuel leakage in the presence of an ignition source could cause a fire. An authorized mechanic replaced the fuel system, since it was designed defectively. The vehicle identification number was unavailable. The failure and current mileages were 53,000.


Other Common Gasoline Fuel System related problems of Chevrolet Cobalt


Fuel Economy of Cobalt Vehicles
Cobalt Service Bulletins
Cobalt Safety Recalls
Cobalt Defect Investigations