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.
Chevy Cobalt and Saturn Ion gas tank leaking.
Chevy Cobalt and Saturn Ion fuel pump recall
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111 Comments on "Fuel Leak Recall On Chevrolet Cobalt And Saturn Ion"
I bought a 2007 Chevy cobalt and it was leaking from the tank
2005 4 door Chevy Cobalt. Went in for an oil change & have a gas leak. The smell is horrible! Called GM & they told me not covered on the recall 😟 Gave me case number. I asked if we would be reimbursed if a recall is issued he said “it’s possible”. Not happy.
My mothers 2008 just got fixed bad smell had read this forum called fm told them about a warrant Colby has never expires whala a nice lady at gm helped us and they fixed it
I have a 2008 Pontiac G5 and I live in Ontario, Canada. Gas runs down the gas lines when my car is running, took it to the dealer for the ‘silent recall’. They charged me $130 to tell me it was not covered by the recall, but they could fix it for $1050 plus tax…
Just called my dealer and told them I had been reading about it and mentioned the almost seemingly silent recall for the fuel pump module and almost instantly he went from not knowing anything to happening to find something about it and was 100% helpful from there out. They are going to replace the tank, pump, and all lines needed free of cost.
I have a 2005 Chevy cobalt I notice a gas smell bad on the outside and the inside of the car. Has anyone found out if there is a recall on this
I have a 2006 Cobalt … the fuel pump was leaking (both fuel lines busted off) .. apparently there is a “silent recall” on the Cobalt … this means the manufacturer attached a “special policy / rider” to these vehicles which does not expire which covers the repair and/or replacement of leaking fuel pump modules. Contact your local Chevy dealership and remind them of this special policy / rider that was attached to the Cobalt. I had no problem getting reimbursed by them after having my vehicle repaired at my local repair shop. I just had to fill out their reimbursement form and they submitted it. As for Saturn vehicles, I do not know… sorry.
Thank you I have the same pump leaking
I own a Saturn 2005 & I am having a fuel (gas) smell coming from under my car for the last 2 or 3 weeks, I called to see if the recall in the above story was on my car & it wasn’t? Now what should I do?
I am having the same issue and no response from the dealer besides we can fix it for a fee
2005 has the same fuel parts as the 2006 and no recall for the 2005 models …gas leaking into our water sewers?? More deaths?? Do not buy GM cars or trucks!!
I had this problem fixed once now it is back
I have a chevy cobalt 2006 lt bought used. For one the salesman lied to me several times during the sales process. I reported him and was told I would recieve a call, but it is literally a year and 4 months later still haven’t recieved a call. Next the car has had several repairs done due to recalls, but none of them were sent to me I had to look them up myself. My ignition switch wasn’t fixed until 4 months after purchase. I was sold an almost 10 year old car with a sticker price of 7400 was financed and told it would all be settled here in rochester. Lies the financing will being the cars total to almost 15000 not including my 2000 dollar down payment. Then I was told I would have a 2 year 100000 mile warranty, that was also a lie. Now my cobalt has a gas leak because of a faulty gas pump but no one has called me about the recall. I will be contacting a lawyer. I am done being lied to and taken advantage of. Jerrel Edmondson
Call this phone number 800-222-1020 promp #3 tell the agent about the file problem ASK FOR A CASE NUMBER. There is a special coverage for this problem. I have a appointment with GM dealership to fix. Also ask if you can get a free hour diagnostic test. Your car is going to be fine . Remember ” seek and ye Shall Find”. Have a blessed day.
P.S. Dealer did same to me?
I just did the same!!2007 Chevrolet cobalt lt seriously fuel lake while the fuel is full!! Very serious ! The police man and fire alarm car all come to my place! I was very scared!! The chervelet decided to check my problem!
I won’t buy America car anymore!!
2007 Chevrolet cobalt very serious fuel leak!! Policemen and fire alarm car come!!! I am so scared! I called the custom service! They give me a case number and I am going to the MAHER to fix it! They said if it was the problem meat ironed before, they will fix it!! Hope everything will be fine tomorrow
GM refuses to fix the recall. 2006 Saturn ION fuel pump leaks. Bastards!
Recall Number: 09V419000
Recall Date: 10/29/2009
Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
replace the fuel pump on 2001 s10 blazer 2 door and it has a strong fuel smell on the outside of truck any answers why it never had before
can GM buy back my 2006 ion Saturn? So much problems that put me in very serious driving conditions
GM hasn’t yet provided a time frame for owner notification, but if you have questions you can read the official press release after the jump or call 1-800-630-2438 (Cobalt), 1-800-972-8876 (Ion) or 1-800-620-7668 (G5).
I recently bought a 2006 cobalt and it has a fuel leak! I called chevrolet and they said that theres no recall for anything on the vehicle! It failed smog test because of the gas leak.dose anyone have any suggestions on were to start?
I bought 2006 Cobalt LS for my daughter. We have same problem. I called local Chevy dealership, gave VIN # and yes there is a recall. Keep calling or go to GM corporate.
We have a 2005 chevy cobalt and the gas tank is leaking
2003 Saturn Ion,smelling gas, took over to my local Good Year and said very dangerous, you can not drive. Gas line rusted out. I will call GM and NHTSA tomorrow January 16, 2015.
Same boat as Joe. Rusty lines at the clamp. My leak was too bad to ignore. GM said cant help me. Its a 2007 ion. Why is the recall state specific ? My fuel pump is leaking and my lines are toast in a two inch section by the clamp. Rest of the line is like new. Car is at the Dealership and I am being told to wait on the air bag recall for a couple of weeks. Make no sense. Air bag light has been blinking on occation and i am scared to drive the death trap.
fuel smell, leak puddle….found the fuel lines rusted through roughly under the passenger door, right near a plastic clamp that secures the lines to the chassis. Fuel line rusted and leaking! worst part…the fuel line is only a few inches from the hot exhaust pipe! and no recall with all these common problems. This is not only a safety hazard, its a fire hazard! GM needs to do something before we have a rash of carbques!
We are experiencing a similar issue with our 2006 Chevy Cobalt SS. Strong gas smell outside the car, but doesn’t to appear to make a difference in the gas gage and not seeing fuel on the ground. Planning on calling the dealer tomorrow am.
I am now noticing a gas smell in the garage and now inside the car on my 2009 Cobalt purchased in Florida, I mam going to check with the dealership this week, 10-6-2014, will post results, next call will be to the NTSB.
I have a 2008 saturn Ion , that smell of gas , real bad and coming home everyday for 45 min
a day give me a headach , is this a recall for saturn ? help someone
thank you
I was wondering if their are any recalls for a 2007 Saturn Ion. I just got mine two or three months ago and if has a fuel tank but I noticed the smell of gas and found out the fuel pump was broke.
Just call your local GM dealer- any Chevy, GMC, Pontiac or Buick and give them your VIN # and tell them to check for any recalls. They will gladly do that for you.
My 2006 Cobalt is leaking too. Right on driver’s side, in front of rear tire. I parked for about 30 minutes smelled gas and saw about a 12 – 15 inch size puddle. I watched it for a few seconds and saw the gas dripping.
My issue was a fuel leak that was evident on the ground as well as a strong fuel stench, both inside and outside the car. I had to inquire about special coverage at the corporate level. I was told the fuel pump mod will be replaced at no cost. The special coverage # was 12191A. Don’t know if this is specific for Saskatchewan, Canada. I also read about fuel line failures, I am hopeful the dealership will tell me if this is also a problem.
Same here. Just called GM yesterday and they have no recalls on file for my 2007 Saturn Ion 2. Whats interesting is that I found a copy of the recall letter online and my VIN is within the range, but GM says its not included.
My Saturn Ion is smelling of gas and I reported it to GM. Their is NO recall for this issue as of today 8/11/14. This is a very dangerous matter for GM to ignore.
Hi Crystal, I had to be specific and tell them fuel was leaking before I got anywhere with GM. Ask if any special coverage applies.
Mine was replaced last week. And towed beforehand. No questions asked. It’s a 2006. Dealer fixed it in one day. No charge for anything. Live in Ohio. If you smell the gas, call GM and they will direct a tow truck to get the car to the nearest dealer.
I don’t think the fuel pump repair has anyihtng to do with this problem and think it is just a coincidence. Most likely the battery itself is failing and will need to be replaced.
my sarurn 2003 ls fuel is leaking only
after rrunning but not when off.
what is reason.
Most likely a leaking gas line or seal.
My 2007 Ion has smelled like gas on and off (most of the time now) for a long time now – it comes in the can and the fumes can be strong. why no recall in northern states for this?