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 ALSO HAVE A GASLINE LEAK WHERE IT RUSTED THROUGH ON OUR 2007 ION THEY ARE REPLACING THE FUEL PUMP ON RECALL BUT ARE CHARGING ME $375 TO INSTALL A NEW FUEL LINE WHEN THE TANK WILL ALREADY HAVE TO HAVE BEEN REMOVED TO FIX THE FUEL PUMP. I THINK THEY ARE DOUBLE BILLING ON SOME OF THE LABOR. WHAT CAN BE DONE?
James,
Would you feel comfortable sharing the last 8 of your VIN that was part of the Fuel Pump recall? I just had to get mine replaced and I think it’s part of the recall, but GM is saying not.
I have a Saturn Ion as well and mine is leaking very bad. It now takes me $20 to go 10 miles down the road. Every time I put gas in it will start pouring out. It’s starting to make me mad. I was told by GM that it would have to be paid for out of my pocket BUT IT WONT!!!! They are going to fix mine if I have to pull it in there to the service part and watch them. I paid for my car in cash so it is paid off. I want my car fixed!!!!
Thanks for the information about the National Highway Traffic Safety Administration. First of all I didn’t know how widespread this problem really is. Second I guess I’m just gonna expect to run into a brick wall with the GM dealership when I make my call tomorrow morning. But this gas leak is pissing me off and making me sick at the same time.
I TOO HAVE BEEN BATTLING MY LOCAL DEALER ABOUT CHEVY COBALT EXTREMELY HAZARDOUS FUEL SYSTEM LEAKING GAS. THIS IS CLASSIFIED UNDER GM’S CRAFTY “HIDDEN RECALL” AND LOCAL DEALERS ARE NOT — AT THIS TIME — AUTHORIZED TO DO THE REPAIR. GM CARES NOT THAT FAMILY’S LIVES ARE IN SERIOUS DANGER OF GOING UP IN FLAMES AS THE COBALT EXPLODES. I AM CURRENTLY BATTLING GM TO COVER THIS DEFECT, AS I AM ALSO REQUESTING THE NHTSA TO OPEN A “DEFECTS INVESTIGATION” OVER THIS DANGEROUS DEFECT. I WOULD STRONGLY ENCOURAGE ANYONE EXPERIENCING THIS PROBLEM TO PLACE A CALL TO THE NHTSA — NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION — IN WASHINGTON D.C., PHONE — 1-800-424-9393, IMMEDIATELY! THIS IS AN OFFICIAL GOVERNMENT AGENCY THAT TAKES ITS RESPONSIBILITY FOR DRIVER SAFETY VERY, VERY SERIOUSLY! IT IS THE ONLY WAY TO GET GM TO DO THE RIGHT THING AND TAKE ACTION TO CORRECT THE DEFECTS THAT GM KNOWS ALL TO WELL EXIST. DON’T TAKE THIS LYING DOWN. YOU CAN, AND SHOULD, CONTACT NHTSA SINCE THEY HAVE THE CLOUT TO HOLD GM ACCOUNTABLE. DO IT NOW!!!!!!!!!!!!!!!!!!
I just filed a complaint today with the NHTSA for the same reason. Hopefully they will do something about it.
I just did the same.
I just had to have mine replaced on 10/8/15, I am filing a compliant today with the NTSB
thank you
Thank you for the info. I had to replace a rusted fuel line as well on my 2007 Ion. My dealer charged almost $600 to replace it. GM gave me the run-around also. It’s good to know I’m not the only one with this problem. I will definitely call the NHTSA. We have to hold GM accountable for this dangerous defect. I strongly encourage everyone who has this problem to report it!
I JUST EXPERIENCED A STRONG SMELL OF GAS ON MY CAR! WE GOT OFF CUZ MY HUSBAND AND I WERE FRELING NAUSIATED. WE LOOKED UNDER CAR AND NOTICED A LEAK COMING FROM THE GAS LINE MEETING THE GAS TANK. PAT LONGORIA
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I have ION II, 2003 which has the same problem, it smells gas, I found gas on the ground when I fill up the tank. I called the GM dealer, he said there is no recall on my car and he is not willing to do the repair free of charge.
I had the fuel pump replace due to the safety alert at the dealer on a 2007 ion. Just over a year the pump has to be replaced for 600.00. Is there a warranty on this type of equipment/service?
We have a 2006 Cobalt. It’s started to have a strong gas smell. Does this recall available in Texas. We live in Uvalde, Tx. Please let me know if it’s good in Tx. So I can take it to be checked