This Preliminary information communicates provides information to the technician on the use of R-99 or R-95 Renewable diesel fuel.
full bulletin at NHTSA ↗2006 Chevrolet Cobalt fuel system problems
moderate 205 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
205
Recalls
0
Avg fix
$1,200
2crashes
1fire
1injury
When does it fail?
Of the 205 fuel system complaints filed for the 2006 Chevrolet Cobalt, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 6 model years of Chevrolet Cobalt we track for fuel system problems, this one carries the most owner complaints on file — 205.
Owners have filed 205 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or P0455 Set.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible cause of engine oil consumption, misfire, cylinder leakage or blow by. Technician will need to inspect the engine for Cylinder damage or scoring, An out of round cylinder bore, Dirt intrusion, and Catalytic Converter failure.
full bulletin at NHTSA ↗This SKU is a Fuel Line Kit. The customer communication requested return of unsold inventory to rework the end connections. If the end connecors are not fixed, the customer will be unable to install the product. This issue does not affect on-vehicle performance, only install.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
2006 Chevrolet Cobalts develop fuel leaks from the fuel pump module, primarily where the plastic supply and return lines crack or connections loosen. Owners detect strong gasoline odor inside the cabin and outside the vehicle, often accompanied by visible fuel puddling under the car, typically near the top of the fuel tank. The problem crops up across a wide mileage range—some owners report it as early as 33,000 miles, others at 130,000-plus. In hot climates or during extended heat waves, the failure seems more pronounced. When fuel leaks near the exhaust or ignition sources, owners correctly flag a fire hazard. Repair costs run $400–$1,100 out of pocket, usually requiring fuel pump module or fuel tank assembly replacement. A significant frustration: GM issued recall 09V419000 (also referenced as 090226) but restricted it to specific states (Arizona, Nevada, California, Florida, Texas, and others) and excluded vehicles outside the recall window by VIN or mileage. Owners in non-covered states or with higher mileage report being denied coverage despite having identical defects. Some dealers claim VINs don't appear in their recall database at all, even when vehicles match the description perfectly. A few owners mention receiving recall notices but encountering dealer resistance or "no problem found" diagnoses despite obvious odor and visible leaks.
Same Chevrolet Cobalt fuel system reports on nearby years: 2005 · 2007 · 2008 · 2009
Failure modes owners describe
Cracked fuel pump plastic supply/return lines
The plastic supply or return port on the modular reservoir assembly (MRA) cracks, allowing fuel to leak from the fuel pump module area at the top of the fuel tank.
When: Occurs across various mileage ranges, typically 28,000–144,000 miles; appears more frequent in hot climates or sustained high temperatures (90+ degrees).
Symptoms owners cite: Strong gasoline odor inside and outside vehicle; Visible fuel puddling beneath vehicle, particularly near top of fuel tank; Gasoline smell present while driving and after parking; Gasoline fumes inside cabin
Repairs/costs cited: Fuel pump module replacement; some owners cite $304–$1,100 in parts and labor. Tank drop-down required. One owner replaced with same defective part under recall in 2008 and experienced failure again by 2014.
Recalls/TSBs owners mention: Recall 09V419000 (GM recall 090226, NHTSA 09V419000) issued October 2009, but limited to vehicles originally sold or currently registered in Arizona, Nevada, California, Florida, and Texas for 2006 models; 2007 models cover additional states. Special coverage adjustment #09275A available in 14 states (Alabama, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee, Texas) for 2006 models. VIN-specific: many owners outside the recall states or with VINs not flagged in the system are denied coverage. Several owners report receiving recall notices but encountering dealer refusal to honor them or diagnostic refusal (no problem found despite visible leaks).
Fuel line detachment or fracture at fuel pump connection
Fuel supply or return lines disconnect or fracture at the point where they attach to the fuel pump or fuel sending unit, causing fuel leakage.
When: One owner reported at 60,000 miles; another at unspecified mileage after notice of abnormal odor.
Symptoms owners cite: Strong fuel odor inside vehicle, affecting driveability; Fuel leak with no warning light illumination
Repairs/costs cited: Fuel line repair or replacement. One owner noted the leak location constituted a fire hazard due to proximity to ignition sources.
Recalls/TSBs owners mention: Covered under recall 09V419000 in select states only. Owner in non-covered state denied reimbursement by manufacturer.
Fuel pump seal leakage
The seal on the fuel pump leaks, causing fuel to drip from the pump assembly onto the ground and into the vehicle cabin.
When: Reported at 60,000 miles and beyond.
Symptoms owners cite: Gasoline odor entering and exiting vehicle; Fuel dripping visible under parked vehicle; Smell present when windows are down
Repairs/costs cited: Fuel pump seal or fuel pump assembly replacement. Repair costs cited as $550+ by at least one dealer.
Recalls/TSBs owners mention: Recall 09V419000 applicable in select states only; owners outside those regions denied coverage even when parts match recall specification.
Defective fuel pump module (repeat failure)
Fuel pump module replaced under recall in 2008 failed again by 2014 with identical symptoms; owner suspects defective replacement part.
When: Original failure 2008 under recall; recurrence 2014 with $569.38 quoted for re-replacement.
Symptoms owners cite: Gas leak and odor recurrence after prior repair; Fuel pump module sealing failure
Repairs/costs cited: Original repair completed February 2008 under recall 09226; second repair cost estimate $569.38 for parts and labor (February 2014).
Recalls/TSBs owners mention: Recall 09226 (2008) covered initial replacement; when same issue recurred, owner received no coverage.
Synthesized from 205 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Tl*the contact owns a 2006 Chevrolet cobalt. The contact stated that there was a strong smell of fuel from the passenger side of the vehicle. The dealer stated that the vehicle was included in recall 09v419000 (fuel system, gasoline: delivery: fuel pump). The current and failure mileages were 35,700.
Had fuel system trouble with your 2006 Chevrolet Cobalt?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2006 Chevrolet Cobalt?
It's a documented issue but not catastrophic. 205 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 173 complaints that reported odometer mileage, most fuel system failures cluster between 56,000 and 97,000 miles, with the median around 76,000. A quarter of owners report trouble before 56,000; a quarter make it past 97,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Chevrolet/Cobalt.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.