One problem related to tank mounting has been reported for the 2005 Chevrolet Cobalt. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Chevrolet Cobalt based on all problems reported for the 2005 Cobalt.
A hose from the fuel tank to the evap canister, came off allowing explosive gasoline vapors to enter the air. This hose is pressed on with no clamp holding the hose in place on the fuel tank. There is a positive lock on the evap canister side of the hose, but nothing holding the hose to the fuel tank. The new fuel tank, (tank and hose one item), also has no clamp at the fuel tank. In addition to allowing explosive vapors into the air, the cost of the repair is huge. The tank assembly, (the hose and fuel tank are one item), is $500, plus installation. Chevy and gm were notified and I was told, "the parts are off the vehicle and nothing will be done about this. " to find this defect, the parts , (tank), must be removed from the vehicle. The car has 45000 miles and has never been in a crash or had any damage to it. This hose has no tension on it, just the lack of a clamp allowing it to come loose. The gasoline vapors escaping from the tank in an enclosed area, like a garage, could lead to an explosion and fire, (I'm a retired firefighter). Damage to the environment by escaping gasoline vapors also occurs, (that's why the hose is there in the first place). This negligence in the design on the part of gm could be corrected with a simple low cost clamp on the hose. This defect causes the consumer to spend a large amount of money needlessly, exposes the environment to gasoline vapor damage and could potentially explode, killing someone. Please look into this issue.