I have an ‘04 and I’ve got bad news. The earlier models came with a flexible crossover, but our comes with a hard crossover. Mine is also leaking, so looking into this it looks like dropping the tank requires the driveline to be pulled. Also, it’s very likely the leak is from the plastic fittings at the top of the fuel pump. So, new pump.

The GM pumps have the same faulty plastic fitting design as the original, so I’m looking at a Bosch 66080, about $327. Bosch has added a plastic gusset to the weak point in their design.

My mechanic has a 6 week waiting list, so I’m keeping below half a tank so it won’t leak in the meantime.

 

Have read about the GM/Delco fuel pump plastic fitting breaking, but if the shop that replaced the left fuel pump (if they actually did??) doubt that it is a broken fitting, unless the shop broke it during the installation(??). It could be this vent line, could be the crossover tube did not get tight, or they broke it. I plan to get the Corvette up and me under it today to have a look-see.
I had the Corvette on jack stands right after it arrived in April so I could install a remote clutch slave bleeder line. So, I had the exhaust mid pipe and tunnel cover off, sure did not appear to me that the torque tube had been removed a month or so earlier as there were no signs that any of the bolts have ever been touched. Perhaps this is the problem as the shop was not able to get the vent or crossover tight, or they broke one or both due to the small space. I did call the shop prior to receiving the Corvette and the guy told me what a PITA doing the fuel pump was. Unfortunately, since the shop is in Florida and me in Arizona....not like I will be taking the Corvette back to them.
Just another reason why I do all my own repairs if at all possible.

Hope to find out more this afternoon. If I do need a new fuel pump, I will get the Bosch one as well.

Thanks

 

My 03 Z06 with BTR Stage 2 cam, stock 243's and full exhaust with stock pump and stock injectors is about at the limit for the injectors.

In preparation for ported 243's, I picked up new injectors and Racetronix 340 pump since I plan on E85 as well.

So you're better off upgrading the pump now while everything is out. Then swap injectors when needed.

 

I'm going to replace EVERYTHING I CAN Just the looks of it is a job you dont ever want to do twice if supplying your own labor. I'm personally looking into racetronix send/pump buckets. A little bit pricier then the OE GM units but better pumps and an ideal time to install their intermediate harness as well as the upgraded hotwire harness they sell. I did a racetronix pump and harness on my C4 and couldn't be happier with it [albeit I will NEVER use the level of fuel that thing puts out]. I heard ligenfelter buckets are pretty good as well.

Joe

 

I have been under the Corvette and have yet to find for sure where the gas leak is from. Other good news is that since I have a manual trans, I have room to get my hand onto the crossover pipe. It was in the locked position, but I was able to easily rotate it until it hit the rubber lock ring. I assume there is a gasket or O-ring on the end of the crossover pipe that goes into the tank???...
I am dropping the tank down just a bit to see if I can get the crossover pipe out, but I need to empty out that left tank.....looking for ways to do this.

 

We’re pulling for ya brother! Be safe

 

Change of thought....instead of draining the tank, I am either going to slowly add fuel to it and see where it leaks, or see if I can apply some air pressure(not much though) via the filler hose and feel for the air.
I am thinking these are the possibilities: 1. crossover tube seal, 2. crossover tube itself, 3. fuel pump seal, 4. or the tank itself has a split in it.

I am so glad that I do not have to drop the drivetrain out, especially after purchasing the Katech remote cutch slave bleeder. If I had to remove the drivetrain I could have got a much cheaper remote bleeder and installed it with the drivetrain out.

 

Both the outlet elbow and power receptacle tend to crack and leak, so let’s hope that’s not it in your case…
Note in lower pic where the receptacle is placed how Bosch has added the gusset.

 

When I was at the fuel station filling-up, the waterfall of fuel that I saw when I looked under the Corvette makes me think it has to be the crossover. Also, if the fuel pump really was replaced, just doubt that it is cracked, unless of course the shop broke it when they installed it. I would sure go with the Bosch unit over the Delco.
I still have not got the crossover tube to come out of the left tank yet. It is difficult to get a good grip on it and pull straight out per the Service Manual.

I have been searching for how to separate the two connections within the crossover tube; have not found anything yet.

Will make another attempt this afternoon.

 

I just had both tanks out not too long ago to replace the pumps and senders on my '04. The crossover tube is not fun to get out - and my driveline was out when I pulled mine. Patience and persistance is what did it for me. When I got the tube far enough out to see the internal pipes, I wiggled and pulled the tank side connectors until they came loose. There are 2 o-rings in each tank where the crossover tube locks in - you should replace those while you are at it - GM 10376929 X2 - one set for each tank.

 

UPDATE: yesterday I forgot to check the EVAP line above the crossover tube, finally did this afternoon and I found it disconnected! Would this be the where the fuel would leak from???
I pulled on the crossover tube, got it to move a small distance out of the left tank, but felt like I was compressing a spring and it would only go so far before snapping back into the left tank.
I assume this is the locking tab for the two plastic return lines that I am bending. I can see why these break.

Anyways, my next step is to add fuel to see if the leak is still there on the outside chance that the un-mated EVAP line was the problem....although I do not see how it could be.
I think I need to replace those two O-rings in the tank. Wonder if the shop removed those O rings, did not put them back as the crossover does move easily for a short distance.

Time to go try adding fuel...I have a tub under the left fuel tank....just in case.

 

It can certainly cause it if the tanks are full enough. If the o-rings for the crossover tube were left out or damaged, that will definiely cause a leak.

 

Well.....crap!!.....added fuel....still leaking. Although it is not from the crossover tube. So either fuel pump fitting or fuel pump seal or tank is damaged. Will have to remove the left tank to find out.
So I get to fight with the crossover tube and HOPE that I do not break those return tubes. Not looking forward to this at all.

Later

 

 

I can pull the crossover tube out of the tank such that I can see the ends of the two plastic tubes, but it will not release and springs back. I have pulled it back and put the end of the crossover tube onto the edge of the tank but it always springs back in. I am only able to hold the crossover tube out for a few seconds as that "spring" is strong! From looking on YouTube I am pulling the two plastic lines that go to the fuel pump out of the tank, cannot believe that I have not broken the anything yet.
I am going to come-up with something that I can put between the tank outlet and the crossover tube that will not block the two tube connector so that I am able to pry on the connector to get this joint to separate.
Do not understand how this joint can be so stuck together IF the fuel pump was replaced three months ago. Hopefully the shop did not glue the tubes in place or something!!
If I have no progess, then I will likely just cut the lines on the fuel pump side and replace them at $90 or try to repair them as I have read in another posting.

 

Got the feed / return lines apart!!!!! Fought me every second. With the end of the crossover pulled-out of the tank and position just right such that the feed / return lines connector was not against the tank opening, I push and pried with a screwdriver on the connector and it finally gave way!
Got the tank out, still has about 3-4 gal of fuel in it, I rotated the tank to bring fuel around the fuel pump seal....yep, fuel came out. Removed the fuel pump ring, lifted pump up to find the tank seal broken and twisted. Good job there shop....NOT!

Anyways, have to get an order in for a new pump seal, crossover O rings, EVAP connector lock, probably get feed / return lines for the tank as well. I did break the upper tab off of the connector.
Oh and some good news.....the fuel pump had been replaced as it is very white and clean. Now the question...do I replace it with the Bosch pump to avoid having to do this again???

What a major PITA!!

 

If you already have a new GM pump go with it. Good job BTW!

Take any pics?

 

I have not taken any pictures, but will and add to this. Anything in particular you want to see?

 

Interested to see how it looks going back together, especially coupling the return lines. I hope they go together easier than they separated 👍

Now would be the time to have GoPro, right? We’d not only collect intel, but also the “dialogue” 😁

Ps. Documented well, you could turn this into a sticky for 2004 cars. I’m ve not seen this covered without removing the drivetrain.

 

From what I read, this is possible ONLY because I have a manual transaxle, which is smaller than the auto transaxle, thus there is room to get hands on the crossover, not much room though.

When the time comes to re-assemble, I am going to apply some silicon grease to the O rings for the return / feed lines and the crossover tube prior, hopefully this helps.

Going to be two weeks before the parts arrive, give my forearms a chance to heal. (Like I said, not much room.)