Understanding the intricacies of your Chevy Corvette’s fuel system is crucial for maintenance and repair. One key component is the fuel crossover line, which utilizes specific O-rings to ensure a leak-free seal. This guide provides detailed specifications for these O-rings, empowering you with the knowledge needed for servicing your Corvette.
The fuel crossover tube/in-tank line in your Corvette features two ports of different sizes. The smaller male port, serving as the pressure line, measures 5/16″ or 0.313″. The larger male port is the low-pressure return line, with a diameter of 3/8″ or 0.375″. Correctly identifying these ports is the first step in ensuring proper O-ring replacement.
For the smaller pressure line port, a “2-011” size O-ring is required. This port utilizes a set of three sealing components: a black O-ring positioned deepest within the port, a PEEK backup ring, and a yellow (softer) O-ring. This configuration is designed for a dual-seal approach. The softer yellow O-ring acts as a pre-seal, preventing debris and unfiltered fuel from reaching the primary (harder) black seal. The PEEK backup ring acts as a separator, maintaining the integrity of the two O-rings.
When selecting replacement O-rings, material choice is paramount, especially with modern fuel formulations. Standard gasoline is compatible with BUNA or Nitrile seals. However, contemporary fuels often contain alcohol, which can degrade Nitrile. For enhanced durability and compatibility with alcohol-containing fuels, Viton, also known as Fluoroelastomer or Fluorocarbon (FKM), is a superior option.
Pressure within the fuel crossover line is relatively low, allowing for specific durometer (hardness) considerations for the O-rings. For the primary seal (black O-ring in the smaller port and the single O-ring in the larger port), a “70 Shore A” durometer is appropriate. The softer yellow O-ring in the smaller port should be made of a softer compound, ideally around “50 Shore A”.
The larger return line port utilizes a “2-012” size O-ring. This port uses a single O-ring. A 70 Shore A durometer is also suitable here. Again, Viton is highly recommended for its resistance to both gasoline and alcohol fuels, offering a more robust and long-lasting seal compared to Nitrile in modern fuel environments.
In summary, when servicing the Chevy Corvette Crossover fuel line, ensure you use the correct “2-011” and “2-012” O-ring sizes. For optimal performance and longevity, especially with today’s fuel blends, choosing Viton O-rings is a worthwhile upgrade. Understanding these specifications will help ensure a proper and durable repair for your Corvette’s fuel system.
