2004 Chevrolet Corvette Fuel System Problems

Which parts fail

• Storage › Tank assembly
  12
• Delivery › Hoses, lines/piping, and fittings
  3
• Delivery › Fuel pump
  2
• Storage
  2
• Storage › Tank assembly › Filler pipe and cap
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  4637%
• 25k–50k
  4234%
• 50k–75k
  2016%
• 75k–100k
  76%
• 100k–150k
  76%
• 150k+
  11%

Owner reports

Selected complaints filed with NHTSA by 2004 Chevrolet Corvette owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2004 Chevrolet Corvette. The contact stated while driving approximately 35 MPH, the odor of gasoline was detected by the contact and his wife. The contact stated no warning light was illuminated. The contact stated that the odor of gasoline was strongest in the cabin after refueling the vehicle to a full tank. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that a cross fill tube needed to be installed. The vehicle had been repaired. The contact stated that the gasoline odor was again detected while driving at various speeds. The contact researched online and related the failure to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The manufacturer had not been informed of the failure. The failure mileage was approximately 44,000.

The contact owns a 2004 Chevrolet Corvette. The contact stated while driving at slow speeds and approaching a stop, an abnormal odor of fuel was detected. The contact noticed there was fuel leaking in the garage. The vehicle was taken to the local dealer where it was diagnosed that the fuel tank and crossover tube cross connector needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but no additional assistance was provided. The contact stated the failure was related to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The approximate failure mileage was 41,000. The contact stated that the vehicle was repaired and is seeking reimbursement from the manufacturer for the cost.

I have owned this vehicle the last 6 years. When the amount of fuel is over one-half tank, there is an abnormal odor of fuel. When pulling into the garage, there's fuel leaking if over one-half tank. Once the engine is cut off the fuel leak ceases. To control the issue, I keep the fuel level at less than one-half tank. A certified local mechanic determined the fuel tank and crossover tube cross connector needed to be replaced. The vehicle has not been repaired. The mechanic stated the failure was related to NHTSA Action Number: PE10015 (Fuel System, Gasoline). The approximate failure mileage was 26,500, when i bought the car. The mechanic stated that GM did issue a service bulletin around 2010 stating that GM would make repairs if the failure occurred within 10 years/100,000 miles. The local GM dealer will not repair my vehicle since it is out of time frame window. …

Have been in contact with 2 employees from GM, called and left voicemails and sent emails. No reply after it was requested that I take the Corvette to my local dealership for diagnosis. The ECL motor is not working property, causing the steering wheel to lock up and fuel supply to shut off. Sent attachment with diagnosis; however, no reply. GM indicated that this was previously fixed, but it obviously was not. My assertion is that there should not be a expiration date on safety recalls, and the ECL motor is not working properly creating a very dangerous situation. This happens every time that I drive the car. There have been several instances of me starting the car, pulling into traffic, and then the car shuts down. It has been very scary as I pull the key and wait 10 seconds to restart the car. Sometimes I have to do it twice. …

In 2011 Chevrolet acknowledged an issue with the fuel system as the the attached letter states. I was not the owner of the vehicle in 2011 and since the issue was not elevated to an official recall it did not show up on the car fax report and I thus was unaware of this potential safety hazard. My car has now developed all the symptoms of the fuel tank leak with fumes in the car and gas dripping on the garage floor when parked. Although my car only has 30,000 miles the end date for GM to provide repair was August 11, 2011. The significant risk to passengers, the car, and my home when the car is parked in the attached garage is unacceptable as caused by a faulty engineered fuel modification in this model year. The fuel leak is both a safety and environmental risk and should warrant a recall and GM to mitigate the costs. …

The vehicle has a fuel leak. I just purchased this vehicle a few weeks ago, it's 16 years old and has only 36,000 miles on it. It smelled terribly of fuel when I purchased it. I had the vehicle looked at and it has a fuel leak where the quick connectors connect to the fuel tanks. Anyhow, there's a special coverage adjustment which extended the warranty to 10 yrs/100,000 miles. I'm obviously outside of those parameters, but I feel that since the manufacturer admitted fault and stated that my particular VIN is affected, they should be held accountable for fixing a safety issue with my vehicle. How they got away with issuing a special coverage adjustment for such an issue rather than a simple recall is beyond me.

A month after I purchased the car with approximately 40k miles, I took the car in for an oil change at the dealership and was told there was a major leak in the left fuel tank and at the crossover tube. This leaking fuel is leaking onto the exhaust. It would cost at least $4,000 to repair. I can not afford this. It is too dangerous to drive. I have no other car. Supposedly, my vin number is 200 numbers away from being included in the recall for the same issue and that you have 43 pages of complaints about. Did I mention that the crossover tube is a backordered part because so many are needed because when you pull the current one out, it breaks and a new one is needed?

Purchased the vehicle in 2015. That same purchased date I filled the vehicle with fuel. The following day my garage was totally covered with gas fumes. No tech could find the problem. On Feb 22 2023 while filling up, gas was pouring out the bottom left side . This is very dangerous. Come to find out that many others have had the same problem. There is a manufacturer defect of the gas tank housing tube . I cannot drive the vehicle because it's to dangerous and to costly to repair.

Drivers side fuel tank/system leak Leaking fuel in this area can/will result in a catastrophic fire which could lead to injury or death The problem just occurred but is a common problem for this generation Z06 Corvette The odd thing is no warning light, check engine light or messages displayed, just the smell of fuel and 18 inch puddle on the floor beneath the drivers side fuel tank. The fuel level according to the gauge is 1/2 tank.

Left side fuel tank developed a leak- this is a problem known to GM- they offered warranty repairs for ten years-I purchased the vehicle after this additional warranty had expired- my complaint is this is a known defective part which I would replace at my expense however GM has discontinued this part- I feel that while GM will no longer cover the cost of parts and labor the replacement parts should be available

NHTSA investigations

Fuel System complaints in other Corvette years