Katerina Swanson
Replacing the fuel lines on a C3 Corvette is a job that requires some space to work, but you won't need to jack up the car. There are two to four flexible rubber fuel lines attached to the gas tank in various places. You'll need about 3 feet of 1/4-inch fuel hose to replace them, and possibly a length of 3/8-inch hose, depending on your model year. You should also order a replacement spill collector and drain line while you've got the tank out.
| Characteristics | Values |
|---|---|
| Number of fuel lines | 2-4 |
| Fuel line material | Flexible rubber |
| Fuel line size | 1/4-inch or 3/8-inch fuel grade hose |
| Fuel line replacement | Replace with fuel grade hose |
| Fuel tank removal | Remove the cross-member and straps, then lower the tank |
| Fuel line reattachment | Reinstall the sender/fuel feed assembly with a new O-ring, tighten with a hammer and screwdriver, then reattach wires and fuel line |
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What You'll Learn
Removing the gas tank
To remove the gas tank from your C3 Corvette, you'll first need to undo the straps hooked into the removable cross-member. The gas tank sits on the fixed cross-member, so you can then work it free and lower it on a jack.
You'll notice two to four flexible rubber fuel lines going to hard steel tubes attached to the frame of the car. These are 1/4-inch or 3/8-inch fuel grade hoses, and you should replace them while the tank is out of the car. You'll also see a rubber spill collector attached to the fuelling neck of the tank, with a drain line running alongside the tank. This is an inexpensive item, so it's worth replacing this too.
To prepare for this job, give yourself plenty of room to work. You don't need to jack up the car, but you will need some space behind it.
Once you've replaced the fuel lines, you can reinstall the sender/fuel feed assembly using a new O-ring. Drift it tight using a hammer and flat-blade screwdriver, then reattach the wires and fuel line.
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Flexible rubber fuel lines
To access the fuel lines, you will need to remove the gas tank from the car. This involves undoing the straps hooked into the removable cross-member and lowering the tank on a jack. With the tank out, you will be able to see the flexible rubber fuel lines attached to the hard steel tubes on the car's frame. There may be two or more of these lines, and they can be challenging to describe due to Chevrolet's frequent design changes over the years.
When replacing the fuel lines, it is recommended to also replace the rubber spill collector and its drain line, as these are inexpensive and easily accessible with the tank removed. You may also want to consider upgrading to braided stainless steel lines, as these are very durable and show zero wear even after many years of use. Additionally, you can run some 3/8-inch plastic flex wire conduit around the lines for further protection from abrasion.
Ensure you have adequate workspace behind the car when undertaking this task. While you don't need to jack up the entire vehicle, having some space to manoeuvre will make the job easier.
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Reattaching the fuel line
To reattach the fuel line, you will need about 3 feet of 1/4-inch fuel hose. Make sure to use fuel-grade hose, not just rubber hose. You may also need a length of 3/8-inch hose, depending on your model year.
With the tank out of the car, you can see the fuel lines. There are two to four of them attached to the tank in various places. The number and placement of the fuel lines may vary depending on the year of your Chevrolet Corvette, as the manufacturer made substantial changes over the years.
You will notice at least two flexible rubber fuel lines going to hard steel tubes attached to the frame of the car. Once you have identified the fuel lines, you can begin the process of reattaching them.
First, make sure that the tank is securely in place. Then, reinstall the sender/fuel feed assembly using a new O-ring. Use a hammer and a flat-blade screwdriver to tighten the assembly. Finally, reattach the wires and fuel line.
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Using the correct fuel hose
When replacing the fuel lines on a C3 Corvette, it is important to use the correct fuel hose. The fuel lines are flexible rubber hoses that connect to hard steel tubes attached to the frame of the car. There are at least two fuel lines, and they are all 1/4-inch or 3/8-inch fuel grade hoses.
It is important to use the correct size and type of hose when replacing the fuel lines. Do not use just any rubber hose; make sure to use a hose that is made to handle fuel. This will ensure that the repair is durable and long-lasting.
The type of hose you use will depend on the model year of your C3 Corvette. For example, if you have a 1978 C3 Corvette, you may want to consider using braided stainless steel lines, as these have been shown to be very durable with zero wear even after many years of use.
In addition to the fuel hose, you will also need a replacement spill collector and drain line. These are inexpensive items that you should replace while you have the tank out of the car. You will need about 3 feet of 1/4-inch fuel hose, and possibly a length of 3/8-inch hose depending on your model year.
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Replacing the spill collector and drain line
To replace the spill collector and drain line, you will need to remove the gas tank from the car. This will allow you to see the fuel lines. There are two to four fuel lines attached to the tank in various places. They are all 1/4-inch or 3/8-inch fuel grade hose.
You will need about 3 feet of 1/4-inch fuel hose to replace the lines. Make sure to get fuel-grade hose, not just rubber hose. You may also need a length of 3/8-inch hose, depending on your model year. You should also order a replacement spill collector and drain line.
To remove the gas tank, first undo the straps that are hooked into the removable cross-member. The gas tank should then sit on the fixed cross-member, and you can work it free and lower it on a jack.
With the tank out, you can replace the spill collector and drain line. The spill collector is a rubber part attached to the fuelling neck of the tank, with the drain line running alongside the tank.
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Frequently asked questions
There are two to four fuel lines attached to the tank in various places.
You should use 1/4-inch or 3/8-inch fuel grade hose. Don't use rubber hose, get the stuff that's made to handle fuel.
You should replace the rubber spill collector and drain line. You may also need a length of 3/8-inch hose, depending on your model year.
Undo the straps that are hooked into it. The gas tank should sit on the fixed cross-member, and you can now work it free and lower it on the jack.
You can reinstall the sender/fuel feed assembly using the new O-ring and drift it tight using a hammer and flat-blade screwdriver.
