2005 Chevrolet Corvette Fuel system Problems

“Vehicle has a very strong gasoline smell following refueling. The gasoline vapors invade the passenger cabin to the extent the windows have to be down for ventilation. It remains that way until the fuel tank reaches half full, and disappears as the tank reaches 1/4 full. Now I only fil the tank to 1/2 full to minimize the vapor. I am concerned that a spark may ignite the vapor if the tank were filled . …”

“If I put more than 1/2 tank of fuel there is a strong odor of fuel coming from the car and inside the passenger cabin. The smell is so strong that I can't drive the car with the windows up. If I park the car in my garage, the garage fills with fumes from the gas. I see fuel puddles under the car in front of the driver rear wheel. The fuel smell is in the car whether the car is moving or not.”

“Vehicle turns over but will not start fuel pump relay was changed and it started but then a week later same thing happened I switched fuel pump relay several times and stiil did not start, finally starting after reapeated attemps and swithing relays. I think there is something wrong with the contacts on the relay box. This has and continues to happen since stated date.”

“With approximately 38,000 miles on my 2005 Corvette, I began smelling gas fumes whenever I would fill the gas tank. The fumes would fill my garage and also leaked into my house. I took the car into the dealership. After about 7 weeks, they informed me that I needed to replace one of the gas tanks and the rear main seal, which cost $2,700. The night I picked my car up from the shop, I parked it in the garage. The next morning, my garage was once again filled with fumes, so I dropped the Corvette off at the dealership and let them know that the problem was not fixed. …”

“The fuel pump assembly is made of plastic. This plastic on fuel pump outlet has developed a small crack due to the inferior plastic, causing high pressure fuel to spray out, pool on top of tank, and drip down the side of the tank near the hot exhaust. Apparently this has been a problem on multiple year c6 corvettes and GM doesn't not want to issue a recall.”