GTP Fires and Gas Line O-ring Leaks

[CarPartSearcher]

[b]Special Viton o-rings need replacing on the GTP's fuel line connection point to the fuel rail on top of the engine under the decorative plastic cover TO PREVENT ANY MORE FIRES.[b]

Somewhere on some forums I read this and I saw a picture of a burning GTP.
This alerted me to the problem of old o-rings causing leaking gas. As others have said they and I have smelled gas when we were driving sometimes. My 97 has 160000 miles. I pulled over, pulled the cover and there was the wet spot.

The nightmare comes when you want to simply replace the special o-rings. I checked with Pontiac. They only list and have the 1 smaller viton (brownish colored) o-ring for the gas "supply" feed line, the smaller of the 2 lines. Their fix is for you to buy $175 new gas lines and spend all day replacing them from the engine to the gas tank! Thanks GM.

After searching every auto parts store around and a special rubber company this is what I found:

1. Forget Napa. They all list one 2 o-ring kit (# 2-18416) which looks wrong and may only be for the "supply" feed line.

2. While the specialty rubber company had viton o-rings, they said I needed metric sizes which they did not have.

3. SOLUTION: Go to Autozone or Carquest or any auto parts store that carries the "HELP!" line of hardware boxes. You need box #80020 O-RING assortment $7 -7.50ea. In there will be only 1 of the larger "return" line size o-ring and 2 of the "supply" feed line o-rings.

NOTE: You will need the special disconnect tool (Autozone Dorman #800-009 $4 to push in to relieve the 4-prong clip that holds the line connector on. If you try multiple screwdrivers to release the clip you will be buying a new clip (Autozone).

Before you start to remove the old o-rings: You will need a bright flashlight (I bought a new superbright LED flashlight - Radio Shack), some way to magnify (I used 2 pairs of prescription glasses together!) and a o-ring removal tool. IF YOU EVEN TOUCH the first white colored o-ring - it will cut thru it like wax. Forget about finding one of those or know what it is or why there is 2 types of o-rings there. Either carefully don't touch it OR replace it with a Viton o-ring as I did. Of course I ruined the larger "return" line white o-ring (which there is only 1 in the assorted kit) so I got to make another 30 minute drive to search the city for another $7 kit! Maybe both should be replaced anyway.

NOTE: It took me a while to figure out where the 2 grooves actualy were for the o-rings. Then finally I discovered there is a rigid fiber ring between the 2 o-rings that may move around, so make sure it is in the middle of them.

I replaced them with a little saliva for lube, it was snug and NO LEAKS! Finally.

I believe eveyone with a GTP with 75000 miles or more should get these replaced to prevent any more fires. Of course GM is not going to do it the cheap way!

[BNaylor]

Good info and write up. Thanks.

[KX2000GTP]

Do you have any pics that would aid in this replacement?