On my 66 mustang, I've installed a new gas tank, sender etc. It leaks around the fuel inlet seal area. It came with a large rubber washer/gasket which I spread a thin layer of blue sealer to. It seemed to hold at first, but now leaks when I put several gallons into the tank. Any better way to seal it up?

Just save yourself some headaches and replace it, heres the one for your car ,, http://www.autopartswarehouse.com/details/QQPontiacQQAztekQQAC_DelcoQQFuel_FilterQQ20032004QQACGF819.html?apwcid=P1135867996W43b3f85c7ab9e&apwiduYv5ZLE

this code is for a large evap system leak. it could be the gas cap not sealing properly or a vent hose has come off possible seal around fuel sender. the most common cause is a loose or faulty gas cap. a smoke tester is what is needed to find a leak it basically fogs the system and pressurizes the fuel tank any leaks will be seen by a "smoke" coming out of the area.

The procedure you are thinking about doing is the correct procedure but you need to know that there is a rubber seal behind the large nut. Best to remove the line, remove the large nut and replace the rubber seal. Overtorquing the nut will crack the plastic radiator tank. Double check BOTH fluid levels and conditions when finished.

1992-96 Models

Be sure this procedure is done in a well ventilated area.

1. Disconnect the negative battery cable.
2. Relieve the fuel pressure.
3. Remove the rear seat cushion.
4. Remove the floor service hole cover.
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.

Fig. 6: Pull back the rug under the rear seat to access the fuel pump and sending unit cover

1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
2. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet

pipe from the pump bracket.

1. Remove the pump bracket attaching screws.
2. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
3. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
4. Remove the sending unit attaching screws, then remove the unit from the bracket.
5. Pull the lower side of the fuel pump from the bracket.
6. Unplug the connector to the fuel pump.
7. Disconnect the hose from the pump.
8. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
9. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
10. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.

To install:

1. Install the pump filter using a new clip. Install the rubber cushion under the filter.
2. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
3. Engage the connector to the fuel pump.
4. Install the fuel sending unit to the pump bracket.
5. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
6. Connect the return hoses to the pump bracket.
7. Install the service hole cover, then the engage the fuel pump and sending unit connector.
8. Install the rear seat cushion.
9. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

Hope this help (remember comment and rated this).

It is the fill pipe rubber seal

In the fuel tank.

2000 Chevrolet Corvette V8-5.7L VIN G

Fuel Pump: Service and Repair
REMOVAL PROCEDURE (LEFT OR RIGHT)
TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Tool Set, Fuel Line Quick Connect Separator
CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the rear wheel and tire assembly.
5. Clean all of the fuel connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the
fuel system.
6. Drain the fuel tanks. Refer to Fuel Tank Draining Procedure.
7. Remove the fuel tank shield.
8. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
9. Disconnect the quick-connect fittings from the fuel sender.
10. Cap all of the fuel pipes.
11. Disconnect the fuel sender electrical connector.
12. Remove the fuel tank strap.
13. Support the fuel tank.
14. Remove the fuel sender attaching bolts. Remove previously installed "break-away head" service bolts using a 5/16 inch open end wrench.
15. Discard the fuel sender attaching bolts.
16. Remove the float arm retaining clip and the float arm (left fuel sender only).
17. Carefully remove the fuel sender with the gasket.
18. Discard the fuel sender gasket.
19. Clean the gasket sealing surfaces.
INSTALLATION PROCEDURE (RIGHT)
CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket
and the fuel sender attaching bolts when reinstalling the fuel sender assembly.
1. Install a new fuel sender gasket on the fuel sender.
2. Fold the long strainer in half over itself and hold the strainer in this position.
3. Pinch both strainers upward toward each other.
IMPORTANT: Do not bend or twist the float arm.
4. Insert the float arm through the fuel tank opening followed by the folded strainers.
5. Release the strainers once the strainers are in the fuel tank. The strainers will spring back to their full position.
6. Continue inserting the fuel sender through the fuel tank opening. It may be necessary to rotate the fuel sender in order to facilitate the installation.
6.1. Look through the fuel tank opening to ensure that the long strainer is visible.
6.2. If the strainer is not visible, rotate the fuel sender clockwise and counterclockwise about 90 degrees. Rotating the fuel sender will free up
the strainer. The strainer should become visible at the tank opening.
7. Align the fuel sender gasket tab (2) with the fuel sender cover mark (1).
8. Align the fuel sender cover mark (1) with the fuel tank mark.
NOTE: Refer to the Fastener Notice in Service Precautions.
9. Hand tighten the new "break-away head" fuel sender attaching bolts until finger tight.
IMPORTANT: The upper hex head portion of the fuel sender attaching bolts is designed to shear off of the lower section of the bolt when the
proper torque is reached. Do not tighten the bolts after the bolt heads have sheared off. A torque wrench or other special tools are not required. Do
not use thread locking or other types of sealers or lubricants when installing these bolts and gasket.
10. Tighten the new "break-away head" fuel sender assembly attaching bolts in sequence until the upper hex head portion of the bolts shear off of the
lower section.
11. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank) and the fuel feed rear crossover pipe (2) (left tank to jet pump).
12. Connect the fuel sender electrical connector.
13. Install the fuel tank strap (3).
14. Install the fuel tank strap bolts (1,2,4).
Tighten
14.1.Tighten the bolt (2) to 25 N.m (18 lb ft).
14.2.Tighten the bolt (1) to 25 N.m (18 lb ft).
14.3.Tighten the remaining bolts (4) to 25 N.m (18 lb ft).
15. Install the fuel tank shield (1).
16. Install the fuel tank shield mount bolt (2).
17. Install the fuel tank shield mount nut (3).
Tighten
^ Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
^ Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).
18. Install the rear wheel and tire assembly.
19. Lower the vehicle.
20. Refill the fuel system.
21. Install the fuel filler cap.
22. Connect the negative battery cable.
23. Inspect for leaks.
23.1.Turn the ignition switch ON for 2 seconds.
23.2.Turn the ignition switch OFF for 10 seconds.
23.3.Turn the ignition switch ON.
23.4.Inspect for fuel leaks.
24. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
25. Perform the idle learn procedure. Refer to PCM Idle Learn Procedure.
INSTALLATION PROCEDURE (LEFT)
IMPORTANT: Always install a new fuel pump strainer before reinstalling the left fuel sender assembly. A fuel pump strainer that has been
exposed to fuel will not unfold in the fuel tank and may block full travel of the float arm.
1. Install a new fuel pump strainer in the same position as noted during disassembly. Push on the outer edge of the strainer ferrule until the strainer
is fully seated.
CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket
and the fuel sender attaching bolts when reinstalling the fuel sender assembly.
2. Install a new fuel sender gasket on the fuel sender.
3. Fold the strainer three times so that the amount of space occupied by the strainer is about equivalent to the diameter of the fuel sender reservoir.
3.1. Fold the long side of the strainer over (1 over 2).
3.2. Fold 3 over 4 and hold the strainer in the folded position.
4. Insert the fuel sender through the fuel tank opening.
5. Release the strainer once the strainer is in the fuel tank. The strainer will spring back to its full position.
6. Continue inserting the fuel sender through the fuel tank opening. It may be necessary to rotate the fuel sender in order to facilitate the installation.
6.1. Look through the fuel tank opening to ensure that the long side of the strainer is visible.
6.2. If the strainer is not visible, rotate the fuel sender clockwise and counterclockwise about 90 degrees. Rotating the fuel sender will free up
the strainer. The strainer should become visible at the tank opening.
IMPORTANT: Do not bend or twist the float arm.
7. Insert the float and the float arm into the fuel tank opening.
8. Install the float arm retaining clip.
9. Align the fuel sender gasket tab (1) with the fuel sender cover mark (2).
10. Align the fuel sender cover mark (2) with the fuel tank mark.
NOTE: Refer to the Fastener Notice in Service Precautions.
11. Hand tighten the new "break-away head" fuel sender attaching bolts until finger tight.
IMPORTANT: The upper hex head portion of the fuel sender attaching bolts is designed to shear off of the lower section of the bolt when the
proper torque is reached. Do not tighten the bolts after the bolt heads have sheared off. A torque wrench or other special tools are not required. Do
not use thread locking or other types of sealers or lubricants when installing these bolts and gasket.
12. Tighten the new "break-away head" fuel sender assembly attaching bolts in sequence until the upper hex head portion of the bolts shear off of the
lower section.
13. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3).
14. Connect the fuel sender electrical connector.
15. Install the fuel tank strap (3).
16. Install the fuel tank strap bolts (1,2,4).
Tighten
16.1.Tighten the bolt (2) to 25 N.m (18 lb ft).
16.2.Tighten the bolt (1) to 25 N.m (18 lb ft).
16.3.Tighten the remaining bolts (4) to 25 N.m (18 lb ft).
17. Install the fuel tank shield (3).
18. Install the fuel tank shield mount bolt (1).
19. Install the fuel tank shield mount nut (2).
Tighten
^ Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
^ Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).
20. Install the rear wheel and tire assembly.
21. Lower the vehicle.
22. Refill the fuel system.
23. Install the fuel filler cap.
24. Connect the negative battery cable.
25. Inspect for leaks.
25.1.Turn the ignition switch ON for 2 seconds.
25.2.Turn the ignition switch OFF for 10 seconds.
25.3.Turn the ignition switch ON.
25.4.Inspect for fuel leaks.
26. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
27. Perform the idle learn procedure. Refer to PCM Idle Learn Procedure.

Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks

1. Drain enough fuel from tank to prevent spilling, no more than 4 gallons (16 liters) of fuel should remain. Use suitable pumping equipment.
2. Remove floor mat and panel from trunk.

1. Disconnect wiring harness connector to sending unit. Remove wires from connector.
2. Disconnect ground wire to sender. Push wires through grommet.
3. Remove cover for access to tank sending unit.

1. All models: Disconnect from the fuel tank sending unit:

1. Breather hose C
2. Return hose A
3. Supply hose B
4. Filler hose D
5. Wiring harness from clip E

1. Clean area and unscrew fuel tank sender/pump cap or equivalent. Remove tank sender/pump and seal.
2. Remove pump from sender/pump assembly.

INSTALLATION

1. Inspect the pump for damage, feed pump hose and wiring for wear. Replace as needed.
2. Install new pump to sender/pump assembly.
3. Install rubber seal in neck of tank. Lubricate inside of seal.

1. Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
2. Apply rustproofing compound to exposed metal portions of tank sender.

CAUTION : With tape or rubber caps, protect fuel sender openings from overspray.

1. Torque fuel tank sender/pump lock ring to: 22 ft-lb (30 Nm)
2. Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.

you'r EVAP system is not purging the system . I suspect it is your charcoal canister located in the left side of the engine compartment located near the master cylinder its a piece of cake to change it just slides up after you diconect the lines .

Best bet is to replace gas tank. It could hae a hairline fracture somewhere. Sounds like pretty much everything else was replaced already.