In automotive engineering, the performance and reliability of fuel systems depend heavily on the quality of their sealing components. Gaskets used in fuel applications must withstand continuous exposure to hydrocarbons, aggressive fuel additives, fluctuating temperatures, and mechanical pressure.

Using the wrong material choice for the role each gasket plays can result in seal degradation, increased emissions from vapour leaks, premature component failure under stress, and safety risks such as fuel leaks and potential fire hazards. Selecting the right fuel-compatible gasket material is therefore critical, not only for ensuring a tight seal but also for maintaining system performance, longevity, and safety. At Dobson Gaskets, we specialise in supplying high-quality, fuel-resistant sealing solutions matched to their specific thermal and chemical conditions.

Gasket Materials for Fuel Systems

Choosing a gasket material with the correct fuel resistance, temperature rating, and mechanical stability ensures the integrity of the fuel system, improves vehicle reliability, and supports regulatory compliance.

Nitrile Rubber (NBR): A Versatile Choice for Conventional Fuel Applications

Nitrile rubber (NBR) is one of the most widely used materials in automotive fuel system gaskets due to its excellent resistance to petrol, diesel, and mineral oils. It offers a cost-effective balance of chemical resistance and flexibility. Typically, NBR seals are ideal for standard petrol or diesel-powered vehicles with conventional fuels and moderate operating temperatures.

• Temperature range: -30°C to +120°C (up to 135°C short-term)
• Chemical compatibility: Excellent with hydrocarbon fuels and lubricants
• Common uses: Fuel pump seals, carburettor gaskets, fuel line connectors

Viton® (FKM): Premium Resistance for Ethanol Blends and High Temperatures

Viton®, a fluoroelastomer (FKM), is ideal for modern fuel systems exposed to E10–E85 ethanol-blended fuels, biofuels, and high under-hood temperatures. It maintains its sealing integrity under chemically aggressive and high-heat environments. These properties make Viton® the ideal choice for high-performance engines and vehicles using ethanol or alternative fuels.

• Temperature range: -20°C to +200°C (up to 250°C short-term)
• Chemical compatibility: Outstanding with petrol, diesel, ethanol blends, and additives
• Common uses: Fuel injector O-rings, fuel rail seals, high-performance engine gaskets

Fuel-Grade Cork-Rubber: Traditional Material for Low-Pressure Fuel Applications

Cork materials, often bonded with NBR, provide compressibility and conformability ideal for low-pressure fuel systems, usually found in older vehicles or classic car restorations. While not suited for high-pressure environments, cork-rubber offers reliable sealing for legacy designs.

• Temperature range: -20°C to +120°C
• Chemical compatibility: Good when combined with nitrile binder
• Common uses: Fuel tank cap gaskets, carburettor base gaskets, vintage engine seals

Aramid Fibre with NBR Binder: Durable Solution for Engine Bay Sealing

Aramid fibre gasket sheets bound with NBR provide a robust sealing option for fuel system components exposed to both chemical and mechanical stress. These materials are reinforced for strength and resilience under compression and are ideal for heavily loaded sealing environments and engine compartment assemblies.

• Temperature range: -30°C to +250°C
• Chemical compatibility: Good with fuels, oils, and coolants
• Common uses: Flange gaskets, fuel manifold seals, pump housings

PTFE (Teflon®): Chemically Inert for Demanding Fuel System Requirements

PTFE (Polytetrafluoroethylene) is a chemically inert material suited for aggressive fuels and additives, offering outstanding thermal and chemical resistance. It is often used in high-performance aftermarket applications and high-specification, performance-critical systems with exposure to aggressive fuel blends or high temperatures.

• Temperature range: -200°C to +260°C
• Chemical compatibility: Excellent – resistant to virtually all fuel types and chemicals
• Common uses: Fuel injector spacers, sealing layers in composite gaskets, custom fuel fittings

Non-Asbestos Fibre (NAF): Reliable Option for Aftermarket and Legacy Systems

NAF materials provide a safe and effective alternative to legacy asbestos gaskets and are commonly used in both OEM and aftermarket applications. They offer decent thermal stability and good fuel resistance when retrofitting or replacing gaskets in older vehicles and non-critical fuel applications

• Temperature range: -30°C to +250°C
• Chemical compatibility: Good with petrol, diesel, and oil
• Common uses: Aftermarket gasket kits, fuel system maintenance on legacy engines

 Trust Dobson Gaskets for Fuel System Sealing Solutions

Choosing the right gasket material is vital to ensuring fuel system integrity, performance, and safety, especially in today’s demanding automotive environments. From conventional petrol and diesel engines to high-performance and ethanol-blended fuel systems, each application demands a sealing solution matched to its specific thermal and chemical conditions. With decades of experience supporting the automotive industry, we offer custom-cut gaskets tailored to your exact specifications.

If you're designing, maintaining, or upgrading a fuel system, partner with Dobson Gaskets to ensure precision, reliability, and compliance every time.