A plastic and brass insert molded connector was leaking fuel vapor. The overmolding shrinkage allowed a leak path. There was no room for a conventional silicone connector seal, and the volume swell from fuel exposure also created unacceptable high forces on the connector. The customer requested help with a fuel resistant seal of the connector pins and the connector housing that would also fit inside the existing connector dimensions. The seal also must not create high assembly force. Within 2 days, concept samples were fabricated and put on test. Low volume production (150 seals) was initiated 1 week after the initial contact. Within 2 weeks, another 500 seals were produced and shipped to the customer for assembly. In an effort to continue the accelerated DV testing, parallel testing of fuel permeation, volume swell and temperature was conducted by IER Fujikura and the customer. Low volume production (hundreds of parts per week) was maintained while the final design of the seal, the connector, and the valve were finalized. In addition to the rubber formulation meeting the fuel, temperature and assembly requirements, a unique terminal pin seal was incorporated to accommodate commercial tolerance variation.