Corvette 1997-2005

Removal & Installation

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2003 With Feedback Fuel System (FFS) And 2004-05 Models



These models have 2 fuel tanks (right and left). The fuel pump is part of the fuel sender assembly in the left fuel tank. The right fuel tank contains a fuel sender assembly with a siphon jet pump which supplies fuel to the left tank through the fuel sender feed pipe. Although there are 2 sending units, the removal and installation procedure is the same for both.

Click image to see an enlarged view

Fig. These models have 2 fuel tanks connected by a fuel sender feed pipe

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Rear tire
     
    Rear wheelhouse panel
     
    Mufflers
     
    Driveline support assembly
     
    Fuel filler hose
     
    Fuel pump electrical connector
     
    Crossover tube
     
    Evaporative emission (EVAP) crossover pipe quick connect fitting
     
    Fuel tank strap
     
    Fuel tank
     
    Jet line insert connector from crossover tube to fuel tank opening
     
    Fuel supply hose from clip on side of the tank
     

  8.  
  9. Using Fuel Sender Lock Ring Tool J-39765-A, remove the fuel pump module locking ring.
  10.  
  11. Carefully remove the fuel pump module from the tank.
  12.  

To install:

  1. Install a new fuel pump module O-ring to the fuel tank opening.
  2.  
  3. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the tank.
  4.  
  5. Install the pump module into the tank halfway.
  6.  
  7. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
  8.  
  9. Secure the line into the module retaining clip and remove the tape.
  10.  
  11. Compress and align the fuel pump module into the fuel tank and fully lock the ring in place using Fuel Sender Lock Ring Tool J-39765-A.
  12.  
  13. Install or connect the following:
    NOTE
    Lubricate the O-ring mating surfaces with the rubber lubricant.



    Fuel supply hose
     
    Jet line insert connector into the crossover tube to fuel tank opening
     
    Fuel tank
     
    Fuel tank strap
     
    EVAP crossover pipe
     
    Crossover tube
     



    Fuel filler hose. Tighten the clamp to 35 inch lbs. (4 Nm).
     
    Fuel pump electrical connector
     
    Driveline support assembly
     
    Mufflers
     
    Rear wheelhouse panel
     
    Rear tire
     
    Negative battery cable
     

  14.  
  15. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.
  16.  

Without Feedback Fuel System (FFS)



These models have 2 fuel tanks (right and left). The fuel pump is part of the fuel sender assembly in the left fuel tank. The right fuel tank contains a fuel sender assembly with a siphon jet pump which supplies fuel to the left tank through the fuel sender feed pipe.

Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tanks.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Both rear wheels
     
    Fuel tank shield
     

  8.  
  9. Clean the area around the fuel sender assembly.
  10.  
  11. Mark each fuel line to help identify them during installation.
  12.  
  13. Remove or disconnect the following:

    Quick connect fittings from the fuel sender
     
    Fuel sender electrical connector
     
    Fuel tank strap and properly support the fuel tank
     
    Fuel sender attaching bolts and discard them
     
    Float arm retaining clip and the float arm (left side sender only)
     
    Fuel sender and gasket. Discard the gasket
     

  14.  

To install:


NOTE
Always install a new fuel strainer before installing the fuel sender. A strainer that has been exposed to fuel will not unfold completely and may interfere with the full travel of the float arm.

  1. Install or connect the following:
    WARNING
    Do not damage the float arm during installation.



    New fuel strainer on the sender
     
    New gasket on the fuel sender
     

  2.  
  3. Fold the strainer 3 times so the strainer is about the same size as the opening in the tank. Insert the fuel sender in the tank. It may be necessary to turn the fuel sender to ease installation. Look into the opening to ensure that the long strainer is about 1 inch from the opening; if not, rotate the pump assembly back-and-forth until the strainer is visible. Install the float arm and retaining clip.

    Click image to see an enlarged view

    Fig. Fold the strainer on itself 3 times so it will fit into the opening in the fuel tank

  4.  
  5. Align the fuel sender gasket tab with the fuel sender cover mark and align the cover mark with the fuel tank mark. Install new break away head attaching bolts to the fuel sender and hand-tighten them.
    CAUTION
    The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower section of the bolt when the proper torque is reached. Do not tighten the bolts after the head is sheared off.

  6.  
  7. Tighten the new break away attaching bolts in sequence until the hex head shears off of the lower section.
  8.  
  9. Install or connect the following:

    Fuel sender fuel feed pipe, fuel return rear pipe and the fuel feed rear pipe
     
    Fuel sender electrical connector
     
    Fuel tank strap. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel tank shield. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Both rear wheels
     
    Negative battery cable
     

  10.  
  11. Fill the fuel tank and install the fuel filler cap.
  12.  
  13. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

    Click image to see an enlarged view

    Fig. Tighten the fuel pump mounting bolts in the sequence shown-5.7L engine

  14.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tanks.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Both rear wheels
     
    Fuel tank shield
     

  8.  
  9. Clean the area around the fuel sender assembly.
  10.  
  11. Mark each fuel line to help identify them during installation.
  12.  
  13. Remove or disconnect the following:

    Quick connect fittings from the fuel sender
     
    Fuel sender electrical connector
     
    Fuel tank strap and properly support the fuel tank
     
    Fuel sender attaching bolts and discard them
     
    Float arm retaining clip and the float arm (left side sender only)
     
    Fuel sender and gasket. Discard the gasket
     

  14.  

To install:


NOTE
Always install a new fuel strainer before installing the fuel sender assembly. A strainer that has been exposed to fuel will not unfold completely and may interfere with the full travel of the float arm.

  1. Install the new gasket on the fuel sender.
    WARNING
    Do not damage the float arm during installation.

  2.  
  3. Fold the long strainer in half over itself and hold the strainer in this position.
  4.  
  5. Pinch both strainers upward toward each other.
  6.  
  7. Install the float arm through the fuel tank opening with the folded strainers. Release the strainers.
    NOTE
    It may be necessary to rotate the sender for proper installation.

  8.  
  9. Look into the fuel tank opening and make certain that the long strainer is visible. If it is not visible, rotate the fuel sender until the strainer is free
  10.  
  11. Align the fuel sender gasket tab with the fuel sender cover mark and align the cover mark with the fuel tank mark.
  12.  
  13. Install the new break away head attaching bolts to the fuel sender and hand tighten them.
    CAUTION
    The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower section of the bolt when the proper torque is reached. Do not tighten the bolts after the head is sheared off.

  14.  
  15. Tighten the new break away attaching bolts in sequence until the hex head shears off of the lower section.
  16.  
  17. Install or connect the following:

    Fuel sender fuel feed pipe and rear crossover pipe
     
    Fuel sender electrical connector
     
    Fuel tank strap. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Fuel tank shield. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Both rear wheels
     
    Negative battery cable
     

  18.  
  19. Fill the fuel tank and install the fuel filler cap.
  20.  
  21. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

    Click image to see an enlarged view

    Fig. Tighten the fuel pump mounting bolts in the sequence shown-5.7L engine

  22.  

 
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