Corvette 1997-2005

Removal & Installation

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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.

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

  1. Negative battery cable
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Remove or disconnect the following:

    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
     

  10.  

To install:

  1. 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
     

  2.  
  3. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.
  4.  

 
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