Corvette 1997-2005

Fuel Pump

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Removal & Installation



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.  

LH Side Fuel Tank (All Other Configurations)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left fuel tank.
  4.  
  5. Place the fuel tank on a suitable work surface.
  6.  
  7. Disconnect the fuel pump jumper harness from the fuel pump module.
  8.  
  9. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
  10.  
  11. Disconnect the fuel feed line from the welded clip on the side of the fuel tank.
    CAUTION
     The fuel pump module is spring-loaded and will spring upward when the locking ring is removed.

  12.  
  13. Using the J39765-A, remove the fuel pump module locking ring.

    Click image to see an enlarged view

    Fig. Removing fuel sending unit from LH fuel tank

  14.  
  15. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
  16.  
  17. Disconnect the jet line quick-connect connectors from the fuel pump module inner port.
  18.  
  19. Remove the jet line from the module retainer cup. This line has no attached connector.
  20.  
  21. Remove the fuel pump module O-ring from the fuel tank opening.
  22.  
  23. Remove the jet line insert through the crossover tube to fuel tank opening.
  24.  

To install:

  1. Inspect the jet line insert for damage and replace if necessary.
  2.  
  3. Install the jet line insert through the crossover tube to fuel tank opening.
  4.  
  5. Install a new fuel pump module O-ring to the fuel tank opening.
  6.  
  7. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the fuel tank.
  8.  
  9. Install the pump module into the fuel tank half way , taking care not to damage the float arm.
  10.  
  11. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
  12.  
  13. Place the jet line with no connector in the module retainer cup.
  14.  
  15. Secure the line into the module retaining clip.
  16.  
  17. Remove the tape from the jet line with a connector.
    NOTE
     Pull on each connector to ensure that the connectors are properly latched.

  18.  
  19. Connect the jet line quick-connect connectors to the fuel pump module inner port.
  20.  
  21. Compress and align the fuel pump module into the fuel tank, while taking care not to damage the float arm.
  22.  
  23. Install the fuel pump module lock ring.
  24.  
  25. Using the J39765-A, fully lock the fuel pump module lock ring in place.
  26.  
  27. Connect the fuel supply line into the weld clip on the side of the fuel tank.
  28.  
  29. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.
    NOTE
    Correct resistance readings are 40 ohms at empty and 250 at full tank.

  30.  
  31. Connect the jet line insert connector into the crossover tube to fuel tank opening.
  32.  
  33. Connect the fuel pump jumper harness to the fuel pump module.
  34.  
  35. Install the left fuel tank.
  36.  

RH Side Fuel Tank (All Other Configurations)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the right or left fuel tank.
  4.  
  5. Place the fuel tank on a suitable work surface.
  6.  
  7. Disconnect the EVAP purge line from the fuel pump module.
  8.  
  9. Disconnect the fuel pump module harness connector.
  10.  
  11. Disconnect the FTP sensor harness connector.
  12.  
  13. If replacing the fuel pump module, remove the FTP sensor.
  14.  
  15. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
    CAUTION
     The fuel pump module is spring-loaded and will spring upward when the locking ring is removed.

  16.  
  17. Using the J39765-A, remove the fuel pump module locking ring.
  18.  
  19. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
  20.  
  21. Disconnect the jet line quick-connect connectors from the fuel pump module, noting the location of the lines for installation.
  22.  
  23. Remove the fuel pump module O-ring from the fuel tank opening.
  24.  
  25. Remove the jet line insert through the crossover tube to fuel tank opening.

    Click image to see an enlarged view

    Fig. Showing fuel line arrangement on 5.7L with FFS, showing the FTP harness (1) and sensor (2), purge line connector (3), EVAP purge line (4), and fuel pump module harness connector (5)



    Click image to see an enlarged view

    Fig. Showing fuel sending assembly removed from tank (right side shown; left side similar)

  26.  

To install:

  1. Inspect the jet line insert for damage and replace if necessary.
  2.  
  3. Install the jet line insert through the crossover tube to fuel tank opening.
  4.  
  5. Install a new fuel pump module O-ring to the fuel tank opening.
    CAUTION
     Pull on each connector to ensure that the connectors are properly latched.

  6.  
  7. Pull the jet line quick-connectors up through the pump module opening, connecting the lines to the pump module as previously noted.
  8.  
  9. Install the pump module into the fuel tank, taking care not to damage the float arm.
  10.  
  11. Compress and align the fuel pump module, while installing the lock ring.
  12.  
  13. Using the J39765-A, fully lock the fuel pump module lock ring in place.
  14.  
  15. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading. Resistance should be 40 ohms when empty to 250 ohms when full.
    CAUTION
     Pull the jet line insert connector to ensure that the insert is properly attached.

  16.  
  17. Connect the jet line insert connector into the crossover tube to fuel tank opening.
  18.  
  19. If replacing the fuel pump module, install the FTP sensor.
  20.  
  21. Connect the FTP sensor harness connector.
  22.  
  23. Connect the fuel pump module harness connector.
  24.  
  25. Connect the EVAP purge line from the fuel pump module.
  26.  
  27. Install the fuel tank.
  28.  

W/O FFS
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and when a hoist supports the vehicle, support the vehicle with jack stands at the opposite end from which the components are being removed.

  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the rear wheel and tire assembly.
  8.  
  9. 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.
  10.  
  11. Drain the fuel tanks.
  12.  
  13. Remove the fuel tank shield.
  14.  
  15. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
  16.  
  17. Disconnect the quick-connect fittings from the fuel sender.
  18.  
  19. Cap all of the fuel pipes.
  20.  
  21. Disconnect the fuel sender electrical connector.
  22.  
  23. Remove the fuel tank strap.
  24.  
  25. Support the fuel tank.
  26.  
  27. Remove the fuel sender attaching bolts.
  28.  
  29. Remove the float arm retaining clip and the float arm for the left fuel sender only.
  30.  
  31. Carefully remove the fuel sender with the gasket.
  32.  
  33. Clean the gasket sealing surfaces.
  34.  

To install:

Left


CAUTION
Do not bend or twist the float arm during installation.

  1. Install 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.
  2.  
  3. Install a sender gasket on the fuel sender.
  4.  
  5. Insert the fuel sender through the fuel tank opening.
  6.  
  7. The fuel sender may need to be rotated in order to facilitate the installation.
  8.  
  9. Insert the float and the float arm into the fuel tank opening.
  10.  
  11. Install the float arm retaining clip.
  12.  
  13. Align the fuel sender gasket tab with the fuel sender cover mark.
  14.  
  15. Align the fuel sender cover mark with the fuel tank mark. Tighten the fuel sender attaching bolts until the bolts are finger tight.

    Click image to see an enlarged view

    Fig. Showing fuel sender assembly bolt tightening sequence

  16.  
  17. Tighten the fuel sender assembly attaching bolts in proper sequence, as shown. Tighten bolts to 7 Nm (62 inch lbs.).

    Click image to see an enlarged view

    Fig. Showing fuel line arrangement

  18.  
  19. Connect the fuel sender fuel feed pipe (1) from the jet pump to the left tank, to the fuel return rear pipe (2), and to the fuel feed rear pipe (3).
  20.  
  21. Connect the fuel sender electrical connector.
  22.  
  23. Install the fuel tank strap (3).
  24.  
  25. Install the fuel tank strap bolts (1, 2, 4). Tighten the bolts as follows:

    Tighten the bolt (2) to 25 Nm (18 ft. lbs.).
     
    Tighten the bolt (1) to 25 Nm (18 ft. lbs.).
     
    Tighten the remaining bolts (4) to 25 Nm (18 ft. lbs.).
     

  26.  
  27. Install the fuel tank shield.
  28.  
  29. Install the fuel tank shield mount bolt.
  30.  
  31. Install the fuel tank shield mount nut. Tighten as follows:

    Tighten the fuel tank shield mount bolt to 25 Nm (18 ft. lbs.).
     
    Tighten the fuel tank shield mount nut to 12 Nm (106 inch lbs.).
     

  32.  
  33. Install the rear wheel and tire assembly.
  34.  
  35. Lower the vehicle.
  36.  
  37. Refill the fuel system.
  38.  
  39. Install the fuel filler cap.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Perform the following steps to inspect for leaks:
  44.  
  45. Turn the ignition switch ON for 2 seconds.
  46.  
  47. Turn the ignition switch OFF for 10 seconds.
  48.  
  49. Turn the ignition switch ON.
  50.  
  51. Inspect for fuel leaks. Program the transmitters.
  52.  

Right


CAUTION
Do not bend or twist the float arm.



Click image to see an enlarged view

Fig. Showing the fuel sending unit assembly on 5.7L V8 engines

  1. Inspect the fuel sender gasket for damage and replace if necessary.
  2.  
  3. Insert the float arm through the fuel tank opening.
  4.  
  5. The fuel sender may need to be rotated in order to facilitate the installation.
  6.  
  7. Align the fuel sender gasket tab (2) with the fuel sender cover mark (1).
  8.  
  9. Align the fuel sender cover mark (1) with the fuel tank mark.

    Click image to see an enlarged view

    Fig. Showing fuel sender assembly bolt tightening sequence

  10.  
  11. Hand tighten the fuel sender attaching bolts until finger tight.
  12.  
  13. Tighten the fuel sender assembly attaching bolts in sequence. Tighten the bolt to 7 Nm (62 inch lbs.).
  14.  
  15. Connect the fuel sender fuel feed pipe (1) (from the jet pump to the left tank, and the fuel feed rear crossover pipe (2) from the left tank to the jet pump).
  16.  
  17. Connect the fuel sender electrical connector.

    Click image to see an enlarged view

    Fig. Showing the fuel sender fuel feed pipe (1) and fuel feed crossover pipe (2) on 5.7L V8 engines



    Click image to see an enlarged view

    Fig. Showing the location of fuel tank strap (3) and retaining bolts (1, 2, 4) on Corvette 5.7L V8 engines

  18.  
  19. Install the fuel tank strap (3).
  20.  
  21. Install the fuel tank strap bolts (1, 2, 4). Tighten as follows:

    Tighten the bolt (2) to 25 Nm (18 ft. lbs.).
     
    Tighten the bolt (1) to 25 Nm (18 ft. lbs.).
     
    Tighten the remaining bolts (4) to 25 Nm (18 ft. lbs.).
     

  22.  
  23. Install the fuel tank shield (1).
  24.  
  25. Install the fuel tank shield mount bolt (2).
  26.  
  27. Install the fuel tank shield mount nut (3). Tighten retainers as follows:

    Tighten the fuel tank shield mount bolt to 25 Nm (18 ft. lbs.).
     
    Tighten the fuel tank shield mount nut to 12 Nm (106 inch lbs.).
     

  28.  
  29. Install the rear wheel and tire assembly.
  30.  
  31. Lower the vehicle.
  32.  
  33. Refill the fuel system.
  34.  
  35. Install the fuel filler cap.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Perform the following procedure in order to inspect for leaks:
  40.  
  41. Turn the ignition switch ON for 2 seconds.
  42.  
  43. Turn the ignition switch OFF for 10 seconds.
  44.  
  45. Turn the ignition switch ON.
  46.  
  47. Inspect for fuel leaks.
  48.  
  49. Program the transmitters.
  50.  

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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