Corvette 2005-2008

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.

Click image to see an enlarged view

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

  1. Disconnect the 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
     
    Jet line insert connector from crossover tube to fuel tank opening
     
    Fuel supply hose from clip on side of the tank
     
    Using Fuel Sender Lock Ring Tool J-39765-A, remove the fuel pump module locking ring.
     
    Carefully remove the fuel pump module from the tank.
     
    Press on the 3 connector position assurance (CPA) lock tabs and slide downward.

    Click image to see an enlarged view

    Fig. Press on the 3 connector position assurance (CPA) lock tabs and slide downward as shown

     
    Disconnect the electrical connector from the module.
     
    Remove the sender wires from the connector.
     
    Push in the lock tab above the level sender body and slide the level sender out of the slot.

    Click image to see an enlarged view

    Fig. Push in the lock tab above the level sender body and slide the level sender out of the slot as shown

     
    Remove the level sender from the module. Ensure wires are routed into the slot in the back of the level sender body
     

  10.  

To install:

  1. Insert NEW level sender assembly into slot and slide down until lock tab (1) engages.
  2.  
  3. Route wires next to regulator ground wire and up to electrical connector.
  4.  
  5. Slide the level sender wires into the open slots in the electrical connector.
  6.  
  7. Connect the electrical connector into the flange.
  8.  
  9. Test the level sender resistance with an ohmmeter.
    1. Empty stop = 38.5-41.5 ohms.
    2.  
    3. Full stop = 247-253 ohms.
    4.  
    5. No open circuits along the full sweep.
    6.  

  10.  
  11. Install the jet line insert through the crossover tube to fuel tank opening.
  12.  
  13. Install a new fuel pump module O-ring to the fuel tank opening.
  14.  
  15. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the tank.
    NOTE
    Pull on each connector to ensure that the connectors are properly latched.

  16.  
  17. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
  18.  
  19. Install the pump module into the tank halfway, taking care not to damage the float arm.
  20.  
  21. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
  22.  
  23. Place the jet line with no connector in the module retainer cup.
  24.  
  25. Secure the line into the module retaining clip.
  26.  
  27. Remove the tape from the jet line with a connector.
    NOTE
    Pull on each connector to ensure that the connectors are properly latched.

  28.  
  29. Connect the jet line quick-connect connectors to the fuel pump module inner port.
  30.  
  31. 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.
  32.  
  33. Measure the resistance across the level sender with tank upright. Should read empty tank.
  34.  
  35. Roll tank over. Resistance should read full stop.
  36.  
  37. Return tank to upright position. Ensure proper empty stop resistance. This is done to ensure the level sender operates freely inside the tank and is not hung up on any of the internal lines.
  38.  
  39. 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
     
    Reconnect the negative battery cable
     

  40.  
  41. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.
  42.  

 
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