Fuel Pump: Installation

Fig 1: Fuel Pump Module

Install the fuel level sensor (3).
Install the fuel level sensor retaining clip.
Connect the fuel level sensor electrical connector.
Install the fuel level sensor electrical connector retaining clip.
Connect the fuel pump electrical connector.
Install the fuel tank pressure sensor (1).
Install the fuel sender assembly.

CAUTION: Always replace the fuel pump "O" ring when reinstalling the fuel pump assembly.

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. DO NOT repair sections of fuel pipes.

NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. DO NOT use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Position the NEW "O" ring on the fuel tank.

CAUTION: Care should be taken not to fold over or twist the fuel pump strainer (4) when installing the fuel pump assembly, as this will restrict the fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

Install the fuel pump assembly and the retainer cam, using the Fuel Sender Locknut Wrench (J-39765). Install the quick-connect fittings at the fuel sender assembly.
Connect the electrical connector to the fuel tank pressure sensor. Connect the electrical connector to the fuel sender assembly.
Install the negative battery cable. Inspect for leaks. Turn ON the ignition switch for 2 seconds. Turn OFF the ignition switch for 10 seconds. Turn ON the ignition switch. Check for fuel leaks.
Install the fuel sender access panel. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Install the rear compartment floor trim.
Install the spare tire, the jack, and the spare tire cover. Add fuel to the fuel tank. Install the fuel filler cap.

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket and the fuel sender attaching bolts when reinstalling the fuel sender assembly.

To install the left fuel sender assembly, Install a NEW fuel pump strainer in the same position as noted during removal. Push on the outer edge of the strainer ferrule until the strainer is fully seated.

Install a NEW fuel sender gasket on the fuel sender. Fold the strainer three times so that the amount of space occupied by the strainer is about equivalent to the diameter of the fuel sender reservoir. See Fig 3. Fold the long side of the strainer over (1 over 2). Fold 3 over 4 and hold the strainer in the folded position. Insert the fuel sender through the fuel tank opening. Release the strainer once the strainer is in the fuel tank. The strainer will spring back to its full position.
Continue inserting the fuel sender through the fuel tank opening. It may be necessary to rotate the fuel sender in order to facilitate the installation. Look through the fuel tank opening to ensure that the long side of the strainer is visible. If the strainer is not visible, rotate the fuel sender clockwise and counterclockwise about 90 degrees. Rotating the fuel sender will free up the strainer. The strainer should become visible at the tank opening.

CAUTION: DO NOT bend or twist the float arm. Insert the float and the float arm into the fuel tank opening. Install the float arm retaining clip.

Align the fuel sender gasket tab (1) with the fuel sender cover mark (2). See Fig 4. Align the fuel sender cover mark (2) with the fuel tank mark. Hand tighten the NEW "break-away head" fuel sender attaching bolts until finger tight.

CAUTION: Use NEW "break-away head" bolts upon installation. The upper hex head portion of the fuel sender attaching bolts is designed to shear off of the lower section of the bolt when the proper torque is reached. DO NOT tighten the bolts after the bolt heads have sheared off. A torque wrench or other special tools are not required. DO NOT use thread locking or other types of sealers or lubricants when installing these bolts and gasket.

Tighten the NEW "break-away head" fuel sender assembly attaching bolts in sequence until the upper hex head portion of the bolts shear off of the lower section. See Fig 5. Connect the fuel sender fuel feed (1) pipe (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3). See Fig 6.
Connect the fuel sender electrical connector. Install the fuel tank strap. Install the fuel tank strap bolts. See Fig 2. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
Install the fuel tank shield (1). See Fig 1. Install the fuel tank shield mount bolt (2). Install the fuel tank shield mount nut (3). Tighten the fuel tank shield mount bolt to specification. Tighten the fuel tank shield mount nut to specification.
Install the rear wheel and tire assembly. Tighten wheel lug nuts to specification. Lower the vehicle. Refill the fuel system. Install the fuel filler cap. Connect the negative battery cable. Inspect for leaks. Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.

Fig 1: Removing/Installing Fuel Tank Shield - Left Tank (Corvette)