Replacing Fuel Pump In C3 Corvette: Step-By-Step Guide

Replacing the fuel pump on a C3 Corvette is not necessarily difficult, but it can be a messy job. You will need to lift the car to remove the old fuel pump and install the new one. You will also need tools such as screwdrivers, pliers, a crescent wrench, standard sockets, extensions, and a ratchet. It is also important to have a basin or bucket to catch the gasoline that will come out once you disconnect the fuel lines.

Remove the right-hand wheel and reach pump bolts with a socket and long extensions

To remove the right-hand wheel and reach the pump bolts with a socket and long extensions, you will first need to lift the car and remove the right-hand wheel. This will give you access to the fuel pump. You will also need to secure the car so that it won't roll and ensure that it is supported by jack stands.

Once you have removed the right-hand wheel, you will need to reach the pump bolts with a socket and long extensions. This can be done by going through the inner fender hole or the wheel well. You will need to remove one of the pump bolts that is almost pointing to the RH fuel pump bolt. This bolt is usually all by itself and looks like it is not doing anything. Remove this bolt and insert a longer bolt (5x16x2 inches) to hold the fuel pump pushrod in place. Make sure to snug the bolt down by hand to avoid damaging the pushrod.

It is important to note that you will need to lock the fuel pump pushrod in place before removing the pump. This can be done by using grease or mechanical fingers to hold it in place. You will also need to disconnect the fuel lines before removing the pump, as fuel will spray out. Have a bucket or basin ready to catch the spilled fuel.

Additionally, you may need to remove the A/C compressor to access the fuel pump bolts. This will involve removing two bolts that hold the compressor in place, as well as a clamp for a hose and one fitting.

Disconnect fuel lines and plug them to prevent fuel spray

Disconnecting the fuel lines can be one of the more challenging tasks when replacing a fuel pump. There are various line styles, and different methods are required to disconnect them.

For a push-type connector, you may need to push from both directions to release it. For a push-and-lock style connector, you push the locking tab through, release the safety latch, and push the connector back through.

A pinch-type connector will require you to pinch the retainers on each side to disconnect it. For a spring-style retainer fitting, pull back on the black ring to release it.

The hose and clamp style fitting, typically used for emissions lines, will need to be pinched with pliers to release the clamp, then the line can be pulled off.

Another pinch-type connector, often found in emissions lines, will also need to be pinched on both sides to release it.

A horseshoe-type fitting will require the use of a screwdriver to release the clip holding it in place.

When disconnecting the fuel lines, be prepared to plug the lines to prevent fuel spray. Rubber hose pincher pliers are a good option to minimize fuel spillage. Drill bits can also be used to plug the lines, but ensure you use the shank portion and not the cutting edge.

It is important to note that fuel will spray out once the lines are disconnected, so have a bucket or basin ready to catch the spillage, and always keep a fire extinguisher nearby.

Remove the pump and the pump base plate

To remove the pump and the pump base plate, you will first need to disconnect the fuel lines. Have a bucket or basin ready to catch the fuel that will come out once you disconnect the lines. You can use rubber hose pincher pliers to minimise the amount of spilled fuel. If you don't have any, you can use drill bits instead—a 3/8" for the fuel delivery line, and a 5/16" for the vapor return line. Make sure to plug the lines with the shank portion of the drill bit, not the cutting edge.

Once the lines are disconnected, you can remove the pump. Before you install the new pump, you will need to remove the pump base plate. You will also need to have a new fuel pump plate gasket or the proper gasket material to make one. Alternatively, you can clean the original pump baseplate if it is in good condition.

To keep the pushrod out of the way while you work, you can use grease to keep it pushed up. You can also remove one of the block bolts next to the pump base and replace it with a longer bolt to hold the pushrod in place. Make sure you only snug this bolt by hand to avoid damaging the pushrod.

Grease the pump pushrod to keep it in place during installation

To grease the pump pushrod, you can use grease or vaseline. This will keep it in place during installation. It is also recommended to use a longer bolt to hold the pushrod in place. This involves removing the short bolt in the tunnel for the FPR and installing a longer one to hold the rod in place. Remember to put the original bolt back in after.

There are a few different methods to hold the pushrod in place. One is to use grease or vaseline, another is to use the longer bolt method. You can also use a U-shaped piece of brass or steel welding rod to hold the rod in place, or a hacksaw blade.

If you are using grease, it is recommended to use a thick grease such as wheel bearing grease or "Lucas Red n Tacky". This will ensure that the grease is able to hold the weight of the pushrod. You can also use "assembly lube", which one user describes as "thick grease".

Reconnect fuel lines and clamps, and use a wrench for the line that connects to the brass fitting

Once you've installed the new fuel pump, you'll need to reconnect the fuel lines and clamps. You should use a flare or line nut wrench for the line that connects to the brass fitting. When you've done this, you're ready to start the engine and check for leaks. If each step has been performed correctly, there shouldn't be any.

To reconnect the fuel lines, you'll need to reach one of the pump bolts with a socket and long extensions. Chevy engineers have made a provision for the removal of the bolt. The remaining bolt can be easily reached from under the vehicle.

Before you put the pump in, disconnect the lines and be prepared to plug them, as fuel will spray out. Mechanical pumps are gravity-fed, but a lot of fuel can gush out of the delivery line. Use a bucket or basin to catch the fuel. Rubber hose pincher pliers can be used to minimise the amount of spilled fuel. Alternatively, you can use drill bits. A 3/8" bit is suitable for the fuel delivery line, and a 5/16" bit for the vapor return line. However, this method is messier. Make sure to plug the lines with the shank portion of the drill bit, not the cutting edge.

Frequently asked questions