Corvette Fuel Pump Replacement: Diy Guide For 1999 Models

Replacing the fuel pump on a 1999 Corvette is a complex process that requires automotive mechanical knowledge and experience. The procedure involves draining the gas tank, relieving fuel pressure, disconnecting and reconnecting fuel lines, removing and installing fuel pumps and assemblies, and drilling and tapping holes in the tank. It is important to prioritize safety precautions when handling gasoline and working with power tools.

Jack up the car and remove the driver's side rear wheel

Jacking up your car and removing the driver's side rear wheel is an important step in changing the fuel pump on your 1999 Corvette. Here is a detailed, step-by-step guide on how to do this:

First, you will need to jack up your car and place it securely on jack stands. Ensure that you are working on a level surface and engage the parking brake for added safety. Place jack stands at the manufacturer's recommended lift points for your Corvette. Once the car is securely lifted, locate the driver's side rear wheel and remove it using a lug wrench or an impact wrench. Set the wheel aside in a safe place.

Next, you will need to remove the plastic wheel well liner. This will give you access to the fuel pump assembly. The liner is typically held in place with clips or fasteners, so carefully remove or undo these to detach the liner. Be gentle to avoid damaging any components. With the liner removed, you should now be able to access the fuel pump assembly, which is located in the driver's side fuel tank.

Before proceeding, it is important to relieve the fuel pressure by depressing the Schrader valve on the end of the driver's side fuel rail. Catch the escaping fuel in an appropriate container. Remember to take all necessary safety precautions when handling gasoline.

Now, you are ready to start working on the fuel pump. The next step would be to remove the metal shield covering the pump assembly. This is typically held in place with bolts, so have your tools ready to remove them. With the shield removed, you will have clear access to the fuel pump assembly, and you can proceed to the next steps of removing and replacing the fuel pump.

Remember to refer to a professional mechanic or technician if you are unsure about any steps or procedures. Working on fuel systems can be dangerous, so always put your safety first.

Remove the plastic wheel well liner

To remove the plastic wheel well liner, you'll need to gain access to the fuel pump assembly, which is located inside the fuel tank. Here's a step-by-step guide:

• Park your Corvette on a level surface, engage the parking brake, and ensure the car is in neutral or park if it's an automatic.
• Loosen the lug nuts on the rear passenger-side wheel slightly, then lift the rear end of your Corvette securely using a jack and support it on jack stands for safety.
• Remove the lug nuts and take off the rear passenger-side wheel. Now, you'll have access to the plastic wheel well liner.
• The plastic wheel well liner is held in place by a combination of screws, clips, and/or fasteners. Inspect the liner to identify the type and location of these securing elements.
• Using the appropriate tools, such as a Phillips-head screwdriver, flat-head screwdriver, or a fastener remover, begin to remove the screws, clips, or fasteners that hold the liner in place. Work your way around the liner, ensuring that you don't miss any securing points.
• Once all the fasteners are removed, the liner should be loose. Carefully pull it out and away from the wheel well, taking care not to damage any surrounding components or wiring. Place the liner aside safely, ensuring it doesn't interfere with your workspace.

By following these steps, you'll successfully remove the plastic wheel well liner, providing the necessary access to continue with the fuel pump replacement procedure for your 1999 Corvette. Remember to place the liner in a secure location, as you'll need to reinstall it once the new fuel pump is installed and you're ready to reassemble the components.

Remove the metal shield covering the pump assembly

To remove the metal shield covering the pump assembly of a 1999 Corvette, you will first need to jack up the car and remove the driver's side rear wheel. Once the wheel is removed, you will need to remove the plastic wheel well liner. This will expose the metal shield that covers the pump assembly.

The metal shield is held in place with several bolts, which will need to be removed. It is important to note that you should find a way to drain the fuel tank before removing the metal shield, as a full tank will result in fuel spilling out. There are a few ways to drain the tank, including using a fuel pump relay and jumper wire to run the fuel pump and drain the tank into a gas can, as described in the A&A Corvette Dual Pump Fuel System Installation instructions.

Once the tank is drained, you can proceed to remove the metal shield. This will involve removing the bolts that hold it in place and carefully lifting or prying it away from the pump assembly. Be cautious when performing this step, as the metal shield may have sharp edges that could cause injury. It is also important to note that you should have a container or pan ready to catch any fuel that may leak or spill during the removal process.

With the metal shield removed, you will now have access to the pump assembly and can proceed with the next steps of the fuel pump replacement process. Remember to work carefully and refer to a repair manual or seek professional assistance if needed.

Remove the pump assembly

To remove the pump assembly of a 1999 Corvette, follow these steps:

First, jack up the car and remove the driver's side rear wheel. Remove the plastic wheel well liner to expose the pump assembly. You will see a metal shield covering the pump assembly. Remove this shield to access the pump assembly bolts. There should be around six bolts holding the assembly in place. Loosen and remove these bolts.

At this point, you should be able to remove the entire pump assembly. However, it is recommended to find a way to drain the fuel tank before removal to avoid spilling fuel. One way to do this is by using a fuel tank drain kit. Alternatively, you can try to drain the tank as much as possible by relieving the fuel pressure and catching the escaping fuel in an appropriate container.

Once the tank is drained, proceed to remove the pump assembly. Be cautious as some fuel may still be present in the lines and tank. Place a pan or container underneath to catch any fuel that may drip or spill during the removal process. With the bolts removed, carefully lift and pull out the pump assembly. Ensure you handle it with care to avoid damaging any attached fuel lines or components.

Now that the pump assembly has been removed, you can proceed to install a new one or perform any necessary maintenance or repairs. Remember always to refer to the vehicle's service manual for specific instructions and safety precautions when working on your Corvette.

Prepare to drain the tank

Before you start, make sure you have the necessary tools and safety equipment. You will need a suitable lift or jack stands to raise the car, a container to catch the escaping fuel, and a jumper wire.

Park the car on a level surface and engage the parking brake. Raise the car using a suitable lift or jack stands. Locate the Schrader valve on the end of the driver's side fuel rail and position your fuel container underneath. Depress the Schrader valve to relieve the fuel pressure, allowing fuel to escape into the container.

Now, locate the braided fuel line that runs from the hard factory fuel line to the fuel rail. Using a quick disconnect tool, remove this braided fuel line. Be prepared to catch any escaping fuel in your container.

At this point, you have completed the initial steps to prepare for draining the tank. The next steps will involve attaching a clear hose to the factory hard line and routing it to a gas can or similar container. You will also need to access the fuse box in the engine compartment to remove the fuel pump relay and insert the jumper wire, as described in the following section.

Frequently asked questions