Replacing The Fuel Pump In Your 1987 Corvette: Step-By-Step Guide

If you're looking to replace the fuel pump in your 1987 Corvette, you'll be glad to know that it's a more straightforward process than with older models. You won't need to seal off fuel lines or fuss with a fuel pump pushrod, and you can access the pump easily from the top of the gas tank. Here's a step-by-step guide to help you get started:

- Disconnect the negative battery cable and relieve the pressure in the fuel system. You can do this by removing the gas cap and letting the car sit for about 15 minutes.

- Drain your fuel tank and remove the tank filler door, screws, and bezel.

- Lift the fuel tank filler pipe housing and disconnect the drain hose.

- Clean all fuel connections and surrounding areas to avoid contaminating the fuel system.

- Disconnect the fuel hoses and EVAP hose from the fuel sender assembly. Plug or pinch the fuel feed and return hoses, and remove the electrical connector.

- Remove the fuel sender assembly attaching screws, assembly, and gasket. If you're installing a new gasket, check that it's positioned correctly with the notch facing forward in the right-hand corner of the tank.

- Carefully fold the strainer and insert it through the opening in the tank.

- Install the new fuel sender assembly, reconnect the electrical connector, and tighten the hose clamps.

- Reconnect the drain hose and place the housing around the filler pipe.

- Reinstall the filler door bezel, add fuel, and reconnect the negative battery cable.

- Before taking your Corvette for a drive, turn the ignition switch on and off to check for any fuel leaks.

Disconnect the negative battery cable and relieve the pressure in the fuel system

To disconnect the negative battery cable and relieve the pressure in the fuel system of a 1987 Corvette, follow these steps:

First, disconnect the negative battery cable. This is an important safety precaution as it will prevent any electrical current from flowing through the system while you work. Once the cable is disconnected, locate the gas cap and remove it. This will release the pressure in the fuel system. Let the car sit for about 15 minutes to ensure that the pressure is completely relieved.

While you wait, gather your tools and prepare your workspace. You will need a rag or towel to wipe up any spilled fuel, as well as a container to catch the drained fuel. Place the container under the fuel tank drain valve, which is located on the bottom of the fuel tank. Once the 15 minutes are up, open the valve and allow the fuel to drain completely.

Once the fuel tank is empty, you can begin to remove the fuel tank filler door by unscrewing the attaching screws and bezel. Be careful not to cross-thread the screws as you remove them, as this can damage the threads and make it difficult to reinstall the screws securely. With the screws removed, carefully lift and remove the fuel tank filler pipe housing. Again, be gentle to avoid damaging the surrounding components.

Now, locate the drain hose connected to the nipple on the filler pipe housing. Carefully disconnect the hose, being mindful of any residual fuel that may be present. Before proceeding, take a moment to clean all fuel connections and surrounding areas to avoid contaminating the fuel system. This is an important step to ensure the longevity and optimal performance of your Corvette's fuel system.

With the drain hose disconnected, you have successfully relieved the pressure in the fuel system and can now proceed with the next steps in replacing the fuel pump in your 1987 Corvette. Remember to work safely and refer to a qualified mechanic or Corvette specialist if you have any questions or concerns during the process.

Drain the Corvette's fuel tank and remove the tank filler door

To drain the fuel tank of a 1987 Corvette, first relieve the pressure in the fuel system. Remove the gas cap and let the car sit for 15 minutes. Next, drain the tank. You can use a syphon and a large sponge to do this.

Now, to remove the tank filler door: open the filler door and unscrew the four screws that hold the assembly in place. Remove the filler door by pulling it toward the rear of the car and up. Remove the rubber gas filler neck.

You will then need to remove the gas gauge electric lines. There are two wires on the right side of the filler. Be careful not to rip or crack the rubber lines.

Finally, use a 1/4" ratchet and a 1/2" socket to remove all of the bolts around the fill port. Once they are loose, you can pull the sending unit up and rotate it so you can pull it out. Be careful not to drop anything in the gas tank, including rust or the old gasket.

Disconnect the fuel hoses and EVAP hose from the fuel sender assembly

To disconnect the fuel hoses and EVAP hose from the fuel sender assembly, you will first need to relieve the pressure in the fuel system. To do this, remove the gas cap and let the car sit for 15 minutes. Once the pressure is relieved, drain your Corvette’s fuel tank.

Next, remove the tank filler door attaching screws and bezel. Lift the fuel tank filler pipe housing and disconnect the drain hose from the nipple. Before disconnecting the fuel tank filler pipe housing, clean all fuel connections and surrounding areas to avoid contaminating the fuel system.

Now you can disconnect the fuel hoses and EVAP hose from the fuel sender assembly. Plug or pinch the fuel feed and return hoses and remove the fuel sender electrical connector.

If you are going to replace the hoses, remove and save the clamps. If you are not replacing the hoses, slide the clamps back onto the hose until they are clear of the sender's steel connections. Pull the hoses off the sender connections. A small amount of fuel may leak out of the fuel feed hose, which you can soak up with a shop rag.

It is important to note that cuts, nicks, swelling, or distortion is common on the fuel feed, fuel return, and EVAP hoses, so be sure to inspect these hoses before proceeding.

Remove the fuel sender assembly attaching screws, assembly, and gasket

To remove the fuel sender assembly attaching screws, assembly, and gasket, you will need to follow these steps:

Firstly, relieve the fuel system pressure. To do this, remove the gas cap and let the car sit for 15 minutes. Once the pressure is relieved, drain your Corvette’s fuel tank. Next, remove the tank filler door attaching screws and bezel. Lift the fuel tank filler pipe housing and disconnect the drain hose from the nipple.

Before disconnecting the fuel tank filler pipe housing, clean all fuel connections and the surrounding areas to avoid contaminating the fuel system. Disconnect the fuel hoses and EVAP hose from the fuel sender assembly. Plug or pinch the fuel feed and return hoses and remove the fuel sender electrical connector.

Now, you are ready to remove the fuel sender assembly attaching screws, assembly, and gasket. You can reinstall the old gasket, but first, check if your new C4 Corvette Sending Unit came with a new gasket. If it did, discard the old gasket and thoroughly clean the gasket sealing surfaces. If you are just installing a new fuel pump, you will need to purchase a gasket separately or reinstall the old gasket.

Reinstall the fuel sender assembly, ensuring it is correctly positioned and oriented

To reinstall the fuel sender assembly, you must first ensure that the gasket is correctly positioned on the fuel tank, with the notch facing forward in the right-hand corner of the tank.

Next, carefully fold the strainer to allow it to fit through the opening in the tank. Then, install the fuel sender assembly into the fuel tank and reconnect the fuel sender electrical connector. Ensure that the assembly is oriented with the mounting head parallel to the fuel tank top surface and the end pointing towards the front of the tank.

Once the sender is in position, clean and reinstall the bolts. Tighten the bolts to 40-in/lb. (4.5 N/m) torque.

Finally, reconnect the fuel and EEC hoses, tightening all screw clamps.

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