Replacing Fuel Pump In 2008 Corvette: Step-By-Step Guide

Replacing the fuel pump in a 2008 Corvette with an automatic transmission is a complex task that requires mechanical expertise and a range of tools. The process involves draining the fuel tank, removing the left rear wheel, wheelhouse panel, mufflers, and driveline support assembly, disconnecting various hoses and connectors, and accessing the fuel pump through the top of the fuel tank. While it is possible for experienced individuals to replace the fuel pump themselves, it is recommended to seek professional assistance or refer to a detailed guide for a successful replacement.

Remove the fuel line

To remove the fuel line of a 2008 Corvette with an automatic transmission, follow these steps:

First, disconnect the negative battery cable. This is an important safety precaution to prevent any accidental electrical discharge. Ensure you are wearing protective gear, such as gloves and eye protection, throughout this process. Next, drain the fuel tank completely. This is a crucial step to avoid any fuel spillage during the subsequent steps. Once the tank is empty, remove the left rear wheelhouse panel to access the fuel lines and other components.

Now, we will disconnect the fuel lines. Start by disconnecting the fuel fill hose and recirculation line from the fill pipe. Then, carefully disconnect the fuel feed pipe at the rear of the left fuel tank. It is important to refer to a repair manual for your specific vehicle to identify the correct pipes and connections. After disconnecting the fuel lines, cap the exposed fuel pipes to prevent any contamination of the fuel system. This will also help to avoid any accidental spillage.

At this point, you have successfully removed the fuel line from the 2008 Corvette with an automatic transmission. The next steps would involve lowering the fuel tank and performing any necessary maintenance or repairs. Remember to exercise extreme caution when working with fuel lines and always refer to a qualified mechanic or repair manual if you are unsure about any steps.

Prep to remove the fuel tank

Before you begin, ensure you have the necessary tools and equipment, including jack stands, a jack, safety gloves, and a fuel tank drain tool. It is also recommended to wear safety goggles and a respirator when working with fuel systems.

• Disconnect the negative battery cable.
• Drain the fuel tank.
• Raise and support the vehicle securely on jack stands.
• Remove the left rear tire.
• Remove the left rear wheelhouse panel.
• Remove both mufflers.
• Remove the driveline support assembly.
• Disconnect the fuel fill hose and recirculation line from the fill pipe.
• Disconnect the fuel pump jumper harness connector.
• Disconnect the fuel feed pipe at the rear of the left fuel tank. Use a fuel line disconnect tool for this step.
• Cap the fuel pipes to prevent fuel system contamination.
• Loosen the fuel tank strap to drop the tank approximately one inch.

Crossover Tube Disconnection:

• Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab outward and rotating.
• Rotate the crossover tube collar counterclockwise to disengage.
• Disconnect the crossover tube from the left fuel tank by pulling it straight out. Be careful not to disturb the internal O-rings.
• Disconnect the evaporative emission (EVAP) crossover pipe quick-connect fitting at the left fuel tank.
• Cap the EVAP pipe to prevent system contamination.

At this point, you have completed the preparation steps and can proceed to physically remove the fuel tank from the vehicle. Ensure the vehicle is securely supported and take extra care when handling the fuel tank and related components to avoid any damage or spills.

Disconnect the crossover tube

Disconnecting the crossover tube is a crucial step when replacing the fuel pump in a 2008 Corvette with an automatic transmission. Here is a detailed guide on how to do this:

Study the Connector: Before attempting to disconnect the crossover tube, it is important to understand how the connector looks and functions. There is a locking mechanism in place that needs to be released before turning the collar.

Locate the Black Plastic Ring: There is a thin black plastic ring with a tab that locks the connector in place. This tab needs to be pulled back to release the locking mechanism. It might not be easily visible, but you should be able to feel it with your fingers.

Release the Locking Tab: Once you have located the black plastic ring, use your fingers to pull the locking tab out of the connector latch. This will unlock the connector and allow you to turn the collar.

Turn the Collar Counterclockwise: After releasing the locking tab, reach up and turn the collar counterclockwise. You don't need to turn it much, just about 20 degrees or so. This will disconnect the fitting.

Separate the Crossover Tube: Now, you need to separate the crossover tube from the nylon fitting inside the tank. This can be tricky because the metal crossover tube cannot be collapsed. You will need to create some play in the tube to be able to pull it out.

Loosen the Passenger Side Tank: Go to the passenger side tank and loosen the five bolts holding the aluminum pan under the tank. This will create some tension on the crossover tube, which is what you need.

Locate the Spring-Loaded C-Clamp: Reach up above the transmission, and you will feel a spring-loaded C-clamp type fitting that the crossover tube is snapped into. It might not be visible, but you can feel it by touching.

Pop the Crossover Tube Out: By pulling down on the crossover tube, it should pop out of the spring-loaded fitting. With this extra play and the loose driver's side tank, you can now pull the coupler out of the tank. Be careful to pull directly back on the coupler to avoid damaging the fragile fuel lines inside.

Disconnect the Vent Line: Before lowering the tank, locate and disconnect the vent line above the tank. This line uses the same type of coupler as the vent you previously removed from the filler neck.

By following these steps, you will successfully disconnect the crossover tube and be ready to proceed with the next steps of replacing the fuel pump in your 2008 Corvette with automatic transmission.

Remove the fuel tank

To remove the fuel tank from a 2008 Corvette with an automatic transmission, follow these steps:

Step 1: Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection for the specific procedure.

Step 2: Drain the fuel tank. Refer to the Fuel Tank Draining procedure for your vehicle.

Step 3: Raise and support the vehicle. Use a jack to lift the car and securely support it on jack stands.

Step 4: Remove the left rear tire. This will give you better access to the fuel tank and its components.

Step 5: Remove the left rear wheelhouse panel. This panel covers the rear wheel well and will need to be removed for access.

Step 6: Remove both mufflers. The mufflers are part of the exhaust system and will need to be detached to access the fuel tank fully.

Step 7: Remove the driveline support assembly. This assembly may restrict access to the fuel tank, so it needs to be removed.

Step 8: Disconnect the fuel fill hose and recirculate line from the fill pipe. These hoses are connected to the fuel tank and will need to be carefully detached.

Step 9: Disconnect the fuel pump jumper harness connector. This connector provides power to the fuel pump, and disconnecting it will allow you to remove the fuel tank.

Step 10: Disconnect the fuel feed pipe at the rear of the left fuel tank. Use a fuel line disconnect tool to safely release the coupling.

Step 11: Cap the fuel pipes to prevent fuel system contamination. Cover the open ends of the fuel pipes to avoid any dirt or debris entering the system.

Step 12: Loosen the fuel tank strap to drop the tank approximately one inch. The tank strap holds the fuel tank in place, and loosening it will allow you to lower the tank slightly for easier access.

Step 13: Disengage the crossover tube connector. The crossover tube connects the two fuel tanks. To disconnect it, first, pull the tab outward and rotate it. Then, rotate the crossover tube collar counterclockwise to disengage it from the tank. Be careful not to disturb the internal O-rings in the fuel tank connections.

Step 14: Disconnect the evaporative emission (EVAP) crossover pipe quick-connect fitting at the left fuel tank. This pipe is part of the evaporative emission control system and will need to be carefully disconnected.

Step 15: Cap the EVAP pipe to prevent system contamination. As with the fuel pipes, cover the open end of the EVAP pipe to avoid any contamination.

Step 16: Remove the fuel tank strap mount bolts. These bolts secure the fuel tank strap to the vehicle. Remove them to detach the strap completely.

Step 17: Remove the fuel tank strap from the vehicle. With the mount bolts removed, you can now take off the fuel tank strap.

Step 18: Remove the fuel tank. With all the connections and straps removed, you can now carefully lower and remove the fuel tank from the vehicle.

Please note that working on fuel systems can be dangerous, and it is essential to take appropriate safety precautions. Always refer to a qualified mechanic or a detailed repair manual for specific instructions and safety guidelines before attempting any repairs or modifications.

Reinstall the repaired fuel pump

To reinstall the repaired fuel pump, follow these steps:

• Compare the new fuel pump to the old fuel pump to verify that you have the correct part.
• Connect every fuel line to the new fuel pump.
• Reinstall the fuel pump and the fuel level sending unit into the fuel tank.
• Reinstall the straps and bolts.
• Reconnect the filler fuel and the electrical connector.
• Reconnect the negative battery cable.
• Fill the gas tank and conduct a road test to verify the new pump's success.

Frequently asked questions