Replacing The Fuel Pump In Your 2009 Corvette Cpe

Replacing the fuel pump in a 2009 Corvette CPE is a complex and time-consuming task, best performed by a professional mechanic or someone with extensive knowledge of car maintenance. The fuel pump is located inside the fuel tank and can be accessed through an access panel in the passenger compartment or by removing the tank from the vehicle. This job typically involves disconnecting various components, such as the fuel filler hose, vent return hose, electrical connectors, and fuel lines, before removing the fuel tank and replacing the pump. It is crucial to take appropriate safety precautions when working with the fuel system to prevent fires. Additionally, some Corvette models have two fuel tanks, which adds to the complexity of the task. While it is possible to replace the fuel pump without dropping the rear drivetrain, it is a challenging process that requires careful handling of various components.

Fuel pump replacement basics

The fuel pump is located inside the fuel tank and delivers fuel to the engine. It is an electric motor that ensures that pressurised gasoline flows to the engine to power the vehicle. The pump is submerged in the fuel, which helps to keep it cool.

Signs of a Failing Fuel Pump

• The engine chokes or struggles to maintain speed
• Noises, backfires and a sputtering engine
• Hesitation at start or take-off
• Overheating engine
• Check Engine light is on
• The car won't start

Replacing the Fuel Pump

Disclaimer: *This is a general guide and may not apply to all vehicles. Always refer to the manufacturer's instructions or seek professional advice if unsure.*

The fuel pump is located inside the fuel tank and can be accessed via an access panel in the passenger compartment or by removing the tank from the vehicle.

• Disconnect the battery to reduce the risk of fire.
• Drain the fuel tank if necessary.
• Remove any components blocking access to the fuel tank, such as the rear wheel, wheelhouse panel, mufflers, and driveline support assembly.
• Disconnect the fuel filler hose, vent return hose, and any electrical connectors.
• Remove the fuel tank strap bolts and lower the fuel tank.
• Disconnect the fuel pump from the fuel lines and electrical connectors.
• Remove the fuel pump locking ring and carefully pull the pump out of the tank.
• Install the new fuel pump, ensuring all connections are secure.
• Reinstall the fuel tank and reconnect all hoses and electrical connectors.
• Refuel the tank and reconnect the battery.
• Test the vehicle to ensure the fuel pump is functioning properly.

Removing the driver's side tank

The driver's side tank must be removed from the vehicle to access the fuel pump. It is recommended to start the job with as little fuel in the system as possible. If your current pump is working, disconnect the fuel line under the hood at the metal pipe at the firewall. Slip a 5' piece of rubber 3/8" fuel line over the metal line and put the other end in a large gas can. Jumper across two terminals of the fuel pump relay under the hood in the fuse box to run the driver's side tank dry. When the tank is dry, shut the car off and disconnect the battery negative terminal. Reconnect the fuel line to the fuel rail.

Remove the driver's side rear inner fender liner. Disconnect the fuel filler hose and the vent return hose at the fuel filler neck. Disconnect the 4-pin connector with larger gauge wires on the outer pins and smaller gauge wires on the inner pins. From below, remove the five bolts that hold the aluminium panel under the tank. Next, disconnect the fuel line that snakes down the rear of the tank.

Now, unlatch the crossover tube. Reach up and pull the black tab back out of the connector latch. Rotate the crossover tube collar counterclockwise to disconnect. Disconnect the crossover tube from the tank by pulling it straight out. Disconnect the evaporative emission (EVAP) crossover pipe quick-connect fitting.

Remove the five fuel tank strap mount bolts and remove the fuel tank strap from the vehicle. You can now safely lower the tank out of the car.

Disconnecting the fuel filler hose

Step 1: Remove the Driver's Side Rear Inner Fender Liner

Start by removing the driver's side rear inner fender liner. This will provide access to the fuel filler hose and other components. There are only a few fasteners holding the liner in place, so it is a straightforward process. You don't have to completely remove the liner if you don't want to. Instead, you can remove the front half of the fasteners and then fold the flexible liner back and tuck it over the axle to keep it out of the way.

Step 2: Disconnect the Fuel Filler Hose and Vent Return Hose

• Now, you need to disconnect the fuel filler hose and the vent return hose at the fuel filler neck. The filler hose coupler is secured with a simple hose clamp, which can be loosened with a screwdriver or a suitable tool.
• The vent line has a quick-disconnect fitting. To release it, push in on the wide spot of the tan/white connector with your fingers. Sometimes, it is easier to press the connector first and then push it in as if reconnecting before pulling it apart. This "in and out" motion can help release the tension on the connector.

Step 3: Unplug the Electrical Connector

In the same area as the fuel filler, you will see a 4-pin electrical connector. The outer pins are typically connected to the positive and ground wires for the electric fuel pump, while the inner pins are for the fuel sending unit. Unplug this connector from the chassis. The loose end of the connector is the wiring harness for the fuel pump.

Step 4: Remove the Bolts Securing the Fuel Tank

From below the vehicle, locate the five bolts that hold the aluminum panel under the fuel tank. These bolts are the only physical connection securing the tank to the car. Remove these bolts. Don't worry; the empty tank will still be held in place by the crossover tube.

Step 5: Disconnect the Fuel Line

Now, you need to disconnect the fuel line that runs down the rear of the fuel tank. This will require the same fuel line disconnect tool that you used to release the fuel line under the hood when draining the tank. Some fuel may spill, so be prepared to catch it with a suitable container.

By following these steps, you will successfully disconnect the fuel filler hose, allowing you to access and replace the fuel pump in your 2009 Corvette CPE. Remember to work carefully and refer to a qualified mechanic or a repair manual for further guidance if needed.

Disconnecting the crossover tube

Step 1: Understand the Basics

Before beginning the process, it is essential to understand the fuel system of the C6 Corvette. The C6 has two tanks, each holding about 9 gallons. When fuelling up, the driver's side tank fills first, and the fuel then spills into the crossover tube and fills the passenger side tank. The fuel from the passenger side tank is expended first and continuously transferred to the driver's side. Therefore, the last half of your fuel supply is always in the driver's side tank.

Step 2: Prepare the Driver's Side Tank for Removal

To access the fuel pump, the driver's side tank must be removed. Start by ensuring the fuel system is as empty as possible, preferably less than half a tank. You will need about 24" of clearance under the car to remove the tank, so a set of jack stands is recommended. If you are removing both tanks, you will need to take out both rear wheels.

Step 3: Remove Remaining Fuel

If your current pump is working, disconnect the fuel line under the hood and attach a rubber hose to drain the remaining fuel into a gas can. To do this, jumper across two terminals of the fuel pump relay in the fuse box and turn the ignition to the start position. Once the tank is dry, be sure to disconnect the battery negative terminal.

Step 4: Gain Access to Fuel Filler Hose and Other Components

Remove the driver's side rear inner fender liner. Disconnect the fuel filler hose and the vent return hose at the fuel filler neck. Disconnect the 4-pin connector near the fuel filler, which is the fuel pump harness. From below, remove the five bolts that hold the aluminium panel under the tank.

Step 5: Disconnect the Fuel Line

Disconnect the fuel line that runs down the rear of the tank using a fuel line disconnect tool. Some fuel will spill, so be prepared to catch it.

Step 6: Unlatch the Crossover Tube

Study the images of the connector and how it latches to understand the process better. There is a thin black plastic ring with a tab that locks the connector in place. Pull this black tab back out of the connector latch. Then, reach up and turn the collar counterclockwise to disconnect the fitting. Do this gently, turning only about 20 degrees.

Step 7: Separate the Crossover Tube from the Nylon Fitting

This step can be challenging as the metal crossover tube cannot be collapsed. To gain the necessary clearance, go to the passenger side tank and remove the five bolts holding the aluminium pan under the tank. Reach above the transmission, and you will feel a spring-loaded C-clamp type fitting that the crossover tube is snapped into. Pull down on the crossover tube to release it from the fitting.

Step 8: Disconnect Remaining Lines

Before lowering the tank, there is one more line to disconnect. Reach above the tank and disconnect the vent line, which uses the same type of coupler as the vent hose removed earlier.

By following these steps, you will successfully disconnect the crossover tube and be ready to lower the tank and continue with the fuel pump replacement process.

Removing the pump

Now that the tank is out of the car, you can remove the fuel pump. There is a large metal locking ring that secures the fuel pump to the tank. You need to rotate it counterclockwise to unlock that ring. I recommend using a plastic mallet and a dowel to rotate the collar.

With the collar released, you can then pull the pump halfway out of the tank. To get the pump completely out, you need to disconnect the line that goes forward to the passenger side tank and the second line that serves as the return line from the passenger side tank. The return line dumps into the white fuel pump bucket.

This is the line set that is in the tank. One end has a connector that you can release with your fingers, and the other end is secured with a plastic hose clamp with its end resting in the pump's sump.

If you look at the above photo closely, you'll recognize that the other end of those two lines is what plugs into the nylon fitting at the top of the tank where the crossover tube mates up.

Once you have the two fuel lines disconnected, you can then begin to fish the pump out of the tank. Be careful because you have a long fuel level float wire and float still attached to the pump.

I have found that the bottom half of the fuel pump seems to expand after it is installed. It can be a challenge to get the bottom half of the pump through the tank's opening. Sometimes it takes a bit of persuasion with a small screwdriver.

Frequently asked questions