Rajan Wilcox
The Chevrolet Corvette C6 has two fuel tanks, each with a capacity of around 9 gallons. The driver's side tank fills up first, and when it is full, the fuel spills over into the large crossover tube and fills the passenger side tank. The fuel pump is located in the driver's side tank, and the fuel in the passenger side tank is transferred to the driver's side via a pump driven by fuel pressure from the electric fuel pump in the driver's side tank. Replacing the fuel pump in a C6 Corvette is a complex task that requires mechanical expertise and can cost upwards of $3000 if done professionally. However, it is possible to replace the fuel pump yourself with the proper tools and precautions.
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What You'll Learn
The driver's side tank must be removed to access the fuel pump
The Chevrolet Corvette C6 has two tanks that hold about nine gallons each. When you fill up, the driver's side tank fills first. When it is full, the fuel spills over into the large crossover tube and fills the passenger side tank. The fuel in the passenger side tank is used first, and it is passed over to the driver's side continuously via a pump driven by fuel pressure from the electric fuel pump in the driver's side tank.
To get to the fuel pump, the driver's side tank must be removed from the vehicle. It has to come out of the top of the tank, and there is no other way to get to it. You should start the job with as close to an empty fuel system as possible. It is not advisable to work with more than half a tank of fuel because there is no easy way to get the fuel out of the passenger side tank. You need about 24 inches of clearance under the car to get the tank out. A set of six-ton or larger jack stands should be enough to get you there.
If you are pulling both tanks, you need to remove both rear wheels. However, you don't need to drop the passenger side tank to remove the pump in the driver's side tank. If you have less than half a tank, you can let the fuel pump remove the rest of the fuel in the driver's tank.
The hardest part of the job is getting the crossover tube in and out and removing the old fuel pump. The retaining ring can be difficult to get off, and you may have to break the plastic housing of the old fuel pump to get it out of the tank as the bottom half swells over time.
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The C6 Corvette has two tanks, each holding around 9 gallons
The C6 Corvette's fuel pump can be replaced, but it is a challenging task. The manual transmission has more room around the sides to work with than the automatic. For automatic transmission cars, the factory service procedures require lowering the rear drivetrain. However, some forum members claim that it is possible to perform the replacement without lowering the drivetrain.
To replace the fuel pump, the driver's side tank must be removed from the vehicle. It is recommended to start the job with as little fuel in the system as possible, preferably less than half a tank. The tank must be raised, and the crossover tube coupler should be plugged into the tank. The fuel line from the tank is then attached to the hard line leading to the engine compartment. Finally, the battery is reconnected, and the fuel pump relay is reinstalled.
The process of replacing the fuel pump can be time-consuming and complex, with many potential challenges. It is important to have patience and be cautious to avoid any mistakes.
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The fuel pump is cooled by recirculating fuel
The Chevrolet Corvette C6 has two fuel tanks, with a capacity of about 9 gallons each. The driver's side tank fills first when fuelling up. When it is full, the fuel spills over into the large crossover tube and fills the passenger side tank. The fuel in the passenger side tank is then used first, and it is passed over to the driver's side continuously via a pump. This pump is driven by fuel pressure from the electric fuel pump in the driver's side tank.
The fuel pump in the C6 Corvette is cooled by recirculating fuel. This means that the fuel in the driver's side tank is used to cool the pump. It is important to maintain a sufficient fuel level in the tank to ensure effective cooling of the pump. Allowing the fuel level to drop below a quarter of the tank's capacity can lead to reduced cooling and a shorter fuel pump life.
To access the fuel pump for replacement or maintenance, the driver's side tank must be removed from the vehicle. It is recommended to start with as close to an empty fuel system as possible for ease of removal. However, working with less than half a tank of fuel can be unsafe, as it may be difficult to completely drain the passenger side tank.
When performing fuel pump replacement, it is crucial to follow the correct procedures and take the necessary safety precautions. Some of the steps involved in the process include disconnecting the negative battery cable, draining the fuel tank, raising and supporting the vehicle, removing the left rear tire and wheelhouse panel, and disconnecting the fuel fill hose and recirculation line.
Additionally, it is important to note that the fuel pump replacement process may vary depending on the transmission type of the C6 Corvette. The manual transmission provides more room to work around the sides compared to the automatic transmission, which requires lowering the rear drivetrain or cradle.
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The rear drivetrain must be lowered for automatic transmission cars
The Chevrolet Corvette C6 has two tanks, each with a capacity of around nine gallons. The driver's side tank fills first when fuelling up, and once full, the fuel spills into the crossover tube, filling the passenger side tank. The fuel in the passenger side tank is used first, and it is continuously pumped to the driver's side.
Replacing the fuel pump in a C6 Corvette is a complex task. It is essential to start with as little fuel in the system as possible, preferably less than half a tank. The driver's side tank must be removed to access the fuel pump, and this requires about 24" of clearance under the car. The process involves jacking up the car, disconnecting the battery, removing the rear tire and wheel liner, and dealing with the fuel inlet hose, vent, and pump electrical on the left side.
When replacing the fuel pump, it is crucial to follow the manufacturer's instructions. For manual transmission C6 Corvettes, the procedure allows for more room to work and does not require lowering the rear drivetrain. However, for automatic transmission C6 Corvettes, the factory service procedures mandate lowering the rear drivetrain. This is because automatic transmissions have less space to work around the sides.
It is worth noting that some forum members claim it is possible to replace the fuel pump on an automatic transmission C6 without lowering the drivetrain. Nevertheless, it is a challenging task with many potential pitfalls, and it is recommended to seek specialist performance shops that can handle the job efficiently, albeit at a higher hourly rate.
Additionally, when performing fuel pump replacement, it is essential to consider the fuel transfer line between the two tanks. Leaks in this line can occur due to cracking, and it is recommended to replace the O-rings and coat the fittings with silicone grease to prevent leaks.
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The hardest part of the job is removing the old fuel pump
The Chevrolet Corvette C6 has two tanks, each with a capacity of around nine gallons. The driver's side tank fills up first when fuelling, and when it is full, the fuel spills over into the large crossover tube and fills the passenger side tank. The fuel pump is located in the driver's side tank.
- Disconnect the negative battery cable.
- Drain the fuel tank.
- Raise and support the vehicle.
- Remove the left rear tire and the left rear wheelhouse panel.
- Remove both mufflers (A6 only).
- Remove the driveline support assembly (A6 only).
- Disconnect the fuel fill hose and recirculation line from the fill pipe.
- Disconnect the fuel pump jumper harness connector.
- Remove the driver's side tank from the vehicle.
- Install the new fuel pump and reconnect the fuel sending unit wire leads to the new fuel pump's connector.
- Reinstall the driver's side tank.
- Reconnect the battery and the fuel pump relay.
It is important to note that the procedure for automatic transmission cars is more involved and requires lowering the rear drivetrain or cradle. The manual transmission has more room around the sides to work, making it a more accessible option for replacing the fuel pump.
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Frequently asked questions
Replacing the fuel pump in a C6 Corvette is a complex process that involves: disconnecting the negative battery cable, draining the fuel tank, raising and supporting the vehicle, removing the left rear tire and wheelhouse panel, removing both mufflers, disconnecting the fuel fill hose and recirculation line, and finally, disconnecting the fuel pump jumper harness connector.
The cost of replacing a fuel pump in a C6 Corvette can vary depending on labour and parts. Some people have reported being quoted around $3000, while others have mentioned amounts in the range of $2000 to $2500.
Yes, it is possible to replace the fuel pump in a C6 Corvette yourself. However, it is a challenging task that requires careful handling and significant time. It is recommended to have a thorough understanding of the procedure and necessary tools before attempting the replacement.
