Changing the fuel pump and tring to remove the fuel tank. We took the shield off, but the tank just wont budge. Is there anything we are missing that is holding the tank in?

Thanks,
Jason

 

Document ID# 776229
2003 Chevrolet Corvette

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Fuel Tank Replacement Right
Tools Required
J 34730-1A Fuel Pressure Gauge
J 37088-A Tool Set, Fuel Line Quick Connect Separator
Removal Procedure





Caution
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.


Disconnect the negative battery cable.
Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
Drain the fuel tanks. Refer to Fuel Tank Draining Procedure .

Caution
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.


Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the right rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Remove the fuel tank shield mount nut (3).
Remove the fuel tank shield mount bolt (2).
Remove the fuel tank shield (1).
Remove the right muffler, for automatic transmission-equipped vehicles only. Refer to Muffler Replacement - Left or Muffler Replacement - Right in Engine Exhaust.



Disconnect the fuel sender electrical connector.
Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
Disconnect the auxiliary fuel return rear pipe (1) that connects the jet pump to the left tank and the auxiliary fuel feed rear pipe (2) that connects the left tank to the jet pump at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
Cap the fuel pipes in order to prevent possible fuel system contamination.



Remove the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
Remove the EVAP canister access cover.



Disconnect the FLVV hose (1) at the EVAP canister (2).
Disconnect the fuel pressure sensor electrical connector.



Disconnect the tank crossover hose (5).
Disconnect the EVAP pipe (2) quick connect fitting at the right fuel tank EVAP pipe (3).
Cap the EVAP pipe in order to prevent possible contamination.



Remove the fuel tank strap mount bolts (1, 2, 4)
Remove the fuel tank strap (3).



Remove the fuel tank.
Installation Procedure

Important
Always replace the fuel system hose clamps with the original equipment or parts that meet the GM specifications for those parts when replacing the clamps.






Install the fuel tank.



Install the fuel tank strap (3).

Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


Install the fuel tank strap bolts (1, 2, 4). Tighten
Tighten the bolt (2) to 25 N·m (18 lb ft).
Tighten the bolt (1) to 25 N·m (18 lb ft).
Tighten the remaining bolts (4) to 25 N·m (18 lb ft).




Remove the cap from the EVAP pipe.
Connect the EVAP pipe (2) quick connect fitting at the right fuel tank EVAP pipe (3).
Connect the tank crossover hose (5).
Push the clamp (4) outboard against the fuel tank, keeping the clamp parallel with the white stripe on the tank crossover hose. Tighten
Tighten the tank crossover hose clamp to 4 N·m (35 lb in).





Connect the fuel pressure sensor electrical connector.
Connect the FLVV hose (1) at the EVAP canister (2).



Install the EVAP canister access cover.
Install the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.



Remove the caps from the fuel pipes.
Connect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank, and the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
Connect the fuel sender electrical connector.
Install the right muffler, for automatic transmission- equipped vehicles only. Refer to Muffler Replacement - Left or Muffler Replacement - Right in Engine Exhaust.



Install the fuel tank shield (1).
Install the fuel tank shield mount bolt (2).
Install the fuel tank shield mount nut (3). Tighten
Tighten the fuel tank shield mount bolt to 25 N·m (18 lb ft).
Tighten the fuel tank shield mount nut to 12 N·m (106 lb in).
Install the right rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Lower the vehicle.
Refill the fuel system.
Connect the negative battery cable.
Perform the following procedure in order to inspect for leaks:
Turn the ignition switch ON for 2 seconds.
Turn the ignition switch OFF for 10 seconds.
Turn the ignition switch ON.
Inspect for fuel leaks.
Program the transmitters. Refer to Transmitter Programming in Keyless Entry.

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Document ID# 776229
2003 Chevrolet Corvette

 

Document ID# 776239
2003 Chevrolet Corvette

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Fuel Sender Assembly Replacement W/O FFS
Tools Required
J 34730-1A Fuel Pressure Gauge
J 37088-A Tool Set, Fuel Line Quick Connect Separator
Removal Procedure (Left or Right)

Caution
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.


Disconnect the negative battery cable.
Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .

Caution
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.


Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Clean all of the fuel connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
Drain the fuel tanks. Refer to Fuel Tank Draining Procedure .
Remove the fuel tank shield.
Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
Disconnect the quick-connect fittings from the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
Cap all of the fuel pipes.
Disconnect the fuel sender electrical connector.
Remove the fuel tank strap.
Support the fuel tank.
Remove the fuel sender attaching bolts.
Remove the float arm retaining clip and the float arm for the left fuel sender only.
Carefully remove the fuel sender with the gasket.
Clean the gasket sealing surfaces.
Installation Procedure (Right)
Inspect the fuel sender gasket for damage and replace if necessary.




Important
Do not bend or twist the float arm.


Insert the float arm through the fuel tank opening.
The fuel sender may need to be rotated in order to facilitate the installation.
Align the fuel sender gasket tab (2) with the fuel sender cover mark (1).
Align the fuel sender cover mark (1) with the fuel tank mark.



Hand tighten the fuel sender attaching bolts until finger tight.
Notice
Refer to Fastener Notice in Cautions and Notices.

Tighten the fuel sender assembly attaching bolts in sequence. Tighten
Tighten the bolt to 7 N·m (62 lb in).

Connect the fuel sender fuel feed pipe (1) (from the jet pump to the left tank, and the fuel feed rear crossover pipe (2) from the left tank to the jet pump). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .



Connect the fuel sender electrical connector.






Install the fuel tank strap (3).
Install the fuel tank strap bolts (1, 2, 4). Tighten
Tighten the bolt (2) to 25 N·m (18 lb ft).
Tighten the bolt (1) to 25 N·m (18 lb ft).
Tighten the remaining bolts (4) to 25 N·m (18 lb ft).




Install the fuel tank shield (1).
Install the fuel tank shield mount bolt (2).
Install the fuel tank shield mount nut (3). Tighten
Tighten the fuel tank shield mount bolt to 25 N·m (18 lb ft).
Tighten the fuel tank shield mount nut to 12 N·m (106 lb in).
Install the rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Lower the vehicle.
Refill the fuel system.
Install the fuel filler cap.
Connect the negative battery cable.
Perform the following procedure in order to inspect for leaks:
Turn the ignition switch ON for 2 seconds.
Turn the ignition switch OFF for 10 seconds.
Turn the ignition switch ON.
Inspect for fuel leaks.
Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
Installation Procedure (Left)




Install fuel pump strainer in the same position as noted during disassembly. Push on the outer edge of the strainer ferrule until the strainer is fully seated.
Install a sender gasket on the fuel sender.
Insert the fuel sender through the fuel tank opening.
The fuel sender may need to be rotated in order to facilitate the installation.

Important
Do not bend or twist the float arm.


Insert the float and the float arm into the fuel tank opening.
Install the float arm retaining clip.



Align the fuel sender gasket tab (1) with the fuel sender cover mark (2).
Align the fuel sender cover mark (2) with the fuel tank mark.
Tighten the fuel sender attaching bolts until the bolts are finger tight.



Tighten the fuel sender assembly attaching bolts in proper sequence. Tighten
Tighten bolts to 7 N·m (62 lb in).





Connect the fuel sender fuel feed pipe (1) from the jet pump to the left tank, to the fuel return rear pipe (2), and to the fuel feed rear pipe (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
Connect the fuel sender electrical connector.



Install the fuel tank strap (3).
Install the fuel tank strap bolts (1, 2, 4). Tighten
Tighten the bolt (2) to 25 N·m (18 lb ft).
Tighten the bolt (1) to 25 N·m (18 lb ft).
Tighten the remaining bolts (4) to 25 N·m (18 lb ft).




Install the fuel tank shield (1).
Install the fuel tank shield mount bolt (2).
Install the fuel tank shield mount nut (3). Tighten
Tighten the fuel tank shield mount bolt to 25 N·m (18 lb ft).
Tighten the fuel tank shield mount nut to 12 N·m (106 lb in).
Install the rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Lower the vehicle.
Refill the fuel system.
Install the fuel filler cap.
Connect the negative battery cable.
Perform the following procedure in order to inspect for leaks:
Turn the ignition switch ON for 2 seconds.
Turn the ignition switch OFF for 10 seconds.
Turn the ignition switch ON.
Inspect for fuel leaks.
Program the transmitters. Refer to Transmitter Programming in Keyless Entry.

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Document ID# 776239
2003 Chevrolet Corvette

 

Have you disconnected the crossover tube from the left side of the tank