Googling C6 Corvette fuel pump replacement will turn up more on here and youtube.
Fuel Tank Replacement Instructions
Thread Starter
Cruising
Joined: Nov 2024
Posts: 11
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Fuel Tank Replacement Instructions
I am new to Corvette and to this forum. Just bought a 2004 Z06 that has the crossover tube connection fuel leak. I need to source new tanks and would like a step-by-step written or video for doing it. Have read a lot of forums about the issue, just having problems finding how to's and where to buy new or mildly used tanks. Thanks for the help.
Tech Contributor
Joined: Jan 2007
Posts: 19,459
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From: Dyer, IN
I am new to Corvette and to this forum. Just bought a 2004 Z06 that has the crossover tube connection fuel leak. I need to source new tanks and would like a step-by-step written or video for doing it. Have read a lot of forums about the issue, just having problems finding how to's and where to buy new or mildly used tanks. Thanks for the help.
Team Owner
Joined: Oct 1999
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From: Guinness Its whats for B'fast JAWGA
CI 3-4-5-9 Veteran
03.5/04 Corvette is much the same:
https://www.corvetteforum.com/forums...fuel-pump.html
Be very careful with the plastic clips retaining the lines inside the crossover tube.
https://www.corvetteforum.com/forums...fuel-pump.html
Be very careful with the plastic clips retaining the lines inside the crossover tube.
Tech Contributor
Joined: Jan 2007
Posts: 19,459
Likes: 1,165
From: Dyer, IN
Thread Starter
Cruising
Joined: Nov 2024
Posts: 11
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Appreciate the heads up. I am new to corvette but have been autocrossing a 1998 BMW 328ic for years so not new to working on cars 😊. Specific tools needed I will figure out. It looks like the crossover tube is the hardest part so thanks for the extra words of caution. The link 93polo sent was perfect and just was I was looking for. Now i just have to find the tanks and time to do the work. Again, thanks for the heads up and information.
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Thread Starter
Cruising
Joined: Nov 2024
Posts: 11
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Project done now new problem
Appreciate all the information before. Switched out the driver side fuel tank with a 2006 tank that had 19,000 miles on it. Came with fuel pump. Started the car and fuel gauge was on empty. We had put at least 8 gallons in the tank. Low gauge warning light came on. Went and filled it up with 8 gallons. Tank went up to half a tank only. Trying to figure out what happened. Any help or pointing in the right direction to another thread would be very helpful. Car runs great
Team Owner
Joined: Oct 1999
Posts: 31,976
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From: Guinness Its whats for B'fast JAWGA
CI 3-4-5-9 Veteran
Tech Contributor
Joined: Jan 2007
Posts: 19,459
Likes: 1,165
From: Dyer, IN
Appreciate all the information before. Switched out the driver side fuel tank with a 2006 tank that had 19,000 miles on it. Came with fuel pump. Started the car and fuel gauge was on empty. We had put at least 8 gallons in the tank. Low gauge warning light came on. Went and filled it up with 8 gallons. Tank went up to half a tank only. Trying to figure out what happened. Any help or pointing in the right direction to another thread would be very helpful. Car runs great
Team Owner
Joined: Oct 1999
Posts: 31,976
Likes: 487
From: Guinness Its whats for B'fast JAWGA
CI 3-4-5-9 Veteran
Symptoms are consistent with being the later fuel level sensor after GM changed the voltages. You maybe able to change a table with HP Tuners, or swap back to the early sensor
For anyone on any C5/6 much of the fuel system stuff is getting expensive so never throw away old lines, solenoids etc if they are in working condition.
For anyone on any C5/6 much of the fuel system stuff is getting expensive so never throw away old lines, solenoids etc if they are in working condition.
Pro
Joined: Nov 2006
Posts: 511
Likes: 65
From: Vancouver BC
I am new to Corvette and to this forum. Just bought a 2004 Z06 that has the crossover tube connection fuel leak. I need to source new tanks and would like a step-by-step written or video for doing it. Have read a lot of forums about the issue, just having problems finding how to's and where to buy new or mildly used tanks. Thanks for the help.
Thread Starter
Cruising
Joined: Nov 2024
Posts: 11
Likes: 1
so now I have a new problem. I’ve been looking for somebody close by to reflash the ECU to pick up the new sending unit from the 07 unit I put in. Now the fuel gauge reads empty the whole time. Here’s what I’m thinking. I need to drop the tank and get a new fuel pump and sending unit formy year, 2004, and just put it in and be done with it. any suggestions?
Pro
Joined: Nov 2006
Posts: 511
Likes: 65
From: Vancouver BC
so now I have a new problem. I’ve been looking for somebody close by to reflash the ECU to pick up the new sending unit from the 07 unit I put in. Now the fuel gauge reads empty the whole time. Here’s what I’m thinking. I need to drop the tank and get a new fuel pump and sending unit formy year, 2004, and just put it in and be done with it. any suggestions?
Thread Starter
Cruising
Joined: Nov 2024
Posts: 11
Likes: 1
Still not sure what to do so asking again. To recap, I bought a 2004 z06 and had to replace the DS tank due to the well known crossover tube to tank issue. Bought a 2007 tank with 19000 miles on it and put it in (had the 2007 fuel pump in it so did not change it. Fuel gauge read 1/2 full when the tank was full. Figured it was the sending unit polarity change that I read about in the forum (evidently GM reversed the polarity on this unit in 2007). Was looking for a tuner to adjust the ECU to accept this but still have not found one locally. In the mean time, the fuel gauge now reads empty all the time and the display center is stuck on low fuel gauge and none of the buttons work to the right of the steering wheel. Car runs great. Any ideas? I think I’m going to have to pull the tank again and put in a new fuel pump for my year (unless one of you knows what’s going on and can help my ignorance).