How to Overhaul the Engine Control System - Removal & Installation Chevrolet Corvette C5

MODEL IDENTIFICATION

Vehicle model is identified by fourth character of Vehicle Identification Number (VIN). VIN is stamped on metal pad on top of left end of instrument panel, near windshield. See MODEL IDENTIFICATION table.

MODEL IDENTIFICATION

INTRODUCTION

This article covers removal, overhaul and installation procedures (when given by manufacturer). If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be supplied.

ELECTRONICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY

Electronically Erasable Programmable Read Only Memory (EPROM) is a permanent memory that is part of PCM. EEPROM cannot be replaced. EEPROM contains program and calibration information that PCM uses to control powertrain. If PCM is replaced, ensure NEW PCM software/calibration is correct and most recent version for vehicle. EEPROM must be programmed when NEW PCM is installed. Program EEPROM using latest software for that specific vehicle.

POWERTRAIN CONTROL MODULE

Note. Before replacing PCM, carefully inspect all wiring and control components. Failure to test for short circuits may result in repeated PCM failure due to shorts. To prevent internal damage to PCM, ensure ignition is off when connecting or disconnecting PCM harness connectors or any electrical components.

Removal & Installation (1.0L & 1.3L - "M" Body)

Turn ignition off. Disconnect negative battery cable. Open glove box. Apply pressure to sides of glove box to disengage 2 clips. Pull glove box down. Remove 3 bolts and PCM bracket. Disconnect harness connectors from PCM. Remove PCM. To install, reverse removal procedure.

Removal & Installation (1.8L - "S" Body)

1. Turn ignition off. Disconnect negative battery cable. Remove glove box. Remove console support bracket. Remove left lower finish panel and backing panel. Remove center finish panel. Remove radio.
2. Remove 2 bolts in rear console box. Remove 2 screws on sides of center console. Slide rear portion of center console back toward rear seats. Remove 2 upper screws on front position of console and remove front portion of console.
3. Disconnect harness connectors from PCM. Remove mounting bolts from PCM. Remove PCM. To install, reverse removal procedure.

Removal & Installation (1.9L - Saturn "S" Series)

Disconnect negative battery cable. Locate PCM. See PCM LOCATION table. Unlock 28-pin PCM harness connector and disconnect. Remove bolt from 80-pin PCM harness connector and disconnect. Remove PCM mounting bolts and remove PCM. To install, reverse removal procedure. Tighten PCM mounting bolts to 53 INCH lbs. (6 N.m). Tighten PCM harness connector bolt to 71 INCH lbs. (8 N.m). Program replacement PCM using appropriate equipment and latest software. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Removal & Installation (2.2L & 2.4L - "J" & "N" Bodies)

Turn ignition off. Disconnect negative battery cable. Locate PCM. See PCM LOCATION table. Remove any necessary components to gain access to PCM. Disconnect harness connectors from PCM. Remove PCM mounting bolts (if equipped). Remove PCM. To install, reverse removal procedure. Transfer any necessary components (i.e., knock sensor module, etc.) to NEW PCM before installation. Program replacement PCM using appropriate equipment and latest software. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Removal & Installation (2.2L - Saturn "L" Series)

1. Remove right side instrument panel lower dash insulator retainers. Remove right side heater outlet assembly retainer and remove outlet. Remove glove box door. Remove glove box with BCM attached. Disconnect BCM harness connectors if necessary.
2. Remove PCM-to-bracket screws. Disconnect PCM harness connectors and remove PCM. To install, reverse removal procedure. Program replacement PCM using appropriate equipment and latest software. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Removal & Installation (3.0L, 3.1L, 3.4L, 3.5L, 3.8L, 4.6L & 5.7L)

Turn ignition off. Disconnect negative battery cable. Locate PCM. See PCM LOCATION table. Remove any necessary components to gain access to PCM. Disconnect harness connectors from PCM. Remove PCM mounting bolts (if equipped). Remove PCM. To install, reverse removal procedure. Transfer any necessary components (i.e., knock sensor module, etc.) to NEW PCM before installation. Program replacement PCM using appropriate equipment and latest software. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

PCM LOCATION

CAMSHAFT POSITION SENSOR

Note. On 1.0L, camshaft position sensor is located in distributor housing and may also be referred to as a pick-up coil. (Scheme 1) Adjust signal rotor air gap to.008-.016" (0.2-0.4 mm) by moving camshaft position sensor in relation to signal rotor.

Disconnect negative battery cable. On 3.1L, remove serpentine belt and power steering pump assembly. On all models, disconnect harness connector from camshaft position sensor. Remove camshaft position sensor mounting bolt and remove camshaft position sensor. To install, reverse removal procedure. Tighten camshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS .

Scheme 1

Removal & Installation (3.8L)

1. Disconnect negative battery cable. Remove serpentine belt from crankshaft pulley. Raise vehicle on hoist. Remove right front tire and wheel assembly. Remove right inner fender access cover.
2. Using 28-mm socket, remove crankshaft harmonic balancer bolt. Using Balancer Remover (J-38197), remove harmonic balancer. Remove crankshaft position sensor shield (DO NOT use pry bar). (Scheme 2) Disconnect crankshaft position sensor harness connector. Remove crankshaft position sensor from engine block.
3. To install, reverse removal procedure. Apply Thread Sealer (GM 1052080) to threads of harmonic balancer bolt. Tighten sensor and harmonic balancer bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications). Perform CRANKSHAFT POSITION (CKP) SENSOR VARIATION LEARN PROCEDURE. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Scheme 2

Removal & Installation (1.0L, 1.3L, 1.8L, 1.9L, 2.2L, 2.4L, 3.0L, 4.6L & 5.7L)

1. Disconnect negative battery cable. Disconnect harness connector from crankshaft position sensor. Remove crankshaft position sensor mounting bolt/nut and remove crankshaft position sensor.
2. Inspect crankshaft position sensor "O" ring for wear, cracks or other damage. Replace as necessary. Lubricate NEW "O" ring with engine oil before installing. To install, reverse removal procedure. Tighten crankshaft position sensor bolt/nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

Removal & Installation (3.1L & 3.4L)

1. Disconnect negative battery cable. Turn steering wheel fully to left. Raise and support vehicle. Disconnect crankshaft position sensor harness connector. Remove crankshaft position sensor mounting bolt. Remove crankshaft position sensor from engine block.
2. Inspect crankshaft position sensor "O" ring for wear, cracks or other damage. Replace as necessary. Lubricate NEW "O" ring with engine oil before installing. To install, reverse removal procedure. Tighten crankshaft position sensor bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

1. Disconnect negative battery cable. Remove serpentine belt from crankshaft pulley. Raise and support vehicle.
2. Remove crankshaft harmonic balancer bolt. Using Balancer Remover (J-24420-B), remove harmonic balancer. Disconnect crankshaft position sensor harness connector. Remove crankshaft position sensor bolts. Remove crankshaft position sensor.
3. To install, reverse removal procedure. Apply Thread Sealer (GM 1052080) to threads of harmonic balancer bolt. Tighten crankshaft position sensor and harmonic balancer bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

Removal & Installation (1.0L)

1. Disconnect negative battery cable. Remove distributor cap. (Scheme 1) Mark distributor housing-to-engine position and distributor rotor-to-distributor housing position for installation reference. Disconnect distributor harness connector. Remove 2 distributor flange bolts. Remove distributor.
2. DO NOT rotate crankshaft with distributor removed, or reference marks will be incorrect. To install distributor, use reference marks and reverse removal procedure. Install 2 distributor flange bolts. Do not fully tighten flange bolts until timing is set. See IGNITION TIMING in appropriate ON-VEHICLE ADJUSTMENTS article. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Installing Distributor When Position Has Been Lost (1.0L)

1. Remove FI fuse from fuse and relay box. Rotate crankshaft until piston No. 1 is at TDC of compression stroke. Align timing mark on crankshaft pulley to zero position on timing cover.
2. Position rotor to cylinder No. 1 position. Install distributor. Reinstall FI fuse. Ensure timing is correct. See IGNITION TIMING in appropriate ON-VEHICLE ADJUSTMENTS article.

Removal & Installation (1.3L & 1.8L)

Disconnect negative battery cable. Remove spark plug wires from ignition coils. Disconnect harness connectors from ignition coils. Remove bolts attaching ignition coils to cylinder head. Remove ignition coils. To install, reverse removal procedure.

Removal & Installation (1.9L, 2.2L, 3.0L, 3.1L, 3.4L, 4.6L & 5.7L)

Disconnect negative battery cable. Remove spark plug wires from ignition coils. On 3.0L and 5.7L, remove screws attaching ignition coils to support bracket. On all models except 3.0L and 5.7L, remove nuts or screws attaching ignition coils to ignition control module. On all models, remove ignition coils. To install, reverse removal procedure.

Removal & Installation (2.4L)

1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove 4 IDI cover assembly-to-camshaft housing bolts. Remove ignition system assembly from engine. Remove 4 coil housing-to-cover screws. Remove housing cover.
2. Disconnect coil harness connector from module. Remove ignition coil, contacts and seals from cover. To install, reverse removal procedure. Tighten screws and bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

Removal & Installation (3.5L)

Note. Ignition control module and ignition coil can not be serviced separately. Replace module and coil as an assembly.

For ignition coil removal and installation, see IGNITION CONTROL MODULE (IDI) .

Disconnect negative battery cable. Disconnect spark plug wires from coil pack. Remove 6 screws retaining coils to ignition control module. Remove ignition coils from module. To install, reverse removal procedure. Tighten retaining screws to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Disconnect 14-pin connector at ignition control module. Disconnect spark plug wires from coil pack. Remove 6 screws retaining coils to ignition control module. Remove ignition coils from module.
2. Remove screws and washers securing ignition control module to bracket. Remove ignition control module. To install, reverse removal procedure. Tighten retaining screws to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

Removal & Installation (1.9L, 2.2L, 3.1L, 3.4L & 4.6L)

1. Disconnect negative battery cable. Disconnect connectors at ignition control module. (Scheme 3)- (Scheme 5). Disconnect spark plug wires from coil pack. Remove coil pack/ignition control module assembly. For ignition control module location, see COMPONENT LOCATIONS in appropriate SYSTEM & COMPONENT TESTING article. Separate ignition coil(s) from ignition control module (if possible).
2. To install, reverse removal procedure. Tighten ignition control module mounting bolts/nuts. On 1.9L, ensure mounting bolt holes are clean of old sealant. Use NEW mounting bolts supplied with module. On all models, tighten mounting bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Scheme 3

Scheme 4

Scheme 5

Removal (2.4L)

1. Disconnect negative battery cable. Disconnect 11-pin harness connector. Remove 4 IDI cover assembly-to-camshaft housing bolts. Remove ignition system assembly from engine.
2. Remove 4 coil housing-to-cover screws. Remove housing cover. Remove coil harness connector from module. Remove module-to-cover screws. Remove module from cover.

Installation (2.4L)

Note. DO NOT wipe grease from module or coil if module is not being replaced. If installing a NEW module, spread silicone grease on metal face of module and on cover where module seats. Grease is included with NEW module and is necessary for module cooling purposes.

To install, reverse removal procedure. Tighten screws and bolts to specification. See TORQUE SPECIFICATIONS .

Note. Ignition control module and ignition coil can not be serviced separately. Replace module and coil as an assembly.

1. Disconnect negative battery cable. Remove fuel injector sight shield. Connect ignition control module harness connector. Lift at end opposite ignition control module to release clip retainer from ball pin on coil cassette. Slide cover out of slide latch in module. Remove 4 ignition control module-to-coil cassette mounting screws. Lift module straight up off cassette. Ensure mating connector and seal came off with module. If mating connector and seal did not come off with module, remove connector and seal from cassette.
2. To install, ensure mating connector and seal are removed from coil cassette. If installing a NEW ignition control module, insert mating connector into module, install seal and apply dielectric to terminals on mating connector prior to installing in cassette. Ensure all harness connector terminals are okay. Clean all mounting surfaces before reinstalling components.
3. Install ignition control module onto coil cassette. Install 4 ignition control module-to-coil cassette mounting screws. Tighten screws to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Install beauty cover. Slide latch tongue into module while holding opposite end slightly away from coil cassette surface to clear and align ball pin on cassette with clip retainer on cover. Press clip retainer down onto ball pin. Connect ignition control module harness connector.

FUEL PRESSURE RELIEF

Fuel system is under pressure. Pressure must be relieved prior to servicing fuel system. Fuel pressure may be relieved by using one of the following methods

1. On 1.0L, 1.3L and 1.8L, loosen fuel filler cap to relieve tank pressure (DO NOT tighten at this time). On 1.0L, remove circuit opening relay. On 1.3L and 1.8L, remove fuel pump relay. On all models, start and run engine until it stalls. Crank starter for 3 seconds to remove remaining fuel from fuel lines. Turn ignition off. Reinstall circuit opening relay or fuel pump relay. Disconnect negative battery cable to avoid possible fuel discharge in accidental attempt to start engine.
2. On 1.9L, 3.0L, 3.1L, 3.4L, 3.5L, 3.8L, 4.6L and 5.7L, disconnect negative battery terminal. Loosen fuel filler cap. Install Fuel Pressure Gauge (J-34730-1A) on fuel pressure connector of fuel rail. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb fuel leakage. Install gauge bleed hose in container. Open bleed valve to bleed fuel pressure.
3. On 2.2L and 2.4L Cavalier and Sunfire, loosen fuel filler cap to relieve tank pressure (DO NOT tighten at this time). Disconnect fuel pump connector. Start and run engine until it stalls. Crank starter for 3 seconds to remove remaining fuel from fuel lines. Turn ignition off. Reconnect fuel pump connector. Disconnect negative battery cable to avoid possible fuel discharge in accidental attempt to start engine.
4. On 2.2L Saturn, connect scan tool to Data Link Connector (DLC). Start engine. Using scan tool special tests function, select PCM/EC, and then select fuel delivery. Select FUEL PUMP and command fuel pump off. Engine will stall in 3-5 seconds. Turn ignition off.

Locating Fuel Filter Components. Scheme 6

The fuel filter (2) is located under the rear of the car, behind the fuel tank. There is no service interval for fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . CAUTION: Provide additional support when a vehicle is on a hoist in the following ways: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
3. Raise the vehicle and suitably support. CAUTION: In order to reduce the risk of fire and personal injury observe the following items: Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
4. Using back-up wrench, remove the fuel filter fitting.
5. Grasp the fuel filter and the fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction in order to loosen any dirt within the fitting. Use compressed air in order to blow dirt from the quick-connect fittings at the end of the fuel filter.
6. Remove the quick connect fitting by pushing inward toward the fuel filter, grasping the plastic tab around the connector, and pulling the fitting apart.
7. Remove the fuel filter.

Installation Procedure

1. Remove the protective caps from the new fuel filter.
2. Install the fuel filter (2) in same position as the old fuel filter. (Scheme 6)
3. Install the fuel filter fitting using a new O-ring. Apply a few drops of clean engine oil to the male tube end of the filter and of the fuel sender assembly. Push the quick-connector (1) together in order to cause the retaining tabs to snap into place. Pull on both ends of each connection to ensure the connections are secure. NOTE: 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. IMPORTANT: Use back-up wrench to prevent damage to the fuel filter O-ring or to the fuel pipe. Install the fuel filter fitting (3). Tighten Tighten the fuel filter fitting to 27 Nm (20 lb ft).
4. Lower the vehicle.
5. Reconnect the negative battery cable.
6. Use the following procedure in order to inspect for fuel leaks: Turn on the ignition for 2 seconds, leaving the engine off. Turn off the ignition for 10 seconds. Turn on the ignition, leaving the engine off. Inspect for fuel leaks.

Removal Procedure (3.4L)

The fuel filter is located under the rear of the vehicle, rearward of the fuel tank. There is no service interval for the fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.

1. Relieve fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. If metal collar quick connect fittings are used, refer to Metal Collar Quick Connect Fitting Service. 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 and strap the vehicle to the hoist.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the quick-connect fitting at the inlet of the in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service.
5. Disconnect the threaded fitting at the outlet of the in-pipe fuel filter.
6. Drain any remaining fuel into an approved gasoline container.

1. Remove protective caps from the new filter.
2. Install the fuel filter fitting using a new O-ring in the same position as the old filter.
3. Connect the quick-connect fitting at the inlet of the in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service. NOTE: 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.
4. Connect the threaded fitting at the outlet of the in-pipe fuel filter. Tighten Use a back-up wrench in order to prevent the in-pipe fuel filter from turning. Tighten the in-pipe fuel filter outlet nut to 27 Nm (20 lb ft).
5. Lower the vehicle.
6. Tighten the fuel filler cap.
7. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
8. Inspect for fuel leaks. Turn ON the ignition for 2 seconds. Then turn OFF for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Removal Procedure (Bonneville)

Tools Required

J 34730 Fuel Pressure Gauge

Disconnecting/Reconnecting Fuel Filter Quick Connections. Scheme 7

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . 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 and strap the vehicle to the hoist.
2. Raise the vehicle.
3. Remove the quick-connect fitting at the fuel feed pipe (4).
4. Remove the threaded connection at the in-line fuel filter (3). IMPORTANT: Inspect the O-ring on the fuel filter outlet pipe for cracks or damage. Replace as required.
5. Inspect the fuel lines for cuts, swelling, cracks, and distortion. Replace the lines as required.
6. Drain any remaining fuel into an approved gasoline container.

Installation Procedure (Bonneville)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.

1. Remove the protective caps from the new in-line fuel filter.
2. Install the new plastic connector retainers on the in-line fuel filter inlet and outlet.
3. Install the quick-connect fitting (4) at the inlet of the in-line fuel filter. (Scheme 7)
4. Install the threaded connection at the in-line fuel filter (3). Use a back-up wrench in order to prevent the nut from turning. Tighten Tighten the outlet nut to 30 Nm (22 lb ft).
5. Lower the vehicle.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable. Turn ON the ignition switch for 2 seconds. Turn OFF the ignition switch for 10 seconds. Turn ON the ignition switch. Check for fuel leaks.

Removal Procedure (Century, Regal)

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

View Of Fuel Filter. Scheme 8

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise the vehicle.
3. Disconnect the quick connect fitting at the inlet of the in-pipe fuel filter.
4. Disconnect the threaded fitting at the outlet of the in-pipe fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Remove the in-pipe fuel filter and mounting bracket.
7. Remove the in-pipe fuel filter from the in-pipe fuel filter mounting bracket.

Installation Procedure (Century, Regal)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

1. Remove the protective caps from the new in-pipe fuel filter.
2. Slide the in-pipe fuel filter into the in-pipe fuel filter mounting bracket.
3. Install the in-pipe fuel filter and mounting bracket. NOTE: 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.
4. Install the in-pipe fuel filter mounting bracket retaining bolt. Tighten Tighten the in-pipe fuel filter mounting bracket bolt to 20 Nm (15 lb ft).
5. Connect the quick connect fitting at the inlet of the in-pipe fuel filter.
6. Install the threaded fitting at the outlet of the in-pipe fuel filter. Tighten Use a back-up wrench in order to prevent the in-pipe fuel filter from turning. Tighten the in-pipe fuel filter outlet nut to 30 Nm (22 lb ft).
7. Lower the vehicle.
8. Tighten the fuel tank filler pipe cap.
9. Install the negative battery cable.
10. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Check for fuel leaks.
11. On Regal, Install the fuel injection sight shield.

Removal Procedure (Intrigue)

Tools Required

J 37088-A Fuel Line Quick-Connect Tools

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . CAUTION: Provide additional support when a vehicle is on a hoist: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
2. Raise the vehicle.
3. Disconnect the quick-connect fitting at the inlet of the in-line fuel filter. Refer to Plastic Collar Quick Connect Fitting Service.
4. Disconnect the threaded fitting at the outlet of the in-line fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Remove the in-line fuel filter assembly attaching bolt and remove the fuel filter assembly.
7. Remove the in-line fuel filter from the mounting bracket.

Installation Procedure (Intrigue)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes. Remove the protective caps from the new in-line fuel filter. Slide the in-line fuel filter into the mounting bracket. Install the in-line fuel filter and the mounting bracket. see scheme 15 NOTE: 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 bolt that retains the in-line fuel filter mounting bracket. Tighten Tighten the bolt to 20 Nm (15 lb ft) Connect the quick-connect fitting at the inlet of the in-line fuel filter. Connect the threaded fitting at the outlet of the in-line fuel filter. Use a back-up wrench in order to prevent the in-line fuel filter from turning. Tighten Tighten the bolt to 30 Nm (22 lb ft). Lower the vehicle. Perform the following procedure to inspect for leaks: Inspect turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF for 10 seconds. Turn the ignition switch to the ON position again. Visually inspect the fuel system for fuel leaks. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.

Removal Procedure (LeSabre, Park Avenue)

1. Turn OFF Ignition.
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . 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 and strap the vehicle to the hoist.
3. Raise the vehicle.
4. Remove the quick-connect fitting at the fuel feed pipe (3). Park Avenue is similar.
5. Remove the threaded connection (2) at in-line fuel filter. Park Avenue is similar. IMPORTANT: Inspect the O-ring on fuel filter outlet pipe for cracks or damage. Replace as required.
6. Inspect the fuel lines, O-rings for cuts, swelling, cracks, and distortion. Replace the lines as required.
7. Drain any remaining fuel into an approved gasoline container.

Installation Procedure (LeSabre, Park Avenue)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

1. Remove the protective caps from the new in-line fuel filter.
2. Install the new plastic connector retainers on the in-line fuel filter inlet and outlet. Install the new plastic connector retainers in the same position as on the old in-line fuel filter.
3. Install the quick-connect fitting at the inlet of the in-line fuel filter. NOTE: 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. IMPORTANT: Make sure that the O-ring is installed on the outlet pipe before installing the pipe.
4. Install the threaded connection (2) at the in-line fuel filter. Tighten Tighten the in-line fuel filter outlet nut to 30 Nm (22 lb ft) using a back-up wrench in order to prevent the nut from turning.
5. Lower the vehicle.
6. Tighten the fuel tank filler pipe cap.
7. Install the negative battery cable.
8. Perform the following procedure to check for fuel leaks: Turn the ignition ON for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON. Check for fuel leaks.
9. On Park Avenue, install the fuel injector sight shield.

Removal Procedure (DeVille)

Tools Required

J 34730-1A Fuel Pressure Gauge

Note. Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Identifying Fuel Pressure Gauge J 34730-1A. Scheme 9

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise the vehicle.
3. Disconnect the fuel feed quick-connect fitting (5) at the inlet of the in-line fuel filter (4).
4. Disconnect the threaded fitting at the outlet of the in-line fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Inspect the lines for cuts, swelling, cracks, and distortion. Replace the lines as required.
7. Inspect the retainer (7), the fuel tank vapor hose (1), the EVAP hose (2), and the purge hose (3).
8. Inspect the fuel return pipe quick connect fitting (6).

Installation Procedure (DeVille)

1. Remove the protective caps from the new in-line fuel filter.
2. Install the new plastic connector retainer in the same position as on the old in-line fuel filter.
3. Slide the in-line fuel filter into place.
4. Connect the quick-connect fitting at the inlet (5) of the in-line fuel filter (4). see scheme 18 NOTE: 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.
5. Connect the threaded fitting at the outlet of the in-line fuel filter. Tighten Use a back-up wrench in order to prevent the in-line fuel filter from turning.
6. Reposition the EVAP pipe. (2) Tighten Tighten the in-line fuel filter outlet nut to 30 Nm (22 lb ft).
7. Lower the vehicle.
8. Tighten the fuel tank filler pipe cap (1).
9. Connect the negative battery cable.
10. Inspect for fuel leaks. Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Check for fuel leaks.
11. Install the rear seat cushion.
12. Install the intake manifold sight shield. Tighten Tighten the intake manifold nuts to 3 Nm (27 lb in).

Removal Procedure (Eldorado)

Tools Required

J 34730-1A Fuel Pressure Gauge

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief).
2. Raise the vehicle.
3. Remove the in-line fuel filter bracket.
4. Grasp the in-line fuel filter and one fuel pipe fitting.
5. Twist quick-connect fitting turn in each direction to loosen any dirt within fitting.
6. Repeat for other fuel pipe fitting. (Scheme 16): Blowing Out Dirt (Plastic Collar) CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
7. Blow out dirt from quick-connect fittings at both ends of in-line fuel filter, using compressed air.
8. Squeeze plastic tabs of male end connector.
9. Pull connection apart.
10. Repeat for the other fitting.
11. Remove the in-line filter.

Installation Procedure (Eldorado)

1. Remove the protective caps from new in-line filter.
2. Install the new plastic connector retainers on in-line filter inlet and outlet tubes.
3. Install the in-line filter in retainer noting the direction of flow indicated on filter.
4. Install the new in-line filter in the same position as the old in-line fuel filter.
5. Apply a few drops of clean engine oil to both pipe ends of the filter.
6. Reinstall the quick connect fittings.
7. Push connectors together to cause the retaining tabs/fingers to snap into place.
8. Pull on both ends of each connection to make sure connection secure.
9. Lower the vehicle.
10. Tighten the fuel filler cap. CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
11. Connect the negative battery cable.
12. Inspect for fuel leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Check for fuel leaks.
13. Install the fuel injector sight shield (1) to the engine. NOTE: 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.
14. Install the fuel injector sight shield nuts (2). Tighten Tighten the nuts 3 Nm (27 lb in).

Removal Procedure (Grand Prix)

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. If plastic collar quick connect fittings are used, refer to Metal Collar Quick Connect Fitting Service for the correct service procedure.
3. Raise the vehicle.
4. Disconnect the quick-connect fitting at the inlet of the in-pipe fuel filter.
5. Disconnect the threaded fitting at the outlet of the in-pipe fuel filter.
6. Drain any remaining fuel into an approved gasoline container.
7. Remove the in-pipe fuel filter and mounting bracket.
8. Remove the in-pipe fuel filter from the in-pipe fuel filter mounting bracket.

Installation Procedure (Grand Prix)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.

1. Remove the protective caps from the new in-pipe fuel filter.
2. Slide the in-pipe fuel filter into the in-pipe fuel filter mounting bracket.
3. Install the in-pipe fuel filter and mounting bracket. NOTE: 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.
4. Install the in-pipe fuel filter mounting bracket retaining bolt. Tighten Tighten the in-pipe fuel filter mounting bracket bolt to 20 Nm (15 lb ft).
5. Connect the quick-connect fitting at the inlet of the in-pipe fuel filter.
6. Connect the threaded fitting at the outlet of the in-pipe fuel filter. Tighten Use a back-up wrench in order to prevent the in-pipe fuel filter from turning. Tighten the in-pipe fuel filter outlet nut to 30 Nm (22 lb ft).
7. Lower the vehicle.
8. Tighten the fuel tank filler pipe cap.
9. Connect the negative battery cable.
10. Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Check for fuel leaks.
11. If equipped, Install the fuel injection sight shield.

Locating Fuel Sender Assembly End Cap. Scheme 10

1. Remove the fuel sender assembly. Refer to «FUEL SENDER ASSEMBLY»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-sender-assembly) .
2. Remove the end cap (1) and the lower cushion from the fuel sender assembly.
3. Remove the fuel pressure regulator.
4. Remove the retaining clip (1) from the fuel pump strainer.
5. Remove the fuel pump strainer (2).
6. Remove the fuel sender assembly housing (2) from the fuel level sensor and gauge unit assembly (1).
7. Remove the fuel filter cushion from the fuel filter.
8. Disconnect the electrical connector (4) from the fuel pump.
9. Remove the fuel pump (3) from the fuel filter (2).
10. Remove the fuel filter (2) from the fuel level sensor and gauge unit assembly (1).

Installation Procedure (Prizm)

1. Install the fuel filter (2) to the fuel level sensor and gauge unit assembly (1). (Scheme 27)
2. Install the fuel pump (3) into the fuel filter (2).
3. Connect the electrical connector (4) to the fuel pump.
4. Install the fuel filter cushion to the fuel filter (2).
5. Install the fuel sender assembly housing (3) to the fuel level sensor and gauge unit assembly (1).
6. Install the fuel pressure regulator (4) to the bottom of the fuel filter (2).
7. Install the fuel pump strainer (2) to the fuel pump. (Scheme 25)
8. Secure the strainer with the clip (1).
9. Install the lower cushion to the bottom of the fuel pump.
10. Install the fuel sender assembly end cap (1). (Scheme 10)
11. Install the fuel sender assembly into the fuel tank. Refer to «FUEL SENDER ASSEMBLY»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-sender-assembly).

Removal Procedure (Seville)

Tools Required

J 34730 Fuel Pressure Gauge

Note. Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . 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 and strap the vehicle to the hoist.
2. Raise the vehicle.
3. Disconnect the fuel feed quick-connect fitting (5) at the inlet of the in-line fuel filter (4).
4. Disconnect the threaded fitting at the outlet of the in-line fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Inspect the lines for cuts, swelling, cracks, and distortion. Replace the lines as required.
7. Inspect the retainer (7), the fuel tank vapor hose (1), the EVAP hose (2), and the purge hose (3).
8. Inspect the fuel return pipe quick connect fitting (6).

Installation Procedure (Seville)

1. Remove the protective caps from the new in-line fuel filter.
2. Install the new plastic connector retainer in the same position as on the old in-line fuel filter.
3. Slide the in-line fuel filter into place.
4. Connect the quick-connect fitting at the inlet (5) of the in-line fuel filter (4). (Scheme 30) NOTE: 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.
5. Connect the threaded fitting at the outlet of the in-line fuel filter. Tighten Use a back-up wrench in order to prevent the in-line fuel filter from turning.
6. Reposition the retainer (7), the fuel tank vapor hose (1), the EVAP hose (2), or the purge hose (3) if necessary. (Scheme 30) Tighten Tighten the in-line fuel filter outlet nut to 30 Nm (22 lb ft). 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 and strap the vehicle to the hoist.
7. Lower the vehicle.
8. Tighten the fuel tank filler pipe cap. CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
9. Connect the negative battery cable.
10. Inspect for fuel leaks. Turn ON the ignition to for 2 seconds. Turn OFF the ignition to for 10 seconds. Turn ON the ignition. Check for fuel leaks.
11. Install the rear seat cushion.
12. Install the fuel injector sight shield (1) to the engine.
13. Install the fuel injector sight shield nuts (2). Tighten Tighten the nuts to 3 Nm (27 lb in).

Removal Procedure (Camaro, Firebird)

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Identifying Fuel Filter Components. Scheme 11

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise the vehicle.
3. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
4. Disconnect the quick-connect fitting at the fuel filter inlet (3).
5. Disconnect the threaded fitting (1) from the fuel filter outlet.
6. Slide the fuel filter (2) from the bracket (4).
7. Inspect the fuel pipe O-ring for cuts, nicks, swelling, or distortion. Replace the O-ring if necessary.

Installation Procedure (Camaro, Firebird)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

1. Slide the fuel filter (2) into the bracket (4). (Scheme 11)
2. Reconnect the threaded fitting (1) to the fuel filter outlet. NOTE: 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. Tighten Tighten the fuel filter fitting to 30 Nm (22 lb ft).
3. Reconnect the quick-connect fitting to the fuel filter inlet (3).
4. Lower the vehicle.
5. Tighten the fuel filler cap.
6. Reconnect the negative battery cable.
7. Inspect for fuel leaks. Turn ON the ignition to for 2 seconds. Turn OFF the ignition to for 10 seconds. Turn ON the ignition. Check for fuel leaks.

Removal Procedure (Cavalier, Sunfire)

fuel filter (2) is located under the rear of the car, behind the fuel tank. There is no service interval for fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . CAUTION: Provide additional support when a vehicle is on a hoist in the following ways: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
3. Raise the vehicle and suitably support. CAUTION: In order to reduce the risk of fire and personal injury observe the following items: Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes. Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
4. Using back-up wrench, remove the fuel filter line fitting from the filter.
5. Grasp the fuel filter and the fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
6. Remove the quick connect fitting by pushing inward toward the fuel filter and grasping the plastic tab around the connector and pull apart.
7. Remove the fuel filter.

Installation Procedure (Cavalier, Sunfire)

1. Remove the protective caps from the new fuel filter.
2. Install the fuel filter (2) in same position as the old fuel filter.
3. Install the fuel filter fitting using a new O-ring. Apply a few drops of clean engine oil to the male tube end of the filter and of the fuel sender assembly. Push the quick-connector (1) together to cause the retaining tabs/fingers to snap into place. Once installed, pull on both ends of each connection to make sure they are secure. NOTE: 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 filter fitting (3). Tighten Use back up wrench to prevent the fuel filter O-ring or fuel pipe from damage. Tighten the fuel filter fitting to 27 Nm (20 lb ft).
4. Lower the vehicle.
5. Reconnect the negative battery cable.
6. Inspect for fuel leaks through the following steps: Turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF position for 10 seconds. Turn the ignition switch to the ON position. Check for fuel leaks.

Removal Procedure (Corvette)

Tools Required

1. J 34730-1A Fuel Pressure Gauge
2. J 37088-A Tool Set, Fuel Line Quick Connect Separator

Identifying Fuel Feed Pipes At Fuel Filter/Pressure Regulator. Scheme 12

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief).
3. Raise the vehicle.
4. Lower the left muffler (auto trans equipped vehicles only).
5. Clean all the fuel filter/pressure regulator connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
6. Disconnect the fuel feed pipe quick-connect fitting (1) from the fuel filter/pressure regulator (2).
7. Disconnect the fuel return pipe quick-connect fitting (4) from the fuel filter/pressure regulator (2).
8. Remove the fuel filter/pressure regulator bracket mount nut (2).
9. Disconnect the fuel feed pipe (3) from the outlet side of the fuel filter/pressure regulator (2). (Scheme 12)
10. Remove the fuel filter/pressure regulator and bracket (1) from the stud (3). (Scheme 34)
11. Cap the fuel pipes in order to prevent possible fuel system contamination.
12. Disconnect the fuel system ground strap.
13. Remove the fuel filter/pressure regulator from the bracket.

Installation Procedure (Corvette)

1. Remove the protective caps from the new fuel filter/pressure regulator.
2. Install the new plastic quick connector retainers on the fuel filter/pressure regulator tubes. Install the new retainers in the same positions as on the old fuel filter/pressure regulator.
3. Install the fuel filter/pressure regulator into the bracket.
4. Connect the fuel system ground strap.
5. Remove the caps from the fuel pipes.
6. Connect the fuel feed pipe (3) to the outlet side of the fuel filter/pressure regulator (2). (Scheme 12)
7. Install the fuel filter/pressure regulator and the bracket (1) to the mounting stud (3). (Scheme 34)
8. Engage the anti-rotation tab (3) of the fuel filter/pressure regulator bracket (2) into the hole of the tunnel reinforcement (1). NOTE: 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.
9. Install the fuel filter/pressure regulator bracket nut (2). (Scheme 34)
10. Connect the fuel return pipe quick-connect fitting (4) to the fuel filter/pressure regulator (2). (Scheme 12)
11. Connect the fuel feed pipe quick-connect fitting (1) to the fuel filter/pressure regulator (2).
12. Raise the left muffler (auto trans equipped vehicles only).
13. Lower the vehicle.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for fuel leaks through the following steps: Turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF position for 10 seconds. Turn the ignition switch to the ON position. Check for fuel leaks.
17. Program the transmitters. Refer to «TRANSMITTER PROGRAMMING & SYNCHRONIZATION»(/chevrolet/corvette/c5-1997-2004/remont/door-locks-anti-theft-systems/#remote-keyless-entry-systems).
18. Perform the idle learn procedure. Refer to «THROTTLE/IDLE LEARN»(/chevrolet/corvette/c5-1997-2004/remont/computer-relearn/#computer-relearn-procedures__throttleidle-learn).

Removal Procedure (Impala, Lumina, Monte Carlo)

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

1. Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise the vehicle.
3. Disconnect the quick-connect fitting at the inlet of the in-pipe fuel filter.
4. Disconnect the threaded fitting at the outlet of the in-pipe fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Remove the mounting bracket retaining bolt.
7. Remove the in-pipe fuel filter and mounting bracket.
8. Remove the in-pipe fuel filter from the in-pipe fuel filter mounting bracket.

Installation Procedure (Impala, Lumina, Monte Carlo)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes. Remove the protective caps from the new in-pipe fuel filter. Slide the in-pipe fuel filter into the in-pipe fuel filter mounting bracket. Install the in-pipe fuel filter and mounting bracket. (Scheme 37) NOTE: 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 in-pipe fuel filter mounting bracket retaining bolt. Tighten Tighten the in-pipe fuel filter mounting bracket bolt to 20 Nm (15 lb ft) Connect the quick-connect fitting at the inlet of the in-pipe fuel filter. Install the threaded fitting at the outlet of the in-pipe fuel filter. Tighten Use a back-up wrench in order to prevent the in-pipe fuel filter from turning. Tighten the in-pipe fuel filter outlet nut to 30 Nm (22 lb ft). Lower the vehicle. Tighten the fuel tank filler pipe cap. Install the negative battery cable. Inspect for fuel leaks through the following steps: Turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF position for 10 seconds. Turn the ignition switch to the ON position. Check for fuel leaks. On 3.8L, Install fuel injection sight shield.

Removal Procedure (Malibu)

The fuel filter is located under the rear of the car, rearward of the fuel tank. There is no service interval for the fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.

1. Relieve fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise vehicle.
3. Disconnect the quick-connect fitting at the inlet of the in-pipe fuel filter.
4. Disconnect the threaded fitting at the outlet of the in-pipe fuel filter.
5. Drain any remaining fuel into an approved gasoline container.

Installation Procedure (Malibu)

1. Remove protective caps from new filter.
2. Install the fuel filter fitting using new O-ring in same position as old filter.
3. Connect the quick-connect fitting at the inlet of the in-pipe fuel filter. NOTE: 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.
4. Connect the threaded fitting at the outlet of the in-pipe fuel filter. Tighten Use a back-up wrench in order to prevent the in-pipe fuel filter from turning. Tighten the in-pipe fuel filter outlet nut to 27 Nm (20 lb ft).
5. Lower vehicle.
6. Tighten the fuel filler cap.
7. Reconnect the negative battery cable.
8. Inspect for fuel leaks through the following steps: Turn the ignition switch to the ON position for 2 seconds. Turn the ignition switch to the OFF position for 10 seconds. Turn the ignition switch to the ON position. Check for fuel leaks.

FUEL INJECTOR (TBI)

Note. Remove injector only for cleaning, "O" ring replacement or injector replacement.

Removal (1.0L)

1. Relieve fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Disconnect Intake Air Temperature (IAT) sensor connector. Disconnect PCV hose from air cleaner. Remove air cleaner assembly and air cleaner stud bracket from TBI unit.
2. Remove 2 mounting screws and injector cover with harness connector from TBI unit. (Scheme 38) Remove injector from TBI unit.

Installation (1.0L)

Note. It is important to replace a fuel injector with an identical part. Injectors may look alike, but are calibrated for different flow rates and are NOT interchangeable.

1. Apply a thin coat of oil to NEW upper and lower injector "O" rings. Install "O" rings on injector. Install NEW lower injector insulator into injector cavity. Insert injector straight down into TBI unit. DO NOT twist injector.
2. Carefully install injector cover with harness connector to TBI unit, and tighten mounting screws. Tighten air cleaner stud bracket bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . To complete installation, reverse removal procedure. Pressurize fuel system and check for leaks.

Identifying Fuel Pressure Gauge J 34730-1A. Scheme 13

Removal (Alero & Grand Am)

1. Relieve the fuel system pressure, if necessary.
2. Drain the fuel tank, if necessary.
3. Remove the fuel tank. Refer to «FUEL TANK (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
4. Remove the fuel sender assembly. Refer to «REMOVAL (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
5. Remove the fuel pump and fuel level sender electrical retaining clip at the top of the modular fuel sender assembly.
6. Disconnect the fuel pump and fuel level sender electrical connector.
7. Depress the 3 tabs securing the upper fuel reservoir and slide upward until free of the lower reservoir.
8. Depress the tab on the fuel level sensor while sliding up and out of the housing.
9. Remove the retaining clip from the electrical connector.
10. Remove the fuel level sender wires from the connector, taking care to note the location of the wires.

Installation (Alero & Grand Am)

1. Install the fuel level sensor by sliding the sensor down into the housing.
2. Slide the upper reservoir into the lower reservoir.
3. Connect the 2 wires into the connector and lock with the retaining clip.
4. Connect the fuel pump and fuel level sensor electrical connector and lock with the retaining clip.
5. Reinstall the fuel sender assembly. Refer to «INSTALLATION (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
6. Reinstall the fuel tank. Refer to «FUEL TANK (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
7. Reinstall the fuel fill cap.
8. Connect the negative battery cable.
9. Inspect for leaks using the following procedure Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

FUEL SENDER ASSEMBLY

Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system. The fuel pipe connections. The hose connections. The areas surrounding the connections.

Note. DO NOT handle the fuel pump assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

Note. Replace the fuel sender "O" rings when re-installing the fuel pump in order to avoid damage to the fuel pump assembly.

Note. When installing fuel sending unit assembly, DO NOT fold or twist strainer. This will restrict fuel flow.

1. Relieve the fuel system pressure.
2. Drain the fuel tank.
3. Remove the fuel tank (4). Refer to «REMOVAL (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) . IMPORTANT: The modular fuel sender assembly may spring up from the proper position. When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir is full of fuel. Tip the tank slightly during removal to avoid damage to the float. Discard the fuel sender O-ring and replace with a new one. Carefully discard the reservoir fuel into an approved container.
4. With the J 39765 Fuel Sender Lock Nut Tool, press down and rotate the cam lock ring (1) until free of the fuel sender retaining tabs.
5. Remove the modular fuel sender assembly.
6. Remove the fuel level sensor. Refer to «REMOVAL (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__removal-alero-grand-am) .

1. Install the fuel level sensor. Refer to «INSTALLATION (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__installation-alero-grand-am) .
2. Install the O-ring on the fuel tank (4).
3. Align the fuel lines parallel with the mark on the fuel tank.
4. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank. IMPORTANT: Be sure that the cam lock ring is fully seated within the tab slots.
5. Install the cam lock ring using J 39765 Fuel Sender Lock Nut Tool.
6. Install the fuel tank. Refer to «INSTALLATION (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
7. Lower the vehicle.
8. Refill the tank and install the fuel fill cap.
9. Connect the negative battery cable.
10. Inspect for fuel leaks using the following procedure: Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for leaks.

Removal (Bonneville, LeSabre & Park Avenue - 3.8L)

1. Relieve the fuel system fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Drain the fuel tank to at least 3/4 of full.
2. Remove the spare tire cover, the jack, and the spare tire. Remove the rear compartment trim. Remove the fuel pump access panel (1). (Scheme 39)
3. Clean all of the fuel pipe connections, hose connections and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Remove the quick-connect fittings at the fuel sender assembly. Disconnect the electrical connector from the fuel sender. Disconnect the electrical connector from the fuel tank pressure sensor.
5. Remove the fuel sender retaining cam, using the Fuel Sender Locknut Wrench (J-39765). Remove the fuel sender assembly and the "O" ring from the fuel tank. Discard the fuel sender assembly "O" ring. Clean and inspect the "O" ring sealing surfaces of the fuel sender assembly.

Scheme 14

Installation (Bonneville, LeSabre & Park Avenue - 3.8L)

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. DO NOT repair sections of fuel pipes.

Note. 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.

1. Position the NEW "O" ring on the fuel tank.
2. Install the fuel pump assembly and the retainer cam, using the Fuel Sender Locknut Wrench (J-39765). Install the quick-connect fittings at the fuel sender assembly.
3. Connect the electrical connector to the fuel tank pressure sensor. Connect the electrical connector to the fuel sender assembly.
4. Install the negative battery cable. Inspect for leaks. Turn ON the ignition switch for 2 seconds. Turn OFF the ignition switch for 10 seconds. Turn ON the ignition switch. Check for fuel leaks.
5. Install the fuel sender access panel. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Install the rear compartment floor trim.
6. Install the spare tire, the jack, and the spare tire cover. Add fuel to the fuel tank. Install the fuel filler cap.

Removal & Installation (Camaro & Firebird)

Note. DO NOT handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

Note. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Note. 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.

1. Disconnect the negative battery cable. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) .
2. Raise car on hoist. Drain fuel from fuel tank. Disconnect exhaust pipe at converter and rear hanger. Allow exhaust to hang over axle assembly.
3. Remove tailpipe and muffler heat shields. Remove fuel filler neck shield behind left rear tire. Remove rear suspension track bar and brace. Disconnect harness connector to fuel pump assembly.
4. Disconnect all fuel lines. Remove fuel line retaining bracket on left side and remove brake line clip from bracket.
5. Position support jack under axle assembly. Disconnect lower ends of shock absorbers. Disconnect rear stabilizer bar from frame (if equipped).
6. On models equipped with 2-piece driveshaft, remove center support bearing-to-rear axle torque arm bolts. On all models, remove rear axle torque arm-to-differential housing bolts/nuts. Wire end of rear axle torque arm aside. Remove driveshaft-to-differential yoke bolts/screws. Wire end of driveshaft aside.
7. Lower rear suspension as far as possible without damaging brake lines and cables and remove both coil springs. Remove fuel tank strap bolts. Remove fuel tank by rotating front of tank down and sliding to the right. Remove fuel pump assembly from fuel tank.
8. Carefully fold the strainer to allow it to fit through the opening in the fuel tank. Make sure the strainer unfolds once it is placed in the tank.
9. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Inspect for leaks. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Check for fuel leaks. On 5.7L models, perform the idle learn procedure. See «CAMARO & FIREBIRD»(/chevrolet/corvette/c5-1997-2004/remont/computer-relearn/#computer-relearn-procedures__camaro-firebird) in COMPUTER RELEARN article in GENERAL INFORMATION.

Removal & Installation (Catera - 3.0L)

Note. 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.

1. Raise and suitably support the vehicle. Remove the right hand rear fascia bolts. Remove the rear frame support.
2. Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter. Remove clamps from the fuel tank breather hose and EVAP hoses at the fuel tank near the fuel filter.
3. Disconnect the fuel tank breather hose and the EVAP hoses. Remove the fuel sender electrical connector retainer. Disconnect the fuel sender electrical connector. Remove the fuel filter retaining bolt from the bracket. Remove the EVAP vent valve retaining bolt from the bracket.
4. With the aid of an assistant, support the fuel tank. Remove the fuel tank retaining strap attaching bolts. Remove both fuel tank retaining straps. Lower the fuel tank.
5. Disconnect the electrical connectors from the fuel tank pressure sensor (6) and the fuel tank connection cover (2). (Scheme 40) Remove the fuel pressure (5) and return lines (1) from the tank connection cover and discard the clamps. Remove the air reference hose (3) from the fuel tank pressure sensor. Remove the fastener (4) securing the fuel tank pressure sensor to the fuel tank connection cover and remove the fuel tank pressure sensor.
6. Remove the spring loaded clamp (1) around the fuel tank boot. (Scheme 41) Note the position of the clamp. The clamp must be reinstalled in the same position. Carefully pull the boot from the outer fuel tank housing.
7. Remove the fuel sender locking nut from the fuel tank by using the Fuel Tank Sender Wrench (J-42219-B) fuel tank sender wrench. (Scheme 42) Lift the fuel tank connection cover from the tank and position aside. Remove the fuel level sensor electrical connector (1) from the fuel tank connection cover. (Scheme 43)
8. Unlock the fuel sensor by pressing the hook outward. Remove the fuel sensor by pulling upward on the hook to slide the unit from the fuel pump housing. Remove the fuel sender seal (lip) from the fuel tank opening. Carefully slide the seal over the wiring and hoses, then pull the seal over the fuel tank connection cover. Discard the seal.
9. Install the fuel level sender in the tank by positioning the float in first and sliding the unit into the slots in the side of the fuel reservoir. Push the unit down in the slot until the tab on the hook engages in the reservoir. Connect the fuel level sender electrical connector to the fuel tank connection cover.
10. Install a NEW lip seal on the tank as follows: Carefully pull the seal over the fuel tank connection cover. Slide the seal over the wires and hoses to the fuel tank opening. Fit the groove in the side of the seal into the lip in the fuel tank opening. Install the fuel tank connection cover on the fuel tank opening.
11. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Removal & Installation (Cavalier & Sunfire - 2.2L & 2.4L)

Note. The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Use a shop towel to absorb any leakage.

1. Disconnect the negative battery cable. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Drain the fuel tank.
2. Raise and support the vehicle. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes. Disconnect the quick-connect fittings at the fuel tank.
3. Disconnect the quick-connect fitting at the fuel filter. Remove the quick connect fittings at the end of the fuel pipe and vapor pipes. Remove the muffler support bolts. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear suspension. Remove the exhaust heat shield. Remove the hoses at the fuel tank from the filler, vent and vapor pipes.
4. With the aid of an assistant, support fuel tank and disconnect the 2 fuel tank retaining straps. With the aid of an assistant, lower the fuel tank. Remove the fuel tank pressure sensor electrical connector. Remove the fuel sender electrical connector. Remove the tank from the vehicle. (Scheme 44)
5. While holding the modular fuel sender assembly (3) down, remove the snap ring (1) from designated slots located on the retainer (2).
6. Install a NEW "O" ring on the modular fuel sender. Install the modular fuel sender to the fuel tank. Align the tab on front of the modular fuel sender with slot on front of the retainer snap ring. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.
7. Insert the snap ring into the designated slots. Install the fuel tank. Lower the vehicle. Refill the fuel tank. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps. Turn the ignition switch to the ON position for two seconds. Turn the ignition switch to the OFF position for ten seconds. Turn the ignition switch to the ON position Check for fuel leaks.

Scheme 19

Removal & Installation (Century, Grand Prix, Impala, Intrigue, Monte Carlo & Regal - 3.1L, 3.4L, 3.8L)

Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections, the hose connections and the areas surrounding the connections.

Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. DO NOT repair sections of fuel pipes.

Note. 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.

1. Relieve the fuel system fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect the negative battery cable. Remove the spare tire cover, the jack, and the spare tire.
2. Remove the rear compartment trim panel. Remove the nuts retaining the fuel sender access panel. (Scheme 45) Remove the fuel sender access panel. Disconnect the fuel tank pressure sensor electrical connector. Disconnect the fuel sender electrical connector.
3. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal. Disconnect the quick-connect fittings at the fuel sender assembly. Remove the fuel sender retaining snap ring. (Scheme 46) Remove the modular fuel sender assembly.
4. Clean the fuel sender assembly "O" ring sealing surfaces. Inspect the fuel sender assembly "O" ring sealing surfaces.
5. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).
6. Inspect the fuel system for leaks by performing the following steps: 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.

Scheme 20

Scheme 21

Removal (Corvette - 5.7L)

Note. Vehicle is equipped with 2 fuel tanks. The electric fuel pump attaches to the fuel sender assembly inside the left fuel tank. The fuel pump supplies fuel to the right fuel tank siphon jet pump in order to transfer fuel from the right fuel tank to the left fuel tank.

1. Disconnect the negative battery cable. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief).
2. Raise and support the vehicle. Remove the left rear wheel and tire assembly. 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.
3. Drain the fuel tanks. Remove fuel tank shield bolt (2) and nut (3). (Scheme 47) Remove the fuel tank shield (1). Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
4. Disconnect the quick-connect fittings from the fuel sender. Cap all of the fuel pipes. Disconnect the fuel sender electrical connector. Remove the fuel tank strap bolts (1), (2) and (4) while supporting fuel tank. (Scheme 48) Remove the fuel tank strap (3).
5. Support the fuel tank. Remove previously installed "break-away head" service bolts (if equipped) using a 5/16 inch open end wrench. Discard the fuel sender attaching bolts and use NEW bolts upon installation. Remove the float arm retaining clip and the float arm for the left fuel sender only. Carefully remove the fuel sender with the gasket.

Installation (Corvette - 5.7L)

Note. 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.

Note. 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.

1. To install the left fuel sender assembly, Install a NEW fuel pump strainer in the same position as noted during removal. Push on the outer edge of the strainer ferrule until the strainer is fully seated.
2. Install a NEW fuel sender gasket on the fuel sender. Fold the strainer three times so that the amount of space occupied by the strainer is about equivalent to the diameter of the fuel sender reservoir. (Scheme 49) Fold the long side of the strainer over (1 over 2). Fold 3 over 4 and hold the strainer in the folded position. Insert the fuel sender through the fuel tank opening. Release the strainer once the strainer is in the fuel tank. The strainer will spring back to its full position.
3. Continue inserting the fuel sender through the fuel tank opening. It may be necessary to rotate the fuel sender in order to facilitate the installation. Look through the fuel tank opening to ensure that the long side of the strainer is visible. If the strainer is not visible, rotate the fuel sender clockwise and counterclockwise about 90 degrees. Rotating the fuel sender will free up the strainer. The strainer should become visible at the tank opening.
4. Align the fuel sender gasket tab (1) with the fuel sender cover mark (2). (Scheme 50) Align the fuel sender cover mark (2) with the fuel tank mark. Hand tighten the NEW "break-away head" fuel sender attaching bolts until finger tight.
5. Tighten the NEW "break-away head" fuel sender assembly attaching bolts in sequence until the upper hex head portion of the bolts shear off of the lower section. (Scheme 51) Connect the fuel sender fuel feed (1) pipe (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3). (Scheme 52)
6. Connect the fuel sender electrical connector. Install the fuel tank strap. Install the fuel tank strap bolts. (Scheme 48) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).
7. Install the fuel tank shield (1). (Scheme 47) Install the fuel tank shield mount bolt (2). Install the fuel tank shield mount nut (3). Tighten the fuel tank shield mount bolt to specification. Tighten the fuel tank shield mount nut to specification.
8. Install the rear wheel and tire assembly. Tighten wheel lug nuts to specification. Lower the vehicle. Refill the fuel system. Install the fuel filler cap. Connect the negative battery cable. 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.

Scheme 22

View Of Fuel Filter. Scheme 23

Scheme 24

Scheme 25

Scheme 26

Removal & Installation (Deville & Seville - 4.6L)

Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections The hose connections The areas surrounding the connections.

Note. DO NOT handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Always replace the fuel sender "O" ring when reinstalling the fuel sender assembly.

Note. 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.

1. Relieve the fuel system fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Drain the fuel tank to at least three-quarters of a tank full.
2. Remove the spare tire cover, the jack, and the spare tire. Remove the rear compartment floor trim to avoid damage from fuel spillage.
3. Remove the rear compartment floor trim (1). Remove the bolts from the fuel sender access panel (2). see scheme 63
4. Disconnect the quick-connect fittings at the fuel sender assembly. Disconnect the electrical connector at the fuel sender. Disconnect the electrical connector at the fuel tank pressure sensor.
5. Remove the fuel sender retaining ring using the Fuel Sender Locknut Wrench (J-39765). see scheme 64
6. Pull the fuel sender straight up while pumping the fuel from the reservoir. Clean the fuel sender assembly "O" ring sealing surfaces. Inspect the fuel sender assembly "O" ring sealing surfaces.
7. Reinstall the fuel sender assembly and the fuel sender assembly retainer using the Fuel Sender Locknut Wrench (J-39765) (1). Install the quick-connect fittings at the fuel sender assembly. Connect the electrical connector at the fuel tank pressure sensor. Connect the electrical connector at the fuel sender assembly. Connect the negative battery cable.
8. Inspect for leaks. Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Check for fuel leaks. Reinstall the fuel sender access panel. Tighten the fuel sender access panel bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).
9. Reinstall the rear compartment floor trim. Reinstall the spare tire, the jack, and the spare tire cover. Add fuel to the fuel tank. Install the fuel tank filler pipe cap. Install the rear seat cushion. Install the fuel injector sight shield to the engine. Install the fuel injector sight shield nuts. Tighten the nuts to specification.

Scheme 27

Scheme 28

Removal & Installation (Eldorado)

1. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Drain the fuel tank.
2. Raise and support the vehicle. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes. Disconnect the quick-connect fittings at the fuel tank.
3. Disconnect the fuel feed pipe at the in-line fuel filter and return pipe near the in-line fuel filter. Disconnect the clamps at the fuel filler neck and fuel filler neck vent pipe at the fuel tank. Remove the fuel filler neck and fuel filler neck vent pipe from the fuel tank. Disconnect the fuel sender electrical connector. Remove the exhaust heat shield screws and reposition shield.
4. With the aid of an assistant, support fuel tank and disconnect the 2 fuel tank retaining straps. With the aid of an assistant, lower the fuel tank and disconnect the EVAP pipe.
5. Remove the fuel sender assembly from the fuel tank using Fuel Sender Locknut Wrench (J-39765).
6. Install a NEW "O" ring on the modular fuel sender. Install the modular fuel sender to the fuel tank using Fuel Sender Locknut Wrench (J-39765).
7. To install fuel tank, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .
8. Connect the negative battery cable. Inspect for fuel leaks using the following procedure: Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Removal & Installation (LS, LS1, LS2, LW1 & LW2 - 2.2L & 3.0L)

Note. Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

1. Remove fuel tank. Disconnect fuel lines from fuel pump module cover. see scheme 65
2. Use the Fuel Sending Unit Wrench (J-43827 2.2L; J-44017 3.0L) to remove the fuel pump module ring. see scheme 66 To prevent bending of the sending unit float arm remove the sending unit first by pulling the retaining clip toward float arm and lift upward. see scheme 67
3. Carefully lift fuel pump straight up from fuel tank. To disengage fuel pump from fuel pump housing clips must be disabled at the same time. Discard fuel pump module to tank seal. Remove fuel pump housing by releasing the four retaining clips. see scheme 68
4. The retaining clips hold fuel pump housing to fuel pump housing bracket (mounted in bottom of tank). Disengage clip closest to the pump (where fuel return line attaches to fuel pump housing) by inserting a small flat blade screwdriver between the clip (on the housing) and the mounting bracket. Leave screwdriver wedged in place to prevent clip from reattaching as the other clips are being disabled.
5. Disengage the clip closest to the one disengaged in previous step (toward rear of tank). Use a second small flat blade screwdriver to disenable this clip. Remove all contaminants and replace in-line fuel filter before installing a NEW fuel pump assembly when debris is present. Stick one of the screwdrivers between the fuel pump housing and base of the fuel tank to prevent clips (previous steps) from re-engaging.
6. Remove second screwdriver from fuel tank. The next clip to be disengaged is at the rear most position. To disengage this clip tilt housing toward jet pump while releasing this clip. Once these clips have been disengaged push module (or roll the module) in the direction of the remaining clip that is engaged. This will force clip to disengage. Remove housing from tank.
7. To install, reverse removal procedure. Replace fuel pump module to tank "O" ring. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Identifying Fuel Pressure Gauge. Scheme 29

Scheme 30

Scheme 31

Removal & Installation (Lumina) - 3.1L)

1. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Drain the fuel tank.
2. Raise and support the vehicle. Remove the fuel tank filler EVAP hose from the fuel tank. Remove the fuel tank filler hose from the fuel tank. Disconnect the quick-connect fittings at the fuel tank.
3. Disconnect the modular fuel sender and the fuel tank pressure sensor electrical connectors. Remove the EVAP pipe from the connection at the front of the fuel tank. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly. Remove the exhaust pipe heat shield bolts and the exhaust pipe heat shield.
4. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips. Disconnect the EVAP pipe to the rear of the fuel tank. Disconnect the EVAP pipe to the fuel sender assembly. Remove the fuel tank from the vehicle.
5. Carefully discard the reservoir fuel into an approved container. With the Fuel Sender Lock Nut Tool (J-39765), press down and rotate the cam lock ring until free of the fuel sender retaining tabs. Remove the modular fuel sender assembly. (Scheme 44) Remove the fuel level sensor.
6. Install the fuel level sensor.
7. To install, reverse removal procedure. Install the NEW "O" ring on the fuel tank. Align the fuel lines parallel with the mark on the fuel tank. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.
8. Connect the negative battery cable. Inspect for fuel leaks using the following procedure: Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Removal & Installation (Malibu) - 3.1L)

1. Disconnect the negative battery cable. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Drain the fuel tank.
2. Raise and support the vehicle. Disconnect the quick-connect fitting at the fuel filter. Disconnect the quick connect fittings at the end of the fuel lines. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle. Remove the exhaust heat shield. Loosen the fuel tank filler hose clamp at the fuel tank.
3. Remove the hoses from the fuel tank filler, EVAP vent and EVAP vapor pipes. Disconnect the electrical harness from the multi-way rear body connector and fuel strap. With the aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps. Lower the fuel tank.
4. Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor. Disconnect the EVAP pipe and fuel pipe from the modular fuel sender and fill limiter vent valve.
5. Using Fuel Sender Lock Nut Tool (J-39765), press down and rotate the cam lock ring until free of the fuel sender retaining tabs. Remove the modular fuel sender assembly.
6. Install a NEW "O" ring on the fuel tank. Align the fuel lines parallel with the mark on the fuel tank. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on the fuel tank. Install the cam lock ring using Fuel Sender Lock Nut Tool (J-39765). Be sure that the cam lock ring is fully seated within the tab slots.
7. To install the fuel tank, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Lower the vehicle. Refill the fuel tank. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps. Turn the ignition switch to the ON position for two seconds. Turn the ignition switch to the OFF position for ten seconds. Turn the ignition switch to the ON position Check for fuel leaks.

Removal & Installation (Metro & Firefly (Canadian) - 1.0L & 1.3L)

1. Fuel pump is located in fuel tank and is integral with fuel sending unit assembly. Relieve the fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Drain the fuel tank. Remove the rear seat cushion from the vehicle.
2. Disconnect the fuel pump, the fuel level sensor, and the electrical connectors. see scheme 69 Push the electrical connectors through the grommet in the floor of the vehicle. Raise and suitably support the vehicle. Remove right rear wheel/tire assembly. Remove rear stabilizer shaft assembly.
3. Remove 2 nuts and the resonator/muffler/tailpipe assembly from the front pipe/Three Way Catalytic Converter (TWC) assembly. Remove one bolt and the hanger from the pipe at the resonator. Remove three bolts and the hangers from the muffler. Turn the resonator/muffler/tailpipe assembly counterclockwise. Pull back the resonator/muffler/tailpipe assembly. Move the resonator/muffler/tailpipe assembly toward the wheel. Remove the resonator/muffler/tailpipe assembly.
4. Remove the clamp and the fuel filler hose from the fuel tank filler neck. Remove the clamp and the fuel breather hose from the fuel tank breather neck. Remove the clamp and the air inlet hose to the EVAP canister from the canister air inlet pipe, if necessary.
5. Remove the 2 bolts from the 2 parking brake cable brackets on the vehicle underbody. Move the cable aside. Remove the clamp and the EVAP canister vapor hose from the EVAP canister vapor pipe.
6. Disconnect the quick connect line from the fuel feed pipe. Disconnect the quick connect line from the fuel return pipe. Remove the 5 fuel tank mounting bolts and the fuel tank.
7. Remove 6 fuel sending unit hold-down bolts and remove fuel sending unit assembly from fuel tank. see scheme 70 Disconnect fuel level sensor harness connector. Depress fuel level sensor retaining tab and slide sensor down to remove from fuel sending unit assembly.
8. To install, reverse removal procedure. Use NEW gasket on fuel sending unit assembly. Tighten fuel sending unit assembly hold-down bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Locating Fuel Filter Components. Scheme 32

Scheme 33

Removal & Installation (Prizm - 1.8L)

1. Fuel pump is located in fuel tank and is integral with fuel sending unit assembly. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove rear seat bottom cushion. Remove the left side door opening sill plate. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
2. Remove fuel sending unit assembly access panel bolts and remove access panel. see scheme 71
3. Disconnect harness connector from fuel sending unit assembly. see scheme 72 Remove the retaining clip from the fuel line fitting. Remove fuel pipe from top of fuel sending unit assembly.
4. Remove 8 fuel sending unit assembly hold-down bolts and remove hold-down plate. see scheme 73 Remove fuel sending unit assembly (1) and "O" ring (2) from fuel tank (3). see scheme 74 Remove No. 2 fuel sending unit support and rubber cushion. Remove fuel pressure regulator. Remove fuel pump strainer hold-down clip and remove fuel pump strainer.
5. Remove No. 1 fuel sending unit support from fuel sending unit plate. Remove No. 1 fuel filter cushion from fuel filter. Disconnect harness connector from fuel pump. Remove fuel pump from fuel filter.
6. To install, reverse removal procedure. Use NEW "O" ring on fuel pressure regulator and fuel sending unit assembly. Tighten fuel sending unit assembly hold-down bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications).

Scheme 34

Scheme 35

View Of Fuel Filter. Scheme 36

Removal & Installation (SC1, SC2, SL, SL1, SL2 & SW2 - 1.9L)

Note. Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

Note. Care must be taken not to bend or twist the fuel pump filter or sending unit float arm during removal or installation of the fuel pump module assembly. A damaged fuel pump filter restricts fuel flow to the pump and a bent sending unit arm will not provide accurate readings. Care must be taken to assure the pump module is not dropped. A dropped pump can dislodged internal parts creating a noisy and/or leakage condition.

1. Remove the fuel tank. Disconnect the fuel feed and return lines from the filter/pressure regulator. Disconnect the fuel pump vapor line from the fuel tank vent pipe.
2. Use the Fuel Tank Lock Ring Remover (SA9156E) and remove the fuel pump module retaining ring. see scheme 75 To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 90 degrees clockwise until the fuel lines are facing the 1 o'clock position. 12 o'clock is front of tank.
3. Carefully lift the fuel pump module, with the sending unit, straight up from the fuel tank until the bottom of the pump module is very close to the fuel tank opening. see scheme 76 Then tilt the pump module about 45 degrees toward the right side of the tank and simultaneously lift it up and out of the tank opening watching that the level sender float arm is not being bent.
4. Inspect the fuel tank for metal chips/debris. Remove all contaminants and replace the in-line fuel filter before installing a NEW fuel pump assembly when debris is present. Discard the fuel pump module-to-tank seal.
5. Verify that the float arm on the fuel level sender has not been bent by standing the fuel pump module on a flat, horizontal surface and measuring the distance from this surface and the bottom of the float. A 5/32 inch diameter drill can be used as a gage. see scheme 77 The gage must freely pass between the float and the horizontal surface with no more than 1/16 inch clearance.
6. If the float arm requires repositioning to meet the clearance specification, assure that any bending is performed at the 90° bend near the level sender. The short section of the float arm going into the level sender must be supported so that bending does not take place at the level sender. Carefully install the fuel pump module with sending unit in the fuel tank by orienting the float to face the right side of the tank, tilting the pump module approximately 45°, and loading the float arm and pump into the tank opening.
7. Insert the pump module all the way down into the tank and then rotate 90° counterclockwise to align the module orientation tabs with slots in the tank opening. Correctly oriented, the lines from the pump module will be facing the 10 o'clock position. 12 o'clock is the front of tank. To install, reverse removal procedure.
8. Using the scan tool, perform the Service Bay Diagnostic Test for the evaporative emission system. This test will verify the integrity of the vapor handling areas of the fuel system.

Scheme 37

Scheme 38

Scheme 39

FUEL PRESSURE REGULATOR

Note. On 1.0L, fuel pressure regulator and throttle body are serviced as an assembly. DO NOT remove pressure regulator from throttle body. See THROTTLE BODY (TBI) .

Note. On 3.0L, fuel pressure regulator and fuel rail are serviced as an assembly only. DO NOT remove pressure regulator or pressure regulator cover from fuel rail. See FUEL RAIL & INJECTORS .

Removal (1.3L)

Relieve fuel pressure. See FUEL PRESSURE RELIEF . Disconnect negative battery cable. Disconnect pressure regulator vacuum hose. Remove fuel return line from pressure regulator. Remove pressure regulator screws. Remove pressure regulator from fuel rail. Remove fuel inlet "O" ring from pressure regulator.

Installation (1.3L)

To install, reverse removal procedure. DO NOT reuse "O" ring. Lubricate NEW fuel inlet "O" ring with oil and install on regulator. Tighten screws to specification. See TORQUE SPECIFICATIONS .

Removal (1.8L)

1. Fuel pressure regulator is located on fuel sending unit assembly, on bottom of fuel filter. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove rear seat cushion. Remove 4 fuel sending unit assembly access panel bolts and remove access panel. Disconnect harness connector from fuel sending unit assembly.
2. Remove fuel pipe from top of fuel sending unit assembly. Remove 8 fuel sending unit assembly hold-down bolts and remove hold-down plate. Remove fuel sending unit assembly and "O" ring from fuel tank. Remove fuel pressure regulator from bottom of fuel filter.

Installation (1.8L)

To install, reverse removal procedure. Use NEW "O" ring on fuel pressure regulator and fuel sending unit assembly. Tighten fuel sending unit assembly hold-down bolts to specification. See TORQUE SPECIFICATIONS .

Removal (1.9L)

1. Fuel pressure filter/regulator is located under vehicle, on left front side of fuel tank. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Raise and support vehicle. Remove 2 fuel filter/pressure regulator bracket screws.
2. Unlatch fuel line bundle retaining clip on left side of fuel tank. Disconnect EVAP purge line at 90-degree quick-connect. Slide filter/regulator outlet out of support on fuel tank bracket. Disconnect fuel feed line at 90-degree quick-connect.
3. Pivot filter/regulator down while moving mounting bracket out from under chassis brakelines. Disconnect fuel feed and return lines at quick-connect fitting on filter/regulator. DO NOT remove filter/regulator from bracket. Filter/regulator and bracket are serviced as an assembly.

Installation (1.9L)

To install, reverse removal procedure. Install NEW fuel line retainers into female portion of quick-connect fuel line fittings. Ensure chassis fuel feed and purge lines are routed on top of parking brake cable. Tighten screws to specification. See TORQUE SPECIFICATIONS .

Removal (2.2L & 2.4L - Alero, Cavalier, Grand Am & Sunfire)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove air cleaner outlet resonator (if necessary). Remove fuel rail bracket (if equipped). Disconnect pressure regulator vacuum hose. Remove fuel return line and "O" ring from pressure regulator. On 2.4L, remove fuel rail. See «FUEL RAIL & INJECTORS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-rail-injectors) .
2. On all models, remove pressure regulator screws. Remove pressure regulator from fuel rail. Remove pressure regulator retainer and spacer assembly from fuel rail (if equipped). Remove fuel inlet "O" ring from pressure regulator. Remove and discard filter screen if dirty.

Installation (2.2L & 2.4L - Alero, Cavalier, Grand Am & Sunfire)

To install, reverse removal procedure. DO NOT reuse "O" ring. Lubricate fuel inlet "O" ring with oil and install in regulator. Replace filter screen as necessary. Tighten screws to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (2.2L - Saturn)

Relieve fuel pressure. See FUEL PRESSURE RELIEF . Disconnect vacuum line from fuel pressure regulator. Remove 2 retaining bolts and fuel pressure regulator. Discard "O" rings. To install, apply clean engine oil to both NEW "O" rings. Install small "O" ring on fuel pressure regulator and large "O" ring into fuel rail. Install fuel pressure regulator on fuel rail and tighten retaining bolts to specification. See TORQUE SPECIFICATIONS . Reconnect vacuum line.

Removal (3.1L & 3.4L)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove intake manifold plenum and gaskets. Disconnect pressure regulator vacuum hose. Remove fuel return line and "O" ring from pressure regulator.
2. Remove fuel pressure regulator screws. Remove fuel pressure regulator from fuel rail. Remove pressure regulator retainer and spacer assembly from fuel rail (if equipped). Remove fuel inlet "O" ring from fuel pressure regulator. Remove and discard filter screen if dirty.

Installation (3.1L & 3.4L)

To install, reverse removal procedure. DO NOT reuse "O" ring. Lubricate NEW fuel inlet "O" ring with oil and install in regulator. Replace filter screen as necessary. Tighten screws to specification. See TORQUE SPECIFICATIONS .

Removal (3.5L & 3.8L)

Relieve fuel pressure. See FUEL PRESSURE RELIEF . Disconnect negative battery cable. On 3.5L, remove fuel injector sight shield. On all models, disconnect pressure regulator vacuum hose. Remove pressure regulator snap ring. Lift and twist pressure regulator from pressure regulator housing attached to fuel rail. Remove back-up "O" ring, large "O" ring, filter screen and small "O" ring from pressure regulator housing.

Installation (3.5L & 3.8L)

To install, reverse removal procedure. DO NOT reuse "O" rings. Lubricate NEW "O" rings with oil and install in regulator housing. Install snap ring.

Removal (4.6L)

Relieve fuel pressure. See FUEL PRESSURE RELIEF . Disconnect negative battery cable. Remove intake manifold top cover. Disconnect pressure regulator vacuum hose. Remove pressure regulator retaining ring. Lift and twist pressure regulator from fuel rail. Remove fuel inlet "O" ring from pressure regulator. Remove and discard filter screen if dirty.

Installation (4.6L)

To install, reverse removal procedure. DO NOT reuse "O" ring. Lubricate NEW fuel inlet "O" ring with oil and install in regulator. Replace filter screen as necessary. Tighten intake manifold cover nuts to specification. See TORQUE SPECIFICATIONS .

Removal (5.7L Camaro)

Relieve fuel pressure. See FUEL PRESSURE RELIEF . Disconnect negative battery cable. Drain fuel tank. Remove fuel tank. Remove fuel sender assembly from fuel tank. Remove pressure regulator retaining ring. Remove pressure regulator from housing on fuel return pipe. Remove large "O" ring and small "O" ring from pressure regulator.

Installation (5.7L Camaro)

To install, reverse removal procedure. DO NOT reuse "O" rings. Lubricate NEW "O" rings with oil and install on regulator. Replace filter screen as necessary. Install retaining ring.

Removal (5.7L Corvette)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Raise and support vehicle. Lower left muffler (A/T only). Clean all fuel filter/pressure regulator connections to avoid fuel system contamination. Disconnect fuel feed pipe quick-connect fitting from fuel filter/pressure regulator. Disconnect fuel return pipe quick-connect fitting from fuel filter/pressure regulator.
2. Remove fuel filter/pressure regulator bracket mount nut. Disconnect fuel system ground strap from fuel filter/pressure regulator mounting stud. Disconnect fuel feed pipe from outlet side of fuel filter/pressure regulator. Remove fuel filter/pressure regulator and bracket from stud. Plug fuel pipes to prevent fuel system contamination. Remove fuel filter/pressure regulator from bracket.

Installation (5.7L Corvette)

To install, reverse removal procedure. Install NEW plastic quick connector retainers on fuel filter/pressure regulator. Remove plugs from fuel pipes. Tighten fuel filter/pressure regulator bracket nut to specification. See TORQUE SPECIFICATIONS .

FUEL RAIL & INJECTORS

Note. If injector is replaced, ensure replacement injector has the same part number as injector removed.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove PCV valve and hose from intake and valve cover. Remove 3 intake manifold brace bolts and remove brace from engine. Disconnect harness connectors from injectors.
2. Disconnect fuel pressure regulator vacuum hose. Disconnect and plug fuel feed hose from fuel rail inlet pipe. Disconnect and plug fuel return hose from fuel rail return pipe. Remove 2 fuel rail retaining bolts. Remove fuel rail from intake manifold. Remove injectors from fuel rail. Remove injector "O" rings and discard.

To install, reverse removal procedure. Coat NEW injector "O" rings with clean engine oil. Ensure injectors rotate smoothly and freely. If "O" ring is installed incorrectly, injector will bind. Tighten fuel rail retaining bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Disconnect 4 spark plug wires from 2 ignition coils. Disconnect PCV and breather hoses from valve cover. Remove nut and accelerator cable bracket from cylinder head.
2. Remove nuts and bolt from wire harness cover plate and remove cover plate. Disconnect harness connectors from injectors. Remove 2 bolts and pull back wiring harness. Disconnect and plug fuel line. Remove fuel line hold-down bolt.
3. Remove 2 fuel rail retaining bolts. Remove fuel rail from cylinder head. Remove 2 fuel rail spacers from cylinder head. Remove injectors from fuel rail. Remove injector "O" rings and discard.

To install, reverse removal procedure. Coat NEW injector "O" rings with clean engine oil. Ensure injectors rotate smoothly and freely. If "O" ring is installed incorrectly, injector will bind. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (1.9L, 3.0L, 3.1L, 3.4L & 3.8L)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove air intake duct (if necessary). On 1.9L, disconnect throttle cable from throttle body lever. On 3.0L, 3.1L and 3.4L, remove intake manifold plenum and gaskets. On 3.8L, remove vacuum line from throttle body. Remove ignition coil wires.
2. On all models, disconnect vacuum hose at fuel pressure regulator. Disconnect and plug fuel return line at pressure regulator. Disconnect and plug fuel inlet line at fuel rail. Disconnect harness connectors from injectors.
3. Remove fuel rail retaining bolts. Remove fuel rail from intake manifold using equal force on both sides of fuel rail. see scheme 78, see scheme 82, see scheme 83, see scheme 85 and see scheme 86. Remove injector-to-fuel rail retaining clip (if equipped). Remove injectors from fuel rail. Remove injector "O" rings and discard.

Installation (1.9L, 3.0L, 3.1L, 3.4L & 3.8L)

To install, reverse removal procedure. Coat NEW injector "O" rings with clean engine oil. Install injector-to-fuel rail retaining clip with open end facing injector harness connection. Position fuel rail on intake manifold. Push down on fuel rail to seat injectors in manifold. Tighten fuel rail retaining bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (2.2L - Cavalier & Sunfire)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove air cleaner outlet resonator. Remove fuel rail bracket. see scheme 80 Push in on injector connector clip and disconnect harness connectors from injectors.
2. Disconnect pressure regulator vacuum hose. Remove fuel return line and "O" ring from pressure regulator. Disconnect and plug fuel inlet line at fuel rail. Remove fuel rail attaching bolts and remove fuel rail assembly. Remove injector retaining clips and remove fuel injectors from fuel rail. Remove injector "O" rings and discard.

Installation (2.2L - Cavalier & Sunfire)

To install, reverse removal procedure. Coat NEW injector "O" rings with clean engine oil. Position injectors into fuel rail and install retaining clips. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (2.2L - Saturn)

Note. When fuel rail is removed for service, fuel injectors must be removed and all injector "O" rings must be replaced.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove air intake tube and fresh air tube. Disconnect fuel pressure regulator hose from throttle body and fuel rail. Disconnect fuel supply line and discard plastic retainer.
2. Remove throttle body. Remove throttle control cable bracket bolts. Disconnect cable from throttle lever and lay over intake manifold. Disconnect fuel injector electrical connectors. Remove fuel rail assembly mounting bolts. Carefully pull fuel rail back and upward to remove injectors from cylinder head ports. see scheme 79
3. Move fuel rail toward power steering pump and rotate injectors downward. Lift No. 1 injector and remove fuel rail. Remove fuel injector retaining clips and pull injectors from fuel rail. Remove injector "O" rings and discard.

Installation (2.2L - Saturn)

1. Install NEW "O" rings lubricated with clean engine oil to each injector. Install injectors on fuel rail. With injectors pointing downward, lower fuel line end of fuel rail into cylinder head ports. Rotate injectors into horizontal position and align injectors with cylinder head ports.
2. Carefully push fuel injectors into cylinder head ports, ensuring they fully seat into cylinder head. Install fuel rail mounting bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . To compete installation, reverse removal procedure using NEW fuel supply line plastic retainers.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove air cleaner outlet duct clamp. Remove air cleaner outlet duct from air cleaner resonator. Loosen air cleaner resonator clamp at throttle body. Remove resonator retaining bolts and nuts. Lift air cleaner resonator from throttle body.
2. Remove crankcase vent hose to bottom of resonator. Remove resonator. Disconnect vacuum hose at pressure regulator. Remove fuel rail attaching bolts. Disconnect camshaft position sensor harness connector. Push in on injector connector clip and disconnect harness connectors from injectors.
3. Using a wrench to hold fuel inlet fitting, disconnect and plug fuel inlet line at fuel rail. Lift fuel rail assembly from cylinder head. Loosen fuel return pipe retaining bracket screw. Rotate retaining bracket for removal of fuel return pipe. Remove fuel return pipe from pressure regulator.
4. Remove inlet and return pipe to fuel feed and return line connections. Remove inlet and return pipe assemblies and discard "O" rings. Remove fuel rail assembly. see scheme 81 Remove injector-to-fuel rail retaining clip. Remove injector from fuel rail. Remove injector "O" rings and discard.

To install, reverse removal procedure. Lubricate NEW injector "O" rings with clean engine oil. Position injectors into fuel rail and install retaining clips. Install NEW injector-to-fuel rail retaining clip with open end facing injector harness connection. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (3.5L)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove injector sight shield. Remove fuel feed pipe quick connect fitting by squeezing tabs and pulling lines apart. Remove return pipe quick connecting fitting from fuel rail. Remove vacuum line from fuel pressure regulator.
2. Remove crankcase ventilation valve hose. Remove throttle body vacuum port hose. Remove snap bracket on throttle body coolant tube. Remove engine electrical harness bolts from camshaft covers. Disconnect fuel injector harness connectors. Release 4 snap locking tabs on fuel rail assembly by pushing toward camshaft covers and lifting. Remove fuel rail assembly. see scheme 84 Remove injector-to-fuel rail retaining clip. Remove injector from fuel rail. Remove injector "O" rings and discard.

Installation (3.5L)

To install, reverse removal procedure. Lubricate NEW injector "O" rings with clean engine oil. Position injectors into fuel rail and install retaining clips. Position fuel rail into intake manifold housing. Push down on rail to seat injectors in manifold housing. To complete installation, reverse removal procedure.

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove intake manifold top cover. Disconnect IAT and MAF sensor harness connectors. Remove air intake duct. Remove fuel rail quick-connect fittings. Remove fuel pressure regulator vacuum hose. Remove crankcase ventilation air tube.
2. Remove fuel rail end-bracket retaining nuts. Disconnect fuel injector electrical connectors. Set harness aside. Remove fuel rail bolts. Raise fuel injectors from intake manifold. Remove fuel rail and injector assembly. see scheme 87 Remove injectors from fuel rail. Remove injector "O" rings and seals, and discard.

To install, reverse removal procedure. Lubricate NEW injector "O" rings with clean engine oil. Position fuel rail into intake manifold housing. Push down on rail to seat injectors in manifold housing. Tighten fuel rail assembly and bracket bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (5.7L)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Disconnect negative battery cable. Remove resonator and resonator bracket. Disconnect quick-connect fitting at fuel rail inlet and return lines.
2. Disconnect accelerator cable from throttle body and accelerator cable bracket. Move accelerator cable aside. Disconnect vacuum hose at pressure regulator. Remove vacuum lines (mark for installation reference) as necessary to gain access to fuel rail and fuel lines. Remove electrical harness from routing clips on fuel rail.
3. Remove fuel line retaining bolt. Disconnect harness connectors from injectors. Remove fuel rail retaining bolts. Remove fuel rail from intake manifold using equal force on both sides of fuel rail. see scheme 88 Remove injector-to-fuel rail retaining clip. Remove injector from fuel rail. Remove injector "O" rings and discard.

Installation (5.7L)

To install, reverse removal procedure. Lubricate NEW injector "O" rings with clean engine oil. Install injector-to-fuel rail retaining clip on right side of injector harness connection. Position fuel rail on intake manifold. Push down on rail to seat injectors in manifold. Tighten fuel rail retaining bolts. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Drain the fuel tank
2. Relieve the fuel system pressure.
3. Raise the vehicle and suitably support.
4. Disconnect the quick-connect fitting at the fuel filter.
5. Disconnect the quick connect fittings at the end of the fuel lines.
6. Remove the rubber exhaust hangers. Allow exhaust system to rest on the rear axle.
7. Remove the exhaust heat shield.
8. Loosen the fuel tank filler hose clamp at the fuel tank.
9. Remove the hoses from the fuel tank filler, EVAP vent, and EVAP vapor pipes.
10. Disconnect the electrical harness from the pass through rear body connector and fuel strap.
11. With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps.
12. Lower the fuel tank.
13. Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor.
14. Disconnect the EVAP pipe and the fuel pipe from the modular fuel sender and the fill limiter vent valve.
15. Disconnect the electrical harness from the multi-way rear body connector.
16. Remove the fuel tank from the vehicle.
17. Remove the fuel sender assembly from the tank. Refer to «REMOVAL (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .

1. Install the fuel sender assembly into the fuel tank. Refer to «INSTALLATION (ALERO & GRAND AM)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) .
2. Connect the fuel pipe and EVAP pipe to the modular fuel sender and fill limiter vent valve.
3. Connect the wiring harness to the modular fuel sender and fuel pressure sensor.
4. With the aid of an assistant, raise the fuel tank to the vehicle.
5. Install the fuel tank retaining straps. Tighten the bolts to 35 N.m (26 lb. ft.).
6. Reconnect the wiring harness into the multi-way rear body connector.
7. Connect the hoses to the fuel tank filler, EVAP vent, and EVAP vapor pipes.
8. Tighten the filler hose clamp at the fuel tank.
9. Install the rubber exhaust hangers.
10. Connect the nylon fuel line and fuel filter quick-connect fittings.
11. Lower the vehicle.
12. Refill the tank and install the fuel fill cap.
13. Connect the negative battery cable.
14. Inspect for fuel leaks using the following procedure: Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Removal (Except 1.3L & 1.8L)

Disconnect harness connector from IAC valve. Remove IAC valve, gasket and "O" ring from throttle body assembly.

Installation (Except 1.3L & 1.8L)

Note. Before installation, clean "O" ring sealing surface, pintle seat and air passage. If air passage has heavy deposits, remove throttle body for complete cleaning.

1. Inspect "O" ring for damage. Replace as necessary. If reusing IAC valve, DO NOT push or pull on pintle. Threads on worm gear will be damaged.
2. If replacing IAC valve, measure distance between tip of NEW IAC valve pintle and mounting flange. Distance should not exceed 1 1/8" (28 mm). If distance is more than specified, use finger pressure to slowly retract pintle. Lubricate "O" ring with clean engine oil.
3. Apply thread locking compound (Loctite 262) to IAC valve retaining screw threads. Install IAC valve to throttle body. Tighten IAC valve retaining screws to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__installation-except-13l-18l) . Reconnect IAC valve harness connector.
4. To reset IAC valve pintle position, turn ignition on for 20 seconds. Turn ignition off for 10 seconds. Start engine and check for proper idle operation. Repeat procedure if proper idle operation is not obtained.

Removal Procedure (DeVille, Eldorado & Seville)

1. Remove rear seat cushion and disconnect negative battery cable.
2. Remove intake manifold sight shield.
3. Remove the electrical connector (1) from the IAC valve (4).
4. Remove the IAC valve attaching screws (2) from the idle air control valve (1).
5. Remove the IAC valve from the throttle body.
6. Remove the IAC valve O-ring.

Installation Procedure (DeVille, Eldorado & Seville)

1. Install the new IAC valve O-ring.
2. Install the IAC valve (1) into the throttle body.
3. Install the IAC valve attaching screws (2) into the IAC valve. Tighten: Tighten the IAC valve attaching screws to 3 N.m (27 lb in).
4. Install the electrical connector (1) into the idle air control valve (4).
5. Reconnect negative battery cable and install rear seat cushion.
6. The powertrain control module (PCM) will reset the idle air control valve whenever the ignition switch is turned ON, then OFF.
7. Turn the ignition switch ON.
8. Turn the ignition switch OFF.
9. Perform the IAC Valve learn procedure. IAC Valve Learn Procedure Start and idle the engine for 15 seconds. Turn the ignition switch to the LOCK/OFF position. Wait 15 seconds. Restart the engine, and check for proper idle operation.

Remove throttle body assembly. See THROTTLE BODY (SFI) . Drain any remaining engine coolant. Remove 4 IAC valve screws and remove IAC valve from throttle body assembly. Install NEW rubber gasket onto throttle body assembly. Install IAC valve on throttle body assembly and tighten IAC valve retaining screws to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

IDLE SPEED CONTROL MOTOR

Note. Open throttle lever to full open position and check if Yellow paint has come off of throttle lever screw. Turn throttle stop screw resin cap on throttle body side with fingers and check entire cap for damage. If throttle lever screw and throttle stop screw has been tampered with, replace throttle body assembly. DO NOT replace ISC motor if Yellow paint has come off throttle lever screw or throttle stop screw resin cap is damaged.

Allow engine to cool. Disconnect Intake Air Temperature (IAT) sensor connector. Disconnect PCV hose from air cleaner. Remove air cleaner assembly and air cleaner stud bracket from TBI unit. Disconnect harness connector from Idle Speed Control (ISC) motor. Remove 3 screws from ISC motor and remove ISC motor from TBI unit.

To install, reverse removal procedure. Tighten ISC motor screws to specification. See TORQUE SPECIFICATIONS . Start engine and operate at normal operating temperature. Ensure idle speed is within 800-900 RPM. See appropriate ON-VEHICLE ADJUSTMENTS article.

OXYGEN SENSOR

Note. Oxygen sensor is mounted in exhaust pipe, below exhaust manifold and is equipped with a permanent pigtail which must remain intact when removing sensor.

1. Ensure oxygen sensor is free of contaminants. DO NOT use cleaning solvents of any type. Oxygen sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Excessive removal force may damage threads in exhaust manifold or pipe.
2. Disconnect negative battery cable. Disconnect harness connector from oxygen sensor. Carefully remove oxygen sensor from exhaust pipe.

1. Whenever an oxygen sensor is removed, coat threads with anti-seize compound before installation. New oxygen sensors already have this compound applied to threads.
2. Install oxygen sensor in exhaust pipe. Tighten oxygen sensor to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Reconnect harness connector to oxygen sensor. Reconnect negative battery cable.

SUPERCHARGER

Note. Servicing of supercharger unit is limited to replacement only.

Removal (3.8L - VIN 1)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove accessory drive belt from supercharger pulley.
2. Remove fuel injector sight shield. Disconnect fuel lines from fuel rail. Disconnect vacuum hoses. Disconnect injector harness connectors. Disconnect harness connectors from front of supercharger. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly. See «FUEL RAIL & INJECTORS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-rail-injectors) .
3. Disconnect harness connectors from IAC valve, TP sensor, MAP sensor, MAF sensor, EGR valve, boost control solenoid, and ECT sensor. Remove air intake duct from throttle body. Remove EGR pipe from supercharger. Disconnect throttle and cruise control cables. Remove boost pressure manifold and vacuum block. Remove cable bracket and tensioner bracket to supercharger mounting stud.
4. Remove throttle body from supercharger. Remove supercharger-to-intake manifold bolts and remove supercharger. Remove supercharger gasket and coolant passage "O" rings.

Installation (3.8L - VIN 1)

Ensure locator pins are in their proper location on intake manifold. Replace gaskets and "O"rings. DO NOT use any type of sealant on gasket. To complete installation, reverse removal procedure. Tighten supercharger-to-intake manifold bolts to 17 ft. lbs. (23 N.m). Tighten fuel rail retaining bolts to 89 INCH lbs. (10 N.m).

THROTTLE BODY (SFI)

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief) . Disconnect negative battery cable. Remove air intake ducts. Disconnect and mark harness connections and vacuum hoses from throttle body. Disconnect control cables from throttle body.
2. Drain cooling system and remove coolant hoses to throttle body (if applicable). Remove throttle body retaining bolts. Remove throttle body and gasket.

Note. Identification number is stamped on throttle body. Use identification number to order replacement components.

1. To install, reverse removal procedure using NEW gasket. Tighten throttle body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Refill cooling system (if drained).
2. If installing NEW Idle Air Control (IAC) valve, ensure IAC pintle length setting is adjusted before installation (if applicable). See «IDLE AIR CONTROL VALVE»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation) . Adjust idle speed and TP sensor (if removed, and if adjustable). See appropriate ON-VEHICLE ADJUSTMENTS article.

Removal & Disassembly (1.0L)

1. Relieve fuel system pressure. See «FUEL PRESSURE RELIEF»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-pressure-relief). Remove air cleaner assembly. Drain cooling system. Disconnect and label all wire connectors, vacuum hoses, fuel lines and cable linkages from throttle body. Unbolt and remove throttle body from manifold and EFE heater. Remove fuel injector. See «FUEL INJECTOR (TBI)»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__fuel-injector-tbi).
2. Disassemble throttle body except for fuel pressure regulator valve (valve is factory calibrated and is not serviceable). see scheme 95 Clean all passages and fuel injector chamber with compressed air. DO NOT immerse throttle body in water or cleaning solution, as component damage will result.
3. Dry components with compressed air. Blow out all passages with compressed air. DO NOT use drill bits, wire or pointed metal objects for cleaning. Inspect throttle body for cracks, warpage or scratches in sealing areas.

Scheme 51

Reassembly & Installation (1.0L)

1. To reassemble, reverse disassembly procedure. Tighten throttle body upper-to-lower retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . To complete installation, reverse removal procedure. Use NEW base gasket without sealer.
2. Tighten throttle body-to-manifold bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) . Refill cooling system. Adjust throttle position sensor. See THROTTLE POSITION (TP) SENSOR in appropriate ON-VEHICLE ADJUSTMENTS article. Reconnect negative battery cable. Cycle ignition on and off to pressurize fuel system. Check for fuel leaks.

Removal & Installation (Except 1.0L, 1.3L & 1.8L)

1. Turn ignition off. Disconnect harness connector from Throttle Position (TP) sensor. Remove TP sensor retaining screws. Remove TP sensor from throttle body.
2. With throttle valve in closed position, install TP sensor on throttle body. Ensure TP sensor lever engages with drive lever on throttle shaft. Install retaining screws and harness connector. TP sensor is self-zeroing and is not adjustable.

Removal & Installation (1.0L, 1.3L & 1.8L)

1. Disconnect negative battery cable. On 1.0L, disconnect PCV hose and Intake Air Temperature (IAT) sensor harness connector. Remove air cleaner assembly. On all models, disconnect harness connector from TP sensor. Remove TP sensor retaining screws. Remove TP sensor from throttle body.
2. To install, mount TP sensor on throttle body with alignment slots slightly counterclockwise of body holes. Turn TP sensor clockwise to align holes and install retaining screws finger tight. To complete installation, reverse removal procedure. Adjust TP sensor. See appropriate ON-VEHICLE ADJUSTMENTS article. Tighten TP sensor retaining screws to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/removal-installation/#how-to-overhaul-the-engine-control-system-removal-installation__torque-specifications) .

Scheme 52

1. Raise the vehicle. Remove the retaining screws from the front portion of the right front wheel well/splash shield. Lower the splash shield far enough to gain access to the AIR pump assembly.
2. Loosen and lower the AIR exhaust hose pinch clamp. Disconnect the AIR exhaust hose from the AIR pump.
3. Carefully remove the AIR inlet hose/filter assembly from the AIR pump.
4. Disconnect the AIR pump electrical connector.
5. Loosen the lower AIR to cradle bracket nuts. Remove the upper AIR pump to cradle bolt. Lift up and pull out to remove the AIR pump from the cradle bracket.

1. Install the lower AIR pump bolts/nuts into the cradle bracket and push down. Install the upper AIR pump to cradle bolt. Tighten Tighten the upper AIR pump to cradle bolt to 90 N.m (80 lb in).
2. Ensure that the rubber o-ring is on the bottom of the AIR pump. IMPORTANT: Listen for a CLICK to ensure proper connection of the AIR inlet hose/filter to the AIR pump.
3. Install the AIR inlet hose/filter assembly to the AIR pump. Install the AIR pump exhaust hose to the AIR pump, and secure with hose clamp.
4. Reconnect the AIR pump electrical connector. Raise the wheel well/splash shield into position. Re-install the wheel well/splash shield retaining screws. Lower the vehicle.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TRANSMITTER PROGRAMMING & SYNCHRONIZATION
• THROTTLE/IDLE LEARN
• CAMARO & FIREBIRD
• MODEL IDENTIFICATION
• TORQUE SPECIFICATIONS
• FUEL PRESSURE RELIEF
• FUEL SENDER ASSEMBLY
• REMOVAL (ALERO & GRAND AM)
• INSTALLATION (ALERO & GRAND AM)
• FUEL RAIL & INJECTORS
• TORQUE SPECIFICATIONS
• THROTTLE BODY (SFI)
• FUEL INJECTOR (TBI)