2004 C5 Corvette Fuel Pump Install

In this video I will be installing a new fuel pump in my 2004 corvette (6 speed manual). C5 corvettes are prone to fuel level sending unit failures due to erosion or sulfur build up on the contacts of the fuel level sending unit. On early c5 corvettes a fuel pump swap is easy but on late model 2003 and all 2004 corvettes you will have to drop the fuel tank in order to fix this problem.
Fuel Pump:
www.summitracing.com/parts/df...
Driver side tank lines:
www.amazon.com/ACDelco-103375...
Crossover tube lines:
www.amazon.com/ACDelco-103375...
Passenger side siphon:
www.summitracing.com/parts/AD...
Passenger tank lines:
www.gmpartscenter.net/oem-par...
2004 c5 corvette
Ls1/t56 (manual)
LT headers
Off road x pipe
SLP loudmouth axle back exhaust
Vararam ram air intake
C6 z06 shocks
C6 z06 OE wheels replicas
275/40/17 front
295/35/18 rear
Ligenfelter clutch return spring
Filming Equipment:
iPhone 11 Pro
DJI Osmo Mobile 3 gimbal
GoPro Hero 9
Hotem iSteady pro 4 gimbal
Instagram: @htpjay
/ htpjay
TikTok: @htp_jay
/ htp_jay
Disclaimer: I am not a licensed professional. If you do not feel comfortable doing any of the things featured in this video please contact or seek professional for advice or help.

[@BoostedMotorsports]

You're a BEAST for tackling this job on the side of your street lol

[@mlc7boosted]

Hey there Jay. Thanks for the vid. My '04 C5 is going into the shop in a few days for a fuel pump. I had to show the person doing the repair quote that the '04's fuel pump is on top of the tank, not the rear bottom like on earlier C5's. Well, the quote for parts and labor is over $2K. He said he thought the fuel filter was outside the tank on the rail like earlier C5's. I needed to tell him that it's basically a C6 fuel system. The car usually does not start first crank, but always second crank, which seems like the fuel pressure regulator. But I can run the car up to 150mph plus without issue, so the sad part is I think the fuel pump is okay, but the pressure regulator is bad and it's all one assembly inside the tank.

[@HTPJay]

Yes everything is in the tank if you have an automatic he’s gonna have to drop the drivetrain on the manuals cars he might be able to do it without dropping it

[@mlc7boosted]

@@HTPJay Thanks Jay. On a side note, I have a built 3.73 differential in storage...with a crack in the case that can't be welded. This would have been a perfect opportunity to get it installed. I have another case but it'll cost several hundred dollars to swap the gear set, bearings, and I think, set the lash. Yeah, the fuel pump job is necessary, the diff swap is an option. I already had the 2.73 diff taken out and a low mileage "performance axle ratio" 3.15 diff put in. But on the auto it had to be retuned on HP Tuners to work right for shift points and 4th gear over drive. I had the 3.73 diff installed for a little while. It was Quick off the line and pulled hard. I got tired of pumping gear oil in it every 3 to 4 days and now it's in storage. All I've been doing for months is wearing out the starter and ignition system. Fuel pump job is scheduled for later next week.

[@HTPJay]

@mlc7boosted sucks that it can’t be welded, can you swap the 3.73 into the other housing?

[@mlc7boosted]

@@HTPJay Hey Jay, thanks for asking. Being in Georgia I called "Driveline Service of Atlanta" a few days ago. It can be swapped over. The quote was $1500 to install new bearings and the 3.73 gearset into the new housing. It would be less if I had them swap the bearings from the cracked case because the entire 3.73 diff has about 5k miles on it, so the bearings are "like new" anyways. It could be done for cheaper. I paid $1500 for the diff initially. It's in my storage unit wrapped in plastic in a box along with the empty case and the 2.73 diff. The fuel pump job would have been a good chance to get the 3.73 diff installed if the gearset was already swapped. Then a HP Tuners re-tune because the auto trans has to be programmed for the gear ratio change. The manual C5 doesn't need to be reprogrammed with a diff swap.

[@robmccance]

Great video Jay! I'm about to tackle this job on my 2010 C6. $3-4k job at Chevy $180 home job (cost of fuel pump) Can't wait to deal with the hidden evap line and reconnecting the xover tube.

[@HTPJay]

Hope you got it done with no issues

[@spreaddeezhazelnutz7511]

GM is diabolical for doing that. 💀

[@HTPJay]

I have to do the passenger side soon too

[@bobmendez7861]

I'm not seeing in ffs in the RPO codes on this 2004 the new system

[@chrisdontkerr]

I hear this is a royal pain in the ass job! labor on labor on labor. good on you for doin this job. i assume you already tried to run techron and what not.

[@HTPJay]

It’s a really tough job, If it doesn’t work after I fill up I will try Techron

[@jackthompson6192]

My 03 Z06 has the same c6 fuel system just like yours, I was going to change my fuel filter but I can't find it anywhere on the frame on the driver's side like the other C5s 😢

[@HTPJay]

Yep fuel filter is inside the driver side tank in the fuel pump

[@RicheySynthetics]

My 2003 has the same system as the 04 and C6. The dealership said my V.I.N. said it was the old. Unfortunately as most of the time they were wrong!!

[@JGCR91]

Why isn't backdooring it possible?, did you take the time to look where the fuel pump is positioned and where it's directly above?

[@HTPJay]

The way the fuel system is set up it just wouldn’t work main reason would be the lines in the tanks there’s just no way of disconnecting them or installing them back without breaking them unless the tank is disconnected from the crossover tube.

[@JGCR91]

​​@@HTPJay​so the lines have to be disconnected from the cross over tube inorder to get the pump to come out, and it'll come out with the lines too?

[@HTPJay]

@JGCR91 the lines are not very flexible and they have to be rotated a certain way when removing the fuel pump so they have to be disconnected from the crossover tube, can they be pulled into the tank? Probably yes but there’s 4 tabs on the lines that latch them into the hole

[@JGCR91]

@HTPJay the fuel pump is located behind what side of the vehicle?, also I did determine that my 6spd late model 2003 C5 fuel pump is failing, would it be possible to just drop the fuel pump side of the tank by just disconnecting the crossover pipe?

[@HTPJay]

@JGCR91 the fuel pump is in the driver side tank, if you car is manual there’s enough room to reach up and disconnect the crossover without dropping the drivetrain

[@vitalirider707]

1999 ghe same?

[@HTPJay]

No 1999 is different

[@710GlassHouse]

Master Tech 💪🏽💪🏽💪🏽

[@HTPJay]

Lmao

[@cbass756]

ok 1st your video is flawed for the diy person you need to show the entire process of getting to the fuel pump DUH ..so this entire video does nothing for a person who wants to learn or needs a guide to make sure ....you skipped too much ..

[@HTPJay]

Sorry I was not able to help