Here's a general outline of the process. Specific details will vary slightly depending on the engine (350, 400, etc.) and whether you have a mechanical or electric fuel pump. Refer to a repair manual specific to your 1978 Corvette's engine for precise instructions and torque specifications. A Haynes or Chilton manual is a good investment.
Safety First:
* Disconnect the negative battery terminal before starting any work on the fuel system.
* Work in a well-ventilated area. Fuel fumes are flammable and hazardous.
* Use safety glasses and gloves.
* Have a fire extinguisher readily available.
General Steps (for a typical in-tank electric fuel pump; mechanical pumps are different):
1. Drain the fuel tank: This is crucial to minimize fuel spillage and make the job easier. Use a fuel pump or siphon to remove as much fuel as possible. You can also lower the fuel tank to aid this process (see below).
2. Access the fuel pump: This usually involves dropping the fuel tank. The exact procedure varies based on the Corvette's configuration. You'll need to:
* Disconnect the fuel lines (carefully!). Use fuel line clamps to prevent spills.
* Disconnect the electrical connector to the fuel pump.
* Disconnect the fuel tank sending unit (fuel level gauge).
* Support the fuel tank safely (often with jack stands and straps) while disconnecting the tank straps. The tank is heavy and filled with fuel!
* Carefully lower the fuel tank.
3. Remove the fuel pump assembly: This often involves removing a retaining ring or bolts that hold the pump assembly to the tank. The pump is usually part of a larger module also containing the fuel level sensor.
4. Replace the fuel pump: Once the old pump is removed, carefully install the new pump, ensuring it's properly seated and oriented.
5. Reassemble everything: Reinstall the fuel pump assembly, fuel tank, fuel lines, and electrical connector in reverse order of removal. Double-check all connections and make sure everything is tight.
6. Fill the fuel tank and check for leaks: Before starting the engine, top off the fuel tank and carefully inspect all connections for leaks.
7. Start the engine and check for proper operation: Once you’ve confirmed no leaks, start the engine and check for proper fuel pressure using a fuel pressure gauge (consult your repair manual for the correct pressure). Listen for any unusual noises from the pump.
Important Considerations:
* Fuel pump strainer: Replace the fuel pump strainer (sock) while you're at it. A clogged strainer can cause pump failure.
* Fuel tank gasket/seals: Replace any worn or damaged gaskets or seals on the fuel tank during reassembly to prevent leaks.
* Fuel pressure regulator: While you are working with the fuel system it is recommended to check the pressure regulator also.
* Repair manual: A factory service manual or a Haynes/Chilton manual is essential for detailed instructions and diagrams specific to your 1978 Corvette.
This is a general overview. The specific procedures can be considerably more complex than described here. If you are not comfortable performing this repair, take your Corvette to a qualified mechanic. Working with fuel is dangerous; improper repair can lead to serious injury or damage.
