How to Install a Fuel Sending Unit on a 1968 Chevelle
You may have to replace the fuel sending unit on a 1968 Chevelle during a restoration or if the fuel gauge stops working properly. The parts are available at classic car restoration shops or speed shops, but because of the age of the vehicle are generally not available from a dealership or auto parts stores. The fuel sending unit must be one for 90 ohms in order for it to work with the original gauge. If you use an aftermarket fuel gauge, be sure to check the ohms required for the fuel sending unit and order the appropriate sending unit for the gauge.
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Things You'll Need
- Siphon pump
- Gas can(s)
- Floor jack
- Jack stands
- Set of wrenches
- Set of sockets
- Screwdriver
- Hammer
Instructions
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1
Remove the fuel tank filler cap. Connect the siphon pump to the 1/4-inch fuel feed hose above the rear axle. You can also access a fuel feed hose under the hood near the fuel pump, on the passenger side of the engine. Work the siphon pump until most of the fuel has been removed from the tank and transferred to the gas cans.
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2
Pull the grommet out of the trunk to access the fuel gauge sending unit wire. Disconnect the wire from the rear wiring harness through the trunk floor hole. Jack up the rear of the Chevelle with the floor jack, then support it with jack stands. Remove the floor jack.
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3
Remove the fuel gauge wire screw from the underbody with the appropriate socket. Disconnect the fuel line at the sending unit pickup line. Slide the floor jack under the fuel tank. Raise the jack up high enough so that it just touches the bottom of the tank. Remove the rear-most fuel tank strap retaining bolts with the appropriate socket. Push the straps out of the way while balancing the tank on the floor jack. Lower the jack to lower the tank and pull it from under the car.
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4
Place the screwdriver against one of the tabs on the lock ring. Tap it in a counterclockwise direction with the hammer to remove the lock ring. Lift the sending unit out of the tank. Reinstall the new sending unit on the lock ring cover and insert it into the tank.
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5
Raise the tank into position under the Chevelle. Bolt the straps into place, tightening the bolts firmly. Reconnect the fuel line at the sending unit pickup line. Reattach the fuel gauge wire and screw to the underbody. Remove the jack stands and lower the Chevelle. Reconnect the fuel gauge sending unit wire at the rear harness connector. Properly reseat the grommet in the trunk. Refill the tank.
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Tips & Warnings
The vapors in the fuel tank are highly flammable, so keep the work area clear of sparks and cigarettes.
