If your 2000 Vette's fuel gauge has been acting up, you may need to replace the fuel tank sending unit. This is a fairly simple process, but it is important to take safety precautions as you will be working with highly flammable gasoline. Before you begin, disconnect the negative battery cable and ensure you are working in a well-ventilated area. You will need a flathead or Phillips head screwdriver, and possibly a pair of groove-joint pliers or a hammer and drift. First, locate the access cover for the fuel tank sending unit, which will be under the back seat or in the rear cargo area. Remove the screws holding the cover in place and set it aside. With the cover removed, you will see the fuel tank sending unit, which will have a wiring harness plugged into it. Unplug the wiring harness and move it out of the way. If the unit is screwed or bolted in place, remove the screws or bolts. Otherwise, it may be a \twist-lock\ type, in which case you can use a flathead screwdriver to gently tap it counter-clockwise until it loosens. Finally, remove the fuel tank sending unit and attach a new one, making sure to plug in the wiring harness for the new unit.
What You'll Learn
Safety precautions
Firstly, it is important to work in a well-ventilated area to prevent breathing in fumes. You could also use a professional respirator. Before you begin, disconnect the negative battery cable to ensure no electrical sparks are possible. This is because you will be dealing with gas, which is highly flammable. Roll down all the windows of your vehicle.
The fuel tank sending unit is located at the top of the fuel tank and is accessible under the back seat or under the carpet in your trunk. It is protected by an access cover, usually held in place with screws. Remove these screws carefully, as snapping one could mean having to replace the entire tank.
Since it is almost impossible to do this job without spilling some fuel, cover part of the work area inside the car with plastic and an old towel. Use this area to stage the parts that will have gas on them.
Another safety note: by removing the fuel tank sending unit, you are opening the gas tank. Be sure there are no sources of sparks or flames nearby. Always do this repair outside and never open your tank in a garage that could have a source of ignition, such as a furnace or water heater.
With the access cover removed, you'll see the fuel tank sending unit. It will have a wiring harness plugged into the top, which tells the gas gauge how much fuel is in the tank. Unplug the wiring harness and move it to the side. If your fuel tank sending unit is screwed or bolted in place, remove the screws or bolts carefully. Be sure not to bend the float arm, as this will cause the gauge to give a false reading.
Some sending units are a ""twist-lock" type and work like the old twist-lock gas caps. You'll see a few notches along the outer ring of the sending unit. Place the tip of a sturdy, flat-head screwdriver in the notch and gently tap it counter-clockwise. The sending unit will rotate until it's loose. Now you can remove the fuel tank sending unit in one piece. Attached to it is a long rod with a float at the end, so you might have to try a few different angles to get it out.
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Locating the fuel sending unit
The fuel sending unit is accessible from the top of the fuel tank, which can usually be accessed by removing the rear seat cushion or the carpeting in the trunk. In most modern vehicles, including the 2000 Vette, there is a dedicated access port for the fuel tank.
To locate the fuel sending unit, follow these steps:
- Disconnect the negative battery cable to ensure there is no possibility of sparks near the gasoline.
- Open the fuel cap to relieve any built-up pressure in the tank.
- Locate the access port for the top of your fuel tank. This is usually found underneath the rear seat cushion or the carpeting in the trunk.
- Remove the screws or bolts securing the access cover, which is typically located underneath the rear seat or trunk carpet.
- Once the access cover is removed, you will see the fuel sending unit directly on top of the fuel tank. It will have a wiring harness plugged into it, which transmits data about the fuel level to the fuel gauge.
Now that you have located the fuel sending unit, you can proceed with the replacement process. Remember to take the necessary safety precautions when working with gasoline and always refer to a repair manual specific to your vehicle for detailed instructions.
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Disconnecting the battery
Prepare the Work Area:
Before you begin, make sure you are working in a well-ventilated area to prevent the inhalation of fumes. Roll down all the windows of your Vette or perform this task outdoors if possible. It is also recommended to cover the work area inside the car with plastic and an old towel to catch any fuel spills.
Disconnect the Negative Battery Cable:
Locate the negative terminal of your battery, which is usually marked with a "-" sign or a black cover. Using a suitable wrench or socket, loosen the clamp that secures the negative battery cable to the terminal. Once it is loose, carefully remove the cable from the terminal. Ensure that the cable does not touch any metal parts of the vehicle to avoid sparks.
Secure the Cable:
After disconnecting the negative battery cable, secure it away from the battery to prevent accidental contact. You can use a cable tie or tape to hold it in place. Make sure that the cable cannot accidentally fall back onto the battery terminal during the rest of the fuel sending unit replacement process.
Work Safely:
With the battery disconnected, it is essential to work safely and avoid any potential sources of sparks or flames. Do not smoke, create sparks, or have any open flames near the battery or the fuel tank. Always have a fire extinguisher nearby as a safety precaution.
Reinstallation:
When you have finished replacing the fuel sending unit and are ready to reconnect the battery, simply follow these steps in reverse. Connect the negative battery cable to the negative terminal and ensure that the connection is secure. Then, tighten the battery clamp. Finally, remove any cable ties or tape used to secure the cable during the disconnection process.
Remember to exercise caution when working with your Vette's electrical system and fuel tank. By following these steps, you can safely disconnect and reconnect the battery during the fuel sending unit replacement process.
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Removing the access cover
To remove the access cover, you will first need to locate it. The access cover is located under the backseat or trunk carpet, which will need to be lifted. Once located, remove the screws holding the cover in place.
It is important to note that you will be dealing with gasoline, which is highly flammable, so it is recommended to take safety precautions such as disconnecting the negative battery cable, rolling down the windows, and working in a well-ventilated area.
After removing the access cover, you will see the fuel tank sending unit. It will have a wiring harness plugged into the top, which sends information to the gas gauge about the fuel level.
Before proceeding further, it is also advised to relieve any built-up pressure in the tank by opening the fuel cap.
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Replacing the unit
Before you begin, disconnect the negative battery cable to ensure no electrical sparks are possible. You will be working with gas, which is highly flammable. Be sure to roll down all your windows and work in a well-ventilated area to prevent breathing in fumes. You could also use a professional respirator.
Your fuel tank sending unit is located at the top of the fuel tank and is accessible under the back seat or under the carpet in your trunk. The sending unit will be protected by an access cover, usually held on with a couple of screws. Lift your back seat or trunk carpet and locate the access cover for your fuel tank sending unit. Remove the screws holding the cover in place and take off the access cover to reveal the fuel tank sending unit.
Another safety note: gasoline is highly flammable. By removing the fuel tank sending unit, you are opening the gas tank. Be sure there are no sources of sparks or flames nearby. Always do this repair outside with the windows of your vehicle rolled down. Never open your tank in a garage that could have a source of ignition, such as a furnace or water heater.
With the access cover removed, you will see the fuel tank sending unit right there on top. It will have a wiring harness plugged into the top, which tells the gas gauge how much fuel is in the tank. Unplug the wiring harness and move it safely to the side. If your fuel tank sending unit is screwed or bolted in place, remove the screws or bolts.
Some sending units are a "twist-lock" type and work like the old twist-lock gas caps. You'll see a few notches along the outer ring of the sending unit. Place the tip of a sturdy, flat-head screwdriver in the notch and gently tap it counter-clockwise. The sending unit will rotate until it's loose. Now you can remove the fuel tank sending unit in one piece. Attached to it is a long rod with a float at the end, so you might have to try a couple of different angles to get it out.
As usual, installation is the reverse of removal. Don't forget to plug in the new sender or it won't send you anything! If your fuel filter is in the tank at this location, it might be a good idea to replace that as well.
Firstly, install a new tank seal in place. Lower the new unit into the tank, being certain that if there are any wires or hoses in the tank, the movable float arm remains clear of interference. Install the lock ring, and do not overtighten it. Reconnect the hoses and wiring connectors, and secure all covers in the reverse order they were removed.
Reinstall the fuel pump relay, and reconnect the battery. Start the car, checking that the fuel gauge works and that there are no fuel leaks. The next time you refill the tank, check to make sure that no fuel is seeping from the top of the tank where the sender is installed.
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Frequently asked questions
If your gas gauge has been acting up or you've been running out of gas regularly, you might need to replace the fuel sending unit.
The fuel sending unit is located at the top of the fuel tank and is accessible under the back seat or under the carpet in the trunk. You will need to remove the screws holding the cover in place and remove the access cover to reveal the fuel tank sending unit.
You will need a flathead or Phillips head screwdriver, a replacement fuel tank sending unit, a replacement lock ring and seal, and rubber gloves.