Replacing The Fuel Tank Sender In Your '68 Camaro

Replacing the fuel tank sender in a 1968 Camaro is a complex task that requires careful attention to detail and a good understanding of car mechanics. The process involves disconnecting the battery, fuel line, and filler neck, as well as removing the old tank and sender unit before installing the new components. It is important to work in a well-ventilated area and take precautions to avoid any open flames or ignition sources. Several online resources provide detailed step-by-step guides and video tutorials on how to replace the fuel tank sender in a 1968 Camaro, with some recommending specific products and suppliers for the required parts.

Disconnect the battery and fuel line, then drain the old gas tank

Disconnecting the battery and fuel line, and draining the old gas tank are the first steps to take when replacing the fuel tank sender in a 68 Camaro. This process requires careful attention to safety precautions and a methodical approach to ensure a successful outcome.

To begin, locate the battery in your Camaro and disconnect it. This step is crucial for safety reasons and to prevent any potential electrical issues during the procedure. Next, focus on the fuel line. Carefully disconnect it, making sure there are no open flames or ignition sources nearby as you work. It is essential to perform this step in a well-ventilated area to avoid inhaling harmful fumes.

With the fuel line disconnected, it's now safe to proceed with draining the old gas tank. Place a fuel container underneath the tank and slowly drain the fuel, ensuring it flows into the container. This step can be messy, so be cautious and have rags or other absorbent materials ready to catch any spills or leaks. Once the tank is empty, you can move on to the next steps with confidence, knowing you've taken the necessary precautions.

At this stage, it's important to take environmental considerations into account. Properly dispose of the drained fuel to avoid causing harm to the environment. Additionally, if you notice any significant rust or damage to the fuel tank or surrounding components, it may be wise to consult a professional mechanic or consider replacing the entire fuel tank assembly for safety and performance reasons.

Remember to work with a partner or assistant whenever possible, as some tasks may require an extra set of hands. With these initial steps completed, you can now proceed with the rest of the fuel tank sender replacement process, ensuring your Camaro's fuel system is in optimal condition for safe and reliable driving.

Disconnect the filler neck from behind the license plate mount

Disconnecting the filler neck from behind the license plate mount is a crucial step in replacing the fuel tank sender in a 68 Camaro. Here is a detailed guide on how to approach this task:

Firstly, it is important to ensure that the fuel tank is completely empty before beginning any work. This is a crucial safety measure as it reduces the risk of fire or fuel leakage. Once the tank is empty, locate the filler neck, which is the tube that connects the fuel filler cap to the fuel tank. It is usually accessible by removing the license plate mount. There may be a protective cover or panel that needs to be removed to access the filler neck.

Next, you will need to disconnect the filler neck from the fuel tank. This process can vary depending on the specific model of your Camaro, but it typically involves loosening or removing any clamps, couplings, or hoses that secure the filler neck to the tank. Be sure to have a drip pan or container ready to catch any residual fuel that may be in the lines. It is also important to wear protective gear, such as gloves and eye protection, during this process.

Once the filler neck is disconnected, carefully lift it out and set it aside. At this point, you should be able to access the fuel tank sender, which is typically located near the filler neck. The sender is responsible for sending fuel level information to the gauge in your Camaro's dashboard. It is usually held in place with bolts or clamps and may be connected to a wiring harness.

Before removing the old sender, make sure to take note of the wiring and any other components that are attached to it, as you will need to transfer these to the new sender. Carefully disconnect the sender from the fuel tank and set it aside. Now you are ready to install the new fuel tank sender.

Finally, when you have finished replacing the fuel tank sender, you will need to reconnect the filler neck to the new tank. Ensure that all connections are secure and properly sealed to prevent fuel leaks. Reattach any protective covers or panels that you removed to access the filler neck.

This process requires careful attention to safety and a methodical approach to ensure that all components are correctly installed and connected. It is always recommended to refer to a qualified mechanic or a detailed Camaro repair manual for further guidance if needed.

Remove the rear strap mounts and drop the tank

To remove the rear strap mounts and drop the tank, you will need to empty the tank to reduce its weight. The less fuel, the easier it will be to remove. You can siphon the fuel out or disconnect the outlet hose at the sending unit or fuel pump inlet.

Next, lightly pressurise the tank into a gas can to pour the remaining fuel into another container or back into your car, if preferred. Ensure this is done in a well-ventilated area with no open flames or ignition sources present.

Spray the nuts and studs with a penetrant like PB Blaster the night before to loosen and lubricate the studs to unscrew the straps.

Now, remove the two nuts for the straps, located just up behind the rear valance. Pull the straps down and lower the tank. You may need some help with this part. Try kneeling down and sliding the tank out, or use a floor jack to support the tank as it is removed.

Finally, drop the tank down and out of the car.

Apply weatherstrip cement to the tank

To apply weatherstrip cement to the tank, it is recommended to use 3M Super Weatherstrip Adhesive 08001 (yellow) or 08008 (black). You will also need to apply the antisqueak strips to the tank and press them into place.

Before applying the weatherstrip cement, make sure you have completed the previous steps. This includes disconnecting the battery, draining the old gas tank, disconnecting the filler neck, and unbolting the rear strap mounts. You should also wrap the new tank in foam and stretch-wrap and box it to protect the product during shipment.

Once you have applied the weatherstrip cement and pressed the antisqueak strips into place, you can move on to the next step, which involves preparing the O-ring.

Place the o-ring in the sending unit hole

To replace the fuel tank sender in a 68 Camaro, you'll need to first disconnect the battery and fuel line, and completely drain the old gas tank into a fuel container. Make sure to do this in a well-ventilated area with no open flames or ignition sources present.

Now, to the part you're interested in. To place the o-ring in the sending unit hole, follow these steps:

Firstly, each Quanta Products GasTanks.com tank comes with a rubber sending unit o-ring. To make the installation process easier, it's recommended that you soak the o-ring in, or rub on, a bit of clean motor oil. This will ensure a smooth and easy installation process.

Next, place the o-ring in the sending unit hole. Insert the GasTanks.com sending unit into the hole, with the fuel line facing towards the front passenger side corner of the tank.

Then, insert the retaining cam (lock ring), which comes with each Quanta Products GasTanks.com tank, into the retaining groove. Use the retaining cam (lock ring) tool, pressing down and turning the lock ring to secure it in place.

Finally, stretch the sending unit wire across the top of the tank and secure it in place with a wide piece of black tape. This will ensure that the wire does not get pinched during installation, which could result in chafing.

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