Fuel Sender Replacement, They all eventually die Options

[pbanders]

Replaced the fuel sender this weekend. Here's a procedure for doing this.

• Disconnect the two small hoses on the right and left sides of the expansion tank.
• The expansion tank is held onto the fuel tank by 10 mm bolts on the right and left sides. Access to the bolt on the driver's side is tight with the tank attachment strap in place. Remove the screw and plastic piece for better access. It is not necessary to remove the fuel filler flange to remove the expansion tank.
• Remove the expansion tank. Note there's a metal guide that slides onto the filler flange, when re-installing, make sure this goes into the right place.
• You should see the fuel sender on top of the tank. Carefully disconnect the electrical plug. Unbolt the five 8 mm nuts holding the sender on, and slowly remove the sender from the tank. I say "slowly" because it's full of fuel, and as you remove it, the fuel drains from it. Have a cloth handy to wipe down the exterior of the sender as you remove it.
• My new sender was the URO aftermarket product. It comes with a new seal, and there's a retaining pin under the sticker on the side that must be removed prior to installation. If you use a different sender, you should also purchase a new seal.
• Before installing, check operation of the new sender. Attach the connector plug to the sender, and turn the car key to the "on" position. Invert the sender, the tank should read full. Turn the sender right side up, it tank should read empty and the reserve light should be on.
• Note that the 5 bolt pattern on the sender is NOT symmetric, and neither is the seal. You must match the seal pattern to the sender, and the sender installs on the tank only one way. Slide the seal on and match the bolt hole pattern. Insert the sender in the tank and tighten the bolts evenly.
• Re-install the expansion tank and attach the hoses. Re-install the fuel tank plastic holder and tighten the strap screw.
• That's it, you're done!

Comments, hints, additions, and corrections are welcome. Hope this is helpful.