For U Solution

Drain the fuel from the plastic tank. Remove the tank from the vehicle.

Pour a mixture of dishwashing soap and water into the top of the fuel tank. Slosh the mixture around, then dump the soapy solution from the tank. Repeat the procedure two more times to remove fuel residue and fumes from the tank.

Plug in the plastic welding gun. Set the welder to the temperature designated on the heat requirement chart affixed to the welder box. Turn on the welder.

Wipe the cracked seam with a clean rag soaked in the soap solution. Rinse the seam with clean water. Allow the seam to dry.

Run the point of a triangle file along the cracked seam to create a 1/16 inch V-groove.

File the raised edges left by the file from the area with 400-grit sandpaper.

Place the tip of the plastic welder on one end of the cracked plastic seam. Push a plastic filler rod into the top socket of the welding tip as you slowly pull the welder along the seam. Pull the plastic welder away from the fuel tank when you reach the opposite end of the cracked seam, leaving the excess filler rod attached to the tank.

Cut the excess filler rod from the tank with a pair of wire cutters.

Allow the repaired seam to cool before installing the tank back into the vehicle.

Raise the vehicle with a floor jack, and support it safely on jack stands.

Remove the fuel pump fuse from the fuse box under the dashboard, using the list on the fuse box as a guide. Start the engine, and allow it to idle until it stalls from fuel starvation.

Turn the ignition off, and disconnect the batterys negative cable with a socket wrench. Wrap a clean shop rag around a connection on the fuel line to soak up spilled fuel. Loosen the connection with a socket wrench to relieve the pressure in the fuel system. Tighten the fuel connection, and replace the fuse for the fuel pump.

Remove the rear seat from the vehicle, and disconnect the access cover under the seat with a socket wrench. Detach the electrical connector and fuel lines from the fuel sending unit.

Turn the retaining ring for the fuel sending unit counterclockwise with a socket wrench, and remove it from the fuel sending unit. Pull the fuel sending unit from the fuel tank, and empty the fuel in the sending unit into a container approved for gasoline. Discard the gaskets for the fuel sending unit.

Mount new gaskets to the new fuel sending unit, and install the sending unit in the fuel tank. Fasten the retaining ring to the sending unit with a socket wrench. Connect the fuel lines and electrical wiring to the fuel sending unit. Fasten the access cover for the fuel sending unit, and replace the rear seat.

Connect the batterys negative cable with a socket wrench, and lower the vehicle.

Strap on your safety goggles. Put the jack under the rear frame of your vehicle and lift the Corvette.

Drain the fuel from the gas tank. Put the drain pan under your gas tank and remove the gas tank from the fuel pump. Disconnect the fuel pump and fuel relay hose with your pliers.

Disconnect the gas tank from your Corvette. Two metal straps hold your Corvettes gas tank in place, mounted by four bolts. Remove the four bolts with your socket wrench set.

Mount your replacement gas tank to your Corvette. Attach the gas tank with the two metal straps and four bolts. Use your socket wrench set to secure the bolts.

Connect the fuel relay hose and fuel pump to your replacement gas tank. Use your pliers to secure the fuel relay hose. Pour the drained fuel into your replacement gas tank.