bootmod3 Flex Fuel Kit – DIY Assembly Instructions

This guide walks through the bootmod3 Flex Fuel Kit assembly procedure. Those customers purchasing the bootmod3 Flex Fuel Kit can use this guide as a DIY manual for assembling their own kit when purchasing it without the GM/Continental Flex Fuel sensor included from us.

NOTE: We do not recommend this DIY as there are multiple steps involved in assembly and the procedure, while not very difficult, does require multiple tools, engine lube, teflon paste and is not very trivial.

Instructions

Tools required for assembly:

3/16” Hex (Allen) Key
5/32” Hex (Allen) Key
-6AN Wrench
GM/Continental Flex Fuel Sensor, Part Numbers: 13507129, 13577429
1. NOTE: Only the short-tube small housing version of this sensor can be assembled into our 3-piece machined sensor adapter. You cannot use the long tube version of it or the large housing 4-bolt version of it (picture below)
Engine oil (any, to lube seals/fittings)
Thread Sealant - fuel/oil/chemical safe
1. We use: Permatex Part Number: 59206 (high temp, chemical (oil/fuel) safe, white teflon paste)

To begin assembly ensure you have all the parts of the bootmod3 Flex Fuel Kit as outlined in the picture below, here’s a listing:

(3) Machined black anodized pieces of the sensor adapter (one is labeled with bootmod3, top right of the picture)
(4) Viton seals (white)
(1) -6 ORB Male » -6 AN Male fitting with an E85 compatible seal (black)
(4) Hex screws (silver)
(2) 1/8 NPT plugs (bronze)

NOTE: You need to source an appropriate high temp chemical safe (fuel/oil/alcohol) thread sealant. We typically use the one from Permatex as outlined above and shown in the pic below.

To start assembly, take the 4 white Viton seals, apply a bit of engine lube on them to not cause a tear during installation, and install them as follows (see pic below):

2 on the flex fuel sensor (one on each side of the tube)
1 on the bootmod3 labeled machined sensor adapter part
1 on the smaller machined sensor adapter part

Once the 4 Viton seals are set, apply thread sealant to each of the bronze 1/8 NPT plugs and install them onto the two sensor adapter pieces as follows:

Once the viton seals are on the sensor tubes and lubed, begin assembly of the flex fuel sensor into the sensor adapter housing. On the bootmod3 labeled side, push the tube inside the housing:

Showing pre-insertion photo on the left side of the sensor

Left side sensor tube pushed in, white Viton seal is now inside the housing sealing that side

Proceed with the right side of the sensor now. There are two seals there, one on the sensor tube and one below on the machined piece. Wiggle and push in the top one carefully first and then wiggle/push the bottom

Showing both sides (tubes) of the sensor and bottom machined part inserted covering 3 Viton seals

Use 2 silver hex screws to fasten these 2 pieces of the adapter

2 silver hex screws set in place

Push this last machined piece with the Viton seal on it into it

Showing the part pressed in, Viton seal portion is now seated inside

Fasten it with the remaining two silver hex screws

Showing final assembly of the last machined piece of the adapter with screws fastened in place

Another angle showing the adapter at this point in assembly

Prepare the black -6AN fitting and apply a bit of engine lube to the black seal

Install the seal to the flat side of the fitting

Thread it into the adapter until the fitting bottoms out and cannot be threaded in any further as shown in pic above

Here are a few more pictures of the final assembled adapter without the XRP hose on it:

Top side view of the sensor inside the adapter.

Upside down view of the adapter with sensor

Note: Sensor can swivel in the housing. However, this is not the correct install position when in the car.

Final assembled picture with the XRP hose installed

Showing installed position on top of the factory fuel hat (under the rear passenger seat)

bootmod3 customer service

bootmod3 Flex Fuel Kit – DIY Assembly Instructions

Instructions

Related articles

Related content