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A bad decision / Fuel sensor source C2 1963

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  • Richard G.
    Extremely Frequent Poster
    • July 31, 1984
    • 1715

    A bad decision / Fuel sensor source C2 1963

    I just electrically powered up my car for the first time since about 1980....
    Things going fairly well. Tracking down of various electrical issues which was expected.

    Like;
    (Don't forget to use the correct bulb in the headlight warning lamp) It won't blink if you don't have the correct blinker style bulb installed..

    Some history first. I failed to drain the tank years ago. Ended up with a mess and regretted it. (I was going to get to it soon so it would be fine. These thoughts went on for decades. When the system was finally looked at the old fuel had destroyed my fuel tank level sensor and the original, 1962 dated, fuel pump that was still on the car!

    When time came to redo the fuel system I replaced the tank, rebuilt the pump and purchased a fuel sensor from EBay.
    The mistake I made is I didn't check it electrically when it arrived some 6 months ago. BTW, I knew it was made in China.
    The locking ring that came with the sensor allowed the sensor to rotate easily by hand after it was installed in the tank. I was sure it would leak if left like that. Remember the sensor is installed from the bottom of the tank not the top. I ended up using the locking ring that came with the replacement tank (Made in USA) to get it to lock in place. I installed the tank and called it good.
    In the interim I found a NOS fuel sensor and purchased it "Just in Case."

    After powering up my car the fuel gauge didn't work, it was stuck on full and the tank didn't have any fuel in it.

    I checked my wiring at the tank.
    The ground was good.
    The wires were connected to the correct sensor posts.
    The sensor has one large diameter and one smaller diameter electrical post.
    Dug up some sensor specifications.
    .6 ohms empty and about 100 ohms full.

    I checked the NOS gauge and it was fine.
    .3 ohms empty and about 93 ohms full.

    Short video attached;


    I unplugged the China senor, that was installed in the car, from the car's wiring.

    I found the circuit was open, between the terminals not at the .6 ohms the specifications called for.
    The EBay purchased fuel tank level sensor was "Junk"..... from the get go.
    The good news is I hadn't added fuel or attached the fuel line, using the one time only usage, fuel hose clamp.
    So installing the NOS gauge sensor will be relative easy.

    A couple lessons here;
    Don't purchase China if you don't have to.
    Check the sensor operation before adding fuel. Preferably before even installing the sensor.
    I'm one for two....
    Rick
    Attached Files
    Last edited by Richard G.; May 29, 2018, 02:17 AM.
  • Joe L.
    Beyond Control Poster
    • February 1, 1988
    • 43219

    #2
    Re: A bad decision / Fuel sensor source C2 1963

    Originally posted by Richard Geier (7745)
    I just electrically powered up my car for the first time since about 1980....
    Things going fairly well. Tracking down of various electrical issues which was expected.

    Like;
    (Don't forget to use the correct bulb in the headlight warning lamp) It won't blink if you don't have the correct blinker style bulb installed..

    Some history first. I failed to drain the tank years ago. Ended up with a mess and regretted it. (I was going to get to it soon so it would be fine. These thoughts went on for decades. When the system was finally looked at the old fuel had destroyed my fuel tank level sensor and the original, 1962 dated, fuel pump that was still on the car!

    When time came to redo the fuel system I replaced the tank, rebuilt the pump and purchased a fuel sensor from EBay.
    The mistake I made is I didn't check it electrically when it arrived some 6 months ago. BTW, I knew it was made in China.
    The locking ring that came with the sensor allowed the sensor to rotate easily by hand after it was installed in the tank. I was sure it would leak if left like that. Remember the sensor is installed from the bottom of the tank not the top. I ended up using the locking ring that came with the replacement tank (Made in USA) to get it to lock in place. I installed the tank and called it good.
    In the interim I found a NOS fuel sensor and purchased it "Just in Case."

    After powering up my car the fuel gauge didn't work, it was stuck on full and the tank didn't have any fuel in it.

    I checked my wiring at the tank.
    The ground was good.
    The wires were connected to the correct sensor posts.
    The sensor has one large diameter and one smaller diameter electrical post.
    Dug up some sensor specifications.
    .6 ohms empty and about 100 ohms full.

    I checked the NOS gauge and it was fine.
    .3 ohms empty and about 93 ohms full.

    Short video attached;


    I unplugged the China senor, that was installed in the car, from the car's wiring.
    I found the circuit was open, between the terminals not at the .6 ohms the specifications called for.
    The EBay purchased fuel tank level sensor was "Junk"..... from the get go.
    The good news is I hadn't added fuel or attached the fuel line, using the one time only usage, fuel hose clamp.
    So installing the NOS gauge sensor will be relative easy.

    A couple lessons here;
    Don't purchase China if you don't have to.
    Check the sensor operation before adding fuel. Preferably before even installing the sensor.
    I'm one for two....
    Rick
    Rick------


    I suspect that these in-tank fuel gauge units are manufactured in China by some "small time" operation. You'd probably be shocked if you saw the "factory" they come out of. You can be sure that this part was not manufactured by any Tier 1 OEM supplier or, even, any major aftermarket firm. So, the tooling and manufacturing technology is probably severely lacking. They can make the part APPEAR like the originals but that's as deep as it goes. This is to be expected. The sales volume by now of a part like this is likely so low that no major, 1st class manufacturer is going to have the slightest interest in manufacturing it.
    In Appreciation of John Hinckley

    Comment

    • Frank D.
      Expired
      • December 27, 2007
      • 2703

      #3
      Re: A bad decision / Fuel sensor source C2 1963

      Also beware of the sending unit "O" ring; many of the repros are not thick like the originals and sooner or later -- a guaranteed leak. I found this out on my 63 and managed to snag an NOS ring to replace the leaking piece of crap repro.

      Some quiz questions: Which one is the repro ?
      Attached Files

      Comment

      • Bob W.
        Very Frequent User
        • December 1, 1977
        • 802

        #4
        Re: A bad decision / Fuel sensor source C2 1963

        Joe - Frank Can you still buy the o-ring from GM, if so what is the part number?

        Thanks BOB

        Comment

        • Frank D.
          Expired
          • December 27, 2007
          • 2703

          #5
          Re: A bad decision / Fuel sensor source C2 1963

          Originally posted by Bob Winters (1653)
          Joe - Frank Can you still buy the o-ring from GM, if so what is the part number?

          Thanks BOB
          I actually don't know Bob - a friend shipped this NOS "O"ring to me from across the country! It was in a ZipLok bag...

          Comment

          • Leif A.
            Extremely Frequent Poster
            • August 31, 1997
            • 3627

            #6
            Re: A bad decision / Fuel sensor source C2 1963

            Originally posted by Bob Winters (1653)
            Joe - Frank Can you still buy the o-ring from GM, if so what is the part number?

            Thanks BOB
            Call a local Chevy dealer. I did about a year ago and they gave me this dealer number to call...they had plenty in stock. 580-938-2031
            Leif
            '67 Coupe L79, M21, C60, N14, N40, J50, A31, U69, A01, QB1
            Top Flight 2017 Lone Star Regional

            Comment

            • Leif A.
              Extremely Frequent Poster
              • August 31, 1997
              • 3627

              #7
              Re: A bad decision / Fuel sensor source C2 1963

              Originally posted by Joe Lucia (12484)
              Rick------


              I suspect that these in-tank fuel gauge units are manufactured in China by some "small time" operation. You'd probably be shocked if you saw the "factory" they come out of. You can be sure that this part was not manufactured by any Tier 1 OEM supplier or, even, any major aftermarket firm. So, the tooling and manufacturing technology is probably severely lacking. They can make the part APPEAR like the originals but that's as deep as it goes. This is to be expected. The sales volume by now of a part like this is likely so low that no major, 1st class manufacturer is going to have the slightest interest in manufacturing it.
              This is the only fuel gauge sensor I would trust today.
              Leif
              '67 Coupe L79, M21, C60, N14, N40, J50, A31, U69, A01, QB1
              Top Flight 2017 Lone Star Regional

              Comment

              • Joe L.
                Beyond Control Poster
                • February 1, 1988
                • 43219

                #8
                Re: A bad decision / Fuel sensor source C2 1963

                Originally posted by Bob Winters (1653)
                Joe - Frank Can you still buy the o-ring from GM, if so what is the part number?

                Thanks BOB
                Bob------


                The gauge gasket, GM #3825206, is discontinued. There should be quite a few around, though.
                In Appreciation of John Hinckley

                Comment

                • Bob W.
                  Very Frequent User
                  • December 1, 1977
                  • 802

                  #9
                  Re: A bad decision / Fuel sensor source C2 1963

                  Joe, Thanks for the reply and part number

                  Bob

                  Comment

                  • Richard G.
                    Extremely Frequent Poster
                    • July 31, 1984
                    • 1715

                    #10
                    Re: A bad decision / Fuel sensor source C2 1963

                    Thanks everyone for the input. I should have asked for it first! :O)
                    I did pay slightly more for my NOS one than LIC charges for there updated part. I couldn't find the ratings so I have to assume the NOS one isn't rated ethanol . NOS one did say "Made in the USA." An inspector can't see this part as the spare tire tub is in the way. If I had to do it over again I would take the advice and purchase the updated ethanol safe part. My bet is comes with a "O" ring rated for ethanol also.

                    I found it it is much more difficult to change out the sensor in the vehicle. I tapped the locking ring around and it appeared the tab I needed to tap on was always the one the rear cross-member blocked access to. It was painless upside down and on the bench!

                    I suspect many of you are like me and would be wondering what went wrong.
                    So I did what I have been doing since I was three, I took the EBay sensor apart.
                    As soon as I took a close look I noticed one wire had a hole it fed through and the wire placement had missed the hole. It was pinched between it an the case. Pictured below;



                    This is what the interior of the sensor looks like.


                    The good news, it the gauge now reads empty with no fuel in the tank!
                    The NOS part also had 90 ohms stamped into the case. This is of course the part's resistance at full tank.
                    Rick
                    Attached Files
                    Last edited by Richard G.; May 29, 2018, 01:00 PM.

                    Comment

                    • Frank D.
                      Expired
                      • December 27, 2007
                      • 2703

                      #11
                      Re: A bad decision / Fuel sensor source C2 1963

                      I installed the Eckler's sending unit in the 63 just because I could drive over there in 45 minutes and pick it up and be back on the road. It works fine with the only complaint being the "O" ring.... I prob should have went with the LICS one but we'll see how the new one holds up.

                      Comment

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