Fuel sending unit replacement for an accurate reading

[TX '90 ZR1]

Originally Posted by carter200

This is also a good time to think about changing out the plastic “y” for the billet replacement unit I machine. It will not break nor leak like the discontinued plastic one will. If interested contact me via email. Thanks for looking.

I'll second this!
I had a fuel pressure leakage issue that I finally traced to a small crack in the fuel sender/pump unit "Y".
Might as well eliminate a possible future issue while you are there.

[Meanmyz]

Originally Posted by Marc Haibeck

I have been cleaning the fuel level sensor as a repair procedure for quite a while. Recently I have encountered two units that would not stop skipping resistance at less than 20 ohms. That's about 3 to 0 bars on the gauge. This can cause the nasty jump from 3 to 0 bars in just a few miles.

I'm using a Stewart Warner universal fit sensor and fabricating an attachment to ZR-1 sender assembly. It's a modern thick film design. I get them from Summit Racing. Number SWW-439363-D. $37.

Hi Marc,

Thanks for the information! With all of the info supplied here, I will troubleshoot and if it is the sender itself, I will keep this in mind as it would be the cheapest way to fix this issue. You have supplied a direct answer/solution to my question. Thank you!

[spork2367]

Originally Posted by Flyman 27

You can buy the sending unit without the pumps, search around the net. I can't remembered where I ordered from.
I was told that the few gallons in the bottom of the tank prevents the fuel pumps from overheating.
When my gage says empty &n shifts in to reserve mode, I still have 4 gallons left. I was told that this was correct.

Not available without pumps, and hard to find period. The whole units are available about two places for 340-370 dollars.

Originally Posted by Flyman 27

I was told by a very reliable source (-=Jef=-) that the sender unit is the same as a standard C4. So you could find a deal on a standard C4 complete unit & swap the sending unit. That would be the least expensive way to get a new sending unit.

Priced a standard C4 assembly lately? Out of stock a lot of places and 150-200 for the assembly without the pump.

[Flyman 27]

I've seen them for less than this:

https://www.ebay.com/i/351242969272?chn=ps

But Mark's idea of using a customized universal sending unit is great, should fit the bill for most of us if you don't mind a little work.

[Flyman 27]

Originally Posted by Marc Haibeck

I have been cleaning the fuel level sensor as a repair procedure for quite a while. Recently I have encountered two units that would not stop skipping resistance at less than 20 ohms. That's about 3 to 0 bars on the gauge. This can cause the nasty jump from 3 to 0 bars in just a few miles.

I'm using a Stewart Warner universal fit sensor and fabricating an attachment to ZR-1 sender assembly. It's a modern thick film design. I get them from Summit Racing. Number SWW-439363-D. $37.

Mark,
Could you give us a little more info on what has to be customized in order to use the Stewart Warner sensor? Maybe a photo or 2?
It sounds like you have worked out the problem quite well.

[kr1276]

I ran into the same problem and have ordered the Stewart Warner unit to replace mine. Any pics or guidance would be appreciated. Thanks!

[Jagdpanzer]

Here is the one I converted to the SW sensor
Image1551752866.083346.jpgImage1551752891.701774.jpgImage1551752923.796872.jpgImage1551753015.250517.jpg


Sent from my iPhone using ZR-1 Net Registry

[kr1276]

Jagpanzer,

Sorry but open your pics for some reason. Would you please send them to my email
kr1276@aol.com

Thanks,
Keith

[-=Jeff=-]

Phil,

did you bend the float rod on the new unit? I assume that is to match the movement and position of the OEM one correct?

[Jagdpanzer]

Yes, had to bend and shorten it some.