DIY - Junkman's Engine Oil Pressure Sensor Replacement/Relocation

[Junkman2008]

Originally Posted by KYROADHOG

Forgot to add,Junkman thanks to you & your family for the sacrifices made for me!! We appreciate our veterans & their families....

Ooh-Rah my friend!

[C5 Dude]

Junkman,

Can you post a pic of the backside of your fuel rail cover that you cut for the OPSU relocation kit. Maybe some with a ruler showing the distances for the cut out and up close of the bracket and how its bent.

Thanks!

[Fly03Z06]

Originally Posted by C5 Dude

Junkman,
Can you post a pic of the backside of your fuel rail cover that you cut for the OPSU relocation kit. Maybe some with a ruler showing the distances for the cut out and up close of the bracket and how its bent.
Thanks!

The way this fits, there is plenty of slack for placement. Depending on which coil nut you attach it to, the length you cut your bracket, mounting hole placement and size, where you may choose to bend the bracket and even the size of your gauge. No two installations could possibly have specifically the same cover hole dimensions, unless performed by the same person at the same time.......waaaaaaaay too many variables..

Before I cut the hole in my original Red cover, I first used a sacrifical "used" gray one (picked up from Corvette Recycling ), and cut a larger than necessary 2.5" hole so that the gauge would fit through. Then took specific centerline measurements for the gauge placement and also bent the bracket so the gauge face matches the pitch of the cover. Then cut one, 1.75" hole in my Red cover exactly where I wanted it

Finding a used, absolutely filthy, LS Corvette "left" coil cover is rather easy, also cheaper than screwing up a good one. (Absolutely amazing.........am I the only one that keeps mine clean?)

The tolerance could vary as much as 2" in any direction comparing two different installations. ....Just loosening the bracket nut will allow the gauge to move 1/2". Just make sure you drill the final hole larger than the gauge diameter.........in order to install or remove the cover, there needs to be a little wiggle room

Also, watch that you DO NOT over torque the 180 degree swivel AN fittings..............or once under pressure, you will snap the aluminum, swivel 180 degree bend and immediately pump out 5 quarts of oil all over the top of the engine and down your stamped and tinted concrete driveway before you discover it and get the engine shutdown. Immediately, and I mean immediately. Did I say immediately, I meant it too. NO, do not ask me how I know about this.

..........hmmmmm NOT the same bracket, mounting nut AJ used....or, the same gauge.




Did I stress a tight enough fit.......




Sacrificial Gray with 2.5" hole.......Red with 1.75" hole after bending bracket and locating gauge. Your location will not be the same. Close, maybe within 2", but not the same.


...and.... why you do not retorque the swivel AN fitting at 10:00pm the night before you have a 5:00am departure......


....unless you have a spare.
I now have two...

[Junkman2008]

Originally Posted by Fly03Z06

The way this fits, there is plenty of slack for placement. Depending on which coil nut you attach it to. Before I cut the hole in my original red cover, I first used a sacrifical "used" grey one (picked up from Corvette Recycling ), and cut a larger than necessary 3" hole so that the gauge would fit through. Then took specific centerline measurements for the gauge placement and also bent the bracket so the gauge face matches the pitch of the cover. Then cut one, 1.875" hole in my red cover exactly where I wanted it

Finding a used LS coil cover is rather easy, also cheaper than screwing up a good one.

The tolerance could vary as much as 2" in any direction comparing two different installations. Just make sure you drill the hole larger than the gauge diameter.........in order to remove the cover, there needs to be a little wiggle room

Also watch that you do not over torque the 180 degree AN fittings..............or under pressure, you will snap the aluminum bend and pump out 5 quarts of oil all over the top of the engine and down your tinted and stamped concrete driveway before you discover it and get the engine shutdown. NO, do not ask me how I know about this.

What he said.

[Fixvet]

Originally Posted by C5 Dude

Junkman,

Can you post a pic of the backside of your fuel rail cover that you cut for the OPSU relocation kit. Maybe some with a ruler showing the distances for the cut out and up close of the bracket and how its bent.

Thanks!

I'd like to see a photo too.

[Junkman2008]

Originally Posted by Fixvet

I'd like to see a photo too.

Read Fly's post. There is not 'exact' location for the hole. It can vary depending on where you mount the gauge.

[Fly03Z06]

Originally Posted by Junkman2008

Read Fly's post. There is not 'exact' location for the hole. It can vary depending on where you mount the gauge.

I added pictures above with no specific dimensions because there are waaaaaaaaaay too many variables

Yes AJ, I added pictures Grab a few cookies and a tall cold milk Enjoy

[Fly03Z06]

Originally Posted by Junkman2008

Oh, I almost forgot. The hole that I cut in the fuel rail cover is 2" in diameter. The problem with giving a specific location is that the gauge can be placed in a myriad of locations within a half inch of where mine is located. Thus, I have a extra fuel rail cover (my original that I messed up... ), that has a 2.5" hole cut in it that I now use to figure out where to cut the hole in the cover after I do the install. That's how I keep from screwing up fuel rail covers.

Gee....wonder where I got that idea from? THANKS AJ!!!!

[Junkman2008]

Originally Posted by Fly03Z06

Gee....wonder where I got that idea from? THANKS AJ!!!!

Yep! I learned the expensive way but I'll never make hat mistake again!

Looks completely stock.

[C5 Dude]

[QUOTE=Junkman2008;1717046](con't)


Once you complete step 28, you are ready to remove the manifold. At this point, you will probably look like me.



[QUOTE=Junkman2008;1717046]

You were right! You will look like that if you do this!



Thanks again Junkman for this awesome write up!

[Junkman2008]

Originally Posted by C5 Dude

You were right! You will look like that if you do this!



Thanks again Junkman for this awesome right up!

Now you have went and started something!

[Talon2006]

I just used your write up... I am an experienced mechanic and this made it easy! Even for a dumb officer! (Cw2 in the army haha)

NCO's lead the way right?

[Junkman2008]

Originally Posted by Talon2006

I just used your write up... I am an experienced mechanic and this made it easy! Even for a dumb officer! (Cw2 in the army haha)

NCO's lead the way right?

Yes they do!

So did you do the relocate or just replace the bad sensor?

[Talon2006]

Originally Posted by Junkman2008

Yes they do!

So did you do the relocate or just replace the bad sensor?

Just replace a sensor....

I know, I know... I should have done the relocate.

BTW, for all the people having trouble making the hole. Have ya'll thought about drilling a small 1/8" pilot hole, fitting the cover up to see if it is centered on the gauge, then drilling a larger one?

[Junkman2008]

Originally Posted by Talon2006

Just replace a sensor....

I know, I know... I should have done the relocate.

BTW, for all the people having trouble making the hole. Have ya'll thought about drilling a small 1/8" pilot hole, fitting the cover up to see if it is centered on the gauge, then drilling a larger one?

No, because the cover won't fit on the car with the gauge in place and you can't tell where the hole goes without the gauge in place.