Effects of high eth content on fuel level sensor

[iamareios]

First and foremost I am tuned for e48. This thread is to open further discussion on the topic. I have been having problems with high ethanol content and fuel level sensors failing. From research I've gathered, it seems gen 2 sensors are more prone to failure. So far I have replaced the original sensor seen in the photos with no luck. The oem replacement sensor failed in less than 2 weeks time. I have yet to pull it out, but have another on the way.

I found other platforms have a similar issue with this type of sensor, but no real fix. My first course of action in attempting to prevent this from happening again will be cleaning this sensor of corrosion and applying an avionics "fuel lube" I discovered called EZ TURN. I'll submerge the sensor in an e50 blend and see what happens. The data sheet shows this stuff as a good candidate to slow down the problem. It's not soluble in fuel or ethanol and has dielectric properties.

Sent from tapioca

 

[Enki]

I'm still on my original genwon sensor and it's never had issues.

 

[iamareios]

I'm still on my original genwon sensor and it's never had issues.

Not exactly sure what the differences are between gens. Is it simply the contact terminal material is different and more ethanol friendly? Are the connectors different? Resistance values maybe.

 

[Easter Bunny]

Gen done has a more resilient material. This seems to be a primarily gen 2 issue

 

[iamareios]

Gen done has a more resilient material. This seems to be a primarily gen 2 issue

If that's the case, I'm willing to buy a gen 1 sensor and compare. Hell, figure out a way to run it on my pu.

 

[Easter Bunny]

If I recall someone compared them and the way they measure the level is too different to make an easy conversion

I wonder if you change that connector to something made with a different alloy if you would have the problem. Gold would probably work but fuck that

 

[iamareios]

If I recall someone compared them and the way they measure the level is too different to make an easy conversion

I wonder if you change that connector to something made with a different alloy if you would have the problem. Gold would probably work but fuck that

I thought the same exact thing. Sourcing a connector similar may be difficult though

 

[L337TurboZ]

Find a three wire variable resistor and wire it inline with the Gen 1 signal wire. Then fill the tank (or empty it) and adjust the dial till you get the desired reading. Measure the resistance of the resistor and buy a regular 10 cent resistor to wire in it's place.

Unless you can find a way to secure the variable resistor so it doesn't change from vibration or contact.

I had to do something similar to make an SAFC2 work on my Starion as the tach signal wasn't reading smoothly and the three wire variable resistor corrected it.

https://www.ebay.com/itm/324731405040?chn=ps&mkevt=1&mkcid=28

 

[Enki]

Best bet is probably to disassemble the genpu sender and do something to protect the parts that have deteriorated in the pic.

 

[iamareios]

Best bet is probably to disassemble the genpu sender and do something to protect the parts that have deteriorated in the pic.

Still leaning forward on this EZ turn stuff. We'll see if smothering it on everything has any effect.

 

[Enki]

I was thinking something more permanent, like a potting or conformal coating.

 

[iamareios]

I was thinking something more permanent, like a potting or conformal coating.

Ethanol and fuel safe. Similar to what ethanol content sensor boards get coated in?

 

[Enki]

Sure? Worth a shot at least. I'd avoid coating the resistor contacts though.

 

[Sho]

@Littleloogy had a thread on this on msf. Gen 2 specific. Unfortunately can't find it in the archives. I reached out to James on fb to see if he's still got the info, but it looks like he hasn't been on there in a while

 

[Enki]

I think he's the one that first tried the dielectric grease, but found it had to be reapplied every so often or somesuch.

 

[Awafrican]

Remind me about this next week I've got a corrosion engineer contact I'll be able to reach out too then that may be able to have some insight

 

[iamareios]

Remind me about this next week I've got a corrosion engineer contact I'll be able to reach out too then that may be able to have some insight

Setting reminder on phone to remind you

 

[Easter Bunny]

Making that connector out of a random strip of metal wouldn't be hard just tedious

 

[Mauro_Penguin]

IIRC the few guys on MSF that beat this issue, did it by just soldering all the connectors together. Some kind of resistance that caused the corrosion.

Back then my buddies with Relentless Customs tried some epoxy that worked for civic guys or something like that. The epoxy was expensive and I don't think it worked.

 

[iamareios]

IIRC the few guys on MSF that beat this issue, did it by just soldering all the connectors together. Some kind of resistance that caused the corrosion.

Back then my buddies with Relentless Customs tried some epoxy that worked for civic guys or something like that. The epoxy was expensive and I don't think it worked.

Yeah I've been trying to find the thread about this to at least bring it back up on this forum. No luck so far though.