Effects of high eth content on fuel level sensor

It looks like it starts with the terminal itself and then blows out the contract pad on the board from what I have seen

 

Damn, if the failure mode involves the sensor track thing itself...that's no bueno.
Maybe there's a way to retrofit one of those tube-float style ones instead. IIRC some of those use hall effect sensors.

 

It's been almost 2 weeks and the gen 1 sensor is still alive and holding up

 

Yep. Longest alive time of tested methods/changes so far right?

 

Unmodified, straight drop in. Yes
Modified, the mercury mkz sensor lasted the longest

 

How long did that one last again?

 

It never failed. I only pulled it out because the resistance levels were off. That sensor had the greatest success from soldering wires directly to the board

 

Here's the link but you must be a member. Just answer a few basic speed questions on fb.
facebook.com/groups/mazdaspeedpartsandadvice/permalink/7981691961858273/

 

I was in talks with this gentleman a few months back about this. Before i got my hands on a gen 1 level sensor, i was about to send him 3 failed gen 2 units to tinker with. The gen 1 sensor fixed my issue so i never pursued. However, being the gen 1 sensors are discontinued- they will only get harder to find.

 

Unfortunately, this doesn't help people that are not on Facebook. Man needs a non-Facebook storefront or something.

 

I take it back. The gen 1 level sensor reporting level is off considerably. Today i clocked a level of 75% and was able to still add close to 7gals of fuel. I'm unsure if the one i received used already had a problem or not.

 

If you can meter it and the resistance is lower than the genpu you might be able to solder in a resistor to compensate. If the resistance is too high, well, not sure.

 

I've said it before but I'll say it again.

Someone should hook up a 3 wire potentiometer inline with the signal wire for the sender. Then measure the resistance of the circuit to determine what ohm resistor could be wired in. All it would take is adjusting the dial until the car reads full or empty whichever the tank is at when doing the calibration.

 

I have been in talks with this gentleman and helping him with different resistance level readouts. I sent him a brand spanking new gen 2 sensor straight from Tasca to modify for me. He is going to start offering them for $150 with a 6 month warranty. I'll post some photos and report back once I receive the modified sensor.

 

6 months huh... Doesn't seem like much.

 

It's something

 

Whatever method he does to counter the effects from ethanol has worked on his Neon SRT-4 for 8 years now, as stated by him. Mine should be a good test for him, as my car sits for months at a time lol

 

So more of a "if it's gonna fail ever, it will do it in 6 months" warranty then.

 

Received. No clue what the coating is haha.

 

Looks like potting.