Ethanol percentage hardware project

Discussion in 'Fiesta ST EcoBoost™ Tuning' started by razorlab, Oct 2, 2014.

  1. razorlab

    razorlab Active Member

    I'm putting together a hardware package to show the ethanol percentage in the Fiesta ST. This will be handy for people that use Ethanol in their FiST to know EXACTLY what you have in the tank. Coupled with the new COBB map switching this will be a great feature. You will be able to run a custom rom that has Ethanol percentages in each switchable map slot to switch to and you know which one to switch to based on what the gauge is telling you. No more math at fill up and no more guessing when you add Ethanol to a non-empty tank.

    My dream is to that the ECU will switch to each map automatically depending on the Ethanol percentage in your tank but that will take COBB getting on board with it and the output of the sensor wired to the ECU.

    I will be outlining the EXACT parts you need to purchase in list form and a how-to assemble them and wire everything up. I will share this freely in the spirit of information and collaboration.

    12-23-2014 UPDATE

    Since some DB on the other forum (gee I wonder who) decided to copy all my and ideas and info and start his own thread (since they deleted all my tech info) about it I am updating this and the first post in this thread with all the required items to get this working.

    I'm currently testing this all out and with the COBB switchable maps, it's going to be a great combo.

    Parts list:

    1. Continental VDO Flex fuel sensor. GM Part # 13577429, approx $55
    I went with the smallest sensor they make for space reasons.

    2. Russell 644123 -6AN Male to 3/8" SAE Fitting (2) $17/each @ Amazon
    These are the quick connect fittings to the sensor. You can go cheaper with the plastic connect versions but there have been reports of the plastic breaking down with E85 so these are much safer and more robust.
    Cheaper version:
    Dorman 800-082 STRAIGHT. 3/8 IN. STEEL TO 3/8 IN. NYLON (pack of 2)

    3. Russell 644113 -6AN Male to 5/16" SAE Fitting (2) $21/each @ Amazon
    This connects to the OEM fuel pipe to the HPFP pump on top of the motor and the other to the OEM Fuel line at the firewall.
    Cheaper version:
    Dorman 800-092 90 DEGREE ANGLE. 5/16IN STEEL TO 3/8IN NYLON (pack of 2)
    Dorman 800-084 STRAIGHT. 5/16 IN. STEEL TO 3/8 IN. NYLON (pack of 2)

    4. Radium PTFE -6AN Hose Assemblies - 11.4" Straight and 90* ends (2) $22.95/each @ Radium
    PTFE for great ethanol resistance and -6AN connections for secure and non-leak fit. Pre assembled.
    Cheaper Version:
    Any 30R9 spec hose, Gates, Goodyear etc. Two feet.
    Fuel injection hose clamps

    5. Zeitronix ECA Ethanol Content gauge $199

    6. Zeitronix ECA 8ft wiring harness $29
    You can find this harness cheaper to build yourself but this is well done and saves time

    If you want to make the Sensor wire harness yourself, here are the part #'s for the connector:
    Delphi GT 150 series connector, part # 13519047 (1) $1.62
    Delphi GT 150 series Terminals part# 15326264 (3) $0.10 each
    Delphi Loose Cable Seal part# 15366021 (3) $0.06 each

    Or buy the GM connector harness already assembled and cut one end off GM Part# 13352241 $9.71
    EFI Connection also sells a pre assembled connector pigtail for $15.00

    7. Add-A-Fuse $9 @ Amazon or local auto store

    The two pre built Radium PTFE hoses and the Zeitronix ECA wiring harness makes this a basically plug and play affair. I highly recommend going this route to save time but of course you can build it all yourself if you want.


    Wiring instructions
    Orange wire : +12V (use Add-A-Fuse connection makes this a plug and play affair to the fuse box)
    Brown: Ground (use one of the many grounds located behind the glove box or foot well areas
    Green: Sensor output to Zeitronix ECA gauge

    Fueling connections
    The OEM hard line is located at the top right of the engine if you are looking at the windshield of the car.


    Undo the L-shaped connection with the two black prongs below:


    Follow this line down towards the firewall and undo the other side the same way you did the engine side of the hose.

    Install the Russell 644113 -6AN Male to 5/16" SAE Fitting on the OEM hard line at the top of the engine. Be sure to lube the o-ring in the connector first. Once you install this fitting onto the OEM hardline, install one of the Radium PTFE -6AN Hose Assemblies on this side, install the Continental VDO Flex fuel sensor on the end of this with the two Russell 644113 -6AN Male to 5/16" SAE Fitting fittings on it, then install the second Radium hose on the other end of this. Install the second Russell 644113 -6AN Male to 5/16" SAE Fitting on the OEM hard line at the firewall and then install the last open end of the second Radium hose. This completes the whole assembly.

    As you are assembly all this you will see the proper way to orientate everything in the engine bay. It's really simple. I used black zip ties to make sure some of the hoses where secure and wouldn't flop around the engine bay.

    Then connect the zeitronix wire harness to the sensor and find the way you want to bring it into the cabin depending on where you want the gauge placed. Wire everything up and there you go!
    Last edited: Dec 23, 2014
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  3. McRib 1s Back

    McRib 1s Back Well-Known Member

    Hey, that's very cool! I'm in for info, even if I don't go the alcohol route! :)
  4. razorlab

    razorlab Active Member


    Test fitting all the fittings to the sensor and wiring. I think I might have to add a 90* fitting and possibly a hose line. I was hoping to not have to make it more complicated but might have to depending on space and location in the engine bay. We'll see when I do some test fitting this weekend.

    I'm updating the first post with part #'s as well.


  5. RodMoe

    RodMoe Well-Known Member

    let me know what to get so I cane feild test it for you in the cold midwest :) then we can ran some E 30-50 tunes ;;; for baselines ,,, :)
  6. razorlab

    razorlab Active Member

    Haven't updated this thread in awhile as I was just updating it over on fiestaSTforum...however now that I was banned and ALL my threads, tech info, etc was deleted off that forum as a foolish move on their part I will be updating this thread a bit more on this forum...

    Stay tuned.
  7. Randy@mountune

    Randy@mountune Active Member

    Why were you banned?
  8. Jonnyz

    Jonnyz Member

    He was probably banned for being both a gentleman and a scholar
    no-pistons, Dyn085, razorlab and 4 others like this.
  9. timboslice

    timboslice Active Member

    +1. Please tell use why. I've always found Razor's posts to be both informative and amusing. The rambling one about eating a sandwich of your own choosing had me laughing audibly at work.

    Sent from my iPhone using Tapatalk
    iLiptiKal and ryst like this.
  10. RodMoe

    RodMoe Well-Known Member

    From what I was told he asked to leave. But I have it on good info that nothing was deleted just when the software see's an account flagged it hides the posts . All waiting for things to be worked out :)
  11. razorlab

    razorlab Active Member

    Asked to leave? Hahaha. If this statement in a reply to an admins PM is being asked to leave? "How do I get out of this shit show?"

    I was banned because I apparently challenged the good ol' boys club too much over there. One member of the staff in particular who just spews nonsense all the time.

    Waiting for things to get worked out? What does that mean? There has been zero communication from the staff there. Other than you posting this.
  12. RodMoe

    RodMoe Well-Known Member

    Always more than one side to any story as we all know . Only know what I was told from my source.
    And dialog has to start some where so this would be a good start as any I guess..
    Though in the Interest of keeping this thread on track we can converse via other means and not clutter up your informative thread on your project .,
  13. razorlab

    razorlab Active Member

    No thanks. Less forums I am on, the more of a real life I have.

    The staff member that banned me in rash judgement just confirms my disdain for most of the "staff" there.
    koozy and Dyn085 like this.
  14. RodMoe

    RodMoe Well-Known Member

    Ok I understand and wish you best on your current projects and your future work on the evo .
  15. timboslice

    timboslice Active Member

    What thread or topic resulted in being banned?

    There's some good people on the other forum (Rod included) but there's also a lot of bs and some dubious staff/vendor conflicts of interest.

    Sent from my iPhone using Tapatalk
    Dyn085 likes this.
  16. razorlab

    razorlab Active Member

    All my threads and replies, topics, etc no longer exist on that forum so nothing to see.

    Yes, Rod is a good one.
  17. RDgolfer

    RDgolfer Active Member

    You made fun of someone...I know Nothing!!! Ok, for real, I am delving into self tuning, so if you don't mind, I would really appreciate your input if I post something in this area...or hard feelings here man...blank slate for me
  18. RodMoe

    RodMoe Well-Known Member

    As with everything it is a learning curve and Thanks for being part of it.. I learned more than a few things some about tuning too.. mostly I learned it is still harder than heck to herd cats.. Enough said on that in my cryptic manner ;)
  19. RDgolfer

    RDgolfer Active Member

    Ha're a rock Rod! Steady Eddy...a role model of sorts...if that is at all possible in the world of typed words...btw, how is your self tune doing? Are you running a Rod tune exclusively or some type of hybrid?
  20. RodMoe

    RodMoe Well-Known Member

    LOL Thanks I try.. No at this point I have decided to go back to a 91 oct tune for winter (will load that sometime soon too love the corn tune though) and that would be a Randy tune as I looked at the self tuning stuff and was just overwhelmed by the number or things you can do to the ECU and tune. And I just don't have the time to invest in it yet if ever. Anyone that does it I tip my hat.. Maybe someday :)

    Thats why this neat gadget (for lack of a better word) will help in tuning and filling the car with corn gas's
  21. RDgolfer

    RDgolfer Active Member

    Going to a 91 tune...are you pumping 93 oct into your tank? And I hear you, self tuning is like acquiring a Masters in I Don't Know...corn, what are you running, and is it helping your performance, and how is your tune dealing with it? This is like 60 Minutes...except we don't have wrinkly people to look at

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