Fuel-Proofing OEM Fuel Sender for e85

[Si Speed 317]

Here's Ainokea's post:

UPDATE 9/19/12 - The top of the sender has started to work. My entire fuel gauge is working now. It has been for the past 3 months or so. I think this may be a solution. Only more time will tell


sup...been a minute. any who...i recently converted to e85 and have great success.

things to know about e85 is that your injector duty cycle would increase from 20-30%, so you need more fuel pumps, injectors, ie.

also, with e85 it corrodes the board inside the tank and makes the gas gauge not work. no one has actually done a diy yourself because...idk why but also it seems to always fail.

hopefully this is the successfully solution for everyone.

i have currently been back to the station for more E85 six different times, and put almost 1000 miles within 20 days. lol i been driving a lot haha

the walbro 400 pump is amazing. it is slightly larger than the walbro pump but you need to modified the heck out of it...lol i done so much already. why stop there?

any way on to the pics ..not for the fate hearted haha

here is the stuff i used...was just trying stuff out.


so here is day 1 installed...now i f'ed up and cover the top...so my pump never shows full again. after about 3 bars are go my gauge comes back on.


this is the sender unit after to fill ups...still pretty clean


and this is today...20 days later. still working great, but also starting to show the signs of wear.



and now on to the pump....here is the first thing you see when you try to put this bad boy in...



dremel goes a long way...you actually have to do more than just the pump, like a 1/4 more.


this is pretty flush...but then the next problem was the cover. the pump had some things on it and...well...more dremel action haha


so cut the bottom top flush too, also you can see where i notched out the cage for the return line here


for the wiring you cant use the stock clip. just pop the clips out of the black harness and they fit right on. i also use the stock hose as a return, and cut the cage so it can go straight down. you can see that in this pic too

also note, that i have already previously cut the cage up around the top where the pump goes into, this was for the line on the feed line.




cool...and thanks. dont have to do what i did, but showing what has worked so far...keep yo fingers crossed! haha

thanks!