The newest GM sensor is only $65 btw...
And as far as I know GM went back to using this newer cheaper, more reliable sensor...
It took some digging to find info on the new GM sensor. You guys are right, after the failure of the early sensors, GM and Ford went with the "virtual ethanol sensors" that estimated ethanol content via the O2 sensors and fuel level. Now, to comply with the new tier III emission requirements, GM has recently implemented a gen II dielectric flex fuel sensor that actually measures ethanol content again, instead of estimating it. The gen II sensor is made by the same company who made the first sensors, VDO/Continental. When digging for info, I made the curious discovery that these look strikingly similar to the Haltech sensor:
http://www.usa.vdo.com/generator/www/us/en/vdo/main/press/releases/aftermarket_replacement_parts/2012/sv_CO1483_C.html
Like Britishturbo said, these Continental sensors can be had for ~$65, but he didn't mention it's the exact same as the Haltech ($226!). Pleasant surprise!
The part #'s are 13577394 and 13577379, the difference between the two being the length of fuel connections (the 13577394 being longer). They can be bought from
www.gmpartsdirect.com for ~$66.
Here's some info about the new flex fuel sensor
Flex Fuel Sensor
The flex fuel sensor measures the ethanol-gasoline ratio of the fuel being used in a flexible fuel vehicle. Flexible fuel vehicles can be operated with a blend of ethanol and gasoline, up to 85 percent ethanol. In order to adjust the ignition timing and the fuel quantity to be injected, the engine management system requires information about the percentage of ethanol in the fuel.
The flex fuel sensor uses quick-connect style fuel connections, an incoming fuel connection, and an outgoing fuel connection. All fuel passes through the flex fuel sensor before continuing on to the fuel rail. The flex fuel sensor measures two different fuel related parameters, and sends an electrical signal to the engine control module (ECM) to indicate ethanol percentage, and fuel temperature.
The flex fuel sensor has a three-wire electrical harness connector. The three wires provide a ground circuit, a power source, and a signal output to the ECM. The power source is battery positive voltage and the ground circuit connects to an engine ground. The signal circuit carries both the ethanol percentage and fuel temperature within the same signal, on the same wire.
The flex fuel sensor uses a microprocessor inside the sensor to measure the ethanol percentage and fuel temperature, and changes the output signal accordingly. The electrical characteristic of the flex fuel sensor signal is a square-wave digital signal. The signal is both variable frequency and variable pulse width. The frequency of the signal indicates the ethanol percentage, and the pulse width indicates the fuel temperature. The ECM provides an internal pull-up to 5 V on the signal circuit, and the flex fuel sensor pulls the 5 V to ground in pulses. The output frequency is linear to the percentage of ethanol content in the fuel. The normal range of operating frequency is between 50 and 150 Hz, with 50 Hz representing 0 percent ethanol, and 150 Hz representing 100 percent ethanol. The normal pulse width range of the digital pulses is between 1 and 5 ms, with 1 ms representing −40°C (−40°F), and 5 ms representing 151.25°C (304.25°F).
The microprocessor inside the sensor is capable of a certain amount of self-diagnosis. An output frequency of 180 Hz indicates either that the fuel is contaminated, or that an internal sensor electrical fault has been detected. Certain substances dissolved in the fuel can cause the fuel to be contaminated, raising the output frequency higher than the actual ethanol percentage should indicate. Examples of these substances include water, sodium chloride (salt), and methanol.
It should be noted that it is likely that the flex fuel sensor will indicate a slightly lower ethanol percentage than what is advertised at the fueling station. This is not a fault of the sensor. The reason has to do with government requirements for alcohol-based motor fuels. Government regulations require that alcohol intended for use as motor fuel be denatured. This means that 100 percent pure ethanol is first denatured with approximately 4½ percent gasoline, before being mixed with anything else. When an ethanol gasoline mixture is advertised as E85, the 85 percent ethanol was denatured before being blended with gasoline, meaning an advertised E85 fuel contains only about 81 percent ethanol. The flex fuel sensor measures the actual percentage of ethanol in the fuel.
So the "ECM provides an internal pull-up to 5 V on the signal circuit, and the flex fuel sensor pulls the 5 V to ground in pulses". Does anyone know if that is how the stock EGT's work, with the ECM providing the pull-up voltage? If so, it looks like it's going to be perfect to use the EGT's 3 wires to power and send the signal from the flex fuel sensor.
I'm banking on these new sensors being more reliable than the old ones, and if they prove to suck, at least they're a lot cheaper. I'm excited to try this out!
