Fuel Rail High Pressure Sensor Upgrade

[JumpingJackson]

Some History:

Cobb recently released the ability to change the targeted fuel pressure in the ECU.
Silverdemon and PTP are both working on upgraded fuel rail pressure relief valves which will allow us to run higher pressures with out hitting the stock valve which opens at ~1875 psi

The problem now is the stock high pressure fuel sensor maxes out at ~140 BAR or 2030 psi. So if your fuel pressure goes higher than this, the ECU cannot correctly measure fuel pressure which it uses to calculate the proper injector duty cycle, causing it to run super rich.

I did some looking around on our forum and someone pointed out an identical sensor that reads 250 BAR but it uses a different connector though other than that it is physically the same. I made some calls and a complete plug and play adapter harness can be made so the upgraded sensor can be used without hacking into the stock wiring harness!

All we need now is the ability to rescale for the higher reading sensor via reflashing the ECU (Cobb Accessport) or piggyback (CP-e Standback).

Stock 140 BAR Sensor Bosch Part Number: 0261545006
Upgraded 250 BAR Sensor Bosch Part Number: 0265005303
I also found out that same upgraded bosch sensor is already used on a Mercedes Benz vehicle with the part number of 0025400917

Attached are the Bosch datasheets in .PDF for both the stock and 250 bar sensors. (REFER TO NEW DRAWINGS BELOW FOR WIRING)

New Information from JumpingJackson
I have been working with BMotorsports, you can now order a preassembled adapter harness from them
http://www.bmotorsports.com/shop/pro...oducts_id/2118


SUPERSKATERS TESTING:


i just purchased my sensor today from here

All European

search for the Mercedes PN or u can use the Bosch PN. make sure you tell them you saw it online to get the $122 price.


i ordered the harness from here. it was free because you can ask to view "samples" of the products.

www.te.com





i also found the connector for the stock harness so you can make this 100% PNP. (note the first 3 parts in the list are put together in a "kit" which is what the last item is)

incase you cant see the PN's they are in order:

CONN-11555
CONN-10555
CONN-56057
CONN-75598p









HERE IS HOW YOU NEED TO WIRE THIS BECAUSE THE DATA SHEET IS WRONG!!!!!!!









PNP Harness:

Please note the picture below is not wired correctly because i took it before i figured out the wiring was backwards. If you want to refer to it just swap the position of the yellow and blue wires ON THE SENSOR SIDE OF THE HARNESS








INSTALL:


I Also found it is EXTREMELY easy to swap the sensor out when your ready to do this. You dont need to remove anything at all!!!

you will need a deep 24mm (for the new sensor) and deep 27mm (for the stock sensor) socket to get these out. i bought them at pepboys for a total of like 13 bucks. all you need to do is put them on a swivel and there should be plenty of room in there to slip it over the sensor (after you have unclipped the harness of course) and get them out. I did not use thread sealant on the threads because i was swapping sensors so often for testing that i just forgot about it but there is a taper on the end of the sensor which is really whats doing the sealing. Also you only need very little torque to get this thing tight and to seal good. something like 5-10 ft-lbs at MOST.