Water Level Sensor Issue?

[andysharp]

Hi Richard

got the HFS-4 system on my Peugeot 207 gti and its been running superb since install last June. No settings or adjustment have been tinkered with.

Yesterday when was out, was accelerating got to the level where it normally injects and was no flow showing.

what was showing was the B in red for a milli second followed by the WINJECTION and WATER LEVEL yellow lights that stayed on solid till I came off the gas, and no flow showing.

The red S for flow sensor shows all the time.

When the water level comes on solid, am I correct in saying it will not let the system inject yes?

Today before I went out, I filled up the tank though was plenty in tank and again the same happened.

Took all the connectors out the back of the circuit board and reconnected them, when you do the manual test and activate the pump, you can hear it but the yellow lights on WINJECTION and WATER LEVEL come on solid again.

Its running off the injector pulses and the F-IDC LED panel flickers away as its picking the signals up from there.

Water level sensor at fault here perhaps?

Thanks
Andy

[Richard L]

I think it could be a jammed flow sensor or blocked jet problem rather the level sensor.

Take the jet out and do a manual activation spray test (SYS).

[andysharp]

will do, thanks for swift reply, will try get up to my mates garage and get car on ramp ASAP.

hope it is just a blockage somewhere, guess if sensor was at fault or that, then would show low level all the time....

will keep u posted! cheers

[Richard L]

If the turbine is jammed with some debris, no flow will be shown.

One remote possibility. If you unknowingly used contaminated methanol, the
FAV will be sealed shut. Let's hope this is not the case.

[andysharp]

don't say that lol

had a quick look into engine bay and looks like fluid in the hose to the jet, so fingers crossed just that is issue!

[Richard L]

Wait for your result.

[andysharp]

hi Richard

had front bumper etc off today so had a look at the set up.....

1. took the jet off the intake pipe its on, no flow.
2. removed the hose from FAV to the jet, no flow.
3. pushed compressed air through FAV and jet to clean any debris or that, no flow.
4. did the SYS test with the FAV taken off, and no flow, when did the SYS it the B goes red for milli second, then the water injection and water level LEDS come on.
5. when the system is switched off, there is no yellow LED on the water level like normal.
6. when doing the SYS tests, u can hear the pump kick in but then goes off when the two yellow LED's come on straight away.
7. we ran separate 12v to the pump itself, and had pefect flow coming out before the FAV, but when FAV was connected no flow.

so from this, sounds like the FAV yeh as suggested as remote possibility?

(we didn't separate the FAV and flow sensor) only seen could do that once got home as never seen it being fitted when was installed)

some pics of it...

http://i270.photobucket.com/albums/jj106/andysharp207gti/C2764582-ADB8-4ED3-BAA6-BA0638CF593F_zpsazebx0xt.jpg (http://s270.photobucket.com/user/andysharp207gti/media/C2764582-ADB8-4ED3-BAA6-BA0638CF593F_zpsazebx0xt.jpg.html)

http://i270.photobucket.com/albums/jj106/andysharp207gti/9D5050C2-3BEA-4ADE-86F1-DCD5AEAD630F_zpshcrsaazl.jpg (http://s270.photobucket.com/user/andysharp207gti/media/9D5050C2-3BEA-4ADE-86F1-DCD5AEAD630F_zpshcrsaazl.jpg.html)

when we 1st got access, there seemed to be air in the hose...
http://i270.photobucket.com/albums/jj106/andysharp207gti/BB0ED0E7-468C-4F8E-9FAE-2315B74CC962_zpsbezn9sgc.jpg (http://s270.photobucket.com/user/andysharp207gti/media/BB0ED0E7-468C-4F8E-9FAE-2315B74CC962_zpsbezn9sgc.jpg.html)

and at front of FAV the connector wasn't on and hose at an angle
http://i270.photobucket.com/albums/jj106/andysharp207gti/EDB90A4B-37D0-4C15-9F2C-DE71DB2150D5_zpscxpuho49.jpg (http://s270.photobucket.com/user/andysharp207gti/media/EDB90A4B-37D0-4C15-9F2C-DE71DB2150D5_zpscxpuho49.jpg.html)

look forward to hearing from you

thanks

[Richard L]

Send me the FAV and flow sensor assembly. I will open it up and what is going on. Before this, pout 12V across the lower two pins of the FAV and see if is opens. SYS is engaged.

[Richard L]

Once more test, when you do the "SYS" test with the 6mm hose detatched form the FAV, are there any liquid shooting out?

[andysharp]

Thanks for that Richard, will prob get it done middle of next week as easier to do work at mates barn where he has a ramp installed.

Will get those tests done and let u know when take the FAV off.

The lower two pins of the FAV, do u mean actually on the FAV? Or could u show me on a picture where they are ??

[Richard L]

when you unplug the FAV at the coil, it will be very obvious.

[andysharp]

cheers, will get onto it next week hopefully.

[Richard L]

Just to recap:

1. test the 6mm line with "SYS" on, make sure there is plenty of liquid shooting out with the FAV disconnected

2. Reinstate the 6mm line to the FAV and apply 12V to the coil manually with the "SYS" on. If there is no fluid coming out of the FAV, it is damaged.

3. Send it to me for repair.

[andysharp]

well not had change to investigate it further yet, but......

on a trip round loch Lomond on sunday and also out for a blast this morning, the WI is injecting :P

it triggered the failsafe twice,(both when going downhill) with the two yellow LED's coming on, but as soon as that went off, back on the throttle and was injecting.

going back to your 1st thought Richard, possibly a blockage but its working and will monitor it over next few weeks and see how it goes and test if required and when back at mates garage.

[Richard L]

This looks hopeful.

It is quite normal for user to suspect a system issue rather do a basic spray test with the installed jet.

Do the test and let me know so we can continue to make uniformed guesses.

[andysharp]

Just to recap:

1. test the 6mm line with "SYS" on, make sure there is plenty of liquid shooting out with the FAV disconnected

2. Reinstate the 6mm line to the FAV and apply 12V to the coil manually with the "SYS" on. If there is no fluid coming out of the FAV, it is damaged.

3. Send it to me for repair.

good news Richard,

1. flows out quickly
2. again flows well and sprays out the jet.

fingers crossed was just a wee blockage, will keep an eye on it as always, many thanks for all your help again.

[Richard L]

Music to my ears...

So, what was the problem? I accept any guesses.

[andysharp]

Tend to think been a blockage somewhere, bit of dirt or something.

Must say that the kit to work with is brilliant.

[andysharp]

Well we have an update!!!

Richard was good enough to check over some parts for me this week I sent down to him, as wanted to make sure they were 100% spot on, which they were!!!

So while speaking to Richard he mentioned about the pump relay cluster, maybe it's corroded.....

So was up at mates barn last night, got car on the ramp and got stuck in to some more fault finding......

And we find this.......

http://i270.photobucket.com/albums/jj106/andysharp207gti/Loch%20Lomond%20Drive%20August%202014/Water%20Injection%20From%20August%202014/th_974E0CAD-BD41-4180-A4B3-8503F3498403_zpsvpyyrmz0.jpg (http://s270.photobucket.com/albums/jj106/andysharp207gti/Loch%20Lomond%20Drive%20August%202014/Water%20Injection%20From%20August%202014/?action=view&current=974E0CAD-BD41-4180-A4B3-8503F3498403_zpsvpyyrmz0.jpg)

Corrosion and a spare one to compare mate had.

So sourced a new fused relay this morning and with parts back from Richard after testing for me, got it all back together again.

So it's all fitted again and this time a cover on the pump relay cluster to stop and moisture getting in there, thought would be safe under the headlights on the car but obviously wasn't, was really the garage who fitted it didn't read instructions properly and just left it out in the open to to speak, but it's done now and nicely covered up. Still to take on test run and probably be done over weekend at some stage but the SYS is working again etc so it's been the corrosion on the pump relay cluster that's been the cause of the issues I been having as all the working parts of the kit are 100% working perfect!!

http://i270.photobucket.com/albums/jj106/andysharp207gti/Loch%20Lomond%20Drive%20August%202014/Water%20Injection%20From%20August%202014/th_48DDDE93-ACDC-407D-8BAF-782CD4806C69_zpscagqywks.jpg (http://s270.photobucket.com/albums/jj106/andysharp207gti/Loch%20Lomond%20Drive%20August%202014/Water%20Injection%20From%20August%202014/?action=view&current=48DDDE93-ACDC-407D-8BAF-782CD4806C69_zpscagqywks.jpg)

[Richard L]

Thank you for posting the repair. Should have the bag upside down so the water cannot trickle up.