Morning all,
Dai suggested I might repair my faulty (now replaced) Hall sensors, and I am going to give it a shot. The supplier says I can get any lead legnth I want.
Before reading that I assumed I would just solder the stock 150mm leads onto my spare plate, but is there a better way? E.G. replace the whole cable up to the under tank connector?

Cheers, Stu

Dai wrote:

“        Do it yourself, seriously.

http://www.hallsensors.de/Hall-Vane.htm 

CYHME56 or CYHME56C. You'll need to drill the rivets out and replace them with small bolts; make sure you glue the nuts on with threadlock of some description.


  “

Use the existing cable from the old HES plate. If you check it and the wiring diagram, you'll see that it has a braided sheath under the outer casing which, in turn, is earthed to the main loom. IIRC it floats free at the HE plate end. The point is that the braid is used to cut down electrical noise as the signal from the HES is tiny. No braid = nasty misfire/no fire at all.

Dai,
Beautiful though Ireland is, I seriously think you should consider a move to Kent.
Cheers mate.
S

did that job a few weeks ago

not hard to do if you have some soldering skills and patience to peen over the standard rivets attached to the sensors , through the backing plate

I think I used a 1/8 drill bit to drill out the original sensors   which matches the new ones , careful how you go










don't forget that the sensors are magnetic and WILL pickup any swarf that exists nearby ...good luck !!

A review of postings on various forums suggests that HES failure may not necessarily just be sensor(s) failing. It appears that when the original HES were made in the early 1980's, the insulation on the wiring was standard plastic and not a high temperature insulation such as teflon. Some posts suggest that a breakdown of insulation over time due primarily to heat and perhaps vibration/rubbing can cause HES malfunction. The location of the HES and its wiring is hot and harsh - 30 years on, things will no longer be pristine.
My conclusion is if overhauling your HES, not only replace the 2 senders, but also replace the wiring and the protective sheathing with heat resistant items. If the plug connector looks dubious it can be replaced with non-BMW options of the identical type.

Good point. If you go looking on ebay, you want CY cable, not SY. SY is 50% braid coverage and is galavanised steel. CY is nickel-plated copper (or just copper) and is 90%-100% braid coverage. I don't have an HES cable to hand, but IIRC it was either 1.0mm or 1.5mm dia per core.