
Running E85 fuel in a Ford Focus ST with an auxiliary fuel kit is a popular modification among enthusiasts seeking increased performance and power. E85, a blend of 85% ethanol and 15% gasoline, offers a higher octane rating, allowing for more aggressive tuning and greater horsepower gains. However, the Focus ST's stock fuel system is not designed to handle the increased fuel demand of E85, necessitating the installation of an auxiliary fuel kit. This kit typically includes additional fuel pumps, injectors, and a dedicated fuel tank to ensure a consistent and sufficient supply of E85 to the engine. By combining an aux fuel kit with proper tuning, Focus ST owners can safely and effectively harness the benefits of E85, unlocking the full potential of their vehicle's performance capabilities.
| Characteristics | Values |
|---|---|
| Compatibility | Ford Focus ST can run on E85 with an auxiliary fuel kit. |
| Auxiliary Fuel Kit Requirement | Necessary to adjust fuel delivery, injection, and engine tuning. |
| Engine Tuning | Required to optimize performance and prevent engine damage. |
| Fuel Economy | Lower compared to gasoline due to E85's lower energy density. |
| Performance | Potential for higher horsepower and torque with proper tuning. |
| Emissions | Generally cleaner-burning, reducing certain emissions. |
| Cost | E85 is often cheaper per gallon but may result in higher fuel consumption. |
| Cold Start Issues | E85 has a higher cold start difficulty; proper tuning mitigates this. |
| Fuel System Compatibility | Standard fuel system components may require upgrades for long-term use. |
| Legal Considerations | Check local regulations for E85 usage and vehicle modifications. |
| Longevity Impact | Properly tuned systems can maintain engine longevity. |
| Availability | E85 availability varies by region; check local fuel stations. |
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What You'll Learn

E85 compatibility with Focus ST engine components
The Ford Focus ST, known for its turbocharged EcoBoost engine, has gained popularity among enthusiasts seeking performance upgrades. One common question is whether the Focus ST can run on E85 fuel, a blend of 85% ethanol and 15% gasoline, using an auxiliary fuel kit. E85 compatibility with Focus ST engine components requires careful consideration of several factors, including fuel system upgrades, engine tuning, and material compatibility. While E85 offers higher octane and potential power gains, it also demands specific modifications to ensure reliability and performance.
Firstly, the Focus ST’s stock fuel system is not designed to handle E85’s lower energy density and higher consumption rates. E85 requires approximately 30% more fuel by volume compared to gasoline, necessitating upgrades such as higher-flow fuel injectors, a larger fuel pump, and possibly a secondary fuel tank or auxiliary fuel kit. The auxiliary fuel kit must be compatible with ethanol to prevent corrosion and ensure consistent fuel delivery. Additionally, the fuel lines and filters should be ethanol-resistant to avoid degradation over time.
Secondly, the engine’s internal components must be assessed for E85 compatibility. The Focus ST’s EcoBoost engine features aluminum components, which are generally compatible with ethanol. However, prolonged exposure to E85 can accelerate wear on certain parts, such as valve seats and piston rings, if they are not specifically designed for ethanol use. Upgrading to ethanol-compatible materials or using lubricants with enhanced ethanol protection can mitigate these risks. Regular maintenance and monitoring are also crucial to ensure longevity.
Tuning is another critical aspect of running E85 in a Focus ST. The engine’s ECU must be recalibrated to account for E85’s different stoichiometric ratio and combustion properties. A professional tune can optimize fuel maps, ignition timing, and boost levels to maximize power while maintaining safety. Flex-fuel tuning systems, which automatically adjust parameters based on the ethanol content in the fuel, are highly recommended for seamless operation. Without proper tuning, running E85 can lead to poor performance, engine damage, or even failure.
Lastly, cooling system upgrades may be necessary due to E85’s cooler running properties. While this can reduce the risk of detonation, it also places additional demands on the cooling system, especially under high-load conditions. Upgrading to a higher-capacity radiator, improved coolant, and possibly an intercooler can help manage temperatures effectively. By addressing these components, Focus ST owners can safely and effectively run E85 with an auxiliary fuel kit, unlocking the fuel’s performance potential while ensuring reliability.
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Auxiliary fuel kit installation process for Focus ST
Running E85 in a Ford Focus ST requires an auxiliary fuel kit to manage the higher ethanol content and ensure optimal performance. The installation process for an auxiliary fuel kit is detailed and requires careful attention to ensure safety and functionality. Below is a step-by-step guide tailored to the Focus ST.
Preparation and Safety Measures
Before beginning the installation, gather all necessary components of the auxiliary fuel kit, including the flex fuel sensor, ethanol content analyzer, wiring harness, and additional fuel lines. Ensure the vehicle is parked on a flat surface, the engine is off, and the fuel system is depressurized to prevent accidents. Disconnect the battery to avoid electrical mishaps during installation. Familiarize yourself with the Focus ST’s engine bay layout to identify the stock fuel lines, injectors, and ECU, as these will be key points of integration for the auxiliary kit.
Installing the Flex Fuel Sensor
The flex fuel sensor is a critical component of the kit, as it monitors the ethanol content in the fuel. Locate the stock fuel line between the fuel tank and the engine bay. Cut the line and install the flex fuel sensor inline, ensuring it is securely connected and sealed to prevent leaks. Use proper fittings and clamps to maintain fuel system integrity. The sensor should be positioned in a location where it can accurately measure the fuel mixture without interference from heat or vibration.
Wiring and ECU Integration
Connect the flex fuel sensor to the provided wiring harness, which will link it to the vehicle’s ECU. Route the wiring carefully, avoiding hot surfaces and moving parts. The wiring harness typically includes a plug-and-play connector for the Focus ST’s ECU, allowing the sensor data to be read and processed. Some kits may require tuning or a standalone ethanol content analyzer to adjust fuel maps based on ethanol percentage. Ensure all connections are secure and insulated to prevent shorts or damage.
Fuel System Modifications
E85 requires larger fuel injectors and a higher flow rate due to its lower energy density. If your auxiliary kit includes upgraded injectors, replace the stock injectors with the new ones, ensuring they are properly seated and connected. Additionally, check if the fuel pump can handle the increased demand of E85; if not, consider upgrading the pump as part of the installation process. Test the fuel system for leaks by pressurizing it before starting the engine.
Final Testing and Tuning
Once the auxiliary fuel kit is installed, reconnect the battery and start the engine to verify proper operation. Monitor the flex fuel sensor readings to ensure it accurately detects the ethanol content. If the kit includes tuning software or a piggyback ECU, use it to adjust the fuel maps for E85 compatibility. Take the vehicle for a test drive to ensure smooth performance and address any issues, such as rough idling or hesitation, through further tuning. Regularly check the fuel system for leaks and sensor accuracy to maintain long-term reliability.
This installation process ensures your Focus ST can safely and efficiently run E85 with an auxiliary fuel kit, maximizing performance and fuel flexibility.
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Performance gains and tuning for E85 on Focus ST
Running E85 on a Ford Focus ST can unlock significant performance gains, but it requires careful tuning and the right auxiliary fuel kit setup. E85, a blend of 85% ethanol and 15% gasoline, has a higher octane rating and cooler combustion properties compared to regular gasoline. This allows the Focus ST’s 2.0L EcoBoost engine to handle more boost pressure and advanced timing, resulting in increased horsepower and torque. However, E85’s lower energy density means the engine requires approximately 30% more fuel, necessitating a flex-fuel system or auxiliary fuel kit to deliver the additional fuel needed for optimal performance.
To achieve performance gains with E85, tuning is essential. The Focus ST’s factory ECU is not optimized for E85, so a custom tune is required to adjust fuel tables, ignition timing, and boost levels. Ethanol’s higher latent heat of vaporization cools the intake charge, reducing the risk of knock, which allows for more aggressive tuning. A professional tuner can tailor the ECU to take full advantage of E85’s properties, potentially increasing power output by 20-30% when paired with supporting modifications like a larger intercooler, upgraded fuel injectors, and a high-flow fuel pump.
An auxiliary fuel kit is crucial for running E85 on the Focus ST, as the stock fuel system is not designed to handle the increased fuel demand. These kits typically include larger fuel injectors (e.g., 650cc or higher), a high-flow in-tank fuel pump, and a flex-fuel sensor to monitor ethanol content. The flex-fuel sensor allows the ECU to adjust fueling in real-time based on the ethanol percentage, ensuring consistent performance regardless of the E85 blend. Without these upgrades, the engine may run lean, leading to detonation and potential damage.
Cooling system upgrades are also recommended when running E85 on a Focus ST, as ethanol’s combustion properties generate more heat. Upgrading to a larger radiator, high-flow fans, and a better thermostat can help manage temperatures under increased load. Additionally, ethanol’s hygroscopic nature means it absorbs moisture, so using a fuel additive to prevent phase separation and corrosion in the fuel system is advisable.
Finally, while E85 offers performance benefits, it comes with trade-offs. Fuel economy will decrease due to E85’s lower energy density, and the fuel’s availability can vary by region. However, for Focus ST owners seeking maximum power and willing to invest in the necessary upgrades, E85 with an auxiliary fuel kit and proper tuning can transform the driving experience, delivering a more responsive and powerful engine. Always consult with experienced tuners and mechanics to ensure the setup is safe and optimized for your specific goals.
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Fuel economy considerations when using E85 in Focus ST
When considering the use of E85 in a Ford Focus ST with an auxiliary fuel kit, one of the most critical factors to evaluate is fuel economy. E85, a blend of 85% ethanol and 15% gasoline, has a lower energy density compared to traditional gasoline. This means that E85 contains less energy per gallon, which directly impacts fuel efficiency. As a result, drivers can expect a noticeable decrease in miles per gallon (MPG) when running E85 in their Focus ST. Estimates suggest that fuel economy can drop by 20-30% when using E85 compared to regular gasoline, primarily due to its lower energy content and the engine's need to consume more fuel to produce the same power.
To mitigate the impact on fuel economy, it’s essential to ensure that the Focus ST’s engine is properly tuned for E85 use. An auxiliary fuel kit alone is not sufficient; the engine’s ECU (Engine Control Unit) must be recalibrated to optimize fuel injection, ignition timing, and other parameters for the ethanol blend. Without proper tuning, the engine may run inefficiently, exacerbating the fuel economy penalty. Many Focus ST owners who switch to E85 invest in professional tuning services or use ethanol-specific tuning software to maximize efficiency and power output while minimizing fuel consumption.
Another consideration is the driving style and conditions. E85’s lower energy density means that aggressive driving, such as frequent hard acceleration or high-speed cruising, will further reduce fuel economy. For Focus ST owners who prioritize performance, the trade-off between power gains and fuel efficiency becomes more pronounced. However, in moderate driving conditions, the impact on fuel economy can be somewhat less severe. It’s important for drivers to adjust their expectations and driving habits to align with the characteristics of E85.
The availability and cost of E85 also play a role in fuel economy considerations. While E85 is often cheaper per gallon than premium gasoline, the reduced MPG means that the overall cost per mile may not always be lower. Focus ST owners should calculate their expected fuel costs based on local E85 prices and their vehicle’s adjusted fuel economy to determine if the switch is financially viable. Additionally, the limited availability of E85 stations in some regions may require drivers to plan their routes carefully, potentially adding inconvenience to their fueling routine.
Lastly, long-term maintenance and engine health should be factored into the decision to use E85. While modern engines like the Focus ST’s EcoBoost can handle E85 with proper modifications, consistent use of ethanol blends may require more frequent maintenance, such as fuel filter replacements or injector cleanings. These additional costs should be weighed against the potential savings or performance benefits of using E85. In summary, while E85 can offer performance advantages, Focus ST owners must carefully consider the fuel economy trade-offs and take proactive steps to optimize their vehicle for efficient ethanol use.
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Potential risks and maintenance for E85-converted Focus ST
Running E85 on a Ford Focus ST with an auxiliary fuel kit can offer performance benefits, but it also introduces potential risks and maintenance considerations that owners must address to ensure reliability and longevity. One of the primary risks is the increased demand for fuel, as E85 has a lower energy density compared to gasoline. This means the engine will consume more fuel, putting additional strain on the fuel system. To mitigate this, it’s crucial to ensure the auxiliary fuel kit is properly sized and installed to handle the higher flow rates required for E85. Inadequate fuel delivery can lead to lean running conditions, which may cause engine damage or misfires.
Another significant risk is the corrosive nature of ethanol in E85, which can degrade certain materials over time. The Focus ST’s fuel system components, such as rubber hoses, seals, and certain metals, may not be compatible with ethanol. Owners should inspect and, if necessary, replace these components with ethanol-resistant alternatives to prevent leaks or failures. Additionally, the increased moisture content in E85 can accelerate corrosion in the fuel tank and lines, necessitating more frequent inspections and maintenance to avoid long-term damage.
Engine tuning is essential when converting to E85, as the fuel’s different combustion properties require adjustments to the air-fuel ratio, ignition timing, and boost levels. Running E85 without proper tuning can result in detonation, overheating, or catastrophic engine failure. It’s imperative to work with a professional tuner experienced in E85 conversions to ensure the engine is optimized for the new fuel. Regular monitoring of knock sensors and engine parameters is also recommended to catch any issues early.
Maintenance intervals may need to be adjusted for an E85-converted Focus ST. The fuel’s cleaning properties can dislodge debris in the fuel system, potentially clogging filters more frequently. Owners should replace fuel filters more often and keep an eye on fuel pump health, as the increased demand can shorten its lifespan. Additionally, the higher combustion temperatures associated with E85 may accelerate wear on spark plugs and other ignition components, requiring earlier replacements.
Lastly, cold-start issues are a common concern with E85 due to its lower volatility. In colder climates, starting the engine may become more difficult, and there’s a risk of stalling or rough idling until the engine warms up. Installing a flex-fuel sensor and a tune that adjusts for temperature can help mitigate these issues. Owners should also consider keeping a small amount of gasoline in the tank during winter months to aid in cold starts. Proper planning and proactive maintenance are key to successfully running E85 in a Focus ST while minimizing risks.
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Frequently asked questions
Running E85 in a Focus ST without an auxiliary fuel kit is not recommended, as the stock fuel system is not designed to handle the higher fuel demand and ethanol content of E85, which can lead to poor performance, misfires, or engine damage.
An auxiliary fuel kit upgrades the fuel system to handle E85 by adding higher-flow fuel pumps, injectors, and sometimes a flex-fuel sensor, ensuring proper fuel delivery and tuning for optimal performance and reliability.
Yes, tuning is essential when using an auxiliary fuel kit with E85 in a Focus ST. Proper tuning ensures the engine can adjust to the different fuel properties, optimize performance, and prevent issues like knocking or lean conditions.


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