Regan Brown
The COBB Tuning Flex Fuel Kit for the Subaru WRX is a highly anticipated performance upgrade that can add over 50 hp and 80 tq to the vehicle. The kit includes a CAN Gateway Flex Fuel Upgrade that allows for seamless integration of flex fuel and true plug-and-play installation. The use of E85 fuel, an ethanol-based blend, is a key component of the flex fuel system, offering a cheap and powerful source of race gas. However, E85 fuel also has lower energy content, impacting fuel consumption and requiring 30-35% more volume than regular gasoline. To accommodate this, upgrades to the fuel pump and fuel injectors may be necessary to ensure the vehicle can support the increased fuel flow. With proper tuning and adjustments, the flex fuel kit for the Subaru WRX can unlock significant performance enhancements.
| Characteristics | Values |
|---|---|
| Flex Fuel Kit | COBB Tuning, eFlexPlus, eFlexPro |
| Flex Fuel Kit Installation Time | 2-3 hours by an experienced mechanic; double the time for first-time DIY installation |
| Flex Fuel Kit Installation Requirements | Removal of the car's Radio/Cockpit Control Unit |
| Fuel Pressure Sensor Kit | REQUIRED for COBB Stage 1+ Flex Fuel OTS Maps |
| Fuel Pump and Injector Upgrade Requirements | Fuel pumps and injectors may need to be upgraded if they're maxed out |
| Fuel Consumption | E85 contains less energy than regular gasoline, resulting in higher fuel consumption |
| Ethanol Content | E85 is 85% ethanol and 15% gasoline |
| Ethanol Sensor Kit | Cobb Tuning, included in the COBB CAN Gateway Flex Fuel Upgrade |
| ECU Compatibility | Ethanol sensor kits interface with the car's ECU to adjust for ethanol content |
| Power Increase | Up to 20% boost in horsepower, over 50 hp and 80tq increase |
| Torque Increase | 49.55 lb-ft of torque increase, over 50 lb-ft and 80tq increase |
| Fuel Flexibility | Flex fuel kits allow for the use of E85, gasoline, or a mixture of both |
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$294.59 $333.32
What You'll Learn
COBB Tuning Flex Fuel Kit
The COBB Tuning Flex Fuel Kit is a highly anticipated performance upgrade for the 2022+ Subaru WRX. The kit allows for seamless integration of flex fuel, enabling users to take advantage of the power potential of E85 fuel. With the COBB CAN Gateway Flex Fuel Upgrade, users can add over 50hp and 80tq to their WRX. The kit offers true plug-and-play installation, making it easy for users to upgrade their vehicles.
The COBB CAN Gateway is constructed of billet aluminum and houses a precision-manufactured PCB. It includes a bracket that allows for a straightforward bolt-in installation on supported cars. The kit also comes with a vehicle-specific wiring harness, which varies depending on the market and whether the car is left-hand or right-hand drive.
The COBB Tuning Flex Fuel Kit provides a means for aftermarket sensor data to be injected into the car's CAN system and utilized by the ECU. This allows for either a COBB Off The Shelf Map or custom calibration. The kit is designed to work with both USDM and ADM vehicles, as well as Right Hand Drive vehicles for the Australian market.
In addition to the flex fuel kit, COBB Tuning also offers a Fuel Pressure Sensor Kit, which is required when using COBB Stage 1+ Flex Fuel OTS Maps. This kit includes a fuel pressure sensor, a bespoke quick-disconnect billet adapter, and a wiring harness for plug-and-play installation with the COBB CAN Gateway.
For those with a 2018 WRX and the Stage 2 NexGen package, COBB Tuning intends to offer a CARB-approved flex fuel kit in the future. However, there is currently no ETA for its release. It's important to note that the current flex fuel components and calibrations are not available for use in California as they do not have a CARB EO.
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ECU and ethanol sensor
The COBB CAN Gateway Flex Fuel Upgrade is a popular option for adding flex fuel capabilities to the 2022-2025 Subaru WRX. It offers a plug-and-play installation and allows for seamless integration of flex fuel. The included COBB CAN Gateway enables aftermarket sensor data, such as that from an ethanol sensor, to be injected into the car's CAN system and utilised by the ECU. This data is used by an Accessport-based tune to optimise the engine's performance based on the ethanol content.
The ethanol sensor, also known as a flex fuel sensor, plays a crucial role in flex fuel systems. It provides accurate ethanol content data to the ECU, allowing the engine to adjust its performance accordingly. The sensor ensures that the ECU can account for variations in ethanol concentration, preventing issues that may arise from running on fuel with a different composition than expected.
The Velocity Element Flex Fuel sensor kit is another option that offers a complete package for converting engines to run on any blend of ethanol and gasoline, including E85. This kit includes all the necessary parts for a clean and reliable installation, ensuring that the engine can utilise flex fuel capabilities without any additional tuning or switches.
Additionally, Delicious Tuning offers a Flex Fuel Kit that includes a FlexFuel Ethanol Content Analyzer with integrated Bluetooth. This kit is compatible with Cobb Accessport V3 and EcuTek ProECU Software, and it provides ethanol content data to the ECU, allowing for dynamic adjustments to air/fuel ratios, ignition timing, boost levels, and more.
By utilising these flex fuel kits and ethanol sensors, along with ECU integration, WRX owners can safely and effectively take advantage of the power gains offered by flex fuels, typically resulting in an increase of over 50 hp and 80 tq.
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E85 fuel
E85 is an abbreviation for a type of ethanol-blended fuel, consisting of up to 85% ethanol and the remainder being gasoline or other hydrocarbons. The exact ratio of ethanol to gasoline may vary, with the allowable ethanol content ranging from 51% to 85%. The higher ethanol content in E85 compared to standard gasoline blends (which usually contain up to a maximum of 10% ethanol) has several implications.
Firstly, not all cars are compatible with E85 fuel. Flexible-fuel vehicles (FFVs) are designed to accept higher concentrations of ethanol and have sensors to detect the amount of ethanol present. FFVs also have different fuel system materials to prevent corrosion by ethanol, which can damage plastics and metals.
Secondly, E85 has a higher octane rating than regular gasoline, making it suitable for use in higher-compression engines that produce more power. The higher octane rating also makes the fuel more resistant to engine knock, allowing engine tuners to extract more power from FFVs.
The use of E85 fuel can result in increased horsepower and torque. For example, the COBB CAN Gateway Flex Fuel Upgrade for the Subaru WRX claims to add over 50 hp and 80 tq to the vehicle. Similarly, Possum Bourne Motorsport achieved the highest power they had ever seen from a stock WRX engine using E85 fuel with a stock turbo.
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Fuel injectors and fuel pumps
The factory fuel injectors and fuel pump may not be sufficient once you upgrade to a bigger turbo. The stock fuel system in the 2015+ WRX, for instance, uses direct fuel injection, which requires a mechanically-driven fuel pump and high fuel pressures. While the stock fuel system can handle more horsepower than a port-injected car, an upgrade to the fuel injectors and fuel pump may be necessary to achieve higher horsepower goals.
Upgrading to larger fuel injectors, such as the 1050cc units commonly used for street cars, can provide the increased fuel flow required for higher horsepower. Additionally, the use of E85 (85% ethanol) fuel requires even larger injectors, up to 70% larger than those used for gasoline.
Upgrading the fuel pump is also essential to achieving higher horsepower. The AEM 340 lph fuel pump is a popular choice due to its higher flow rate and E85 compatibility. For the 2002-2007 WRX, the fuel pump must be replaced with any turbo upgrade. The 2008+ STI pump can support mild turbo upgrades but may need to be upgraded for more significant modifications.
Aftermarket fuel injectors and fuel pumps are readily available from various manufacturers, including Injector Dynamics, AEM, Nostrum, DeatschWerks, Radium Engineering, COBB, and Walbro. These upgrades can significantly enhance the performance of your WRX, especially when combined with other modifications and flex fuel usage.
COBB offers flex fuel upgrades for the Subaru VB WRX, which can add over 50 hp and 80 tq. This upgrade includes a CAN Gateway that allows for the integration of aftermarket sensor data, providing seamless flex fuel capabilities. The included wiring harness and bolt-in installation make it a straightforward process.
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Ethanol content and tuning
Ethanol, specifically E85 fuel, is a blend of 85% ethanol and 15% gasoline. This high ethanol content has several advantages. Firstly, it increases the oxygen content in the fuel, allowing for a significant horsepower gain. By burning cleaner and running cooler, E85 fuel can enhance engine performance while reducing the need for additional boost. Additionally, ethanol vaporises in the engine, further improving combustion and power output.
Tuning a WRX engine for flex fuel involves installing a flex fuel kit and adjusting the engine's calibration. The flex fuel kit typically includes an ethanol sensor that measures the ethanol content in the fuel. This sensor communicates with the engine's computer, allowing it to adapt to different ethanol concentrations. Tuners create custom maps that enable the engine to run on various fuel blends, from pure gasoline to E85.
The Cobb Flex Fuel Ethanol Sensor Kit is a popular choice for WRX owners. It comes with a billet aluminium converter case, electrical and fuel line connectors, and an ethanol sensor. This kit, combined with Cobb's Accessport and professional tuning services, ensures that the engine can effectively utilise E85 fuel. Other options, such as the Possum Bourne Motorsport Stage 6 package, also offer flex-fuel conversion, allowing the use of both E85 and regular gasoline.
It is important to note that running an ethanol tune without a flex fuel kit can be risky due to varying ethanol contents at different pumps. The ethanol concentration directly impacts the fuel's energy content and the engine's performance. Therefore, it is essential to have a flex fuel sensor that can adapt to these variations and ensure the engine runs smoothly and efficiently.
In conclusion, ethanol content and tuning play a critical role in the performance and reliability of a WRX engine with flex fuel capabilities. By understanding the characteristics of E85 fuel and properly calibrating the engine, WRX owners can unlock the power potential of ethanol while maintaining the longevity and drivability of their vehicles.
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Frequently asked questions
Flex fuel can add over 50 hp to a WRX.
Flex fuel is an ethanol-based fuel blend that is supposed to be 85% ethanol and 15% gasoline.
Flex fuel offers a safe and effective increase in power and torque. It is also cheaper by the gallon than regular pump gas.
Yes, one of the biggest disadvantages of flex fuel is its availability. It is not always available at gas stations and may require some searching.
Depending on your fuel system, you may need to upgrade the fuel pump and fuel injectors if they are maxed out. When running flex fuel, your engine will require 30-35% more fuel.
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