Converting 06 Gto Fuel System To E85

The Pontiac GTO is a car that can be modified to run on E85 fuel. E85 is a type of fuel that is a blend of 85% ethanol and 15% gasoline, and it has a higher octane rating than regular gasoline, which can lead to increased engine performance. To convert a 2004-2006 Pontiac GTO to run on E85, several modifications are typically required, including:

- Installing a flex fuel sensor or kit: This allows the car to detect the ethanol content in the fuel and adjust the engine tuning accordingly.

- Upgrading the fuel injectors: Larger injectors, such as 36-40 pound injectors, may be needed to deliver the increased fuel flow required for E85.

- Upgrading the fuel pump: A high-flow fuel pump, such as the DW300 or DW265, may be necessary to ensure adequate fuel delivery.

- Tuning the engine: A professional tuner can adjust the engine's fuel and timing maps to optimize performance and fuel efficiency when using E85.

- Ensuring fuel system compatibility: Some fuel system components, such as rubber hoses and o-rings, may need to be replaced with ethanol-compatible materials to prevent damage or leaks.

It is also recommended to drain the E85 fuel from the tank before extended periods of storage, such as during winter, to avoid potential issues with cold-weather starting.

Flex fuel sensor installation

The flex fuel sensor is a vital component of the fuel system, as it measures the ethanol content in the fuel and sends this data to the ECU, which then adjusts the ignition timing, fuel injection, and boost levels accordingly. This is important because the ethanol content in E85 fuel can vary, and so having a flex fuel sensor ensures that the engine is always safe and maximizes power.

When installing a flex fuel sensor, it is important to consider the placement of the sensor. Traditionally, the sensor is placed on the feed line of the fuel system, which is the line going into the engine or the pressure side. This allows for consistent sampling of real fuel to pass through the sensor for an accurate reading. However, some tuners also place the sensor in the return line, although this is debated as it can cause read errors and sensor bypass.

Another important consideration is the wiring of the flex fuel sensor. These sensors are 5v reference types, which means they use a sensor power, a sensor ground, and a signal wire that sends data back to the ECU. It is important to note that the sensor power and sensor ground wires must be supplied from the ECU, as noise and incorrect signals from power and ground outside of the ECU can create an unreliable signal and false data.

When installing a flex fuel sensor, it is also important to follow the instructions specific to your vehicle's year, make, and model. For example, for a 2004 GTO, you would need to pin in and plumb a flex fuel sensor, and then adjust the tuning accordingly. Additionally, it is recommended to use better clamps during installation, as some users have reported that the supplied clamps can fail.

Finally, when switching to E85 fuel, it is important to consider the compatibility of your fuel system components, such as fuel lines, tank, rails, etc. While some users have reported no issues running E85 on stock components, others have recommended upgrading to larger injectors and a high-flow fuel pump to accommodate the higher flow rate required for E85.

Injector and fuel pump selection

When changing the fuel system of a 2006 GTO to E85, selecting the right injectors and fuel pump is critical. The stock injectors may not be sufficient for E85, and a fuel pump upgrade may be necessary, especially if the vehicle has a lot of modifications.

For a stock 2006 GTO, the factory fuel injectors may be adequate for E85. However, if the vehicle has a cam upgrade or other modifications, larger injectors are typically required. Ford Cobra injectors are often recommended for E85 conversions. It is also important to ensure that the fuel pump can deliver enough volume to match the flow rate of the injectors.

When selecting injectors, it is essential to consider the estimated horsepower of the engine and the type of induction system. There are online injector calculators available that can help determine the appropriate injector size based on these factors. It is also crucial to choose injectors that are compatible with E85 fuel, as some injectors may not be designed for ethanol blends.

In addition to injector selection, a fuel pump upgrade may be necessary, especially for vehicles with extensive modifications. The stock fuel pump may not be able to keep up with the increased flow rate of the larger injectors. When choosing a fuel pump, consider the flow rate, pressure, and compatibility with E85 fuel. Some fuel pumps may not be designed for ethanol blends and could experience issues over time.

It is always a good idea to consult with a professional or a reputable tuning company that has experience with E85 conversions. They can provide specific recommendations for injector and fuel pump selections based on your vehicle's modifications and performance goals.

Fuel line compatibility

The fuel lines in the 2004-2006 Pontiac GTO are compatible with E85 fuel. The factory fuel lines are made of rubber and are designed to withstand the ethanol content in E85 without issue. There is no need to replace the factory fuel lines when converting your GTO to run on E85.

However, it is important to note that some aftermarket fuel lines may not be compatible with E85. If you have installed aftermarket fuel lines, it is crucial to verify their compatibility with E85 before filling your tank with this fuel. Using incompatible fuel lines can lead to leaks, damage, and unsafe conditions. Always consult a trusted mechanic or the manufacturer of the aftermarket parts to ensure compatibility.

In addition to fuel lines, it is essential to consider the compatibility of other fuel system components when converting to E85. The fuel tank, fuel rails, and injectors in the GTO are made of steel and are compatible with E85. However, some other components, such as the fuel pump and seals, may need to be upgraded to ensure reliable operation with E85.

When converting your GTO to E85, it is recommended to use high-quality, E85-compatible fuel system components to ensure optimal performance and longevity. Upgrading the fuel pump to a high-flow, E85-compatible unit can enhance fuel delivery and support the increased fuel demands of modified engines. Additionally, ensuring that all seals, gaskets, and O-rings are compatible with ethanol-blended fuels is crucial to prevent leaks and damage.

It is also worth noting that while E85 is generally safe for the GTO's fuel system, there are some considerations to keep in mind. The ethanol content in E85 can vary by season, and using E85 with lower ethanol content may require adjustments to your tune. Additionally, E85 has a lower energy density than gasoline, resulting in reduced fuel mileage. Finally, E85 can be more challenging to start in cold weather, so taking precautions during winter storage is recommended.

Fuel tuning

Tuning your fuel system to run on E85 is a great way to increase the performance of your 2006 Pontiac GTO. Here is a detailed and instructive guide on how to do it:

Fuel System Components

First, you will need to upgrade your fuel system components to handle the higher flow rate and pressure required for E85 fuel. This includes:

• Fuel injectors: You will need larger fuel injectors, such as LS3 injectors, to supply the engine with enough fuel. Injector size will depend on your specific setup, but generally, you will need injectors in the 36-40 pound range or higher for boosted applications.
• Fuel pump: A high-flow fuel pump, such as the DW300, is necessary to deliver sufficient fuel to the injectors.
• Fuel lines: It is important to ensure that your fuel lines are compatible with ethanol-based fuels. Stainless steel or rubber lines are recommended.
• Fuel regulator: An adjustable fuel regulator, such as the Aeromotive fuel regulator, will allow you to fine-tune the fuel pressure for optimal performance.

Tuning the Engine Management System

To run E85 fuel, you will need to modify your engine management system. This typically involves installing a flex fuel sensor and tuning the system for E85. Here are the steps:

• Install a flex fuel sensor: The flex fuel sensor will monitor the ethanol content in the fuel and provide this information to the engine management system. You can purchase a flex fuel kit, such as the DSX Tuning flex fuel kit, which includes the sensor and all the necessary fittings. The installation process involves disconnecting the fuel line at the fuel rail, installing the sensor, and reconnecting the fuel line to the new setup.
• Tune for E85: Once the flex fuel sensor is installed, you will need to tune your engine management system specifically for E85 fuel. This can be done using a handheld tuner, such as HP Tuners, or by consulting a professional tuner. The tuner will adjust the fuel and timing maps to optimize the engine's performance on E85.

Maintenance and Storage

When running your GTO on E85, there are a few things to keep in mind:

• Fuel mileage: While E85 has a higher octane rating and can provide performance gains, it may result in slightly lower fuel mileage. However, this is often offset by the lower cost of E85 fuel.
• Winter storage: It is recommended to drain the E85 fuel from your tank before long-term storage during winter. E85 can absorb water over time, which can lead to potential issues with starting and fuel system components.

By following these steps and working with a professional tuner, you can safely and effectively tune your 2006 GTO's fuel system to run on E85, unlocking the potential for increased performance and a more exciting driving experience.

Cold weather considerations

When switching your 2006 GTO's fuel system to E85, there are a few cold weather considerations to keep in mind. Firstly, E85 is not as cold-start friendly as gasoline. This is because ethanol is an effective coolant and has a higher volatility (vapor pressure) than gasoline. As a result, it requires more energy to vaporize, which can make cold starts more challenging. However, this issue can be mitigated by ensuring you have some gasoline mixed with E85 in your vehicle, even during winter. Flex fuel producers also offer a winter blend with a lower ethanol content, which can improve cold starts.

To ensure smooth cold starts with E85 during winter, consider parking your vehicle in a garage, as it provides a warmer environment. Additionally, you can use an engine block heater, which helps to heat the engine before a cold start. It is also a good idea to maintain your engine by checking and replacing spark plugs and ignition components as needed before the winter season.

It is worth noting that modern fuel injectors and OEM fuel systems are designed to handle some ethanol content. Aftermarket fuel injectors are also typically compatible with E85. However, it is always a good idea to consult with a professional and ensure your vehicle is equipped for E85 usage.

Overall, while there may be some challenges with cold starts when using E85, these issues can be managed through proper maintenance, fuel blending, and the use of engine block heaters or parking in a garage during colder months.

Frequently asked questions