Mercedes Mullins
Flex-fuel vehicles are those that have internal combustion engines designed to run on more than one type of fuel. They can use any combination of gasoline and ethanol, whether it's 100% unleaded gas or 85% ethanol. Ethanol is a renewable and domestically produced alternative fuel that is gasoline blended with ethanol. It is produced from plant biomass like corn, which absorbs carbon dioxide from the atmosphere as it grows, resulting in reduced lifecycle emissions compared to fossil fuels. To convert your engine to flex fuel, you will need an electronic control module and a fuel sensor that detects the ethanol-gasoline ratio.
| Characteristics | Values |
|---|---|
| What is flex fuel? | A combination of gasoline and methanol or ethanol. |
| What is E85? | A blend of 51-85% ethanol and the rest gasoline, depending on the season and region. |
| What is FFV? | Flexible Fuel Vehicle. |
| What are the benefits of flex fuel? | Reduced harmful emissions, cheaper, better performance, and reduced reliance on foreign oil. |
| What are the drawbacks of flex fuel? | Not as efficient, can damage older vehicles, and is not as widely available. |
| How to make a car flex fuel? | Install a conversion kit, which includes an electronic control module and a fuel sensor. |
| What else to keep in mind? | Flex fuel is harsher on vehicles and can dry out fuel lines and other parts. It also gets poorer mileage. |
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What You'll Learn
Injector pulse width
The injector pulse width determines the time a fuel injector is held open, allowing fuel to flow through it. In flex-fuel vehicles, the injector pulse width is wider than in traditional gasoline engines, allowing up to 40% more liquid fuel into the fuel-air mixture. This adjustment is necessary to compensate for the lower energy content of ethanol and ensure the engine receives an adequate amount of fuel.
When converting a vehicle to flex-fuel, it is essential to consider the injector size and its impact on pulse width. As injector size increases, the injectors are operated further into the nonlinear zone, making fuel delivery less accurate. Therefore, careful selection of injector size is crucial to achieving the desired fuel flow rates.
Additionally, the dead time of the injector, or the lag between the pulse and the start of fuel flow, becomes more significant at very low pulse widths, such as during idle and light throttle operation. Providing accurate injector data to the on-board computer is essential for optimal engine performance.
Overall, understanding injector pulse width and its interaction with injector size and dead time is vital when converting a car to flex-fuel. By making the necessary adjustments, you can ensure your vehicle runs smoothly and efficiently on a range of ethanol blends.
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Ethanol-related problems
One of the main concerns with ethanol is its impact on engine performance. Ethanol has 25% less energy than gasoline, requiring a larger volume to produce the same energy output as gasoline. This can lead to a "lean" fuel-air mixture, with too much air and not enough fuel, resulting in rough engine operation and potential damage over time. To address this issue, flex fuel vehicles have a wider range of injector pulse width, allowing up to 40% more liquid fuel into the fuel-air mixture.
Another issue with ethanol is its tendency to absorb dirt, which can potentially corrode and damage the engine. This is a concern for flex-fuel vehicles as ethanol blends can increase the likelihood of dirt entering the engine. Additionally, ethanol is susceptible to evaporation, particularly at higher temperatures, which can impact the performance of flex-fuel vehicles in warmer climates.
Ethanol-related issues also extend to cold weather conditions. At temperatures below 11°C (52°F), the upper limit of ethanol content in fuel blends is typically reduced to E70 or E75 to avoid cold-starting problems. In regions with extremely low temperatures, such as below -15°C (5°F), flex-fuel vehicles may require an engine block heater or the addition of more pure gasoline to the tank to prevent engine issues.
Furthermore, the production of ethanol from crops like corn and sugar can impact food prices. The dedication of crops to fuel production reduces their availability for other purposes, potentially driving up the cost of animal feed and affecting the economy of regions dependent on crop exports.
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Electronic control module
The Electronic Control Module (ECM) is a crucial component in converting a traditional fuel car to a flex-fuel vehicle. The ECM is an electronic module that is installed in the vehicle's engine compartment. It serves as the brain of the flex-fuel system, controlling and monitoring various aspects of the vehicle's performance and operation.
In a flex-fuel vehicle, the ECM is responsible for managing the fuel mixture, ignition timing, and emissions system. It ensures that the correct amount of fuel is injected into the engine, taking into account the type of fuel being used, such as ethanol or gasoline. The ECM adjusts the fuel flow based on the ethanol content in the fuel, as higher ethanol concentrations require increased fuel flow. This adjustment is made possible through the use of a fuel sensor that detects the ethanol-gasoline ratio and communicates this information to the ECM.
Additionally, the ECM plays a vital role in safeguarding the engine from potential abuse. It monitors the operation of the vehicle and detects any problems or abnormalities, allowing for timely troubleshooting. This protective function helps to maintain the engine's performance and longevity.
The installation of the ECM is typically done by plugging it in between the fuel injectors and the factory fuel injector electrical connectors. It is important to note that the ECM should be compatible with the specific make, model, and year of the vehicle. There are various companies that manufacture ECMs, and they can often be purchased online.
It is worth mentioning that while the ECM is a critical component, it is not the only modification required to convert a car to flex-fuel. Depending on the vehicle's age and existing fuel system, additional changes may be necessary. For example, older vehicles might need to replace the fuel pump, fuel tank, fuel injectors, or modify fuel lines to prevent corrosion and damage caused by ethanol.
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Fuel sensor
Modern flex-fuel vehicles are equipped with electronic sensors that can detect the blend of fuel and make the necessary adjustments. These sensors are an essential component of the flex-fuel system, allowing the vehicle to run on various combinations of gasoline and ethanol.
The flex fuel sensor is traditionally placed on the feed line of a fuel system, which is the line going into the engine or the pressure side. This placement ensures that consistent sampling of real fuel passes through the sensor for an accurate reading of the fuel mixture. The sensor measures the amount of alcohol (ethanol) in the fuel by sending a pre-calibrated signal in the form of a 0-5v voltage, indicating the amount of alcohol present. The ECU (Electronic Control Unit) then interprets this voltage to determine the corresponding ethanol content using standard calibration data.
The flex fuel sensor is connected to the electronic control module, which uses the sensor data to regulate fuel flow based on the ethanol content. Ethanol has 25% less energy than gasoline, so a higher ethanol content requires a higher fuel flow to maintain the same energy output. This adjustment in fuel flow is achieved by varying the injector pulse width, which refers to the time a fuel injector is held open to allow fuel to flow through.
It is important to note that not all vehicles can be easily converted to flex fuel. While newer vehicles, especially those manufactured after 1995, may only require an electronic control module and a fuel sensor, older vehicles may need more extensive modifications. These modifications can include changing the fuel pump, fuel tank, fuel injectors, and steel and rubber fuel lines, as older fuel systems using steel or cork gaskets may be susceptible to corrosion and damage from long-term exposure to ethanol and water.
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E85 conversion kits
ZZPerformance also offers an E85 conversion kit that connects inline with your fuel line. It constantly monitors the fuel's ethanol percentage and reports it to the ECM. This kit is designed to work with specific car models, including the 2013-2020 ATS/CTS/Camaro 2.0-liter LTG models. It allows you to run any mix of E85 and premium gasoline, with the PCM adjusting the fueling, timing, and boost accordingly.
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Frequently asked questions
Flex fuel is a blend of ethanol and gasoline. It is designed for specific vehicles that can run on more than one type of fuel.
E85 is the official name for flex fuel. It contains between 51% and 85% ethanol, depending on the season and region.
Flex fuel is a renewable and environmentally-friendly alternative to gasoline. It is also generally cheaper than regular gas.
You can convert your car to flex fuel by purchasing a conversion kit and installing it. You may also need to make some mechanical changes to your vehicle, such as installing an electronic control module and a fuel sensor.
