e85 ethanol Conversion


A. This is a frequent question that is asked. There is not a simple answer though. In the strictest sense, yes, a vehicle that was made to operate on unleaded fuel only could be converted to operate on E85 ethanol. Realistically speaking, the conversion can be extremely difficult.
During the 80’s and early 90’s, many companies were formed that altered gasoline powered vehicles to use other forms of fuels such as propane, compressed natural gas, e85, and 85 percent methanol. The basic marketing strategy of these conversion companies was based on the idea that it was much cheaper to operate a vehicle on alternative fuels. However, the vehicles being converted were made, designed and built to operate on unleaded fuel only. Shortly after the start of the "conversion firms" the US Environmental Protection Agency (EPA) decided that when converted from gas to another form of fuel, the exhaust emissions from these converted vehicles were often much dirtier than prior to the conversion. The use of alt-fuels in the transportation sector has been engineered around the objectives of using cleaner, non-gasoline based fuels.

Based on authority provided to the EPA through the Clean Air Act Amendments of 1990, the EPA began regulations that required exhaust emissions from vehicles converted to operate on alternative fuels be as clean as the exhaust emissions of the original gasoline equipment. That is, if Ford Motor Company built a car to meet federal emissions standards on gas, a company converting that vehicle to operate on e85, must be able to certify that the emissions from the converted vehicle was as clean as the original. A process to license such after-market equipment was initiated and few if any conversion kits were actually able to pass.

99.9 percent of all the vehicles that are able to operate on alternative transportation fuels are produced by the original manufacturers such as Ford, General Motors, and DaimlerChrysler. Engineers from these auto companies are able to create vehicles that meet the EPA exhaust emission standards. These automobile companies are required to warranty the exhaust emissions from these vehicles for 10 years or 100,000 miles. Very few conversion companies
are able to accomplish.


A. Yes, but, there are no flex fuel conversions or after-market parts that have been certified by the EPA. None of the flex fuel products have met the standards to maintain clean exhaust emissions. Technically, converting a vehicle that was made to run on gasoline only to operate on another form of fuel is a violation of federal law and the offender may be subject to penalties. Unfortunately, no after-market conversion company has been able to certify a E85 flex fuel kit that would allow a gasoline vehicle to operate on e85.

The differences in fuel injector size, air-fuel ratio, PCM calibrations, material composition of the fuel lines, pumps and tanks are just a some of the components that contribute to allowing an ethanol conversion extremely complicated. It is our understanding that at least one company is working to obtain EPA certification. The situation will be monitored closely. Understand the certification process could be lenghty, hard and expensive.

5 thoughts to “e85 ethanol Conversion”

  1. In your answer to the question about converting a vehicle to run on ethanol, You stated “there are no conversions or after-market parts that have been certified by the EPA”. I am a distributor for the Ethanol Injection System made by Intelligent Ethanol Systems in Ohio. We have recently received EPA approval for OBD-II testing on our conversion kit. A copy of the EPA letter and information about our conversion kit can be viewed at [link removed…]

  2. Please don’t confuse people. Your system is not EPA approved. Just the first step for one particular make and model of car…
    Verbatim copy of email from EPA to Mr. John Pruett 10-19-06

    Source: National Ethanol Vehicle Coalition
    Mr. Lampert asked for clarification about EPA’s OBD approval letter recently issued to you and signed by Ted Trimble of EPA. Ted is the EPA lead on issuing OBD approval letters when a manufacturer (in your case an aftermarket alternative fuels converter) is requesting a Federal OBD approval. If the manufacturer wishes to sell their product in California, the manufacturer must satisfy the California Air Resources Board (CARB) OBD requirements. When CARB is satisfied, the approval letter is issued by CARB. An OBD approval letter issued by CARB fully satisfies EPA requirements.

    OBD approval letters are issued on a combined Test Group basis as a function of manufacturer and model year. The words “combined Test Group” are important because although EPA Certificates of Conformity are issued on a specific manufacturer, model year, and test group basis, for purposes of OBD approval, manufacturers are allowed to combine multiple test groups and receive EPA or CARB approval. The alternative fuel converter could also receive an OBD approval letter for multiple test groups if the OEM sought such EPA or CARB approval. Typically, a large volume OEM may have as many as 50 test groups for a given model year but possibly only about 10 OBD groups.

    The OBD approval letter you have from Ted is applicable to a specific test group, a specific manufacturer, and a specific model year. The approval letter does not apply to other vehicles in other model years.

    An OBD approval letter is an important part in the application for certification, but is not a substitute for the Certificate of Conformity which is issued when EPA approves the application for certification. To date we have not received an application for certification from Intelligent Ethanol Systems.

    Source: National Ethanol Vehicle Coalition

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