E85 Retrofit Project: Installation: Getting Started with the FuelFlex E85 Conversion Kit

by Joanne Ivancic (Advanced Biofuels USA) Fourth in an original Advanced Biofuels USA series about retrofitting a 2002 Ford Focus to use E85 --- As excited and optimistic as we were to get this project underway, we didn't want to do anything harmful to the car or engine--intentionally or by accident. So when what was under the hood was a bit different from what was expected; I calmly fought lurking disappointment and Bob Kozak, who was doing the installation, calmly analyzed the situation.

Essentially, the kit has two elements: the upgrade system's control box and the upgrade systems injector connectors.

They come all connected together along with an instruction booklet and FuelFlex decal.

Basically, you install the upgrade system into the electrical circuit between the vehicle's injector wires and the injector.

The messages to the onboard computer just take a quick detour through the upgrade system that helps it recognize the higher levels of ethanol that it had not previously been programmed to see so that it can give proper instructions to the engine on how to use the higher octane, higher ethanol fuel. I think of it as learning to digest a healthier diet.

Keeping wires protected from serving as lunch for squirrels (although I'm not sure that was the primary intent), Ford had installed a nice plastic box or housing that kept injector connectors and their wires organized, but which left no room for the retrofit.

Afraid of disassembling the nice plastic box without talking to someone who had done it before, Kozak emailed, Alex Conger at Fuel Flex International, the producer of the E85 retrofit kit, for a consult. They talked about the problem, then Conger consulted others who had done installations. He got back with advice that the box could be taken apart and removed without any harm to the system. That allowed the installation to go forward.

I was relieved. We had been promoting understanding, development and use of advanced biofuels for so long, and I wanted to be able to use more renewable fuel for my transportation. My hopes revived.

A bit of an emotional roller coaster here. Excited to get started, disappointed that it wasn't going to be as quick and easy as hoped, wondering if we'd even be able to do the retrofit or if we might have to return the kit, unused; then relief and excitement again to confidently resume taking things apart and putting them back together.

Kozak and I have enough experience working on old houses to know that any project takes twice as long as expected and takes at least a few unplanned trips to the hardware store. Working on an old car is apparently no different. Having Conger and his team available to answer questions was crucial to our continuing the installation.

Also, it became apparent that due to Ford's efficient use of space, finding room for the control box would also take some doing.

So, another slight delay ensued trying to find just the right place for the upgrade system's control box.

It reminded me of Goldilocks and the Three Bears, with Goldilocks looking for just the right place to rest: not too hard, not too soft; not in the way of something else, easy to take off if repairs to other parts of the car are needed; looking for a place that was just right. The videos show Kozak checking a variety of options and settling on the one that was just right.

Once the entire system was installed, Kozak gingerly started the engine. He and I were confident that he'd followed the instructions properly, but were still aware that unpleasant surprises are not impossible.

All went well. No "check engine" light, no scary noises. The onboard computer and the new system were getting to know each other, so there were some rumblings, but they were understandable and expected.

For my part, I'll focus on the more personal aspects. Excitement of the first ride with high performance high octane high ethanol blend fuel. Anger on the Pennsylvania Turnpike where not only was the E85 much more expensive than regular; but you have to stand in line at the cashier before being permitted to purchase it. Fun ways that stations avoid potential misfueling. The thrill of putting the Fuel Flex insignia on the bumper. And stories of the people who make this possible.