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2G 450 whp and e85

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jmonterful

Proven Member
56
1
Aug 25, 2015
grand island, Nebraska
Okay, is my firts post guys so idk if i'm posting this in a wrong side but hopefully someone would give me an answer. I have a 95 talon tsi with a 6 bolt swap. Has an upgraded 20g turbo, mount intercooler, 680cc injectors, stock fuel system, i:m about to buy dsmlink v3, i left the fuel system alon because i want to do a e85 conversion and i want to know what i will need. Also my goal is to be around 450 whp what else do you guys suggest me to get there? Also at 450 hp will the motor or tranny be at risk? i want it to be kind of reliable so i'm not sure. I've never taken it to the dyno so idk what it will make rn.
 

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If I was to convert my fuel system to 100% ethanol, I would convert everything. First you'll need a pump that specific for multi fuel use. I picked up a AEM 320LPH multi fuel pump, it'll do E85, E100, methanol, alcohol etc. I would change all my lines to some heavy duty braided AN stuff. Then you'll need a fuel filter that's good with E85 like a fuel lab with a stainless steel element.

Look into a AFPR too. Extreme Psi had a fuel lab regulator, with hose and a fuel rail adapter in a nice little kit. I've set mine once and never messed with it since, but sure is nice to have for future uses. And you'll need some pretty serious injectors too, atleast 1000cc. My personal preference is I want 2x the injector I'll need for pump gas if I'll run ethanol
 
Pretty much what he said. A good place to check out is both Extreme PSI and RTM Racing. E85 isn't big around my way which is way I haven't done it. Injectors were a deal killer for me at the time as well. (I recommend FIC.). But plan on the AFPR, filter, pump, and lines as stated previously. Some recommend upgrading the fuel rail, but I wouldn't think it's necessary. Are you looking at going full e85 all the time or running pump gas on occasions? Dual-mapping? DSM Link is a wise investment regardless.
 
With link you can also have a nifty little sensor that lives down in your tank that can detect what fuel your running and change the map accordingly. Definitely NY far the group favorite tuning option.

In regards to your drive train there's really so many variables to take into account. It's not just your trans, but tcase, drive lines, and clutch assembly too. Hopefully the previous owner was meticulous with their maintenance, and service intervals. You'll need a good clutch that will hold the extra power, and adjusted properly to not have any clutch drag issues. I would run some redline heavy weight shockproof in your diff and tcase, and OEM diaqueen in the tranny.

And it comes down to you and your driving habits that will decide how reliable the drivetrain will be
 
I did the E85 swap about a year ago. Here is/was my shopping list:

I assume you already have ecmlink...
AEM 320 E85 fuel pump
Andonized on the inside fuel rail
1000cc+ injectors, I swapped out my 1050s for 1250s to be safe, targeting 500awhp
GM flex fuel sensor (need to go speed density to run this IIRC, so add SD parts...)
Teflon fuel lines tank to rail
AFPR
SS fuel filter (no paper filters here)

I think that is all unless I forgot something. I love E85. I cry when the super cold weather forces me to add pump gas because it will take forever to cold start in <20 degree temps.
 
Don't think you have to change everything to run E85. Getting a larger pump is neccesary but I run the Walbro 255 LHP with an inline Tsunami, been running E85 at 580 awhp with no problems. I still have stock lines and a stock fuel. You can run a fuel filter with a steel filter element but people run with the paper. AFPR is a must since your upgrading you fuel pump so find one in the classified section and same money there.

Injectors I would recommend the FIC Blue series and get some 1150/1250's since you will have extra room with ECMLink. The flex fuel sensor is nice since the ethanol percentage switches quite often between fill ups, get the plug and play wire at ECMLink. You can mount the sensor on your return line which would take five minutes to install.
 
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This is not recommend but all I did was fill up with e85 and tuned for it. At the time was running 1000cc injectors and a walbro 255. I used the stock paper filter, and simply replace it every few months. Stock feed and return lines. Has been about year and half and dont see any problems yet, though the injectors and fuel pump have been upgraded bigger.
 
Wow! I didnt think i was gonna get this much help so quickly. Awesome! Well i would like to use pump gas occasionally but is not a big deal if i have to go 100% ethanol. What u guys think is better? & the trany, motor, and head were all redone not so long ago, so they should be in pretty good condition. Assuming everything is good i should be safe around 400-450 hp right? Thank you guys btw
 
Like others said, assuming that you already have ECMLink.
Minimum setup for 450whp(ish) on E85:
-255lph pump;
-1000cc injectors;
-Stainless Steel filter;
-AFPR due the pump;

Recomendend setup:
-320lph pump;
-1150cc or 1200cc injectors;
-Stainless Steel filter;
-AFPR;
- -6AN fuel lines;

If you like to add more, can consider an aftermarket Fuel Rail, and that's it.

Good luck and post results after the conversion!
 
Awesome! Well i would like to use pump gas occasionally but is not a big deal if i have to go 100% ethanol.

That's what ECMlink is for when you add the flex fuel sensor and tune for "E85". It will interpolate between the two fuels (93oct, E85) as long as its tuned to do so. Also, unless you are getting it shipped to your house, or have a racetrack nearby, I doubt you will find 100% ethanol anywhere. My findings are 75-80% in the summer, 65-75% in the winter. The sensor has margin of error of +- 5%, but its consistent.

Or you could just tune for each fuel directly and switch maps, but that could be a PITA when you do switch especially when ethanol % changes.

A lot of mis-information about E85 posted daily but it's proven, not just in DSMs, but EVOs, Subarus, etc that E85 does not require aftermarket lines or even aftermarket fuel filters. I'll make it simple: Wally 255 or better, 1000cc injectors or better, Adjustable FPR, and a great tune.

Like I said, my route was overkill. Normal gas has ~10% ethanol anyway. But if you consider what the "unnecessary" stuff costs (lines/rail/filter = ~$200-300), compared to what a clogged fuel injector during WOT costs, I would say the former is much cheaper.

Also, there is a thread on here about e85 goo, and although new lines may not entirely prevent it, they help. Also, adding an easy to clean/change fuel filter is helpful. And, there is a thread on link forums about aluminum parts that are not coated/andonized such as the oem fuel rail getting an oxidation/scale buildup that could potentially clog an injector. Again, a gamble I am not willing to take personally, but others are just fine with.
 
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I agree with the above statement. If I'm getting into my fuel system, just do it all once. I'm barely trusting my 25 year old OEM lines with pump 91. And I want to be covered if I run any kind of fuel, E100, alcohol, methanol, who knows maybe some mix with jp4, or even dump in some toluene :rocks:.
 
Have you considered staying on premium? The stock 6 bolt is a 7.8:1 compression ratio which is very low. If i was you and just wanted 450whp i'd run premium and a methanol injection kit. Depending on where you live E85 can be really hard to get. Just an option
 
I like the way you think ,it's always faster and cheaper in the long run to do it right the first time than to do it over again when it fails because you cut a corner.
 
I wouldn't say it is cutting a corner, I would say it is building for a power goal. If your going to build it all out for a 450 awhp goal it is a waste to be honest. It would be the same as saying your building a block to handle 1000 hp for a power goal of 450 hp. Not saying that is wrong but you will spend three times the money on it to achieve the exact same goal. There is a different in building a car for a certain goal and cheaply building a car.
 
I wouldn't say it is cutting a corner, I would say it is building for a power goal. If your going to build it all out for a 450 awhp goal it is a waste to be honest. It would be the same as saying your building a block to handle 1000 hp for a power goal of 450 hp. Not saying that is wrong but you will spend three times the money on it to achieve the exact same goal. There is a different in building a car for a certain goal and cheaply building a car.
Oh so like my car LOL
I plan on running e85 soon but still ordering parts.
I plan on 450-500 hp but it could handel more
Almost 10k in my motor so yah its all over built just for ease of mind or one day i get a bigger turbo LOL
What's youre budget going to be?
 
Have you considered staying on premium? The stock 6 bolt is a 7.8:1 compression ratio which is very low. If i was you and just wanted 450whp i'd run premium and a methanol injection kit. Depending on where you live E85 can be really hard to get. Just an option
I live in the cornland, nebraska! LOL... So it is very easy to get e85 here
 
Oh that is so nice! I wish more gas stations had it where i'm from.

It depends completely on who you have tune it and what they use/ if you want to keep the tuner so you can change it in the future.
 
I live in the cornland, nebraska! LOL... So it is very easy to get e85 here

Lucky you!! We have two gas stations that carry e85 within like a 100 mile radius where I live. I was going to run e85, but once I thought about I just decided to run 93 w/Meth. Just couldn't get over that hurdle of not being able to just stop at any gas station and gas up. Good luck with your project.
 
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