Subaru Flex Fuel Update!

As promised, we have a TON of updates regarding our forthcoming release of Subaru Flex Fuel.  Buckle up, this is a long one!

If you frequent the COBB Blog you’re someone that could always use some more horsepower.  You also have or at least consider modifying your car with different bolt-on parts.  That, along with proper tuning, can yield some nice power gains.  But, there are even easier ways to gain power than bolting on a new part.  Easier gains can be achieved through the use of different fuels. The potential for more power exists through simply increasing the octane content of the fuel feeding your car’s engine. Many take advantage of high octane race gas. While this is good option, it can be very expensive and is often impractical when it comes to refueling. That’s where ethanol comes in.

What the heck is Ethanol?

Ethanol is an alcohol based fuel that is distilled from plants like corn and sugar cane. It is often touted as green and renewable but I’ll leave the eco-consciousness verdict up to you.  One thing it certainly is is a fuel that delivers a higher octane content than pump gas. Technically the octane rating of alcohol cannot be measured.  However, with some solid math and good estimations, pure ethanol is concluded to be over 100 octane.

Most ethanol can be easily obtained in the US in the form of E85.  E85 is a mixture of up to 85% ethanol and 15% [insert hydrocarbon here].  The 85 doesn’t refer to pure ethanol but instead denatured fuel ethanol.  Since ethanol is made using the same process as adult beverages, a mix of 2% hydrocarbons must be added to make denatured fuel ethanol.  This makes it “unsuitable for beverage use under a formula approved by a regulatory agency to prevent the imposition of beverage alcohol tax.”   So essentially, we’re looking at a maximum of 83% ethanol.  The remaining 15 non-ethanol part can be “Unleaded gasoline, gasoline blendstocks for oxygenate blending (BOB), natural gasoline, or other hydrocarbons in the gasoline boiling range.”  It’s also important to note the ethanol content will not always be 83%.  In fact, it can be as low as 51% and still be sold as E85.  Since the ethanol content varies, and the “gas” part can’t be identified, it’s difficult to estimate the actual octane rating.  This discrepancy can be disregarded when using race grade E85 or E98 which have more strict content grades but buying fuel by the drum defeats our purpose.  Even with those huge discrepancies in mind, with a few modifications, pump E85 can still provide a cheap and reliable fuel alternative and increase power.

What parts do I need?

Since E85 has less energy by volume compared to gasoline, your fuel system must be capable of additional flow requirements. Upgraded fuel pumps and injectors can be expected on traditional port injection vehicles. It’s important these upgrades are specifically cordial with ethanol based fuels. Fuel pumps rely heavily on fuel to keep themselves lubricated. Unlike gasoline, ethanol is not petroleum based. Not only does it not lubricate, it actively cleans lubrication. Aside from the cleaning trait of alcohol, it’s also hygroscopic. This means it pulls moisture from the surrounding air. If E85 sits in the injectors for long periods it can cause them to rust. Rust in injectors when you’re dealing with tolerances of a few thousandths of an inch results in drastic changes in flow rates. Even with stainless internal injectors it’s a good idea to start the car at least weekly if ethanol is in the system to prevent this from happening. Long story short, make sure your fuel system upgrades comply with E85 or you’re gonna have a bad time.

Since there is such a disparity in E85 from station to station and from season to season an ethanol content sensor is necessary. This can be used on certain platforms in conjunction with Accesstuner to account for necessary tuning changes caused by differences in fuel content. As an added bonus, especially if you travel through places where E85 is not available, this sensor will allow you to accommodate any fuel from regular pump gas all the way to E85 and anywhere in between.

COBB Flex Fuel Parts and Packages

The key to our Flex Fuel system is the COBB Ethanol Sensor Kit.  This kit consists of an ethanol sensor along with a converter that translates the signal from the sensor into something your vehicle’s ECU can use.  We will also be including a harness and replacement fuel lines that make this a true plug-and-play solution.

315600_main

COBB has also developed a Fuel Pressure Sensor Kit.  This will allow users to monitor fuel pressure at the fuel rail on the Accessport V3.  In our testing, the Fuel Pressure sensor kit is very important to verify a Flex Fuel car (or any car really!) is running safely. It will be a requirement for our Flex Fuel Off The Shelf maps.

315650_main

Beyond that, we will be offering a host of Flex Fuel Packages that make it very easy to configure any car to utilize our Flex Fuel implementation.  From completely stock vehicles to those already utilizing a Stage 2 or Stage 3 setup, we’ll have you covered!  Some examples are listed below.

315F03_main

616X30FF_main

 

315F05_main

315F04_main

 

Awesome, now what cars will this be compatible with?

Our initial release will be compatible with the 2008-2016 STI and 2008-2014 WRX.  Additional vehicle support will be added in the following months.  2015-2016 WRX support will be the second release, followed afterwards by Pre-2008 WRX/STi.  We are still investigating support for select Legacy GTs and Forester XTs.

Shut up and take my money!  When can I have it?!

The above listed hard-parts will be in stock at COBB Dealers, COBB Shops, as well as www.cobbtuning.com in the coming weeks.  Subaru Flex Fuel compatible software along with these hard-parts will be available everywhere at the beginning of January 2016.


128 responses to “Subaru Flex Fuel Update!”

  1. Do the flex fuel + fuel upgrade package have the fpr as well? I see it in the stage 3 + FF graphic but not in the previous.

    • The images posted here are just a few examples of what we’ll be offering. I believe we do have a package planned that includes the Fuel Pressure Regulator kit as well!

      Marshall@COBB

    • Exact pricing of the components and packages will be announced with the official release. It will be very competitive with (or less than) the current options available.

      Marshall@COBB

  2. Hi. I am really excited for this to be released. Do you guys have price points available yet? Also will there be any pre orders or promotions?

    • We’re super excited as well! It has been in the works for what seems like eternity! No exact pricing quite yet, though it will be extremely competitive (or less than) the current options on the market.

      Marshall@COBB

  3. Very cool!

    So how does the custom tune process work? Do you just do two tunes for a full tank of 93 and e85 each and then the flex system automatically adjust based on fuel mixture, or do you need more tunes based on the ethanol%, like a tune for each 25% increment?

    Do the ots maps for this require 1000cc injectors, and if so do they have to be your specific injectors?

    Also are you guys going to make install videos for everything(flex and pressure sensors, injectors, fuel pump)?

    • So I just saw haltechs vids on tuning for e85 and their system only requires two tunes and then adjusted timing based on the % of ethanol so i’m assuming that your system is the same. However what does your system do when you get pump gas that has 10% ethanol in it already? Is 10% the lower bounds and anything equal to or less than use the 93 tune?

      • A Protuner could likely interpolate data to create a tune for fuels with less than 10% ethanol content, however finding that fuel is relatively rare so most will likely use 93 octane (with 10% ethanol) as the base.

        Marshall@COBB

    • Hey Mark, that is essentially how it works! Tune for both extremes and the ECU will take care of all necessary blending based off of ethanol content. The OTS maps we are working on will require our 1000cc injectors made by ID. We will eventually have install videos available and installation instructions will be available upon release.

      Marshall@COBB

    • Yes! The packages posted above are just a few out of the many that we’ll have available at release.

      Marshall@COBB

  4. Do we need TGV deletes for this, assuming this will be using the TGV inputs? Do the TGV’s default to open when there is no signal? Thanks in advance!

    • TGV deletes will not be required to use our flex fuel kit. It will utilize the sensor inputs however the motors remain connected and will still function as normal.

      Marshall@COBB

  5. I have a completely stock 16′ sti can I just do the accessport+flex fuel+fuel upgrade package to run e85? Or will I need supporting mods like a DP or intake or both?

    • You can, you would simply not see the same power gains as a car with those other upgrades. As a note – We likely will not offer an OTS map for that setup, so you would need to contact a Protuner about getting a custom tune.

      Marshall@COBB

  6. For those of us who are already running E85, Injectors, fuel rails, lines, FPR and a flexfuel sensor, will we be able to buy the individual items, rather than a kit? For example, I would want the fuel pressure sensor, and wiring, and flex fuel analyzer and wiring only. I have the similar sensor (GM 13577429) to the one pictured, and have been running E85 for a while now.

    • Hey David, we do not currently have plans to offer everything minus the ethanol content sensor. That said, if there is an overwhelming demand upon release it would definitely be considered!

      Marshall@COBB

  7. will their be maps available for people already on the stage 2 map? I already have a full TBE so I hope I can just buy the flex fuel+ fuel upgrade kit and reflash and go

  8. Looks like (judging from the proposed package images) OTS maps for flex fuel could support the 1000 cc injectors, is this correct? Current stage 3 maps require the 725cc injectors, which are a bit light for most previous E85 applications, will those be updated as well to run 1000 cc injectors, or will the OTS flex fuel maps include everything for 91 and E85?

    • The Stage3+FF package will indeed include 1000cc fuel injectors. For those who do not have any intention to utilize flex fuel, the normal Stage 3 Power Package will remain as-is with 725cc injectors.

      Marshall@COBB

    • You will not! The Flex Fuel Sensor Kit will be compatible with your existing Fuel Pressure Regulator Kit.

      Marshall@COBB

  9. What kind of general HP increase can we expect? I know it’s going to very quite a bit but just a general guess.

    • Power gains will depend heavily upon vehicle setup and tuning. On a typical Stage 2 setup on an STI it would be safe to expect an additional 5-10% in top end power and potentially 15-20% gains in low-mid range torque.

      Marshall@COBB

  10. I’ve currently got a ’12 STi with AP, Cobb DP, and AEM CAI with your stage II OTS maps. However, I checked recently for updated maps and didn’t see any support for the AEM intake anymore, did Cobb discontinue support for that intake?

    Also, If Cobb still currently supports the AEM intake, will they also be providing OTS support for that intake going forward with the flex fuel setup?

    • Hey Matthew, we have moved the +AEM maps to an archived location in our COBB Support Knowledge Base. Currently, there are no plans to update those maps with new features such as Flex Fuel. With that said, a Protuner would definitely be able to create that map relatively easily for you once the software is available.

      Marshall@COBB

        • GD STi Flex Fuel is next in line after we complete DIT WRX Flex Fuel. We are hoping to release by the end of this year.

          Marshall@COBB

  11. So would we need to get separate tunes for 91 vs e85? As in, would we need to keep switching between maps? Or will there be a FF map that will take care of that.

    Also, is there be any difference from a dedicated e85 setup vs the flex fuel setup?

    • A complete calibration for Flex Fuel would cover tuning for both straight pump fuel (91, 93, etc.) all of the way through a high ethanol blend fuel (e85, e98, etc). There will be no need to change maps as ethanol content changes. The difference between a dedicated e85 tune and a true Flex Fuel setup is the ability of the vehicle to automatically compensate for the changing ethanol content.

      Marshall@COBB

  12. ‘m sorry, maybe it is just me, but looking at it in a business aspect..you are making a mistake pushing the 15-16 wrx prior to the pre 08 sti models. There are way more owners of the 04-07 sti/wrx then 15/16 wrx. Not only that but why wait on something (04-07sti) using practically the same engine as the first release(08-16 sti)…to make something for a whole new engine in between the two(15 16 wrx). Doesn’t make sense .

    • Hey Cullen,

      We definitely understand your point. However, with projects like this we also have to look at the time to market for each group of cars. The 2015-2016 WRX implementation is much more straight forward as there is one ECU and one mechanical configuration. When we get into the pre-2008 WRX/STis there are multiple ECU and ROM types along with varying mechanical setups. This not only affects development time but we also have many more vehicles to test on before releasing this to the public.

      Marshall@COBB

  13. I’d just like to throw in my please make this for the 05-09 LGTs. Gonna have all this Christmas money burning a hole in my pocket, I’d much prefer to burn corn with it.

  14. Currently I have an Ouback XT that is open source tuned but I would love to have the opportunity to make the switch to your products and support. With that I’d like to add a request on behalf of the state of iowa subaru community for support of flex fueling for Legacy gt’s and outback xt’s. Our state is very privileged to have such a great Cobb tuner right here at our doorsteps, and, thanks in part to his success our community of enthusiast continues to grow stronger in all lines of Subaru’s.

  15. Will the ’15+ WRX require the Fuel Pressure Sensor? It’s already available on the AP so I would think that would not be needed.

    • You are correct! Since the DIT cars already have a Fuel Pressure monitor from the factory they would not need an aftermarket solution.

      Marshall@COBB

  16. so sick. please tell there are plans to develop one for the Speed3. this would be a game changer for us as well. i’d love to stop having to flash my maps back and forth.

    • No plans for Flex Fuel on the Mazdaspeed platform right now, but if the demand is there we can certainly look into it!

      Marshall@COBB

  17. Will it be possible to add on only the analyzer wiring for a car running the Cobb V3 and a full E85 setup already (pump, injectors, fuel lines, E85 sensor, etc.)?

    In particular, will this work with a Zietronix ECA-2 sensor or is the Cobb sensor required? Will the only option be to purchase the sensor, analyzer and fuel line kit and discard what is not needed or can single items be purchased, as if they were replacements for damage and repair?

    Looking forward to updating.

    • Hey Peter, we do not currently have plans to offer the components ‘a la carte’ however if we continue to see requests it may be something we can consider. The main concerns would be connector compatibility and sensor calibration.

      Marshall@COBB

  18. Another vote for the 05-09 LGTs. As the owner of MotoIQ’s project LGT, I would love to implement this alongside the forthcoming turbo and fuel system upgrades we have planned.

  19. Please don’t forget about us Forester XT owners as well, I know there are a bunch of 09-13 owners wanting/waiting for this ability.

  20. So you guys are NOT going to have a OTS map for this Flex fuel setup for a Stage 2 with the AEM cai?? I got one of the first 08 Sti’s when they came out and the first OTS map you had for a cai was for turbo back exh and the AEM cai, so I bought that one!! I really don’t have or trust any tuners where I live and I’ve always followed the guidelines so I can use your guys OTS maps to be safe! Please consider it for those who have already bought the AEM cai because the Cobb cai was not out yet!

    • We do not currently have plans to offer an Off The Shelf map for the AEM Intake. I can definitely relay the request to our Subaru group and if the demand is there it may be something to consider!

      Marshall@COBB

  21. So, Let me get this straight. This is basically a monitoring system that allows you to run whatever gas and it will convert it with the ecu so it could run properly? So if you mix and match gases when the sensor is monitoring it. It’ll adjust accordingly?

    Also, what happens if we run bigger turbo, do we go to a tuner to get that properly adjusted? If so, is it the same method to get the maps, they would have to get the codes from you guys before they can adjust?

    • Hey Darren, I think you have the basics of it down. Essentially, our Flex Fuel Kit will monitor the ethanol content being fed into the engine and enable the ECU to make changes to the tune based upon that ethanol content. If you have a setup that is outside the scope of our OTS map offerings, you would need to have the car custom tuned by one of our Protuners.

      Marshall@COBB

  22. With the stage 3+FF package will you still run into boost creep? Also will these packages allow you to run a mix of e85 on the fly i.e. half tank e85 and half 93 octane or no?

    • Our hope is to combat boost creep as well as we can before changing other hard parts (such as a turbocharger exhaust housing or wastegate). And yes, the idea behind the system is to enable customers to run any blend of ethanol based fuel.

      Marshall@COBB

  23. If we already have the stage 3 setup installed, will we need to swap the injectors and fuel pump or just the injectors? And are there any plans to allow some kind of trade in for the 725CC to 1000CC swap?

    • Hey Basel, both the injectors and fuel pump will need to be changed when moving from our standard Stage 3 setup to the Flex Fuel kit. More on that tomorrow. We do not have any plans to offer a trade-in program for injectors, but there is a nice discount when purchasing the “Flex Fuel + Fuel Upgrade” kit.

      Marshall@COBB

  24. Since I travel for work therefore don’t use my car and not even turn on for weeks. So I shouldn’t get the upgrade since it is going to rust the inject or there is an alternative.

    • Ethanol can cause issues if it sits for extended periods of time. I believe there are additives you can use to combat those issues or just finish off the E85 and leave regular pump fuel in the car if you know it is going to sit for a while.

      Marshall@COBB

  25. Will we get a parts list together with the pricing next week, for the WRX 2015+? Also, would you happen to have a firm release date? Thanks.

    • Our initial release will be for the 2008-2016 STI and 2008-2014 WRX. 2015+ WRX Flex Fuel will come in the near future and will use a very similar hardware configuration. We will have more information on that front when close to release.

      Marshall@COBB

  26. I am currently stage 2+ 2011 sti and have walbro 255lph fuel pump and 1000cc ID injectors waiting to be put in. Will this be compatible with the flex fuel kit? Looking forward to release updates.

    • Hey Craig, those parts are definitely compatible with our Flex Fuel software. I may suggest contacting a Protuner in regards to the fuel pump, as the 255lph pumps will be right at it’s max with the ID1000s.

      Marshall@COBB

  27. What’s the release looking like? Got a poor, sick car waiting on this last bit to go in the shop and come out happy. heh

    • Hey Joseph, nothing new yet! We’re shooting for a late spring release that will hopefully include both a hardware and software solution.

      Marshall@COBB

  28. Any harm in running 93 most of the time (>80%) with the stage 3 + FF package and OTS map? Closest E85 station from me is > 50 miles away.

    • Nope, that’s the beauty of Flex Fuel! You can use either one, or a combination of both, without any issues.

      Marshall@COBB

  29. Is the OTS map available at this time? I’m about to buy the FF upgrade kit but I cant find the map I would use after the install.

    • We’ve been battling some issues with our dyno but should finally be getting close to having OTS maps available for 2015-2016 STI.

      Marshall@COBB

  30. Any word or progress pertaining to the development of the ’15/’16 WRX products at this time?

    • No updates as of yet. It is still actively being worked on and will be the next Flex Fuel compatible vehicle!

      Kyle@COBB

    • We’re making great progress on Flex Fuel for the DIT WRX. Hoping to have that available by the end of this summer!

      Marshall@COBB

  31. Is the OTS map available at this time? I’m looking to buy the Stage3 +FF kit but I cant find the map.

    • Hey Jason,

      We will likely not be offering an OTS solution for any Flex Fuel configurations. It would be best to have the car custom tuned by one of our Protuners.

      Marshall@COBB

    • Hey Kyle,

      We do plan to offer a Flex Fuel solution for GD-chassis Subarus. It will likely be available for 2005+ STI and 2006+ WRX around the end of this year.

      Marshall@COBB

    • We have indeed experienced multiple HPFP failures during testing, most of which occurred once running beyond ~E40. The issues are related to the mechanical configuration of the fuel pump thus cannot really be prevented via tuning changes. While users will be able to run higher ethanol content blends if they choose, any OTS solution will likely be limited to around E30 (which still provides a significant bump in power).

      Marshall@COBB

  32. Hey any updates for the ’15 WRX+?

    I need this kit! It will unleash all the potential the FA20DIT due to the increased compression ratio of 10.5:1 and issues with knock when increasing HP.

    • Hey Joel, we’re on schedule to have DIT Flex Fuel launched in the next couple of months. Unfortunately, we had to put that project on pause while working on adding new vehicle support for MY2017 WRX and STI.

      Marshall@COBB

    • Hey Michael,

      The “Ethanol Concentration (Raw)” monitor is the raw value coming from the Ethanol Sensor Kit. The “Ethanol Concentration (Final)” monitor is a result of some smoothing and is the actual value referenced by the ECU for Flex Fuel compensations.

      Marshall@COBB

  33. I have Understood That the systems of E85 ethanol blends or other water Tends to accumulate in the fuel lines. No problems in using additives in the fuel tank to remove water in These lines? The other question is. If possible use other additives for cleaning Carbon deposit on valves and injectors?

    • Hey Carlos! We have seen where additives cause issues with the ethanol content sensors themselves. It is possible that using certain additives will cause issues while others do not, just depends on what they are made up of. Essentially, anything that has a relative permittivity beyond that of ethanol (~25) is going to throw an error.

      Marshall@COBB

    • We’re getting closer every day. Our shop cars have been using production sensor kits and software for a few weeks now without issue. We have some rather intensive software testing to complete before everything is deemed ready for release. Still looking at mid-November.

      Marshall@COBB

  34. I am definitely looking forward to this for my upcoming build for my 2006 WRX.
    Do you have any rough idea of when this flex fuel kit will be available for my vehicle? As it will determine what and when I am able to get my car to the shop for the build or if I will have to delay. Thanks

    • Flex Fuel is a nice addition to any level build! We are currently shooting for a March-ish release.

      Marshall@COBB

      • Marshall that is actually awesome news if that holds true and you guys do come out with the Flex Fuel kit for my 2006 WRX. Christmas would come early.

        I heard that the odds of it happening or coming out for the Flex Fuel Kit for the 2006 WRX was probably not going to happen, for some reason but the main reason is the ECU is not robust enough to handle the calculations, etc. Does this sound true or should I just ignore everything and expect the 2006 WRX Cobb Flex Fuel Kit to come out March-ish?

        • That is more true for the 2002-2005 WRX which doesn’t have the room required to add custom features. We fully intend to support the 2006-2007 WRX!

          Marshall@COBB

          • Marshall sweet that is good to hear. I am hoping for early March with some good news. How will be the best way to get the update or news once it is released?

            Will you think pricing will be relatively the same as the other kits for the other model year groups you have released?

          • Pricing should be similar to existing COBB FF kits. We’ve unfortunately been hit with a bit of a delay with some of the connectors for the GD FF kit so early March does not look likely.

            Marshall@COBB

  35. Well I guess I will settle on March since my hopes for early March wont work. If in March that would still work but hopefully wont be a long setback delay and hopefully is a minimal impact on release. So excited.

      • We do not currently have plans to implement Flex Fuel on the Forester platform however if demand is seen we can certainly look into it.

        Marshall@COBB

        • there should be a lot of SG folks in subaruforester.org and facebook group forester XT that would like to get hand of those flex fuel kits.

    • Marshall was just wondering if there has been any news or updates you are allowed to provide at all regarding the release of the 2006 WRX Flex Fuel kit?

      • We are moving along as expected and are hoping to have both hardware and software available for release near the end of April!

        Marshall@COBB

        • Marshall that is awesome news. I am hoping it sticks to that date if not a bit sooner. As I have my short block on order and the build ready to go. It would be awesome to be able to get the Flex Fuel Kit before the build is complete and breaking it in. Fingers crossed and hopefully maybe a bit earlier.

          • Marshall, just checking in again since we are getting close to the end of April with a little more than a week and a half left. So wanted to see if you had any other new info or tid bits you could throw my way in regards to the release of the hardware and software for the 2006 WRX Flex Fuel Kit?

          • Hardware and software are both trending towards a release in the next couple of weeks. We haven’t set a hard date quite yet, but should be able to very soon!

            Marshall@COBB

  36. Thanks Marshall, looking forward to hearing and seeing something on the website sooner rather than later. I will drive myself crazy checking as I keep checking daily just in case I miss the email newsletter update. Fingers crossed for something within the next week so I can order it.

  37. Marshall anything new you can tell me on the 2006 Flex Fuel Kit? Was hoping I would see something on the Cobb website pop up since it has been 2 weeks since we last spoke.
    We are going to be finishing up the build in a short order here since we just got the long block the other day.
    I really want to incorporate the Flex Fuel Kit and trying to see if I can or should delay in order to get the flex fuel kit and be able to install it since it will be out like yesterday. Or if it is still going be a while a couple weeks, etc and I should just continue the build and look for the flex fuel kit at another time?

    Thanks any info or thoughts would be greatly appreciated.

    • Hey Donnie! We are in the home stretch for GD Flex Fuel. Software is ready and hardware should be ready to ship early next week.

      Marshall@COBB

    • We have plans to investigate potential LGT and FXT Flex Fuel options, nothing set in stone quite yet though.

      Marshall@COBB

  38. Any chance of a complete kit including a pump and injectors for the 04-07 sti? i know it would have to involve fuel rails and lines as well…

    • Hey Steven, we haven’t seen much demand for a full package for the GD cars as many of them have custom fuel systems. We may have the ability to put something together in the future. In the meantime, we can certainly put together a package for you with the products we currently have available!

      Marshall@COBB

  39. Hello I recently purchased Cobb flex fuel kit without the sensor. Will my tuner be able to tune me for e85 without the AP 3? I also have my upgraded my injectors and fuel pump. Do I need the AP 3 for this to work or can I add it in the near future?

    • Hey Adrian, our Flex Fuel logic is only available through the use of a V3 Accessport. If you are currently using a V2 your Protuner would not be able to tune the car using Flex Fuel. Luckily, we do have a Trade-In Program to help get you into a V3 Accessport at a heavy discount!

      Marshall@COBB

Leave a Reply

Your email address will not be published. Required fields are marked *