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Discussion Starter #1
Hi everyone,
it's been a while sinds my last post here and I want to share my knowledge about the fuel problems we have here in Europe (Holland) with the Ethanol blending.
In my other posts you can read how I found this out last year.
A little resumé: I got a lot of problems with al my TBI cars when using normal E95 gas the last years.
Problem is "they" blend more and more bio-Ethanol with the fuel. Then the engine wil run too lean and you get al sorts of errors (codes) especially code 51 and 52!
It even goes in limb mode and then it burns more fuel to keep the engine running rich.
Now you can put in the most expensive fuel, E100 and it wil running okay I guess.
But I'm cheap and won't sponsor the fuel company more than nessesary. In Holland, fuel is very expensive.

Second option is buying a programmable ECU, and play with the parameters to get more fuel out of the injector. (TBI)
But this will be a time and money consuming project.
I also had a brainfart to fake or modify the O2 sensor, so the ECU won't go in limb mode al the time. But I found that too tricky.
You also can modify the vacuüm to the MAP sensor, but this not the way to go.

My idea was to crank up the fuel pressure, so it injects a little bit more fuel to prevent running too lean.
Normally the regulaor it set to 1 BAR. (15 psi)
The old stock fuelpump is capable to 2 BAR (30 psi).

Now I put a cheap Chinese fuel regulator in the return hose. Let's see what happens.....:wink2:
 

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Discussion Starter #2 (Edited)
Here's the $10,- shiny regulator from Ali.
It's a bit of a hazzle to set it right, becaus it's ment for high pressure from 30 psi and up, but I succeeded to set it to 20 psi about 1,5 bar and it runs great!!!

The milage is better than ever, 33 mpg is doable!
No errors anymore, yes maybe 51, 52 once and a while but not enough to trigger limb mode!
I also ran it on full pump pressure (30 psi) and this works well also.
So just block the return hose and you're done! :grin2:
 

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Discussion Starter #4
Just did a testdrive with the blocked returnhose and fuel economy is extreemly better!
6L/100KM OR 39mpg @ 100km/h or 63mph
Drives smooth, BUT ........
At idle (trafficlight) too much fuel is injected. Engine runs rough and can stall. When pulling up you see gley blue smoke.

So an adjustable regulator is better, but still a have this idle rich also at my lebaron, but less....

So a bypass at idle would be nice. There are several ways to do this.
 

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Discussion Starter #5
In this picture you see the Chinese adjustable regulator.

Now there is a vacuüm hose outlet on top. I didn't use this, because it's for pressure compensation for MPI injectors, my TBI injector is not in the vacuum (before trottle plate).
BUT...if I do connect this hose to my manifold vacuum (high at idle), the valve will open a bit so the fuel pressure will drop!!
That sounds to good to be thru! :surprise:

I will test this soon, (rainy outside now)
Plus the regulator has not arrived yet for my Town&Country, wich I am working on now.
Exiting!
 

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Discussion Starter #6
Okay,
Yesterday I filled up the tank of my Lebaron, the trip computer told an amazing consumption of almost 40 mpg!
But my calculation says something drifferent, 24 mpg.
Ofcourse I had a lot of cold starts, trafficlights, city driving etc.
But, the cars runs greath and has no problems with E95 fuel.
But how much the gain is in saved money.....
"Cheap" fuel with higher pressure or expensive fuel with lower (normal) pressure?

I will test it, but I don't drive a lot, so that's for later.
Next post is the Town & Country, same engine same conversion...
 

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Discussion Starter #7
Today I installed the second fuel regulator in the T&C, same type, but black.
A surprise was that the fuel pump was capable of doing 4 Bar! My Lebaron only 2!
Maybe that pump is old and worn.

Anyway, also this car is running beautiful on E95 now also! With the regulator set to 1.5 BAR. So Idle is good and highway is good. Did a short drive and also 35mpg average! But that will be less in reality, just like the Lebaron.
Now first drive the tank empty for real results.
Keep you informed.....
 

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cool ! 2 very nice cars you have there :)

good clever engineering there to fix the fuel problem !

my only suggestion is to use 'fuel injection' hose clamps as they clamp better, are more reliable, and don't damage the fuel line
 

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Discussion Starter #9 (Edited)
I'm not finished unfortuanally.......

Still I smelled the car was running too rich.... trip computer wasn't reliable. So I took a "real" meter to doubbel check the fuelpressure.
And indeed, it was not 1.5 but 2 BAR! Twice as much as normal!
Also I monitored the new original regulator, it was 0.8 B that's lower than OEM.

Problem is that the Chinese regulator won't drop below 2 bar now...

That made me decide to modify the original regulator, just cutted a M5 thread and put a bolt in.

And you wouldn't belief it, but it works better than the Chinese!! I can set it from 0.8 to 4 bar! LOL! :grin2:
Now I put it to 1.3 BAR to run it nice, smels and runs even better now! Yes I don't have an exaust tester.....
How cheap can it be?! LOL

I put a jumper cable to the coil to run the pump, so I don't need to run the engine while testing and adjusting. After this I did a short testdrive and it was stable.
The pictures are in logic order left to right.
Tomorrow I'll make a long drive with it to a job.

The only thing is a little grey smoke when accelerating, it burns oil too I guess. I'll hope to get rid of that by putting in new piston rings.... that's another story...
 

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Discussion Starter #10
As promised, after a few full tanks it seems to be working fine.

The best pressure seems to be about 1.2 BAR. (18 PSI)
Then the trip computer is close to reality.

With higher pressure, the engine runs good while driving, beacause the O2 sensor adjust the injector to a very small duty cycle. So it looks to be very fuel efficient on the display, but al idle the injector seems to be ignoring the O2 sensor? So it almost stalls due a too rich F/A ratio.
So the tripcomputer only sees the duty cycle of the injector, nothing else.
(Besides the fuel gauge)

The pictures shows a very nice average of 28 MPG and it was close to reality too! :smile2:

So far so good
 

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