These changes were necessary to adapt the engine to the properties of ethanol-rich fuel.
Union Minister Nitin Gadkari recently introduced the Toyota Innova Hycross flex fuel prototype, which is capable of running on a greener fuel with up to 85 percent ethanol blend. The prototype uses the Hycross’ 2-liter strong-hybrid petrol powertrain, allowing the car to switch between fuel and electricity for propulsion.
However, in order to accommodate the high percentage of ethanol blending, Toyota had to make several changes to the locally-manufactured engine and related components. Here are the key changes made to ensure compatibility with E85 fuel:
1. Motor Driven VVT
In order to address cold start issues with ethanol vehicles, changes have been made to the Innova Hycross engine to enable it to start in temperatures as low as -15 degrees Celsius.
2. Improved Corrosion-Resistance Within The Engine
Due to ethanol’s acidic nature and higher water absorption, the engine is at a higher risk of corrosion. To combat this, the flex fuel prototype is equipped with ethanol-compatible spark plugs, valves, valve seats, and piston rings that resist corrosion and improve wear and tear.
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3. Three-Way Catalyst
Ethanol-powered cars require a more advanced three-way catalyst to significantly reduce emissions. Ethanol combustion produces different hydrocarbons and emissions compared to regular petrol engines, so a different catalyst is necessary to comply with BS6 phase 2 norms.
4. High Pressure Fuel Injectors
Ethanol requires higher temperatures to burn compared to gasoline, so the Hycross engine employs high-pressure fuel injectors that provide the required flow rate and are resistant to heat and corrosion.
5. Changes To The Fuel Tank
The Innova Hycross flex fuel prototype is equipped with anti-oxidant materials and coatings in the fuel tank and fuel pipe to prevent corrosion and rusting, ensuring smooth fuel flow over a longer period of time.
6. Ethanol Sensor
The flex fuel MPV version of the Hycross features an ethanol sensor that measures the concentration of ethanol in the fuel. This information is relayed to the specialized ECU, which adjusts other aspects of the engine accordingly. This is similar to how regular petrol models can detect octane ratings. The system can also assess the current blend of fuel in the tank to ensure smooth engine operation, even with lower blend ratios like E20.
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7. Changes To The ECU
The Hycross flex fuel ECU determines the electronically controlled functions of the engine based on the percentage of ethanol blend detected by the ethanol sensor. This allows the engine to seamlessly operate on different ethanol blends, ranging from E20 to E85, as well as petrol, making it a true flex fuel vehicle.
The Innova Hycross flex fuel prototype can run on electric power 60 percent of the time and biofuel for the remainder. This makes it more economical and environmentally-friendly compared to a flex fuel car running solely on ethanol.
However, further testing and calibration are required before the vehicle is ready for the Indian market. By 2025, all vehicles in India will need to be E20 compatible, and the Toyota Innova Hycross hybrid flex fuel could be ready for production in another 3 to 4 years.
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