Whether ethanol fuel can be handled by a fuel pump is yes, but that solely depends on the type of the fuel pump and the material composition. Adding ethanol, especially in higher concentrations like E85-a mix of 85% ethanol and 15% gasoline-results in corrosive properties that might degrade some components of the fuel system over a long period. The normal fuel pumps, though conceptualized to work with petrol, are not constructed to resist the chemical action of ethanol over extensive usage and would render them susceptible to failure like low flow of fuel and also internal abrasion that leads to failure.
Ethanol contains less energy compared to gasoline; hence, for the same power produced, engines running on ethanol-blended fuels would need more fuel. Because of this, fuel pumps have to support a higher flow rate; those that are not designed for ethanol might not provide the required pressure and volume on a continual basis. For example, E85-compatible fuel pumps are designed to pump more fuel and usually maintain pressures at 50-60 PSI to ensure the engine will get enough flow to operate.
One of the major problems with ethanol is that it is a moisture-sucking type of fuel, and this can lead to phase separation in the fuel tank. The effect may be an accumulation of water in the fuel system that accelerates corrosion in fuel pumps made of non-ethanol-resistant materials. For that reason, stainless steel, fluoropolymer linings, and ethanol-resistant plastics are common materials from which to build fuel pumps intended for ethanol-blended fuels. These materials prevent the corrosion of internal components and increase the life of the pump.
In 2020, a huge recall involved motors fitted with non-ethanol-compatible fuel pumps. These pumps started showing early failure due to higher ethanol content and hence caused stalling and poor performance in engines. The incident has once again emphasized the use of ethanol-compatible fuel pumps in cars that are running predominantly on ethanol blends.
As Mike Johnson, a car expert says, “Fuel pumps designed for ethanol provide the needed durability and performance required in vehicles using modern fuel blends. Ethanol-resistant pumps ensure that performance is not sacrificed, even while running E85 fuel regularly.”
Flex-fuel systems can run comfortably on ethanol blends of up to E85 with no damage to the fuel pump or other components in most modern vehicles. Those in vehicles that are not so equipped need to make sure their fuel pumps can accommodate ethanol before taking on an ethanol-blended fuel on a regular basis.
The fuel pump selection must be designed to handle the corrosive effect of ethanol, along with the higher flow requirements of ethanol in service for vehicle owners who use ethanol-blended fuels. This will assure long-term performance and reliability and extend fuel system life.