60mpg Geo Metro XFI
Last Updated on July 22, 2024 by Mutiara
A 1992 Suzuki Swift built under license in Canada, with a modern US federal EPA mileage rating of 43/51 mpg (46 average) per US gallon. The initial mpg goal for the vehicle was 60/60 (To cause the car to return 60 miles per US gallon at 60 miles per hour).
Modifications are listed in four categories; driver aids, friction reduction, aerodynamics, engine / transmission modifications. The weight of the vehicle is 1582 lb (with no fuel, spare wheel, or jack on board). The weight of the driver is about 205 lb.
Driver aids
The single largest area for improvement in any car is driving technique. Shown above is the replacement instrument console with tachometer. Vacuum gauge shown above. Not attached to the car except to charge it up, but probably the best driver aid ever devised is of course the GPS. Every time the brake pedal is pressed, fuel is wasted, thus avoiding it as much as possible is recommended.
Aerodynamics
Front profile showing no outside mirrors, flush headlights, 100% front grill block, turn signals removed from front bumper and incorporated in the amber pods next to the headlights. Side skirts can be seen in the image at the top of the page. Electrical connection for the 110V coolant heater can be seen below the bumper.
Rear showing spoiler on top of the hatch to “kick” the air stream off the rear window.
Internal drivers (and passenger) side mirrors. The law in Washington state requires a mirror on the left side of the car. It does not however, have to be on the outside of the car. I have a letter from the Washington Highway Patrol to this effect and have not been stopped by a patrol officer including the one that drove along side me one day for over a mile having a good look at the mirrors. Local state requirements should be checked because they may differ.
Bosch “Icon” wipers, they are more aerodynamic and lower profile than regular windshield wipers.
Friction reduction
- Mobil 1 0-30 synthetic engine oil
- Mobil 1 ATF Synthetic transmission oil
- New, full set of SKF wheel bearings lubricated with Mobil 1 synthetic grease
- Pirelli P3000 175/65-14 tires inflated to 50 psi. Tire diam is 22.96 inches, a 8.85% increase over the stock 21.1 in.
- Four wheel alignment with zero toe alignment.
- NanoLube added to engine and transmission
Engine / Transmission modifications
Engine compartment showing cooler air induction for summer driving to reduce spark knock (pinging).
Engine compartment showing warmer air induction for winter driving (now in use, October).
Combustion chamber showing new valves and the three “Singh” grooves.
Fuel warmer (not connected)
Fuel heater connected. Coil now somewhat crudely soft soldered to the body for better heat transfer and, some basic insulation added.
110V 25W KAT coolant warmer (recently changed for a 850W canister type also from KAT which is simply superb)
Single row light alloy under-drive pulley.
Tuned exhaust manifold (header) wrapped and leading into a 2″ dia exhaust system with 4-wire (grounded and heated) O2 sensor. Also shown is the high capacity Mobil M1-209 oil filter
Pulstar capacitor discharge Spark Plugs.
3.52 final drive gearing (74/21) taken from a New Zealand 1.3 liter 4 cylinder Suzuki Swift. An approx 8.5 % change over the 3.85 stock XFI gears. Car now turns 2400 rpm at 60 mph in 5th gear.
Results
The following results are in US gallons, add approximately 20% for imperial gallons.
Getting to 60 mpg was quite easy. The march to 65+ mpg not quite so and may not happen.
Typical results per tank of fuel on daily commute during the summer months is 60.5 to 62 mpg with a worst of 59.75 and a best of 62.41 driving at 60-65 mph for about half distance and 40 mph average for the rest. A 415 mile run on the freeway (I-5 Washington and Oregon) at 60-65 mph with two adult riders (total weight approx 350 lbs) during the summer returned 60.11 mpg. Averaging 61mpg for this daily driver, it has a 30% improvement over federal EPA ratings for this vehicle. The daily commute is 54 miles from Port Orchard to Enumclaw. 25 miles of fairly level four lane highway, a brief section of congested freeway, a long fierce hill and about 25 traffic lights on two/four lane highway of which 6-8 usually require coming to a stop.
Current MPG (November 2008) with some effort, especially keeping the engine warm when not in use utilizing the 110V heater, remains at a pleasing 60 mpg. This would indicate that next summer 65-67 mpg will be obtainable with the latest improvements. Possibly even 70 mpg highway with the new final drive gears installed.
A trip to Wilsonville, Oregon . 379.5 miles door to door. Temperature was 48-50F with some rain showers. 95% freeway, driving at a steady 60 mph I used 6.114 gallons. 62.07 MPG. Total cost for fuel that day was $13.38 USD.
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This article originally written by Trevor Heath, was reproduced with permission from livesteaming.com.
