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Standard pump gas is the bottleneck for your Hellcat. If you are chasing 800, 900, or 1,000+ rear-wheel horsepower, 93 octane will not get you there safely. To push the Gen III HEMI to its absolute limit, you need a fuel system designed for high-volume delivery and high-octane stability.

E85 is the liquid gold of the modern muscle world. It offers the cooling properties and knock resistance of race gas at a fraction of the cost. However, converting a Hellcat, Redeye, or TRX to run E85 requires more than just a software tweak. You need to overhaul the hardware.

As a leading automotive performance shop online, DTX Performance provides the components required to bridge the gap between stock performance and track dominance. This guide breaks down the essential fuel system upgrades every high-HP Hellcat owner needs to consider.

Build the Advantage: Why E85?

The Dodge Hellcat platform is incredibly resilient, but it is sensitive to heat and detonation. E85 (85% Ethanol, 15% Gasoline) provides two primary benefits that transform the 6.2L Supercharged V8:

1. High Octane Rating: E85 typically carries an effective octane rating of 100 to 105. This allows tuners to advance spark timing and increase boost without the risk of engine-destroying knock.
2. Charge Cooling: Ethanol has a high latent heat of vaporization. As it is injected into the intake tract, it absorbs heat, significantly lowering intake air temperatures (IATs). This cooling effect is vital for maintaining power during back-to-back pulls.

In documented testing, a stock-pulley Hellcat can gain upwards of 30-40 horsepower just by switching to E85 and optimizing the tune. When you add a smaller pulley and more boost, that gap widens to over 100 horsepower compared to 93 octane.

Select the Injectors: Sizing for Success

The stock Hellcat injectors are impressive for a factory car, but they lack the headroom for E85. Because ethanol has lower energy density than gasoline, your engine requires approximately 30% more fuel volume to maintain the correct air-fuel ratio.

When you increase boost and switch to E85, the factory injectors will hit 100% duty cycle almost immediately. This leads to a lean condition and catastrophic engine failure.

Top Injector Brands for Hellcats

To build a reliable high-horsepower machine, you must select injectors that offer precision at idle and massive flow at wide-open throttle.

• Injector Dynamics (ID): The gold standard in the industry. The ID1300x2 is specifically designed with stainless steel internals to handle the corrosive nature of ethanol. For builds aiming north of 1,100 HP, the ID1700x or ID2600-XDS are the preferred choices.
• Fuel Injector Clinic (FIC): A powerhouse in the HEMI community. Their 1000cc and 1200cc sets are staples for E85 conversions, offering excellent data for tuners to ensure a "factory-feel" driveability.

Shop with confidence knowing that choosing the right injector size: typically 1300cc for most E85 Hellcat builds: is the single most important hardware decision you will make.

Push the Volume: High-Flow Fuel Pumps

Injectors can only spray what the fuel pump delivers. The factory Hellcat pump is a stout unit, but it hits a wall once you move beyond basic bolt-ons.

The 1,000 HP Threshold

For builds targeting up to 1,000 crank horsepower, a single high-flow drop-in pump or a voltage booster (like a Boost-A-Pump) might suffice on gasoline. On E85, however, the volume requirements are too high.

Dual and Triple Pump Systems

For serious performance, you need a multi-pump fuel hanger.

• Dual Hellcat Pumps: Many enthusiasts opt for a dual-pump setup using two OEM-style Hellcat pumps in a specialized housing. This setup can support over 1,100 wheel horsepower on E85.
• Fore Innovations Systems: For those pushing the absolute limit, Fore Innovations offers triple-pump systems that utilize TI Automotive (Walbro) 450 or 525 pumps. These systems often include upgraded fuel lines and external regulators to manage the massive flow.

Tune for Impact: PCM Unlocking and Flex Fuel

Hardware is useless without the software to control it. To run E85, your Hellcat’s PCM (Powertrain Control Module) must be unlocked.

Flex Fuel vs. Dedicated E85

You have two choices when tuning for ethanol:

1. Dedicated E85 Tune: This tune is optimized for a specific ethanol content (usually E85-E90). You must test your fuel at the pump to ensure it meets the requirements.
2. Flex Fuel Kit: By installing an ethanol content sensor, your PCM can adjust timing and fueling parameters in real-time based on the exact percentage of ethanol in the tank. This is the ultimate "no-compromise" solution for street-driven Hellcats.

Expert tuning ensures that your fuel injectors and pumps work in perfect synchronization, protecting your investment while maximizing output.

Maximize the Flow: Exhaust and Airflow

High-volume fuel delivery creates high-volume exhaust gases. If you are fueling for 900 HP, your exhaust system must be capable of evacuating those gases efficiently. Backpressure is the enemy of horsepower.

Upgrading to a high-flow exhaust system complements your E85 conversion by reducing heat soak and improving the supercharger's efficiency. For Dodge Charger owners, the AWE Tuning 2015+ Dodge Charger 6.2L Track Edition Exhaust provides the straight-through flow needed to handle the increased demands of a "corn-fed" HEMI.

Protect the Build: Supporting Modifications

Increased power from E85 puts immense strain on the rest of the drivetrain. When you upgrade your fuel system, you must also address the following:

• Driveshaft: The factory two-piece driveshaft is a known weak point. Increased torque from E85 often leads to failure at the carrier bearing or U-joints. Upgrade to a one-piece aluminum or carbon fiber unit.
• Heat Exchangers: While E85 cools the combustion chamber, the supercharger itself still generates massive heat. Upgrading your intercooler bricks or adding a larger heat exchanger is essential for consistency.
• Spark Plugs: Switch to a colder heat range spark plug (like NGK 2309) and gap them tighter to prevent spark blowout under the increased cylinder pressures of an E85 tune.

Shop with Confidence at DTX Performance

Navigating the world of fuel systems can be daunting. At DTX Performance, we aren't just an automotive performance shop online; we are enthusiasts who understand the technical nuances of the Mopar platform. We promise to only send you good things: parts that have been proven on the street and the strip.

Whether you are looking for Injector Dynamics sets, high-flow fuel rails, or a complete exhaust overhaul to match your new power levels, we have the inventory and expertise to guide your build.

Summary Checklist for E85 Conversion:

• Unlock PCM: Necessary for all 2015+ models.
• Select Injectors: 1300cc minimum recommended for E85.
• Upgrade Pumps: Dual-pump systems for 1,000+ HP goals.
• Install Ethanol Sensor: For true Flex Fuel capability.
• Cold Heat Range Plugs: To handle increased cylinder pressure.
• High-Flow Exhaust: To clear the extra volume of spent gases.

Conclusion: Push the Limits

The transition to E85 is the single most effective way to unlock the hidden potential of your Hellcat. By investing in high-quality injectors from brands like Injector Dynamics and ensuring your fuel pump can keep up with the demand, you transform your car from a fast street machine into a dominant force.

Don't settle for mediocre performance. Build it right, tune it safely, and experience the full raw power of a high-HP Hellcat. Ready to start your build? Explore our curated selection of performance parts and take the first step toward the 1,000 HP club.