Geo Metro XFI

("Suzuki Swift" in other countries)

"Project 60/60"

This is the car as purchased in May 2008 for $1900 US dollars

It is a 1992 model. with a federal EPA mileage rating of 53 city and 58 highway giving a combined circuit rating of 55 mpg (using the old rating system) .

This is the highest rating ever given to a non-hybrid car in the USA

I'm told under the new (more achievable) system 41/46 would be the published numbers.

The goal for this car is "60/60"

(60 miles per US gallon at 60 miles per hour)

The engine compartment with one mod already in place. The air cleaner housing has been rotated 180 degrees and now draws warm air from behind the radiator.

Modifications

Engine

New valves and keepers to achieve a compression cranking pressure of 190 psi minimum on all cylinders

Skimming the cylinder head to raise the compression to 10.5:1 before inserting the "Singh" grooves

Combustion chamber showing new valves and the three "Singh" grooves.

Cranking pressure after installation is 205 psi, exceeding expectations.

Speedometer - Tachometer console

Purpose of the tachometer is to aid with precise "short shifting" at lower rpm's than guessing would allow.

Cruising at 60 mph in top gear is approx 2600 rpm

Mobil 1 0-30 synthetic oil in engine

 Mobil 1 ATF 3 Synthetic transmission oil

Warm air induction (see image above) with air filter removed

Bosch Platinum 2 spark plugs

Body

Front grill block

Solid disc wheel covers on 14" wheels and 45 psi tire pressure

Removed spare tire, jack and lug wrench

Replaced with one can of "fix a flat"

I weighed the car without driver and no cargo but with 3/4 tank of gas, 1630lbs

Results to date

Well.....success came a little too easy,

Testing is simply driving to work on a mix of freeway, four and two lane highways, passing several stop signs and at least 25 traffic lights. 

I use regular 87 octane gas.

First one day test returned 62  mpg

The following day, 67 mpg was achieved.

I cannot tell you the reason for the difference except that I have been "tinkering" with the ignition timing and, I try every day to improve my driving. Of course, some days I "hit the lights" better than on other days.

I then ran a full tank test. This test including some in town driving. I'd estimate 5% and included one trip with a passenger.

 However,  not knowing the accuracy of the gas gauge, I refilled at 463 miles with the needle hovering above the "red zone". The car took 7.71 gallons to refill to the top of the neck. (the tank holds 10.5 gallons).

60.14 miles per US gallon

(approx 72.17 per imperial gallon)

Drivability

With the "Singh grooves" (see www.somender-singh.com) inserted in the cylinder head, it is possible to let the revs drop to 1500 in 5th gear and on level ground,  just pull away with no ill effects on the drive line at all. 

Additional modifications 

Flush fitting headlights

110V Coolant heater fitted into radiator bottom hose

Full set of new wheel bearings lubricated with Mobil 1 synthetic grease

Increased tire pressure to 50 psi

Future planned modifications

Fuel warmer

O2 sensor modifications

Water injection

Relocate drivers door mirror (required by law) inside the car.

(Law states "left side of car" it does not state that it has to be on the outside of the door)

Conclusion

It may be possible to achieve a single trip result of 70 mpg with a tank average of 65 mpg

We will have to wait and see....

With many thanks to Somender Singh in India and Pete Rogers, Skip Irving, Travis Weigal, Geoff Robinson, Brenton Netz and Carl Christy here in the USA

Trevor Heath

Port Orchard, Washington USA

Page updated: July 1st 2008

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