Sunoco Tech Corner

How Sunoco Fuels Support Modern Emissions-Compliant Race Cars

Written by Sunoco | Oct 19, 2025

THE MODERN PERFORMANCE CHALLENGE

Modern performance engines face a unique challenge: delivering high horsepower while staying emissions-compliant. As emissions systems like catalytic converters and oxygen sensors become standard even in performance and track-oriented vehicles, the need for specialized race fuels has never been greater. What was once primarily a concern for street vehicles has now extended into many forms of motorsports competition, requiring fuel solutions that can satisfy both performance and environmental requirements.

Sunoco Race Fuels has been developing unleaded, oxygenated fuels that meet these modern requirements without sacrificing power or consistency. The company's experience working with professional race teams and sanctioning bodies has helped refine formulations that address the complex demands of emissions-compliant racing.

The evolution of racing regulations reflects broader changes in how motorsports interact with environmental concerns. Many racing series now mandate unleaded fuels or impose restrictions on certain additives. Time attack events, track day organizations, and even some professional racing classes require participants to use fuels that won't damage emissions equipment. This shift has created demand for high-performance unleaded options that can match the power output of traditional leaded race fuels.

THE RISKS OF INCOMPATIBLE FUELS

Many racers underestimate the risks of using incompatible fuels in today's engines. Traditional leaded race fuels can wreak havoc on sensitive emissions components, damaging oxygen sensors and catalytic converters that are vital to modern performance tuning. The lead compounds that once provided valve seat protection and octane enhancement now represent a liability in engines designed around unleaded fuel and emissions control.

OXYGEN SENSOR CONTAMINATION

Oxygen sensors, both narrow-band and wideband types, use precious metal elements that are poisoned by lead exposure. Even small amounts of leaded fuel can permanently damage these sensors, rendering them unable to provide accurate readings. For racers using data logging and closed-loop tuning strategies, non-functional oxygen sensors eliminate critical feedback needed for optimization.

Research from Bosch Automotive, one of the world's leading oxygen sensor manufacturers, confirms that lead contamination causes rapid sensor degradation. Once poisoned, these sensors cannot be cleaned or restored and must be replaced, often at considerable expense.

CATALYTIC CONVERTER DAMAGE

Catalytic converters face similar risks. The precious metal catalyst materials, platinum, palladium, and rhodium, become coated with lead deposits that prevent them from functioning properly. A catalytic converter damaged by leaded fuel cannot be repaired and must be completely replaced. Given that high-flow racing catalytic converters can cost $500 to $2,000 or more, the financial impact of using incompatible fuel adds up quickly.

Beyond the monetary cost, a damaged catalytic converter means the vehicle can no longer pass emissions testing, effectively ending its useful life for any application requiring emissions compliance. For street/track cars or vehicles competing in emissions-regulated racing series, this is unacceptable.

THE SOLUTION: PURPOSE-BUILT UNLEADED RACE FUELS

Unleaded, oxygenated fuels are specifically engineered to maintain emissions compliance while ensuring engines perform at their peak under competition or high-demand conditions. These fuels provide the octane and combustion characteristics needed for racing without the emissions system damage that leaded fuels cause.

Modern unleaded race fuel technology has advanced to the point where performance matches or exceeds what was possible with leaded options. Through careful selection of hydrocarbon components, oxygenation strategies, and additive packages, fuel chemists have created unleaded formulations capable of supporting extreme power levels while keeping emissions systems intact.

SUNOCO 260 GT: THE STREET-LEGAL PERFORMANCE BENCHMARK

Sunoco 260 GT stands as a benchmark for street-legal, high-performance fuel. With a 100-octane rating and oxygenated composition, 260 GT is designed to deliver stable combustion, improved throttle response, and optimal power output for both carbureted and fuel-injected engines.

The fuel's formulation strikes an ideal balance between performance and practicality. Its 100-octane rating provides sufficient knock resistance for moderately aggressive street/strip builds, high-compression naturally aspirated engines, and moderate boost applications. The oxygenated formulation enhances combustion efficiency, providing power gains similar to those seen with higher-octane leaded fuels but without any emissions system compatibility concerns.

BROAD APPLICATION RANGE

260 GT is ideal for modern turbocharged, supercharged, and naturally aspirated applications that demand more from every drop of fuel. Street performance enthusiasts use it in daily-driven vehicles that see occasional track use. Time attack competitors rely on it for events where emissions compliance is required. Engine builders specify it for builds that need to pass emissions testing while making serious power.

The fuel's consistency and stability also make it popular for applications where fuel might sit for weeks or months between uses. Its unleaded formulation and quality additive package provide excellent storage characteristics compared to pump fuel, making it suitable for weekend warriors who don't burn through fuel inventory quickly.

ADVANCED UNLEADED OPTIONS: 260 GT PLUS AND EVO 10

For racers pushing their setups further, Sunoco 260 GT Plus and EVO 10 offer the next level of unleaded performance. With higher oxygen content and precise chemical stability, these fuels are perfect for engines tuned aggressively for maximum power while retaining clean combustion.

SUNOCO 260 GT PLUS

260 GT Plus builds on the 260 GT foundation with increased oxygenation that provides additional performance benefits. The higher oxygen content supports more complete combustion, translating to improved power output, better throttle response, and enhanced detonation resistance. These characteristics make it particularly well-suited for forced-induction applications where every bit of knock resistance matters.

The fuel maintains the emissions-friendly unleaded formulation while delivering performance that approaches higher-octane leaded options. Professional teams use 260 GT Plus in applications ranging from road racing to off-road competition, where rules mandate unleaded fuel but performance cannot be compromised.

SUNOCO EVO 10

EVO 10, in particular, supports 4-stroke motocross, supercross, and high-performance automotive applications that require predictable, repeatable results under extreme conditions. Its highly oxygenated formulation provides exceptional cooling characteristics that help manage the intense heat generated during sustained high-RPM operation.

The fuel has become popular in powersports applications where engines operate at elevated temperatures and RPM ranges that would quickly overwhelm lesser fuels. Its combustion characteristics remain stable even under the most demanding conditions, providing consistent performance from the first lap to the last.

Professional motocross and supercross teams have embraced EVO 10 for its combination of power delivery, thermal management, and emissions compatibility. The fuel meets requirements for unleaded-only racing series while providing the performance needed to compete at the highest levels.

UNDERSTANDING EMISSIONS COMPLIANCE IN RACING

Understanding emissions compliance in racing environments is key to making smart fuel choices. Racing regulations vary widely depending on the sanctioning body, class, and location. Some series mandate specific fuels or fuel types, while others set performance limits but allow flexibility in fuel selection as long as certain criteria are met.

REGULATORY LANDSCAPE

Sunoco's unleaded and oxygenated race fuels comply with various sanctioning body rules and emissions regulations, allowing racers to compete responsibly while maintaining the integrity of modern emissions systems. These fuels provide a solution for drivers who want to stay on the right side of regulations without compromising on speed or reliability.

Many track day organizations now require unleaded fuel for environmental reasons and to protect their facility's relationship with local communities. Time attack and time trial events often mandate emissions-compliant vehicles and fuels. Even some professional racing series have moved toward unleaded formulations as part of broader sustainability initiatives.

The Environmental Protection Agency sets baseline fuel standards that influence racing regulations, though motorsports typically operate under different rules than street vehicles. Understanding these distinctions helps racers navigate the regulatory landscape and select appropriate fuels for their specific situation.

COMPLIANCE WITHOUT COMPROMISE

The key insight is that emissions compliance doesn't require accepting reduced performance. Modern unleaded race fuels like those from Sunoco deliver power output equivalent to or exceeding traditional leaded options while protecting emissions systems and meeting regulatory requirements. This represents a genuine win-win scenario for racers who want to compete responsibly without giving up competitive advantages.

For racers building engines for emissions-compliant applications, fuel selection should be considered early in the planning process. Engine management strategies, turbocharger sizing, compression ratio selection, and other critical decisions can be optimized around the fuel that will be used, maximizing performance within the constraints of unleaded, emissions-friendly operation.

SUNOCO'S TECHNICAL LEADERSHIP IN UNLEADED FORMULATION

Behind these products lies Sunoco's technical expertise in unleaded fuel formulation. Each batch of fuel is refined to maintain exact consistency, giving tuners and engine builders confidence in every data log and dyno pull. The precision required to produce consistent race fuel batch after batch cannot be overstated. Variations in fuel properties can mask tuning changes, create confusion during engine development, and ultimately cost performance.

QUALITY CONTROL AND CONSISTENCY

Sunoco's refining processes and quality control protocols ensure that 260 GT purchased in California performs identically to 260 GT purchased in Florida. This consistency extends across production runs and storage periods, provided proper storage practices are followed. Professional teams depend on this reliability when developing engine calibrations that must work across multiple race venues and varying atmospheric conditions.

The company's Double Distilled technology, which removes impurities and creates highly refined hydrocarbon blends, contributes to both performance and consistency. The cleaner the fuel, the more predictable its combustion characteristics and the better it performs in precision-tuned race engines.

COLLABORATIVE DEVELOPMENT

Sunoco collaborates with professional engine builders, performance shops, and race teams to ensure its unleaded race fuels deliver precision, reliability, and performance every time. This collaborative approach provides real-world feedback that laboratory testing alone cannot replicate.

When a professional team discovers an opportunity for improvement or identifies a specific need, that information flows back to Sunoco's fuel chemists and engineers. This continuous feedback loop drives product refinement and ensures that Sunoco's fuels evolve alongside engine technology and racing requirements.

PERFORMANCE BENEFITS BEYOND EMISSIONS COMPLIANCE

The benefits of Sunoco's modern unleaded fuels extend far beyond emissions compliance. Racers experience cooler combustion temperatures, improved throttle response, and enhanced detonation resistance, critical advantages in today's tightly tuned engines.

THERMAL MANAGEMENT

The oxygenated formulations used in fuels like 260 GT Plus and EVO 10 provide significant charge cooling effects. This cooling reduces intake temperatures, increases air density, and allows engines to make more power safely. The thermal benefits are particularly noticeable in forced-induction applications where heat management directly impacts performance and reliability.

Lower combustion temperatures also reduce thermal stress on pistons, rings, valves, and cylinder heads. This translates to longer component life and reduced risk of heat-related failures during competition. Professional teams appreciate these durability advantages, which reduce maintenance costs and improve finishing rates.

COMBUSTION EFFICIENCY AND THROTTLE RESPONSE

The complete combustion enabled by proper oxygenation improves throttle response by creating a more direct relationship between throttle input and engine output. Drivers notice sharper response and better control, particularly important in road racing and other disciplines where precise throttle modulation matters.

Testing featured in Grassroots Motorsports magazine has documented that properly tuned engines on oxygenated unleaded race fuels often produce broader powerbands than the same engines on conventional gasoline. This improved power delivery across the RPM range translates into faster acceleration and better overall performance.

DISPELLING THE UNLEADED POWER LOSS MYTH

Contrary to popular belief, unleaded fuels don't have to mean a loss of power. With Sunoco's advanced formulations, racers can achieve both clean emissions and high output. This flies in the face of conventional wisdom that once held leaded fuel as necessary for maximum performance.

The reality is that modern unleaded race fuel technology has evolved to the point where lead is no longer required for valve seat protection in most applications. Improved metallurgy in valve seats and guides, combined with advanced fuel formulations, has eliminated the need for lead additives in the vast majority of racing engines.

Where ultimate octane rating is required, Sunoco offers unleaded options like Supreme that provide extremely high knock resistance without lead content. For applications where emissions compliance matters, the 260 series and EVO 10 deliver excellent performance while protecting sensitive emissions components.

RACING RESPONSIBLY IN THE MODERN ERA

In an era where performance and responsibility must coexist, Sunoco Race Fuels provides the bridge between innovation and compliance. From the street to the track, fuels like 260 GT, 260 GT Plus, and EVO 10 empower racers to compete confidently with unleaded, emissions-friendly options that perform as hard as they protect.

THE PATH FORWARD

The future of racing lies in technologies that deliver excitement and performance while minimizing environmental impact. Unleaded, emissions-compliant race fuels represent an important part of that future. They demonstrate that motorsports can evolve and adapt without sacrificing the core values of speed, competition, and engineering excellence.

For racers building new combinations or converting existing engines to unleaded fuel, the performance possibilities are broader than ever. Modern fuel formulations, combined with advances in engine management, turbocharger efficiency, and combustion chamber design, allow unleaded engines to match or exceed power levels that once required leaded fuel.

The key is understanding that fuel selection is not an isolated decision but rather part of an integrated approach to engine development. Choosing the right unleaded fuel for your application, tuning appropriately, and maintaining proper fuel system components all contribute to extracting maximum performance while protecting emissions equipment and complying with regulations.

SUPPORT AND RESOURCES

Sunoco's technical support team is available to help racers navigate the transition to unleaded fuels and select appropriate products for specific applications. Whether you're building a street/strip car that needs to pass emissions testing, competing in a racing series with unleaded fuel requirements, or simply want to protect your vehicle's emissions systems while making power, Sunoco has solutions that meet your needs.