A Comprehensive Experimental Analysis of Ethanol 27% Fuel Blend in a Turbocharged Gasoline Direct Injection Engine

India is committed to achieving a 20% ethanol blend in petrol (E20) by 2025, as part of its national biofuels policy to reduce carbon emissions, enhance energy security, and support the agricultural economy. Building on E20's achievement in reducing GHG emissions, E27 fuel—which contains 27% ethanol in gasoline—is one of the means of advancing India's ethanol strategy and reducing dependency on fossil fuels. In line with the literature and the preliminary study, an experimental analysis utilizing fuel blends ranging from E10 to E40 was conducted. It was found that E27 provides the optimal balance of emissions reduction and performance without requiring engine modifications, complying with the government's aim to boost ethanol blending and cut carbon emissions by 2030. This study examines a turbocharged gasoline direct injection (TGDI) engine powered passenger car that was tested using E27 fuel for a mileage accumulation of 20,000 km under real-world driving conditions. This evaluation programme involved evaluation of different ethanol-gasoline blends on different vehicle category with a cumulative mileage accumulation of over 1,00,000 km. The present study evaluates the performance, emissions, combustion patterns, used engine oil analysis and wear associated with extended use of E27 fuel. The study also examines catalytic conversion efficiency for both regulated and uncontrolled emissions as the ethanol energy share increases. The test vehicle's engine oil was collected in specific intervals and analysed to assess wear metal content and fuel dilution. Performance and emissions tests, conducted at regular intervals, showed marginal power gains and improved initial acceleration with mileage accumulation on the passenger car. NOx and THC emissions decreased marginally, while CO and CO2 remained stable, indicating consistent combustion. Results also showed that E27 fuel demonstrated reliable performance, providing effective emissions control and engine durability. These findings suggest that E27 fuel as a viable option for supporting India’s emission targets and sustainability goals, without any engine modifications and ensuring users experience minimal impact.