E-87-2 and DOE V4 Projec

Presented by Brian West

CRC Emissions Committe

May 14, 2009
CRC-DOE confidential – Do not Cite

Overview DOE V4 Project: Vehicle aging and Catalyst • a.k.a. CRC E-87-2

− Follow-up to DOE V1 (16 vehicle emissions/W

CRC E-87-1 WOT study

• E-87-1 screened 25 vehicles − DOE/Labs selected 12 vehicle models• DOE V1 screened 16 vehicles (with som

87 and V2/EPAct vehicle models)

• Competitive solicitation in 2008

− Contract through ORNL− Award to SwRI – October 2008

• DOE is supporting 2 additional parallel 

expand and accelerate data collection

− ORNL => TRC− NREL => ETC
CRC-DOE confidential – Do not Cite

V4/E-87-2 Workplan Overview• Acquire 2-4 “matched” vehicles for each mode

E0, E10, E15, or E20 for aging

− Vehicle inspection, recruitment− Correlation FTP and WOT to confirm proper oper− Vehicles instrumented similar to E-87-1 and V1 (U

thermocouples)

− Dedicate vehicles to a fuel for aging on MAD or te

(E0, E10, E15, E20 or some subset)1. Emissions test all vehicles with E0, in dup2. Emissions test vehicles on respective E-b3. Age 25-50k on MAD or track using SRC

*

4. Repeat 2, repeat 15. Age additional 25-50k or to full useful life6. Repeat 2, repeat 1• At each emissions testing interval

− conduct compression check and leak-down test− At TRC and ETC, conduct evap leak check
CRC-DOE confidential – Do not Cite

E87-2 (V4) - Catalyst AginTable shows protocol for 1 vehicle ty

Baseline

SRCAging50k Emissions 

E0E0 + E10E0 + E15E0 + E20

E0E0 + E10E0 + E15E0 + E20

RE0RE10RE15RE20

RE0RE10RE15RE20

SRC Ato FUL
CRC-DOE confidential – Do not Cite

Recent modification: Add WO

each emissions test interval

• WOTs at each emissions interval (inste

project start)

• Recent 50k test on Hondas: each vehic

E20 WOT

Question: What fuels should we run on m

life WOTs?

Proposal:

• At project start, each vehicle gets E0 an• E10 and E15 vehicles get WOT on their • Subsequent WOTs at emissions test wi

blend and E0 only 

− Avoids need for additional E20 prep on 3 veh

− Avoids additional exposure of non-E20 vehic
CRC-DOE confidential – Do not Cite

V4 Project Status

• Vehicle emissions testing and aging 

underway at SwRI (E-87-2 with CRC)

− Aging on mileage accumulation 

dynamometers

− 20 vehicles purchased and under test (5 

matched sets of 4 – 4 fuels per model)

• 2006-2008 model year

− Additional vehicles TBD

• Parallel V4 contracts underway

− TRC (Ohio)

• Aging on track• 12 new 2009 vehicles (4 matched sets of 3 – 

3 fuels per model)

− 10 vehicles purchased, 2 pending)

• Additional vehicles TBD

− ETC (Colorado) – contract pending

• Mileage accumulation dynamometers• 8 new 2009 vehicles (4 matched pairs – 2 

fuels per model)

• additional vehicles TBD

Ford 

Niss

Che

MA
CRC-DOE confidential – Do not Cite

SwRI Program Status• SwRI has purchased 21 vehicles

−5 models, 4 matched vehicles per model, 1 vehicle p

• 2007 Accord compl

• 2006 Chevrolet Silverado approa

• 2008 Nissan Altima compl

• 2008 Ford Taurus instrum

• 2007 Dodge Caravan purcha

• A few incidents so far...

−High oil consumption on 1 Accord

• vehicle replaced

−Chevrolet Silverados

• Failed E20 fuel pump• Stuck throttle actuator on Chevrolet

− adding additional safeties (to all vehicles)

−Nissan Altima

• TCU reflash for dyno testing• Inadvertent “manual” shift selected on Nissan 

− Selector gate blocked

−Ford Taurus manifold – instrumentation challeng
CRC-DOE confidential – Do not Cite

2006 Silverado Safety Shutdown C

Hot in Run and Start

External 20 amp normally-open double-throw relay 

Active when MAD is enabled Bank 1 and 2 fuses 

for coils and injectors

Bank 1 fuel injectors 

Bank 2 ignitiocoils 

Bank 1 ignition coils 

Bank 2 fuel injectors 

• Sim

beiveh

• No 

witagr
CRC-DOE confidential – Do not Cite

Signage and metal plate over shto prevent Nissan incident from 
CRC-DOE confidential – Do not Cite 

Ford Taurus UEGO Placeme

• Close-coupled catalyst creates instrum

challenge

− No space between cast exh manifold and f

• Options considered:

− Fabricate spacer, install b/w catalyst and e

− Install only for emissions and WOT t

− Weld UEGO boss to manifold

− Concern about cracking weld or man

• Swap manifolds before emissions/WOT te

duration

− Drill and Tap manifold

− Swap manifolds before emissions/W

Leave on for duration

• SwRI recommends drill and tap of man

− Leave on car for duration. Check integrity 

each service interval
CRC-DOE confidential – Do not Cite 

Taurus Exhaust presents challenge for UEGO placement
CRC-DOE confidential – Do not Cite 

Taurus - Spacer Option

• Fabricate s

install b/w and exhaus

• Install o

emissiotesting

• Could be 
CRC-DOE confidential – Do not Cite 

Taurus – Drill and Tap Option

Drill and tap manifold

− Use extra care in 

installing instrumentation

− Leave manifold on 

for duration (remove UEGO, install plug for aging)

− Inspect at each 

service interval

OEM

UEGO
CRC-DOE confidential – Do not Cite 

• Several relevant criteria impact vehicle selection

− Model year, emissions standard (e.g., Tier 2, non-

− Manufacturer, sales volumes

− LFT or non-LFT at WOT

• Guidance and screening studies impact selectio

− EPA V2 vehicle list (19 popular models – test all)

− CRC E-87-1 (e.g., “CRC Top Ten” non-LFT vehicle

− DOE V1 (additional info on LFT/non-LFT)

• DOE/EPA guidance of January 2009 and April 20

− Test all V2 vehicle models, multiple model years o

• CRC Proposal of November 2008 (20 vehicles)

− 50/50 LFT and non-LFT

• 70% Tier 2• 30% NLEV/Tier 1

Vehicle Selection Challenge
CRC-DOE confidential – Do not Cite 

40 Vehicles Currently Under Test at 3 13 models, 2006-2009, Tier 2, all on V2/EPA EPAct list (with som

variation). Many V2 models screened in V1 and E-87-1.

Year Vehicle number

2006 Chevrolet Silverado 4 E0 E12007 Honda Accord 4 E0 E12008 Nissan Altima 4 E0 E12008 Ford Taurus 4 E0 E12007 Chrysler Caravan 4 E0 E1

TBD TBD TBD

Year Vehicle number

2009 Jeep Liberty 3 E0 E1

2009 Ford Explorer 3 E0 E1

2009 Honda Civic 3 E0 E1

2009 Toyota Corolla 3 E0 E1

TBD TBD TBD

Environmental Testing Corp (Colorado), mileage accumulation 

Year Vehicle number

2009 Saturn Outlook 2 E0 E1

2009 Toyota Camry 2 E0 E1

2009 Ford Focus 2 E0 E1

2009 Honda Odyssey 2 E0 E1

TBD TBD TBD

Southwest Research Institute (Texas), mileage accumulati

TBD

Fu

V4 Project Vehicle Summary (Vehicle A

Transportation Research Center (Ohio), test trac

Fu

TB

20

Vehicles

12

Vehicles

8

vehicles
CRC-DOE confidential – Do not Cite 

Planned V4/E-87-2 Fleet Mix (19 mo

Black text: veh under test; Red text: proposed for next 

Year make/model no vehicles/fuels Year make/model 

2006 Chevrolet Silverado 4 (E0, E10, E15, E20) 2007 Honda Accord 

2008 Ford Taurus 4 (E0, E10, E15, E20) 2007 Chrysler Caravan 

2008 Nissan Altima 

2005 Toyota Sienna 3 (E0, E15, E20) 2006 Chevrolet Cobalt 

2007 Dodge Caliber 

2009 Ford Explorer 3 (E0, E15, E20) 2009 Honda Civic 

2009 Toyota Corolla 3 (E0, E15, E20) 2009 Jeep Liberty 

2006 Chevrolet Impala 3 (E0, E15, E20)2004 Toyota Tundra 3 (E0, E15, E20)2005 Ford F150 3 (E0, E15, E20)

2009 Saturn Outlook 2 (E0, E15) 2009 Honda Odyssey 2009 Toyota Camry 2 (E0, E15)2009 Ford Focus 2 (E0, E15)

Vehicles with LFT at WOT* Vehicles that DO N

Vehicles Currently Under Test (or in acquisition) - BLACK. Propo

* LFT based on screening in V1 or E-87-1 o
CRC-DOE confidential – Do not Cite 

Summary of proposed plan forwV4 vehicle selection (red=currently under • 19 models (13)

− 4 GM (2)

− 4 Ford (3)− 3 Chrysler (2)− 4 Toyota (2)− 3 Honda (3)− 1 Nissan (1)

• 11 confirmed or 

expected LFT at WOT (7)

• 8 confirmed or 

expected non-LFT at WOT (6)

• 1999 to 2009 model years

− 8 – 2009 (8)

− 2 – 2008 (2)

− 3 – 2007 (2)

− 3 – 2006 (1)

− 2 – 2005

− 1 – 2004 

• Summary of Sw

− 8 models, 29 

• 5 models x 

• 3 models x 

• 3 LFT, 5 no• 2005-2008
CRC-DOE confidential – Do not Cite 

Project Review Meeting in San A• Following Dates proposed

− June 9

− June 11

− June 16

− June 17

• 8-2:30 (tours 3-5 PM if available/inte
CRC-DOE confidential – Do not Cite 

Thank You

Brian West

westbh@ornl.gov

865-946-1231
CRC-DOE confidential – Do not Cite 

Backup Slides
CRC-DOE confidential – Do not Cite 

V1- Test Vehicles

OEM (make) Model Year Engine

Initial 

odometer 

reading 

(miles)

Emissio

standar

Chrysler Town & Country 2007 3.3 L V6 35,000 Tier 2, Bin 5 

Ford F150 2007 5.4 L V8 28,600 Tier 2, Bin 8 

Ford F150 2003 5.4 L V8 57,000 Tier 1 LEV 

Ford Taurus 2003 3.0 L V6 89,600 Tier 2, Bin 8 

GM (Buick) Lucerne 2007 3.8 L V6 10,000 Tier 2, Bin 5 

LEV II)

GM (Buick) LeSabre 2003 3.8 L V6 78,000 Tier 2, Bin 8 

GM Silverado 2007 4.8 L V8 12,800 Tier 2, Bin 8 

Honda Accord 2007 2.4 L I4 11,400 Tier 2, Bin 5 

LEV II)

Nissan Altima 2003 3.5 L V6 53,300 LEV 

Toyota Camry 2007 2.4 L I4 26,440 Tier 2, Bin 5 

Toyota Camry 2003 2.4 L I4 72,800 ULEV 

Chrysler PT Cruiser 2001 2.4 L I4 93,400 NLEV 

Ford Crown Victoria 1999 4.6 L V8 50,900 ULEV 

Honda Civic 1999 1.6 L I4 79,680 Tier 1 

Toyota Corolla 1999 1.8 L I4 96,400 Tier 1 

VW Golf GTI 2004 1.8 L I4 Turbo 32,900 Tier 2, Bin 8 

*Round-robin vehicle tested at two sites
CRC-DOE confidential – Do not Cite 

V2 - EPAct Program Vehicl

Make Year Brand Model Engine GM 2008 Chevrolet Cobalt 2.2L I4 GM 2008 Chevrolet Impala 3.5L V6-FFGM 2008 Saturn Outlook 3.6L V6 GM 2008 Chevrolet Silverado 5.3L V8-FFToyota 2008 Toyota Corolla 1.8L I4 Toyota 2008 Toyota Camry 2.4L I4 Toyota 2008 Toyota Sienna 3.5L V6 Toyota 2008 Toyota Tundra 4.0L V6 Ford 2008 Ford Focus 2.0L I4 Ford 2008 Ford Taurus 3.5L V6 Ford 2008 Ford/Mercury Explorer/Mountaineer 4.0L V6 Ford 2008 Ford F150 5.4L V8-FFChrysler 2008 Dodge Caliber 2.4L I4 Chrysler 2008 Dodge Caravan 3.3L V6-FFChrysler 2008 Jeep Liberty 3.7L V6 Honda 2008 Honda Civic 1.8L I4 Honda 2008 Honda Accord 2.4L I4 Honda 2008 Honda Odyssey 3.5L V6 Nissan 2008 Nissan Altima 2.5L I4