E-87-2 and DOE V4 Project StatusPresented byBrian WestCRC Emissions CommitteeMay 14, 20092CRC-DOE confidential – Do not CiteOverviewDOE V4 Project: Vehicle aging and Catalyst Durability•a.k.a. CRC E-87-2−Follow-up to DOE V1 (16 vehicle emissions/WOT study) andCRC E-87-1 WOT study•E-87-1 screened 25 vehicles−DOE/Labs selected 12 vehicle models•DOE V1 screened 16 vehicles (with some overlap of E87 and V2/EPAct vehicle models)•Competitive solicitation in 2008−Contract through ORNL−Award to SwRI – October 2008•DOE is supporting 2 additional parallel contracts toexpand and accelerate data collection−ORNL => TRC−NREL => ETC3CRC-DOE confidential – Do not CiteV4/E-87-2 Workplan Overview•Acquire 2-4 “matched” vehicles for each model, dedicate each toE0, E10, E15, or E20 for aging−Vehicle inspection, recruitment−Correlation FTP and WOT to confirm proper operation−Vehicles instrumented similar to E-87-1 and V1 (UEGOs andthermocouples)−Dedicate vehicles to a fuel for aging on MAD or test track(E0, E10, E15, E20 or some subset)1.Emissions test all vehicles with E0, in duplicate2.Emissions test vehicles on respective E-blend, in duplicate3.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*mileage intervaldependent on age.4k, 60k, 90k, 120ktest interval onnew vehicles atTRC and ETC4CRC-DOE confidential – Do not CiteE87-2 (V4) - Catalyst AgingTable shows protocol for 1 vehicle type at SwRIBaselineSRCAging50kEmissionsEmissionsE0E0 + E10E0 + E15E0 + E20E0E0 + E10E0 + E15E0 + E20E0E0 + E10E0 + E15E0 + E20RE0RE10RE15RE20RE0RE10RE15RE20SRC Agingto FUL5CRC-DOE confidential – Do not CiteRecent modification:Add WOT tests ateach emissions test interval•WOTs at each emissions interval (instead of only atproject start)•Recent 50k test on Hondas: each vehicle got E0 andE20 WOTQuestion: What fuels should we run on mid-life and fulllife WOTs?Proposal:•At project start, each vehicle gets E0 and E20 WOT•E10 and E15 vehicles get WOT on their fuel as well•Subsequent WOTs at emissions test with dedicated eblend and E0 only−Avoids need for additional E20 prep on 3 vehicles−Avoids additional exposureof non-E20 vehicles to E206CRC-DOE confidential – Do not CiteV4 Project Status•Vehicle emissions testing and agingunderway at SwRI (E-87-2 with CRC)−Aging on mileage accumulationdynamometers−20 vehicles purchased and under test (5matched 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 (4matched 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 – 2fuels per model)•additional vehicles TBDFord TaurusNissan AltimaChevy SilveradoTRC TrackMAD ConsolesHondaAccord7CRC-DOE confidential – Do not CiteSwRI Program Status•SwRI has purchased 21 vehicles−5 models, 4 matched vehicles per model, 1 vehicle per fuel for aging•2007 Accordcompleted 50k•2006 Chevrolet Silveradoapproaching 50k•2008 Nissan Altimacompleted 0k, on MADs•2008 Ford Taurusinstrumentation•2007 Dodge Caravanpurchased•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 Altima−Selector gate blocked−Ford Taurus manifold – instrumentation challenge8CRC-DOE confidential – Do not Cite2006 Silverado Safety Shutdown CircuitHot in Run and StartExternal 20 ampnormally-opendouble-throw relayActive when MAD is enabledBank 1 and 2 fusesfor coils andinjectorsBank 1 fuelinjectorsBank 2 ignitioncoilsBank 1 ignitioncoilsBank 2 fuelinjectors•Similar circuits and logicbeing applied to othervehicles•No new safeties employedwithout consultation/agreement of that OEM9CRC-DOE confidential – Do not CiteSignage and metal plate over shift gateto prevent Nissan incident from recurring10CRC-DOE confidential – Do not CiteFord Taurus UEGO Placement•Close-coupled catalyst creates instrumentationchallenge−No space between cast exh manifold and first cat•Options considered:−Fabricate spacer, install b/wcatalyst and exhaust manifold−Install only for emissions and WOT testing−Weld UEGO boss to manifold−Concern about cracking weld or manifold•Swap manifolds before emissions/WOT tests – OR - Leave on forduration−Drill and Tap manifold−Swap manifolds before emissions/WOT tests – OR -Leave on for duration•SwRI recommends drill and tap of manifold(me too)−Leave on car for duration. Checkintegrity of UEGO plug ateach service interval11CRC-DOE confidential – Do not CiteTaurus Exhaust presentschallenge for UEGO placement12CRC-DOE confidential – Do not CiteTaurus - Spacer Option•Fabricate spacer,install b/w catalystand exhaust manifold•Install only foremissions and WOTtesting•Could be insulated13CRC-DOE confidential – Do not CiteTaurus–Drill and Tap OptionDrill and tap manifold−Use extra care ininstallinginstrumentation−Leave manifold onfor duration(remove UEGO,install plug foraging)−Inspect at eachservice intervalOEMUEGO14CRC-DOE confidential – Do not Cite•Several relevant criteriaimpact vehicle selection−Model year, emissions standard (e.g., Tier 2, non-Tier 2)−Manufacturer, sales volumes−LFT or non-LFT at WOT•Guidance and screening studies impact selection−EPA V2 vehicle list (19 popular models – test all)−CRC E-87-1 (e.g., “CRC Top Ten” non-LFT vehicles)−DOE V1 (additional info on LFT/non-LFT)•DOE/EPA guidance of January 2009 and April 2009−Test all V2 vehicle models, multiple model years okay•CRC Proposal of November 2008 (20 vehicles)−50/50 LFT and non-LFT•70% Tier 2•30% NLEV/Tier 1Vehicle Selection Challenge15CRC-DOE confidential – Do not Cite40 Vehicles Currently Under Test at 3 Sites13 models, 2006-2009, Tier2, all on V2/EPA EPAct list(with some model yearvariation). Many V2 modelsscreened in V1 and E-87-1.Year Vehicle number2006 Chevrolet Silverado 4E0E10E15E202007 Honda Accord 4E0E10E15E202008 Nissan Altima 4E0E10E15E202008 Ford Taurus 4E0E10E15E202007 Chrysler Caravan 4E0E10E15E20TBD TBD TBDYear Vehicle number2009 Jeep Liberty 3E0E15E202009 Ford Explorer 3E0E15E202009 Honda Civic 3E0E15E202009 Toyota Corolla 3E0E15E20TBDTBD TBDEnvironmental Testing Corp (Colorado), mileage accumulation dynamometersYear Vehicle number2009 Saturn Outlook 2E0E152009 Toyota Camry 2E0E152009 Ford Focus 2E0E152009 Honda Odyssey 2E0E15TBDTBD TBDFuelsSouthwest Research Institute (Texas), mileage accumulation dynamometers (E-87-2)TBDFuelsV4 Project Vehicle Summary (Vehicle Aging)TBDTransportation Research Center (Ohio), test track agingFuelsTBD20Vehicles12Vehicles8vehicles16CRC-DOE confidential – Do not CitePlanned V4/E-87-2 Fleet Mix(19 models, 58 vehicles)Black text: veh under test;Red text: proposed for next phasesYear make/model no vehicles/fuelsYear make/modelno vehicles/fuels2006 Chevrolet Silverado 4 (E0, E10, E15, E20)2007 Honda Accord4 (E0, E10, E15, E20)2008 Ford Taurus4 (E0, E10, E15, E20)2007 Chrysler Caravan 4 (E0, E10, E15, E20)2008 Nissan Altima4 (E0, E10, E15, E20)2005 Toyota Sienna 3 (E0, E15, E20)2006 Chevrolet Cobalt 3 (E0, E15, E20)2007 Dodge Caliber 3 (E0, E15, E20)2009 Ford Explorer 3 (E0, E15, E20)2009 Honda Civic3 (E0, E15, E20)2009 Toyota Corolla 3 (E0, E15, E20)2009 Jeep Liberty3 (E0, E15, E20)2006 Chevrolet Impala 3 (E0, E15, E20)2004 Toyota Tundra 3 (E0, E15, E20)2005 Ford F1503 (E0, E15, E20)2009 Saturn Outlook 2 (E0, E15)2009 Honda Odyssey 2 (E0, E15)2009 Toyota Camry 2 (E0, E15)2009 Ford Focus 2 (E0, E15)SwRITRCETCVehicles with LFT at WOT*Vehicles that DO NOT apply LFT at WOT*Vehicles Currently Under Test (or in acquisition) - BLACK.Proposed - RED* LFT based on screening inV1 or E-87-1 or best guess at this time17CRC-DOE confidential – Do not CiteSummary of proposed plan forward forV4 vehicle selection(red=currently under test)•19 models(13)−4 GM(2)−4 Ford(3)−3 Chrysler(2)−4 Toyota(2)−3 Honda(3)−1 Nissan(1)•11 confirmed orexpected LFT atWOT(7)•8 confirmed orexpected non-LFTat 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 SwRI Program−8 models, 29 vehicles•5 models x 4 fuels•3 models x 3 fuels•3 LFT, 5 non-LFT•2005-200818CRC-DOE confidential – Do not CiteProject Review Meeting in San Antonio•Following Dates proposed−June 9−June 11−June 16−June 17•8-2:30 (tours 3-5 PM if available/interested)19CRC-DOE confidential – Do not CiteThank YouBrian Westwestbh@ornl.gov865-946-123120CRC-DOE confidential – Do not CiteBackup Slides21CRC-DOE confidential – Do not CiteV1- Test VehiclesOEM (make)ModelYearEngineInitialodometerreading(miles)EmissionstandardTest siteLFT atWOT?ChryslerTown & Country20073.3 L V635,000Tier 2, Bin 5NREL/CDPHENFordF15020075.4 L V828,600Tier 2, Bin 8TRCYFordF15020035.4 L V857,000Tier 1 LEVTRCYFordTaurus20033.0 L V689,600Tier 2, Bin 8TRCNGM (Buick)Lucerne20073.8 L V610,000Tier 2, Bin 5 (CALEV II)NREL/CDPHE andORNL*YGM (Buick)LeSabre20033.8 L V678,000Tier 2, Bin 8NREL/CDPHEYGMSilverado20074.8 L V812,800Tier 2, Bin 8TRCYHondaAccord20072.4 L I411,400Tier 2, Bin 5 (CALEV II)TRCNNissanAltima20033.5 L V653,300LEVTRCNToyotaCamry20072.4 L I426,440Tier 2, Bin 5ORNL andNREL/CDPHE*YToyotaCamry20032.4 L I472,800ULEVORNLNChryslerPT Cruiser20012.4 L I493,400NLEVNREL/CDPHEYFordCrown Victoria19994.6 L V850,900ULEVNREL/CDPHEYHondaCivic19991.6 L I479,680Tier 1ORNLNToyotaCorolla19991.8 L I496,400Tier 1NREL/CDPHEYVWGolf GTI20041.8 L I4 Turbo32,900Tier 2, Bin 8ORNLY*Round-robin vehicle tested at two sites22CRC-DOE confidential – Do not CiteV2 - EPAct Program VehiclesMake Year Brand ModelEngine Family BinGM 2008 Chevrolet Cobalt 2.2L I4 8GMXV02.4025 5GM 2008 Chevrolet Impala 3.5L V6-FFV 8GMXV03.9052 5GM 2008 Saturn Outlook 3.6L V6 8GMXT03.6151 5GM 2008 Chevrolet Silverado 5.3L V8-FFV 8GMXT05.3373 5Toyota 2008 Toyota Corolla1.8L I4 8TYXV01.8BEA 5Toyota 2008 Toyota Camry2.4L I4 8TYXV02.4BEA 5Toyota 2008 Toyota Sienna3.5L V6 8TYXT03.5BEM 5Toyota 2008 Toyota Tundra4.0L V6 8TYXT04.0AES 5Ford 2008 Ford Focus2.0L I4 8FMXV02.0VD4 4Ford 2008 Ford Taurus3.5L V6 8FMXV03.5VEP 5Ford 2008 Ford/Mercury Explorer/Mountaineer 4.0L V6 8FMXT04.03DB 4Ford 2008 Ford F1505.4L V8-FFV 8FMXT05.44HF 8Chrysler 2008 DodgeCaliber2.4L I4 8CRXB02.4ME0 5Chrysler 2008 DodgeCaravan3.3L V6-FFV 8CRXT03.3NEP 5Chrysler 2008 JeepLiberty3.7L V6 8CRXT03.7NE0 5Honda 2008 Honda Civic1.8L I4 8HNXV01.8LKR 5Honda 2008 Honda Accord2.4L I4 8HNXV02.4TKC 5Honda 2008 Honda Odyssey3.5L V6 8HNXT03.54KR 5Nissan 2008 Nissan Altima2.5L I4 8NSXV02.5G5A 5