Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B1CRC Project No. CMCRC Project No. CM-136-09-1BEngine Durability Study of MidEngine Durability Study of Mid-Level Ethanol BlendsLevel Ethanol BlendsMid-Level Ethanol Research Coordination Group MeetingLevel Ethanol Research Coordination Group MeetingMay 5, 2010Presented by Coleman Jones, GMJaime Dettore, Henning Kleeberg, FEV, Inc.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B2ContentsBackgroundObjective & Vehicle SelectionEngine Test Life CycleEngine Durability CycleEngine Data MeasurementsEngine Service IntervalsSet up of Engines in Test CellsCurrent Testing StatusNext StepsResultsEngine Specific DataGeneral SummaryMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B3BackgroundThere is interest in expanding theamount of ethanol that can be used inconventional vehicles beyond the current 10% limit. This is due to:Rising ethanol production from the Energy Independence and Security Act,passed in December 2007. This mandates 35 billion ethanol equivalentgallons of bio-fuel be used by 2022Growth Energy's waiver application for E15Higher ethanol content would have animpact on 2 main areas of theengine and emissions performance:Valve wear and valve seat wearAbrasive and adhesive wear and corrosionCan lead to compression loss, misfire, and catalyst damageCatalyst DurabilityResults from ethanol effects on calibrationMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B4Study ObjectiveThis study will investigate the effects of a mid-level ethanol blends,starting with E20, on the current on-road, non-flex fuel vehiclepopulation. The effects of the fuelon engine durability will be studied indetail.Engines failing on E20 will be referenced on E0 and then retested on E15Vehicle SelectionCurrent test plan envisions testing 8 vehicle types with model yearsranging from 2001 to 2009. Two vehicles of each type will be tested oneach fuel. The first pairs of vehicles selected are as follows:2004 Scion xA, 1.5L I4 Tier 2 Bin 9; (61,351 & 56,671 Miles)2005 Chevy Colorado, 3.5L I5 Tier 2 Bin 9; (48,109 & 33,972 Miles)2007 Ford Edge, 3.5L V6 Tier 2 Bin 5; (17,906 & 14,450 Miles)2009 Dodge Caliber, 2.4L I4 Tier 2 Bin 4; (11,941 & 12,494 Miles)Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1BEngine Test Lifecycle1.Pre-test vehicle to ensure the vehicle meets emissions andengineering specifications and document condition2.Run aging cycle3.Post-test engine and catalyst to determine if there are anychangesMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B6Durability CycleThe following durability cycle is used to test the engine durability usinga mid-level ethanol blend fuel:The test lasts for 500 total cycles and each cycle is 60 minutes induration.The maximum speed for any engine was 3500 RPM.This was chosen because high speed testing can conceal wear issues byincreasing oil pullover through PCV and lubricating valve seats.This test cycle is substantially less severe than a standard high RPMdurability cycle and should ensure that the engine will complete the test.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B7Engine Data MeasurementsMeasurementDescriptionMeasurement FrequencySOTEvery50 hrsEOTVehicle FTP 75A baseline emissions testis completed on thevehicle to determine thatit meets the requiredspecifications for emissions levelsXValveMeasurementsValve clearance measurements are conductedper the service manual unless otherwiseinstructed by the OEM.X XEngineDynamometerFTPThe same schedule that was completed on thevehicle level was replicated at the engine/dynolevel to correlate the results from the vehicle tothe engine dyno.X XEngine 7 SteadyState Point FTPcorrelationIt calculates the areas of concentratedoperation points and reduces the second bysecond data (speed and load) from the FTP 75into 7 representative points. These 7 speed &load points are run every 50 hours.XX XCylinderCompressionIf any value is below service manual limits,then the technical contact is notifiedimmediatelyXX XLeakageIf any of the valuesis above the 10%threshold, the technical contact is notifiedimmediatelyXX XMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B8Engine Service IntervalsThe figure below illustrates the service intervals for all engines:Engine Checks every 50 hours0 50 100 150 200 250 300 350 400 450 500Engine Fluid Levels X X X X X X X X X X XOil & Filter Change X X X X X X X X X X XOil Sample & Keep OilFilter X X X X X X X X X X XCylinder Compression X X X X X X X X X X XCylinder Leak-Down X X X X X X X X X X XSpark Plug Inspection X X X X XSpark Plug Change X X X X X XAir Filter Replacement X X X X X XValve ClearanceMeasurement X XMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B9Set-up of Engines in Test CellsThe figure below shows the engine combinations in each of the test cells..NorthCell 4Cell 5Dyno 1 Dyno 3Dyno 2Dyno 42005 Chevy Colorado164 kW @ 5600305 Nm @ 28002007 Ford Edge198 kW @ 6250339 Nm @ 45002009 Dodge Caliber128 kW @ 6000224 Nm @ 44002004 Scion xA81 kW @ 6000142 Nm @ 4200Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B10Set-up of Engines in Test CellsTest Cell 4Engine Setup2005 ChevyColorado164 kW @ 5600305 Nm @ 28002009 DodgeCaliber128 kW @ 6000224 Nm @ 4400DynoDynoNorthMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B11Set-up of Engines in Test CellsTest Cell 5Engine SetupNorth2007 Ford Edge198 kW @ 6250339 Nm @ 45002004 Scion xA81 kW @ 6000142 Nm @ 4200DynoDynoMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B12Set-up of Engines in Test CellsThe Chevy Colorado, Scion xA, Ford Edge and Dodge Caliber requirean umbilical setup for this testing. The vehicle shells are locatedoutside the test cell and wire extensions are made to connect theengine harness to the vehicle harness.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B13Current StatusCompletion Status of the first 4 vehicles shown below:Round 1 Vehicles2004Scion xA(black)2005Chevy Colorado(red)2007Ford Edge(white)2009Dodge Caliber(silver)100%Individual Vehicle Report-out / Anaylsis 3%EndEOT Valve Clearance Msmts 2%End of Test FTP evaluation 4%500 Hr Durability Testing with checks 45%SOT checks 3%Run initial FTP cycle & review 3%Initial setup of dyno FTP cycle 4%Set up Data Monitoring Systems 3%Initial Startup and Debug 5%Install Engine in Test Cell 10%SOT Valve Clearance Msmts 2%Remove Engine From Vehicle 4%Vehicle FTP Testing 6%Initial Compression/Leakdown 2%Acquire Vehicle 2%Research Vehicle 2%Start93% 100% 100% 100%Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B14Current StatusCompletion Status of the second 4 vehicles shown below:Round 2 Vehicles2004Scion xA(silver)2005Chevy Colorado(white)2007Ford Edge(red)2009Dodge Caliber(blue)100%Individual Vehicle Report-out / Anaylsis 3%EndEOT Valve Clearance Msmts 2%End of Test FTP evaluation 4%500 Hr Durability Testing with checks 45%SOT checks 3%Run initial FTP cycle & review 3%Initial setup of dyno FTP cycle 4%Set up Data Monitoring Systems 3%Initial Startup and Debug 5%Install Engine in Test Cell 10%SOT Valve Clearance Msmts 2%Remove Engine From Vehicle 4%Vehicle FTP Testing 6%Initial Compression/Leakdown 2%Acquire Vehicle 2%Research Vehicle 2%Start18% 91% 71% 100%Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B15TimelineThe current timeline is shown below:Timing Plan for Durability TestDescription of Taskweek #day#4 weeks for 500 hr test & checksSwap Engines & prepRound 2: 4 weeks for 500 hr test & checks4 weeks for 500 hr test & checksSwap Engines & prepRound 2: 4 weeks for 500 hr test & checks4 weeks for 500 hr test & checksSwap Engines & prepRound 2: 4 weeks for 500 hr test & checks4 weeks for 500 hr test & checksSwap Engines & prepRound 2: 4 weeks for 500 hr test & checks19 20 21May May MayMay18AprApr/May16 171511 12 13 14Apr Apr3 4 5 6 7 8 9 10

Dodge Caliber

Chevy Colorad o

Ford Edge Scion xAFebJan JanJan/FebMar / ApFeb/ Ma Mar Mar MarFeb FebMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B16General Test SummarySome select test results are found on the following pages.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B17Engine Specific Data (preliminary)Scion xA (black)The Scion xA has passed all themain checks for the 500 hours withoutissue.Valve leakage was less than 10% at EOT.Compression was within specification at EOT.Valve clearance measurements were found to be within thespecification required in the service manual.No Diagnostic Trouble Codes (DTC) were found related to fuel orother emissions items.The FTP simulation data is currently ongoing, so no evaluation ispossible at this time.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B18Engine Specific Data (preliminary)Chevy Colorado (red)The Chevy Colorado has passed all the main checks for the 500 hoursexcept for leakage.At 500 hrs, the leakage measurements on cylinders 3 & 5 were 22% and18%, respectively. All other cylinders were OK.An additional 50 hours was run atEOT. The leakage measurements oncylinders 3 & 5 were 15% and 9%, respectively.

LEAKDOWN (%)0510152025Cylinder #1

LEAKDOWN (%)0510152025CYCLE050100150200250300350400450500550Cylinder #3

LEAKDOWN (%)0510152025Cylinder #2 LEAKDOWN (%)0510152025Cylinder #4

LEAKDOWN (%)0510152025CYCLE050100150200250300350400450500550Cylinder #5Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B19Engine Specific Data (preliminary)Chevy Colorado (red) cont’dCompression and valve clearance measurements were found to be withinthe specification required at EOTNo DTC’s were found related to fuel or other emissions items.The FTP simulation data showed that the engine would have passedemissions testing at EOT.Engine teardown revealed that incylinder #3, there was uneven wearand pitting on the intake valve seats.This has been seen by the OEM as an effect of ethanol wear.This test was considered a failure.2005 Chevy Colorado (red) 3.5L I5Applicable (Lowest)Emission StandardCertificationResultsVehicle EmissionResultsDyno SOT FTPequiv g/mileDyno EOT FTPequiv g/mileDelta SOTto EOTSOT VehicleResults + DeltaCO4.2 0.7 0.2524 1.5720 3.1130 1.54101.7934g/mileTHC0.0949 0.3033 0.3175 0.0142 0.1091 g/mileNOX0.3 0.2 0.0843 0.0342 0.1858 0.15160.2359g/mileCO2507.50 562.20 54.7000 g/mileFE19.3 17.5717.44 15.68 -1.7548 mpgMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B20Engine Specific Data (preliminary)Ford Edge (white)The Ford Edge passed all the main checks for the 500 hours.Leakdown measurements all remainedbelow 10% for all 500 hours.Compression was within specification at EOT.Valve clearance measurements were found to be within thespecification required.No DTC’s were found related to fuel or other emissions items.The FTP simulation data showed that the engine would have passedemissions testing at EOT.2007 Ford Edge (white) 3.5L V6Applicable (Lowest)Emission StandardCertificationResultsVehicle EmissionResultsDyno SOT FTPequiv g/mileDyno EOT FTPequiv g/mileDelta SOT toEOTSOT VehicleResults + DeltaCO1.7 0.82 0.4414 1.7030 2.0560 0.35300.7944g/mileTHC0.0298 0.1520 0.2936 0.1416 0.1714 g/mileNOX0.05 0.031 0.025 0.0622 0.0432 -0.01900.0060g/mileCO2537.70 523.00 -14.7000 g/mileFE20.1 18.2916.47 16.90 0.4280 mpgMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B21Engine Specific Data (preliminary)Dodge Caliber (silver)The Dodge Caliber passed all the mainchecks for the 500 hours except forleakage and the emission results. The emissions results are currentlyunder further investigation.The increase leakage in the beginning of test is likely attributed to theengine not being complete broken in at the start of test. The ring frictionstabilized over time and gave consistent compression and leakageresults for the second half of testingAt 500 hrs, the leakdown measurements on cylinder 4 increased to 11%Engine Leakdown (%)

(%)05101520Cylinder #1

(%)05101520Cycle0.050.0100.0150.0200.0250.0300.0350.0400.0450.0500.0Cylinder #4

(%)05101520Cylinder #2

(%)05101520Cylinder #3Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B22Engine Specific Data (preliminary)Dodge Caliber (silver) cont’dCompression was within specification at EOT.Valve clearance measurements were found to be within the specificationrequired.No DTC’s were found related to fuel or other emissions items.The FTP simulation data results are currently being investigated furtherand will be reported out at a later date.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B23Engine Specific Data (preliminary)Dodge Caliber (blue)The Dodge Caliber passed all the main checks for the 500 hours exceptfor the emission; these results are currently under investigation.Leakdown measurements all remainedbelow 10% for all 500 hours.Compression was within specification at EOT.Valve clearance measurements were found to be within thespecification required.No DTC’s were found related to fuel or other emissions items.The FTP simulation data results are currently being investigatedfurther and will be reported out at a later date.Mid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1B24General Test SummaryThe results of the testingare found on the following pages.Summary of Durability Testing Results(V1 = vehicle 1, V2 = vehicle 2):EmissionsDTCValveClearanceCompressionLeakageV1 - 2004 Scion xA (black)TBD Pass Pass Pass PassV1 - 2005 Chevy Colorado (red)Pass Pass Pass PassFailV1 - 2007 Ford Edge (white)Pass Pass Pass Pass PassV1 - 2009 Dodge Caliber (silver)TBD(under furtherinvestigation)Pass Pass PassFailV2 - 2004 Scion xA (silver)V2 - 2005 Chevy Colorado (white)V2 - 2007 Ford Edge (red)V2 - 2009 Dodge Caliber (blue)TBD(under furtherinvestigation)Pass Pass Pass PassMid-Level Ethanol Blend, Engine Durability – May 2010CRC Project No. CM-136-09-1BNext StepsFEV will continue with execution of the program as follows:Finish durability evaluation of Round 2 (second set of 4) enginesEOT FTP cycle simulationPeriodic engine measurements at FTP correlation points500 hour durability schedule with standardized maintenanceConduct EOT engine measurements for valve wearProcurement of next vehicles is ongoing. These next vehicles are:2001 MY Honda CRV 2.0L (add emissions levels)2007 MY Dodge Ram 5.7L2009 MY Chevrolet Aveo 1.6L2002 MY VW Jetta 2.0LVehicles types that have failed E20 testing will be reference tested on E0Vehicles types that pass on E0 will be tested on E15Complete Final Report for delivery to CRC