Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

CRC Project No. CM CRC Project No. CM

-1

Engine Durability Study of Mid Engine Durability Study of Mid

-Level Et

Level Et

Mid

-Level Ethanol Research Coordination G

Level Ethanol Research Coordination G

May 5, 2010

Presented by Coleman Jones, GM

Jaime Dettore, Henning Kleeberg, FEV, Inc.
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Contents Background Objective & Vehicle Selection Engine Test Life Cycle Engine Durability Cycle Engine Data Measurements Engine Service Intervals Set up of Engines in Test Cells Current Testing Status Next Steps Results

 Engine Specific Data  General Summary
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

BackgroundThere is interest in expanding the amount of ethanol that c

conventional vehicles beyond the current 10% limit. This is 

 Rising ethanol production from the Energy Independence an

passed in December 2007. This mandates 35 billion ethanol gallons of bio-fuel be used by 2022

 Growth Energy's waiver application for E15

Higher ethanol content would have an impact on 2 main aengine and emissions performance:

 Valve wear and valve seat wear

Abrasive and adhesive wear and corrosionCan lead to compression loss, misfire, and catalyst damag

 Catalyst Durability

Results from ethanol effects on calibration
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Study ObjectiveThis study will investigate the effects of a mid-level ethanostarting with E20, on the current on-road, non-flex fuel vehpopulation. The effects of the fuel on engine durability will detail. Engines failing on E20 will be referenced on E0 and then retesVehicle SelectionCurrent test plan envisions testing 8 vehicle types with moranging from 2001 to 2009. Two vehicles of each type wileach fuel. The first pairs of vehicles selected are as follow

 2004 Scion xA, 1.5L I4 Tier 2 Bin 9; (61,351 & 56,67 2005 Chevy Colorado, 3.5L I5 Tier 2 Bin 9; (48,109 & 33,97 2007 Ford Edge, 3.5L V6 Tier 2 Bin 5; (17,906 & 14,45 2009 Dodge Caliber, 2.4L I4 Tier 2 Bin 4; (11,941 & 12,49
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Test Lifecycle1. Pre-test vehicle to ensure the vehicle meets emission

engineering specifications and document condition

2. Run aging cycle3. Post-test engine and catalyst to determine if there are 

changes
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Durability CycleThe following durability cycle is used to test the engine d

a mid-level ethanol blend fuel:The test lasts for 500 total cycles and each cycle is 60 mduration. The maximum speed for any engine was 3500 RPM. 

 This was chosen because high speed testing can conceal 

increasing oil pullover through PCV and lubricating valve s

 This test cycle is substantially less severe than a standard 

durability cycle and should ensure that the engine will com
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Data Measurements

Measurement Description

Measureme

SOT E

5

Vehicle FTP 75

A baseline emissions test is completed on the vehicle to determine that it meets the required specifications for emissions levels

X

Valve Measurements

Valve clearance measurements are conducted per the service manual unless otherwise instructed by the OEM.

X 

Engine Dynamometer FTP

The same schedule that was completed on the vehicle level was replicated at the engine/dyno level to correlate the results from the vehicle to the engine dyno.

X 

Engine 7 Steady State Point FTP correlation

It calculates the areas of concentrated operation points and reduces the second by second data (speed and load) from the FTP 75 into 7 representative points. These 7 speed & load points are run every 50 hours.

X

Cylinder Compression

If any value is below service manual limits, then the technical contact is notified immediately

X

Leakage

If any of the values is above the 10% threshold, the technical contact is notified immediately

X
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Service Intervals The figure below illustrates the service intervals for all e

Engine Checks every 50 hours

0 50 100 150 200 250 300 350 400 

Engine Fluid Levels X X X X X X X X X Oil & Filter Change X X X X X X X X X Oil Sample & Keep Oil Filter X X X X X X X X X Cylinder Compression X X X X X X X X X Cylinder Leak-Down X X X X X X X X X Spark Plug Inspection X X X X Spark Plug Change X X X X X Air Filter Replacement X X X X X Valve Clearance Measurement X 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Set-up of Engines in Test Cells The figure below shows the engine combinations in each of th

North

Cell 4 Cell 5

Dyno 1 Dyno 3

Dyno 2 Dyno 4

2005 Chevy Colorado

164 kW @ 5600

305 Nm @ 2800

2007 Ford Edge

198 kW @ 6250

339 Nm @ 4500

2009 Dodge Caliber

128 kW @ 6000

224 Nm @ 4400

2004 Scion xA

81 kW @ 6000

142 Nm @ 4200
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Set-up of Engines in Test Cells Test Cell 4

 Engine Setup 20

C

164 

305 

20

128 

224 

North
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Set-up of Engines in Test Cells Test Cell 5

 Engine Setup

North

200

198 

339 

20

81 

142 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Set-up of Engines in Test Cells

The Chevy Colorado, Scion xA, Ford Edge and Dodge C

an umbilical setup for this testing. The vehicle shells are loutside the test cell and wire extensions are made to connengine harness to the vehicle harness. 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Current Status Completion Status of the first 4 vehicles shown below:

Round 1 Vehicles

2004

Scion xA 

(black)

2005

Chevy Colorado 

(red)

2007

Ford Edge 

(white)

100%

Individual Vehicle Report-out / Anaylsis 3% End

EOT 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% Start

93% 100% 100% 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Current Status Completion Status of the second 4 vehicles shown below:

Round 2 Vehicles

2004

Scion xA 

(silver)

2005

Chevy Colorado 

(white)

2007

Ford Edge 

(red)

100%

Individual Vehicle Report-out / Anaylsis 3% End

EOT 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% Start

18% 91% 71% 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Timeline The current timeline is shown below:

Timing Plan for Durability Test

Description 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 & checks

Apr

Ap

11 12 13 14 15 16 

Apr Apr

3 4 5 6 7 8 9 10

Dodge 

Caliber

Chevy 

Colorad

o

Ford 

Edge Scion xA

Jan Jan Jan/Feb Feb Feb Feb Feb/ Ma Mar Mar Mar

Mar / Ap
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

General Test Summary Some select test results are found on the following page
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Scion xA (black)

 The Scion xA has passed all the main checks for the 500 h

issue. 

 Valve leakage was less than 10% at EOT. Compression was within specification at EOT. Valve clearance measurements were found to be within 

specification required in the service manual.

 No Diagnostic Trouble Codes (DTC) were found related 

other emissions items.

 The FTP simulation data is currently ongoing, so no eva

possible at this time.
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Chevy Colorado (red)

 The Chevy Colorado has passed all the main checks for the 

except for leakage. 

 At 500 hrs, the leakage measurements on cylinders 3 & 5 w

18%, respectively. All other cylinders were OK.

 An additional 50 hours was run at EOT. The leakage mea

cylinders 3 & 5 were 15% and 9%, respectively. 

LEAKDOWN (%)

05

10152025 Cylinder #1

LEAKDOWN (%)

05

10152025

CYCLE

0 50 100 150 200 250 300 350 400 450 500 550

Cylinder #3

LEAKDOWN (%)

05

10152025

Cylinder #2

LEAKDOWN (%)

05

10152025

Cylinder #4

LEAKDOWN (%)

05

10152025

CYCLE

0 50 100 150 200 250 300 350 400 

Cylinder #5
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Chevy Colorado (red) cont’d

 Compression and valve clearance measurements were fou

the specification required at EOT

 No DTC’s were found related to fuel or other emissions item The FTP simulation data showed that the engine would hav

emissions testing at EOT.

Engine teardown revealed that in cylinder #3, there was u

and pitting on the intake valve seats.

 This has been seen by the OEM as an effect of ethanol we

 This test was considered a failure.

2005 Chevy Colorado (red) 3.5L I5

Applicable (Lowest) 

Emission Standard

Certification 

Results

Vehicle Emission 

Results

Dyno SOT FTP 

equiv g/mile

Dyno EOT FTP 

equiv g/mile

Delta 

to 

CO 4.2 0.7 0.2524 1.5720 3.1130 1.5

THC 0.0949 0.3033 0.3175 0.0

NOX 0.3 0.2 0.0843 0.0342 0.1858 0.1

CO2 507.50 562.20 54.

FE 19.3 17.57 17.44 15.68 -1.7
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Ford Edge (white)

 The Ford Edge passed all the main checks for the 500 hou

 Leakdown measurements all remained below 10% for a

 Compression was within specification at EOT. Valve clearance measurements were found to be within 

specification required.

 No DTC’s were found related to fuel or other emissions  The FTP simulation data showed that the engine would 

emissions testing at EOT.

2007 Ford Edge (white) 3.5L V6

Applicable (Lowest) 

Emission Standard

Certification 

Results

Vehicle Emission 

Results

Dyno SOT FTP 

equiv g/mile

Dyno EOT FTP 

equiv g/mile

Delta SOT 

EOT

CO 1.7 0.82 0.4414 1.7030 2.0560 0.3530 

THC 0.0298 0.1520 0.2936 0.1416 

NO

X 0.05 0.031 0.025 0.0622 0.0432 -0.0190 

CO2 537.70 523.00 -14.7000 

FE 20.1 18.29 16.47 16.90 0.4280 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Dodge Caliber (silver)

 The Dodge Caliber passed all the main checks for the 500 h

leakage and the emission results. The emissions results are under further investigation. 

 The increase leakage in the beginning of test is likely attr

engine not being complete broken in at the start of test. Tstabilized over time and gave consistent compression anresults for the second half of testing

 At 500 hrs, the leakdown measurements on cylinder 4 inc

Engine Leakdown (%)

(%)

05

101520 Cylinder #1

 (%)

05

101520

Cycle

0.0 50.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0 450.0 500.0

Cylinder #4

(%)

05

101520 Cylinder #2

 (%)

05

101520 Cylinder #3
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Dodge Caliber (silver) cont’d

 Compression was within specification at EOT. Valve clearance measurements were found to be within the 

required.

 No DTC’s were found related to fuel or other emissions item The FTP simulation data results are currently being investig

and will be reported out at a later date.
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Engine Specific Data (preliminary) Dodge Caliber (blue)

 The Dodge Caliber passed all the main checks for the 500 

for the emission; these results are currently under investiga

 Leakdown measurements all remained below 10% for a Compression was within specification at EOT. Valve clearance measurements were found to be within 

specification required.

 No DTC’s were found related to fuel or other emissions  The FTP simulation data results are currently being inve

further and will be reported out at a later date.
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

General Test Summary The results of the testing are found on the following pag Summary of Durability Testing Results (V1 = vehicle 1, V

Emissions DTC

Valve 

Clearance Compressi

V1 - 2004 Scion xA (black) TBD Pass Pass Pass V1 - 2005 Chevy Colorado (red) Pass Pass Pass Pass V1 - 2007 Ford Edge (white) Pass Pass Pass Pass V1 - 2009 Dodge Caliber (silver) TBD

(under further 

investigation)

Pass Pass Pass 

V2 - 2004 Scion xA (silver)V2 - 2005 Chevy Colorado (white)V2 - 2007 Ford Edge (red)V2 - 2009 Dodge Caliber (blue) TBD

(under further 

investigation)

Pass Pass Pass 
Mid-Level Ethanol Blend, Engine Durability – May 201

CRC Project No. CM-136-09-1B 

Next Steps FEV will continue with execution of the program as follow

 Finish durability evaluation of Round 2 (second set of 4) eng

 EOT FTP cycle simulation

 Periodic engine measurements at FTP correlation points 500 hour durability schedule with standardized maintena Conduct EOT engine measurements for valve wear 

 Procurement of next vehicles is ongoing. These next vehicl

2001 MY Honda CRV 2.0L (add emissions levels)2007 MY Dodge Ram 5.7L 2009 MY Chevrolet Aveo 1.6L2002 MY VW Jetta 2.0L 

Vehicles types that have failed E20 testing will be reference Vehicles types that pass on E0 will be tested on E15Complete Final Report for delivery to CRC