# SOUTHWEST RESEARCH INSTITUTE ®

6220 CULEBRA ROAD i POST OFFICE DRAWER 28510 i SAN ANTONIO, TEXAS, USA 78228-0510 i (210) 684-5111 i WWW.SWRI.ORG HTTP://ENGINEANDVEHICLE .SWRI.ORG
ENGINE, EMISSIONS, AND VEHICLE RESEARCH DIVISION ISO 9001 CERTIFIED FAX: (210) 522-3950 ISO 14001 Certified

SAN ANTONIO, TEXAS

HOUSTON, TEXAS i WASHINGTON, DC 

### July 15, 2009

Brian H. West Fuels, Engines, and Emissions Research Center Oak Ridge National Laboratory NTRC Building 2360 Cherahala Boulevard Knoxville, TN 37932

Subject: Monthly Progress Report No. 9 for the Pe riod June 1, through June 30, 2009; for theprogram, "Catalyst Screening and Durability for Intermediate Ethanol Blends," UTBattelle/Oak Ridge National Laborator y Subcontract No. 4000071456, SwRI Project 03.14530.

1.0 INTRODUCTION

The objective of this project is to help quantify emissions system durability of E15 and E20 on the US fleet. Specifically, this project will study the effects of ethanol blends on openloop stoichiometry and resulting ca talyst and oxygen sensor temperat ures. This project will also generate valuable data on vehi cle emissions and performance.

Vehicles selected for this st udy will include a wide range of manufacturers across several model years. Some of the vehicles that will be tested include vehi cles that have been identified as having leaner and hotter opera tion on ethanol blends than on gasoline when in wide-open throttle (WOT) open-loop operation. Other vehicles will be tested because of their large numbers in the in-use vehicle fleet. New vehicles with unknow n open-loop fuel control at WOT may also be selected.

In this project, SwRI will age vehicles and emission control systems operating on three levels of ethanol blended fuels (E10, E15, a nd E20) and compare emissions and vehicle performance to similar vehicles operating on the base gasoline (E0). Vehicle service accumulation and emissions testing are to be perf ormed on multiple sets of matched vehicles. For each matched set, vehicles are to be aged a nd emissions tested on the four fuel blends (E0, E10, E15, and E20). Emissions testing will be performed at three adde d service accumulation levels: 0 miles (start of service accumula tion), between 25,000 and 50,000 miles (mid service accumulation level), and at the end of the vehi cle’s full-useful life ( nominally 120,000 miles).Brian West Oak Ridge National Laboratory July 15, 2009 Page 2 of 4



### 2.0 PROGRESS FOR THE PE RIOD JUNE 1-30, 2009

2.1 Honda Accords, Chevrolet Silverados, and Nissan Altimas

The Honda Accord and Nissan Altima vehicle sets continued their service accumulation on the SwRI Mileage Accumulation Dynamomete rs this reporting peri od. The Chevrolet Silverado vehicle set completed 50,000 miles of service accumulation during the previous reporting period. Emissions testing began this period on the Silverado vehicle set, but was curtailed due to emissions equipment service a nd calibration checks. Silverado emissions and wide-open-throttle (WOT) testing is scheduled to resume next month.

Short- and long-term fuel trim data, along with lubricating oil change interval history to date, is given in Appendix A for the Honda Accord and Nissan Altima vehicle sets. Graphs of vehicle oil consumption are provided in Appendix B.

2.2 Ford Taurus’

The Ford Taurus vehicle set continued its preparation for emissions testing and service accumulation this past reporting period. The in strumented exhaust manifold approach to collecting exhaust system lambda and temper ature data was approved by Oak Ridge and CRC. Taurus vehicle set preparation is expected to be completed in July. The Taurus’ have begun exhaust manifold machining and manifo ld installation onto the vehicles.

2.3 Vehicle Procurement – Dodge Caravans

Southwest Research Institute took delivery of the four matching 2007 Dodge Caravan minivans equipped with 3.3L V-6 engines early in June. These vehicles have begun set-up for project testing and are scheduled for exhaust sy stem instrumentation and initial emissions and WOT testing in July. It is expected that the Caravan vehicle set will begin emissions testing ahead of the Ford Taurus vehicle set. Dodge Caravan vehicle specifi cations are provided in Appendix C. A photograph of the D odge Caravans is given in Figure 1.

2.4 Data Format and Archiving

Data format and archiving activities previous ly reported continued this reporting period. All previously obtained emissions test data has been reformatted and st ored in project test folders. Data presentation development and a review of the emissions limits of quantification (LOQ) and the limits of detection (LOD) will continue into the next reporting period.

2.5 Project Review Meeting held on June 17, 2009

A technical project review meeting was held on June 17, 2009, for Oak Ridge and CRC project committee members in San Antonio, Texas. The meeting covered the technical progress of the vehicle sets tested to date, including FTP emissions test results, the WOT performance test data, vehicle service accumulation, fuel blendi ng activities, and data format and archiving development. Several Oak Ridge/ CRC projec t committee members participated by telephone and video conference. Detailed meeti ng minutes are provided in Appendix D.Brian West Oak Ridge National Laboratory July 15, 2009 Page 3 of 4



### FIGURE 1. 2007 DODG E CARAVAN VEHICLE SET

3.0 WORK PLANNED FOR THE NEXT REPORTING PERIOD

The Silverado vehicle set will be re-sch eduled for mid-level (50,000 test mile) WOT performance and FTP emissions tests with emissi ons test fuels E0, E10, E15, and E20 following emissions systems service and calibration. The additional WOT performance tests previously requested will be included.

The Honda Accords will finish their vehicl e service accumulation to full-useful life on RE0, RE15, and RE20 fuels. These vehicles w ill undergo full-useful life emissions tests after other vehicle sets are emissions tested an d set-up on the SwRI Mileage Accumulation Dynamometers. Vehicle ORHA10B will continue its service accumulation to 50,000 test miles on RE10 fuel, and then begin its emissions testing. Following emi ssions testing, an additional SwRI Mileage Accumulation Dynamometer will be dedicated to Oak Ridge/CRC for vehicle ORHA10B when it is ready to begin serv ice accumulation to full-useful life.

The Nissan Altimas will continue service accumulation on the Mileage Accumulation Dynamometers. Altima vehicle service accumulation will continue through July.

The Ford Taurus vehicle set wi ll continue to be instrument ed for temperature and lambda measurement. Federal Test Procedure emissions and WOT performance testing will likely begin in August.Brian West Oak Ridge National Laboratory July 15, 2009 Page 4 of 4



### The four 2007 Dodge Caravans will begin ve hicle emissions and WOT testing. Data archiving and spreadsheet development will continue. Data presentation and archiving for statistical analysis will be de veloped in conjunction with John Orban at Battelle Institute.

4.0 CONCLUSION

If you have any questions regarding this proj ect report, please contact Marty Heimrich at (210) 522-3022 or by e-mail at mheimrich@swri.org

.
Prepared by: Reviewed by:

Martin J. Heimrich Jeff J. White Manager Director Department of Emissions Research Department of Emissions Research and Development and Development



### /sat

cc: Brent Shoffner, SwRI Kevin Brunner, SwRI

This report shall not be reproduced, ex cept in full, without the written approv al of Southwest Research Institute ®

. Results and discussion given in this report relate only to the test items described in this report.

## APPENDIX A

SHORT- AND LONG-TERM FU EL TRIM MEASUREMENTS AND OIL CHANGE INTERVAL HISTORY

Vehicle Sets Honda Accord Nissan AltimaA-1Honda AccordLong Term Fuel TrimDate Odometer Test FuelAverageDriveEnginecodes? Comments31,686Min. Max. Min. Max. Min. Max.After Zero Mile Emisions (E20 WOT) 1/20/2009 32,026 340 E20 3.9 4.6 4.6 4.6 4.6 5.4 4.63 NoApprox. 2,222 miles SRC w/E0 2/5/2009 34,248 2,562 E0 0.7 0.8 0.75Oil Change 1 2/26/2009 38,603 6,917 E0 0.0 0.7 0.7 1.5 0.7 1.5 0.73 NoOil Change 2 3/9/2009 45,947 14,261 E0 -6.2 -6.2 -6.2 -7.0 -6.2 -7.0 -6.40 NoDuring mileage accumulation audit 3/12/2009 48,609 16,923 E0 -1.5 -1.5 -1.5 -1.5 -1.5 -1.5 -1.50 NoOil Change 3 3/17/2009 53,291 21,605 E0 1.6 1.6 1.6 1.6 0.8 0.8 1.20 NoOil Change 4 3/25/2009 60,516 28,830 E0 1.6 1.6 2.3 2.3 1.6 1.6 1.60 NoOil Change 5 4/2/2009 68,222 36,536 E0 0.0 0.0 0.0 0.0 0.8 0.8 0.40 NoOil Change 6 4/9/2009 75,460 43,774 E0 3.9 4.6 3.9 3.9 2.3 3.9 3.68 NoOil Change 7 5/4/2009 82,394 50,708 E0 -0.8 -1.6 -0.8 -1.6 -0.8 -1.6 -1.20 NoOil Change 8 5/11/2009 88,702 57,016 E0 -3.1 -3.1 -1.5 -1.5 -1.5 -1.5 -2.30 NoOil Change 9 5/18/2009 95,096 63,410 E0 0.0 0.7 0.0 0.7 0.0 0.0 0.18 NoOil Change 10 5/26/2009 101,884 70,198 E0 -1.5 -0.7 -1.5 -0.7 -0.7 -0.7 -0.90 NoOil Change 11 6/5/2009 108,609 76,923 E0 1.5 0.7 0.7 0.7 0.7 0.7 0.90 NoOil Change 12 6/15/2009 115,233 83,547 E0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 NoDate Odometer Test FuelAverageDriveEnginecodes? Comments32,281Min. Max. Min. Max. Min. Max.As-received (Initial) 4/6/2009 32,281 0 As-recd -15.6 -16.4 -15.6 -16.4 -14.8 -16.4 -15.80 NoAs-received after oil change 4/6/2009 32,281 0 As-recd -12.5 -12.5 -11.7 -12.5 -10.9 -10.9 -11.70 NoOil Change 1 5/12/2009 39,595 7,314 E10 -3.9 -3.9 -3.1 -3.1 -3.1 -3.1 -3.50 NoOil Change 2 5/21/2009 47,088 14,807 E10 -3.9 -3.1 -3.9 -3.9 -3.1 -3.1 -3.30 NoOil Change 3 5/29/2009 54,643 22,362 E10 0.0 0.7 0.7 0.7 0.7 0.7 0.53 NoOil Change 4 6/5/2009 61,943 29,662 E10 3.9 4.6 2.3 3.1 1.5 2.3 3.08 NoOil Change 5 6/15/2009 69,237 36,956 E10 -5.4 -5.4 -5.4 -5.4 -5.4 -5.4 -5.40 NoOil Change 6 6/23/2009 76,475 44,194 E10 -1.5 -0.7 -0.7 0.0 -1.5 -0.7 -1.10ORHA0Idle in Drive Idle in ParkIdle in Drive Idle in Park Idle in DriveIdle in DriveORHA10BA-2Honda AccordLong Term Fuel TrimDate Odometer Test FuelAverageDriveEnginecodes? Comments31,369Min. Max. Min. Max. Min. Max.After Zero Mile Emisions (E10 FTP-75) 2/16/2009 31,777 408 EO -14.8 -17.1 -17.9 -18.7 -16.4 -20.3 -17.15 Yes 02 Heater bank 1 P0135 clearedcodeOil Change 1 3/4/2009 39,220 7,851 E15 -3.9 -4.6 -3.9 -3.9 -3.9 -3.9 -4.08 NoOil Change 2 3/13/2009 47,111 15,742 E15 1.6 1.6 1.6 1.6 1.6 1.6 1.60 NoOil Change 3 3/23/2009 55,034 23,665 E15 0.7 1.5 0.7 1.5 1.5 1.5 1.30 NoOil Change 4 3/1/3109 62,333 30,964 E15 4.7 4.7 5.5 5.5 5.5 6.3 5.30 NoOil Change 5 4/8/2009 70,039 38,670 E15 7.0 7.0 6.2 7.0 7.0 7.0 7.00 NoOil Change 6 4/15/2009 77,277 45,908 E15 8.8 10.1 8.5 9.3 8.5 9.3 9.18 NoOil Change 7 5/11/2009 84,211 52,842 E15 3.9 3.9 3.1 3.9 3.1 3.9 3.70 NoOil Change 8 5/21/2009 90,520 59151 E15 3.9 4.6 3.9 4.6 3.1 3.9 3.88 NoOil Change 9 6/2/2009 96,913 65544 E15 3.9 4.6 3.9 4.6 3.9 4.6 4.25 NoOil Change 10 6/9/2009 103,701 72332 E15 0.7 0.7 0.7 1.5 0.7 1.5 0.90 NoOil Change 11 6/18/2009 110,419 79050 E15 1.5 1.5 1.5 2.3 1.5 1.5 1.50 NoDate Odometer Test FuelAverageDriveEnginecodes? Comments34,383Min. Max. Min. Max. Min. Max.After Zero Mile Emisions (E10 FTP-75) 2/6/2009 34,842 459 E20 2.3 2.3 3.1 3.9 2.3 2.3 2.30 YesPO135 02 heater circuit (bank 1, sensor1) Cleared codeOil Change 1 3/3/2009 41,556 7,173 E20 6.2 7.0 7.0 7.8 7.8 7.8 7.20 NoOil Change 2 3/11/2009 48,726 14,343 E20 4.7 4.7 4.7 4.7 4.7 5.5 4.90Oil Change 3 3/19/2009 56,199 21,816 E20 5.5 5.5 5.5 5.5 5.5 5.5 5.50 NoOil Change 4 2/27/2009 63,481 29,098 E20 4.7 5.5 5.5 4.7 5.5 4.7 5.10 NoOil Change 5 4/4/2009 71,187 36,804 E20 6.2 7.0 6.2 6.2 6.2 7.0 6.60 NoOil Change 6 4/11/2009 78,425 44,042 E20 10.9 11.7 10.1 10.1 10.9 10.9 11.10 NoOil Change 7 5/5/2009 85,359 50,976 E20 3.1 3.9 3.9 3.9 3.9 3.9 3.70 NoOil Change 8 5/12/2009 91,667 57,284 E20 3.9 3.9 3.9 3.9 4.7 4.7 4.30 NoOil Change 9 5/26/2009 98,061 63,678 E20 1.5 1.5 1.5 2.3 1.5 1.5 1.50 NoOil Change 10 6/3/2009 104,855 70,472 E20 8.5 9.3 7.8 8.5 7.8 8.5 8.53 NoOil Change 11 6/1109 111,567 77,184 E20 4.7 4.7 4.7 5.5 4.7 5.5 4.90 NoOil Change 12 6/18/2009 118,198 83,815 E20 4.7 4.7 4.7 4.7 3.9 4.7 4.50 NoIdle in Drive Idle in DriveIdle in Drive Idle in DriveIdle in ParkORHA15ORHA20A-32008 Nissan AltimaLong Term fuel TrimDate Odometer Test FuelAverageDriveEnginecodes? Comments19,284Min. Max. Min. Max. Min. Max.As Received 2/10/2009 19,264 As-recd As-recd -2.3 -2.3 -2.3 -2.3 -2.3 -2.3 -2.30 NoOil Change 1 5/26/2009 26,784 7,500 E0 -7.8 -7.8 -7.0 -7.0 -7.8 -7.8 -7.80 NoOil Change 2 6/6/2009 34,284 15,000 E0 -9.3 -9.3 -7.0 -7.0 -7.0 -7.0 -8.15 NoOil Change 3 6/15/2009 41,784 22,500 E0 -7.0 -7.0 -8.5 -7.0 -8.5 -8.5 -7.75 NoOil Change 4 6/24/2009 49,284 30,000 E0 -5.4 -5.4 -5.4 -5.4 -5.4 -5.4 -5.40 NoP1573 Brake Switch / Including pendingcode checkOil Change 5 7/2/2009 56,784 37,500 E0 -9.3 -9.3 -8.5 -8.5 -8.5 -9.3 -9.10 No Including pending code checkDate Odometer Test FuelAverageDriveEnginecodes? Comments19,524Min. Max. Min. Max. Min. Max.As-Received 2/10/2009 19,518 As-recd As-recd -5.4 -5.4 -5.4 -5.4 -5.4 -5.4 -5.40 NoOil Change 1 6/1/2009 27,024 7,500 E10 -0.7 -0.7 -1.5 -1.5 -0.7 -0.7 -0.70 NoOil Change 2 6/9/2009 34,524 15,000 E10 -1.5 -1.5 -1.5 -1.5 -1.5 -1.5 -1.50 NoOil Change 3 6/17/2009 42,024 22,500 E10 -2.3 -2.3 -3.1 -3.1 -2.3 -2.3 -2.30 NoOil Change 4 6/27/2009 49,524 30,000 E10 -5.4 -5.4 -3.9 -3.9 -5.4 -5.4 -5.40 No Including pending code checkDate Odometer Test FuelAverageDriveEnginecodes? Comments9,950Min. Max. Min. Max. Min. Max.As-Received 2/10/2009 9,935 As-recd As-recd -5.4 -5.4 -5.4 -5.4 -5.4 -5.4 -5.40 NoOil Change 1 6/9/2009 17,450 7,500 E15 -0.7 -0.7 0.0 0.0 -0.7 -0.7 -0.70 NoOil Change 2 6/19/2009 24,950 15,000 E15 0.0 0.0 0.0 3.9 3.9 3.9 1.95 NoOil Change 3 6/29/2009 32,450 22,500 E15 3.1 3.1 3.1 3.1 -1.5 -1.5 0.80 No Including pending code checkDate Odometer Test FuelAverageDriveEnginecodes? Comments10,307Min. Max. Min. Max. Min. Max.As-Received 2/10/2009 10,296 As-recd As-recd -8.5 -8.5 -8.5 -8.5 -8.5 -8.5 -8.50 NoOil Change 1 6/12/2009 17,807 7,500 E20 0.0 0.0 0.0 0.0 0.0 0.0 0.00 NoOil Change 2 6/20/2009 25,307 15,000 E20 0.0 0.0 0.0 0.0 0.0 0.0 0.00 NoOil Change 3 6/29/2009 32,807 22,500 E20 -0.7 -0.7 -0.7 -0.7 -0.7 -0.7 -0.70 No Including pending code checkORNA0Idle in ParkIdle in ParkIdle in ParkORNA10Idle in DriveORNA15Idle in DriveIdle in Drive Idle in DriveIdle in DriveORNA20Idle in DriveIdle in DriveIdle in Drive Idle in Park

## APPENDIX B

OIL CONSUMPTION HISTORY GRAPHS

Vehicle Sets Honda Accord Nissan AltimaB-12007 Honda Accord Oil Consumption024681012141618200 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000Test Miles

Total Oil Consumption (lbs.)ORHA0ORHA10ORHA15ORHA20ORHA10BB-2Nissan Altima Oil Consumption0123456780 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000Test Miles

Total Oil Consumption (lbs.)ORNA0ORNA10ORNA15ORNA20

## APPENDIX C

DODGE CARAVAN VEHICL E SPECIFICATIONS

### C-1 

## Dodge Caravan Vehicle Group Test Specifications

ORDC0 ORDC10 ORDC15 ORDC20 Vehicle make Dodge Dodge Dodge Dodge Vehicle model Caravan Caravan Caravan Caravan Model yea r 2007 2007 2007 2007 VIN 1D4GP24R67B186773 1D4GP24RX7B138127 1D4GP24R07B137987 1D4GP24R77B138117 Tire size (wheel size) P215/70R15 P215/70R15 P215/70R15 P215/70R15 Tire manufacturer Firestone Firestone Firestone Firestone

Tire pressure specification 36 psi 36 psi 36 psi 36 psi Steel or alloy wheels Steel Steel Steel Steel Odomete r 46,467 44,721 40,024 45,080

Engine code (Engine family) 7CRXT03.8NEO 7CRXT03.8NEO 7CRXT03.8NEO 7CRXT03.8NEO Engine evap code 7CRXR0177GHA 7CRXR0177GHA 7CRXR0177GHA 7CRXR0177GHA Engine displacement and configuration 3.3L / V6 3.3L / V6 3.3L / V6 3.3L / V6

Climate control/ std air cond. STD STD STD STD

Head lamps (std. Or Xenon) STD STD STD STD

State insp. Expiration date May-2010 May-2010 May-2010 May-2010

License plate expiration date None None None None

Is there a license plate in front and rear? No No No No License Plate Numbe r N/A N/A N/A N/A Transmission Auto - 4 Speed Auto - 4 Speed Auto - 4 Speed Auto - 4 Speed

Two-wheel or four wheel drive 2wd 2wd 2wd 2wd Axle Ratio Axle – Open carrier or limited slip Open Carrier Open Carrier Open Carrier Open Carrier

Calibration ID #1 05187657AD 05187657AD 05187657AD 05187657AD Calibration Version #1 CVN01:878AC361 CVN01:878AC361 CVN01:878AC361 CVN01:878AC361

Calibration ID #2 N/A N/A N/A N/A Calibration Version #2 CVN01:49728AEF CVN01:49728AEF CVN01:49728AEF CVN01:49728AEF

Calibration ID #3 N/A N/A N/A N/A Calibration Version #3 N/A N/A N/A N/A

Calibration ID #4 N/A N/A N/A N/A Calibration Version #4 N/A N/A N/A N/A

Record existing PCM codes PO700 PO700 None None

Clear codes with approval of project manager. N/A N/A N/A N/A

Exhaust Aftertreatment - Number of catalytic converters 1111

With vehicle at idle place red rag over the end of the tailpipe and look for exhaust leaks None None None None

## APPENDIX D

PROJECT REVIEW MEETING MINUTES JUNE 17, 2009

# SOUTHWEST RESEARCH INSTITUTE ®

6220 CULEBRA ROAD i POST OFFICE DRAWER 28510 i SAN ANTONIO, TEXAS, USA 78228-0510 i (210) 684-5111 i WWW.SWRI.ORG ENGINE, EMISSIONS, AND VEHICLE RESEARCH DIVISION HTTP://ENGINEANDVEHICLE .SWRI.ORG
FAX: (210) 522-3950 ISO 9001 Certified ISO 14001 Certified

SAN ANTONIO, TEXAS 

### D-1
HOUSTON, TEXAS i WASHINGTON, DC i ANN ARBOR, MI 

### July 3, 2009

SUBJECT: Meeting Minutes Program E-87-2 Catalyst Durability with Ethanol Blends

DATE OF MEETING: 6/17/09

LOCATION: Southwest Research Institute (SwRI ® 

### )

MEETING RECORDER: Brent Shoffner, SwRI bshoffner@swri.org

1.0 INTRODUCTION

Martin Heimrich of Southwest Research Institute (SwRI) called the meeting to order at 8:00 AM. The list of personnel attending the mee ting at SwRI is included in Attachment A. Several people, also listed in Attachment A, participated in the meeting via a telephone conference call. Microsoft ® 

### Office “Live Meeting” was se t up and used to display the presentation material to the remote location computers of the individuals participating by telephone. The agenda is included as Attachment B. The electronic files of the presentations given during the meeting, as listed below, ha ve been uploaded to the dedicated password protected ftp site established for this pr ogram or are included in the attachments.

TABLE 1. LIST OF PRESENTATIONS

Number Title Presenter Location for Reference 1 Oak Ridge Project E-87-2 Vehicle Status Brent Shoffner ftp site 2 Oak Ridge Project E-87-2 Emissions Status Marty Heimrich ftp site 3 2007 Honda Accord Emissions Results Evaluation Keith Knoll ftp site 4 Emissions Output Example – ORCS 10 – E10 Chris Sharp Attachment E

2.0 Automotive Fleet laboratory Presentation – Brent Shoffner

Brent Shoffner gave the presentation noted as #1 in the Introduction Section I. One of the critical issues for this program is the length of time that E0 will be commercially available in the San Antonio, Texas area. When E0 is no longe r commercially available, the current fuel supplier for the program could potentially supply E0 at the terminal, but it would likely be a “BOB” or subgrade fuel, which (before mixing with ethanol) is not lega l for the public road system. It would probably have a lower than 87 -octane rating in antici pation of mixing it with ethanol. SwRI has a 19,000-gallon stor age tank being used for storage of E0 and is ordering aBrian West Oak Ridge National Laboratory July 3, 2009 Page 2 of 6



### D-2 tanker truck when the fuel remaining is approx imately 11,500 gallons or less. The shelf life of gasoline is about 1 year, so it is not possible to order all th e E0 required for the program up front and store it.

Action Item 1 – Brent Shoffner Contact the supplier of the fuel and develop the best plan fo r providing E0 for the length of the program. It was asked whether more than 8 mileage accumulation dynamometers (MADs) could be used for the program. Additional MADs will be used if they are available and Oak Ridge vehicles are waiting in the queue. When the replacement Honda is accumulating mileage with two other groups of 4 vehicles, 9 MADs will be made available.

SwRI is accumulating mileage on the vehicles in a group with the difference between the highest and lowest test miles typically less than 10,000 miles. The replacement Honda is an exception. With scheduled maintenance and no other problems, mileage accumulation averages about 800 miles per vehicle per day or 96,000 miles per vehicle group per month

Action Item 2 – Brent Shoffner

SwRI technicians have been checking for the presence of engine di agnostic trouble codes (DTCs) at every oil change. Brian West requested that SwRI ensure that this includes a formal check for pending codes as well. (Note: This procedure has been implemented.)

3,0 Light Duty Vehicle Emissions Labo ratory Report – Martin Heimrich

The presentation is noted as #2 in the Introdu ction Section I. The presentation included the following:

1. Thermocouple locations in the exhaust system 2. Summary of the wide-open throttle procedure 3. Status of emissions results.

The thermocouple wire that senses the catalytic converter substrate te mperature is 0.020-inch diameter thermocouple wire pushed into a substrat e cell in the front of th e catalytic converter 1- inch from the converter front face. Two thermoc ouples are placed in the substrate in this manner because the wires are delicate and tend to break over time with use.

Wide-open throttle testing has been added to the E10 and E15 vehicles as added scope. Refer to Table 2. The “wide-open throttle” or “WOT” procedure used in the E-87-2 program is the same as the procedure used in the E-87-1 pr ogram. It is a modified “EPEFE” or “Sulfur Purge” cycle.Brian West Oak Ridge National Laboratory July 3, 2009 Page 3 of 6



### D-3 TABLE 2. EMISSIONS TESTING SEQUENCE

Both fuel economy in miles-per-gallon and CO2 will be reported as results. The Code of Federal Regulations (CFR) method was used to cal culate the fuel economy in the presentation and in past monthly status re ports. These fuel economy values will be recalculated based on carbon balance and fuel properties. The data in the monthly status reports are considered preliminary. It was asked whether there was a pa rameter, which would qu antify the difference of the degradation of emissions between vehicles aged on different ethanol fuel s. Statisticians at Battelle will analyze the emissions resu lts with regards to this question.

Action Item 3 – Marty Heimrich

For the data analyses of th e wide-open throttle (WOT) tests, it was recommended that more than one WOT be averaged.

Action Item 4 – Marty Heimrich

SwRI will use the E-87-1 protocol to calc ulate and produce data for the WOT tests, including the catalytic converter substrate temper atures. The emissions “prep” consists of three EPA Urban Dynamometer Dr iving Schedules (UDDS). E0 Vehicle E10 Vehicle E15 Vehicle E20 Vehicle Fuel Change - E0 Fuel Change - E0 Fuel Change - E0 Fuel Change - E0 FTP Emissions Test Prep - E0 FTP Emissi ons Test Prep - E0 FTP Emissions Test Prep - E0 FTP Emissions Test Prep - E0

FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 WOT Test - E0 WOT Test - E0 WOT Test - E0 WOT Test - E0 Fuel Change - E20 Fuel Change - E10 Fuel Change - E15 Fuel Change - E20

WOT Prep - E20 FTP Emissions Test Prep - E10 FTP Emissions Test Prep - E15 FTP Emissions Test Prep - E20 WOT Test - E20 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20
FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 WOT Test - E10 WOT Test - E15 WOT Test - E20 Fuel Change - E20 Fuel Change - E20

WOT Prep - E20 WOT Prep - E20 WOT Test - E20 WOT Test - E20

E0 Vehicle E10 Vehicle E15 Vehicle E20 Vehicle Fuel Change - E0 Fuel Change - E10 Fuel Change - E15 Fuel Change - E20 FTP Emissions Test Prep - E0 FTP Emissions Test Prep - E10 FTP Emissions Test Prep - E15 FTP Emissions Test Prep - E20

FTP Emissions Test - E0 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 FTP Emissions Test - E0 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 WOT Test - E0 WOT Test - E10 WOT Test - E15 WOT Test - E20 Fuel Change - E20 Fuel Change - E20 Fuel Change - E20 Fuel Change - E0

WOT Prep - E20 WOT Prep - E20 WOT Prep - E20 FTP Emissions Test Prep - E0 WOT Test - E20 WOT Test - E20 WOT Test - E20 FTP Emissions Test - E0 Fuel Change - E0 Fuel Change - E0 FTP Emissions Test - E0 FTP Emissions Test Prep - E0 FTP Emis sions Test Prep - E0 WOT Test - E0

FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 WOT Test - E0 WOT Test - E0 Pre-Mileage Accumulation

Post Mileage AccumulationBrian West Oak Ridge National Laboratory July 3, 2009 Page 4 of 6



### D-4 Action Item 5 – Marty Heimrich

It was recommended that the E20 WOTs on the Hondas be rerun with longer preps.

Action Item 6 – Marty Heimrich

It was theorized that the Sulfur Purge/WOT test procedure could potentially improve the baseline catalyst performance following long pe riods of vehicle serv ice accumulation. As a consensus, the group revised the emissions test orde r given in Table 2 to the sequence in Table 3, so that both sets of duplicate emissions tests would be preconditioned by a sulfur purge/ WOT cycle (and not just the second pair of tests). Start with the Ca ravan group as a running change.

TABLE 3. MODIFIED EMI SSIONS TESTING SEQUENCE

E0 Vehicle E10 Vehicle E15 Vehicle E20 Vehicle Fuel Change - E0 Fuel Change - E0 Fuel Change - E0 Fuel Change - E0

WOT Prep - E0 WOT Prep - E0 WOT Prep - E0 WOT Prep - E0 FTP Emissions Test Prep - E0 FTP Emissi ons Test Prep - E0 FTP Emissions Test Prep - E0 FTP Emissions Test Prep - E0

FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 WOT Test - E0 WOT Test - E0 WOT Test - E0 WOT Test - E0 Fuel Change - E20 Fuel Change - E10 Fuel Change - E15 Fuel Change - E20

WOT Prep - E20 FTP Emissions Test Prep - E10 FTP Emissions Test Prep - E15 FTP Emissions Test Prep - E20 WOT Test - E20 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20
FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 WOT Test - E10 WOT Test - E15 WOT Test - E20 Fuel Change - E20 Fuel Change - E20

WOT Prep - E20 WOT Prep - E20 WOT Test - E20 WOT Test - E20

E0 Vehicle E10 Vehicle E15 Vehicle E20 Vehicle Fuel Change - E0 Fuel Change - E10 Fuel Change - E15 Fuel Change - E20

WOT Prep - E0 WOT Prep - E10 WOT Prep - E15 WOT Prep - E20 FTP Emissions Test Prep - E0 FTP Emissions Test Prep - E10 FTP Emissions Test Prep - E15 FTP Emissions Test Prep - E20

FTP Emissions Test - E0 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 FTP Emissions Test - E0 FTP Emissions Test - E10 FTP Emissions Test - E15 FTP Emissions Test - E20 WOT Test - E0 WOT Test - E10 WOT Test - E15 WOT Test - E20 Fuel Change - E20 Fuel Change - E20 Fuel Change - E20 Fuel Change - E0

WOT Prep - E20 WOT Prep - E20 WOT Prep - E20 FTP Emissions Test Prep - E0 WOT Test - E20 WOT Test - E20 WOT Test - E20 FTP Emissions Test - E0 Fuel Change - E0 Fuel Change - E0 FTP Emissions Test - E0 FTP Emissions Test Prep - E0 FTP Emis sions Test Prep - E0 WOT Test - E0

FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 FTP Emissions Test - E0 WOT Test - E0 WOT Test - E0 Pre-Mileage Accumulation

Post Mileage AccumulationBrian West Oak Ridge National Laboratory July 3, 2009 Page 5 of 6



### D-5 The following observations were made and di scussed during this portion of the meeting.

1. The time at WOT during the WOT tests is not exactly the same. 2. It was noted that the Chevrolet Silverado trucks have comparable lambda values during the start-of-test WOT procedures w ith E0 and the WOT tests with E20 fuel. 3. The temperature reduces slightly at WO T over time potentially due to enrichment.

4. The Nissan Altima could potentially have a “rich” deceleration condition. Nissan representatives had previously stated that they expected a lean deceleration. The condition is low air and low fuel flow. It could be an instrumentation problem. Nissan was given a copy of the data during these conditions for review. If Nissan representatives are concerned, they will alert the Oak Ridge project manager.

Action Item 7 – Marty Heimrich and Brent Shoffner

With regards to the installation of a lambda sensor in the Ford Taurus exhaust manifold, the exhaust manifold will be drilled and tapped a nd installed on vehicle. Th e Lambda sensor will be installed into the tapped hole and tightened to a specified torque. An exhaust system leak check will be performed before emissions. SwRI wa s asked to ensure that that the lambda sensor does not restrict exhaust flow. It was decide d to leave the exhaust manifold in place during mileage accumulation with a plug installed in the tapped hole used for the lambda sensor.

Keith Knoll of NREL gave th e presentation noted as #3 in the Introduction Section I. The graphs compare the emissions levels of total hydrocarbons, car bon monoxide, NOx, ethanol, formaldehyde, and acetaldehyde by the fuel used for conducting the FTP-75 tests. The general conclusion was that the scatter in the data is greater than any notable trend at this time.

It had been reported in the EPA program that baffles in the fuel tank of the Nissan Altimas may reduce the efficiency of the fuel flush.

Action Item 8 – Brent Shoffner and Don Hart

SwRI was asked to look inside the Nissan Alti ma fuel tank to investigate this issue and recommend a fuel tank flushing t echnique. During the week of June 22, Brent Shoffner and Don Hart reviewed the fuel tank of ORNA0, which was in the Automotive Fleet Laboratory for a scheduled oil change. A discussion of the findings is included in Attachment D. SwRI offers the following procedure to enhan ce the effectiveness of a single drain operation.

1. With the vehicle on level ground activate the fuel pump and drain the fuel through the fuel rail until the stream turns to drips. 2. Using a floor jack raise the passenger side of the vehicle appr oximately 18 inches and then lower the vehicle. 3. With the vehicle on level ground activate the fuel pump and drain the fuel through the fuel rail until the stream turns to drips.Brian West Oak Ridge National Laboratory July 3, 2009 Page 6 of 6



### D-6 4.0 Review of Data Format for Statistici ans and Data Archiving - Chris Sharp

Chris Sharp of SwRI gave th e presentation noted as #4 in the Introduction Section I and included in Attachment E. The following are definitions:

1. ND (Non-detectable) = raw data values belo w the instrument detection limit prior to background correction. 2. Trace = Raw data values above ND but below the “limit of quantif ication” (LoQ). These data are detected, but in the “noise” of the method.

The regular non-methane organic gas (NMOG) pr otocol includes more (up to 130) compounds. For this program a simplified NMOG calculation is to be used that incorporates the most relevant compounds. The ND and LoQ vary with vehicle/engine exhaust gas flow rates. There was a discussion of the method to report ND and trace va lues. The following is a consensus of the meeting participants.

Action Item 8 – Chris Sharp and Marty Heimrich

ND will be reported as “ND.” A trace value w ill be reported and identified as a trace value. The limit of quantification will be doc umented for each value re ported as trace.

Action Item 9 – Marty Heimrich, Brent Shoffner, and Brian West

Produce a program timetable through completio n of the Dodge Caravans. This timetable is included in Attachment C.

Brian West, the Oak Ridge Project Manage r, asked for recommendations from group members for vehicles, which should be tested.

The meeting was adjourned at 2:30 PM.

### D-7 

# Attachment A

List of Meeting Attendees

### D-8 

## Attendance List

Name Company In Attendance By Telephone Brian West ORNL X Chris Tennant CRC X Coleman Jones GM X Ken Wright Conoco Phillips X Marie Valentine Toyota X Brent Bailey CRC X King Eng Shell Global Solutions X Keith Knoll NREL X Charlie Schleyer Exxon X James Uihlein Chevron X John Orban Battelle X Ken Kimura BP X Andy Mabutol Mitsubishi X Dominic DiCicco Ford X Connie Hart EPA X Tony Fernandez EPA X

Martin Heimrich SwRI X Jeff White SwRI X Brent Shoffner SwRI X Kevin Whitney SwRI X Don Hart SwRI X Lee Grant SwRI X Chris Sharp SwRI X Terry Westrum SwRI X

### D-9 

# Attachment B

Meeting Agenda

### D-10 V4/E-87-2 Oak Ridge National Laboratory/ CRC Project Meeting Agenda June 17, 2009 Engine, Emissions, & Vehicle Research Division Southwest Research Institute 6220 Culebra Road San Antonio, TX 78238-5165

Project Engineer/Host: Martin J. Heimrich Emissions Research and Development Department Phone: (210) 522-3022 FAX: (210) 522-3950 Email: mheimrich@swri.org Directors: Jeff J. White Michael D. Lochte Emissions Research and Fuels and Lubricants Development Department Research Phone: (210) 522-2649 Phone: (210) 522-5430 FAX: (210) 522-3950 FAX: (210) 684-7523 Email: jjwhite@swri.org Email: michael.lochte@swri.org Division Vice President: Bruce Bykowski Phone: (210) 522-2937 Fax: (210) 522-3950 Email: bbykowski@swri.org

Visiting Client Staff: Brian West, ORNL (by phone) James Uihlein, Chevron Chris Tennant, CRC Keith Knoll, NREL Dominic DiCicco, Ford (by phone) Coleman Jones, GM (by phone) Marie Valentine, Toyota (by phone) Ken Kimura, BP Andy Mabutol, Mitsubishi (by phone) John E. Orban, Battelle Ken Wright, Conoco Phillips King Eng, Shell Global Solutions Charlie Schleyer, Exxon

________________________ Confirmed as of 6/16/09 

### Purpose of Visit: V4/E-87-2 Project Review Meeting 

### Bldg. 87, Main Conference Room – June 17, 2009, from 8 am to 5 pm

Wednesday, June 17, 2009 8:00 - 8:10 Arrivals & Introductions...........................................................................................

.............. . 8:10 Opening Remarks ....................................................................Brian West, Marty Heimrich, 8:15 Mileage Accumulation:....................................................................................................

....... Accords to almost full useful life Silverados to 50K miles (Altimas are under test) Caravans check-in/initial inspection 9:30 FTP Emissions and WOT Data:............................................................................................ M Accords - 0K and 50K miles Silverados - 0K miles Altimas - 0K miles Taurus' Instrumentation 11:30 Lunch at SwRI cafeteria .................................................................................................

........ . 1:15 Review of data format presentati on for statisticians and data archiving ................................

. 2:15 Concluding discussions...................................................................................................

........ . 3:00 - 5:00 Emissions lab and mileage accumu lation dynamometer tours ....................Marty Heimrich, 6:00 - 8:00 Dinner .............................................................................................................

........................ . cc/ B Bykowski, D Barranco, L Cruz, J White, T Davison, C Sharp, K Whitney, S Sampson, E Krueger, K Echtle, S Tondre, D Reeh, L Grant, B Shoffner, K Brunner, M Lochte. 

### Form 9.5-1, Rev. 2 (1/05/07)

### D-11 

# Attachment C

Projected Time TableD-12Oak Ridge Project E-87-2 Time TableDates shown assume data collection complete 4-6 weeks earlier. Allows ~2 weeks for SwRI analysis and data delivery and additionalexternal analysis and reporting (e.g. Honda FUL tests will be completein mid-July 2009, Gantt shows Honda data reported to DOEinAugust). Odometers areapproximate odometers of fleet (not test miles).2009 2010Number of Veh ModelYear Model Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec4 2007 Honda Accord35k85k120k 10B4 2006 Chev Silverado27k77k120k4 2008 Nissan Altima20k70k120k4 2007 Dodge Caravan45k95k120k4 2008 Ford Taurus17k67k120kDodge Caravan and Ford Taurus vehicle order changed.Updated on 7/09/09

### D-13 

# Attachment D

Nissan Fuel Tank

### D-14 2008 Nissan Altima

The rear seat can be removed to expose an inspection port over the fuel pump and sending unit assembly, which is located on the driver’s side of the vehicle. The fuel pickup is about 3/16 inch above the bottom of the fuel tank.

Below is a photograph of the right side of th e tank. The ridge shown in the photograph traps fuel. Most of the fuel will drain to the left side of the tank if the passenger side of the vehicle is raised by a floor jack approximately 18 inches.



# Ridge

### D-15 2008 Nissan Altima Photograph showing the fuel tank and the exhaust pipe shield

Photograph showing the ridge area at the edge of the fuel tank strap

### D-16 

## Cross-Section Schematic of the 2008 Nissan Altima Fuel Tank

Pump and sending unit assembly

Strap

Exhaust pipe Shiel

Passenger Driver ’ s Side

### D-17 

# Attachment E

Emissions Results Output Sample

### D-18 Ethanol, mg/mi Methanol, mg/mi

Formaldehyde, mg/mi ND ND

0.2 Trace Trace

ND

Acetaldehyde, mg/mi 0.1 Trace

2.7 6.2 0.5 ND Weighted 6.7 Trace

16.3 18.0 Ethanol, mg/mi Methanol, mg/mi

Formaldehyde, mg/mi Acetaldehyde, mg/mi Phase 1 Phase 2 Phase 3 RoadLd A (N) RoadL B (N/kph)

0.235 0.001 THC, g/mi COL, g/mi NOx, g/mi NMHC, g/mi

0.003 0.050 Phase 3
0.016

569.1
0.008 0.000 17.40 15.35 Weighted

14.41 NOx, g/mi CO2, g/mi CH4, g/mi 602.7
0.030 THC, g/mi

Fuel Economy, mpg COL, g/mi 0.213 0.409
0.000

0.002 0.176 0.402
0.020
502.1
0.011 2.246
0.107 10.45 0.20 10.27

0.009 Phase 1 Phase 2 0.03
1.149 0.048 1.105 65.35 0.67 64.74

4.21 2.67 1.77 2.14 0.03 2.12 0.88

0.48 Sample
15.29 3.28 12.30 Ambient Net
3.25 3.48 0.0
3.6 99.4
6.7 22.6
419.3 3795.1

11.6

3.6
99.4 23.3 279.7
4442.4

13.4
0.0 3.9 372.7 3373.1

12.5
0.0

Ambient Sample Ambient Net 99.4

Net 6.8 0.886

3.89 3.13 1.02 6.6 0.881 Sample

CH4, ppm NMHC, ppm 11.50 0.78

0.996 0.04

2.85 0.047

0.20 2.65 THC, ppm COL, ppm NOx, ppm CO2, % 10.77 13.55 0.65 12.96 Density(kg/m^3): NHV(btu/lbm):
Driver Errors: Fuel Name: CWF:
HWF: OWF: Shift Table 1 Shift Table 2 Shift Table 3 Shift Table 4

Phase Phase 1 Phase 2 VIN: Model Year: Displacement (l): Engine Family: Odometer (mi):
Transmission: FTP75
OR-CS10-1-E10-F-0k-T4 03.1453 Project No.

Vehicle #: Vehicle Make: Vehicle Model: SW021598 Dyno 7 2/20/2009

0.865
0.135
0

RoadLd C (N/kph^2) 0.73 Run Number: Test Cell:
Test Date: Test Init Time: Test Type Test Number Operator:
Driver:

Distance (mi) Avg. Cell Temp.(degC) Phase 3

Avg. CVS Flow Rate (scfm) CVS Volume (ft^3, 20degC) Test Time (sec): 888.5 506.4 506.3
23.4

0.45 0.953 1.07155 0.04628 1.02897 0.47 0.02 0.00 Requester: Inertia (kg):

0.40 3.11 NOx Hum Corr Factor: Barometer (kPa) Specific Humidity (gr/lbm) Dilution Factor: Driver Out of Limits (sec):

2.57 0.74 0.16 0.20 0.01 0.32 0.17

CO2, g/mi CH4, g/mi NMHC, g/mi 0.053
0.790 0.028 557.7

NMOG, g/mi 15.64 0.013 0.037

NMOG, g/mi Fuel Economy, mpg R