CRC Project No. CM-136

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1 1 CRC Project No. CM B Engine Durability Study of Mid-Level Ethanol Blends Mid-Level Ethanol Research Coordination Group Meeting May 5, 2010 Presented by Coleman Jones, GM Jaime Dettore, Henning Kleeberg, FEV, Inc.

2 2 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

3 3 Background There is interest in expanding the amount of ethanol that can be used in conventional vehicles beyond the current 10% limit. This is due to: Rising ethanol production from the Energy Independence and Security Act, passed in December This mandates 35 billion ethanol equivalent 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 areas of the engine and emissions performance: Valve wear and valve seat wear Abrasive and adhesive wear and corrosion Can lead to compression loss, misfire, and catalyst damage Catalyst Durability Results from ethanol effects on calibration

4 4 Study Objective This study will investigate the effects of a mid-level ethanol blends, starting with E20, on the current on-road, non-flex fuel vehicle population. The effects of the fuel on engine durability will be studied in detail. Engines failing on E20 will be referenced on E0 and then retested on E15 Vehicle Selection Current test plan envisions testing 8 vehicle types with model years ranging from 2001 to Two vehicles of each type will be tested on each 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)

5 Engine Test Lifecycle 1. Pre-test vehicle to ensure the vehicle meets emissions and engineering specifications and document condition 2. Run aging cycle 3. Post-test engine and catalyst to determine if there are any changes

6 6 Durability Cycle The following durability cycle is used to test the engine durability using a mid-level ethanol blend fuel: The test lasts for 500 total cycles and each cycle is 60 minutes in duration. The maximum speed for any engine was 3500 RPM. This was chosen because high speed testing can conceal wear issues by increasing oil pullover through PCV and lubricating valve seats. This test cycle is substantially less severe than a standard high RPM durability cycle and should ensure that the engine will complete the test.

7 7 Engine Data Measurements Measurement Vehicle FTP 75 Valve Measurements Engine Dynamometer FTP Engine 7 Steady State Point FTP correlation Cylinder Compression Leakage Description A baseline emissions test is completed on the vehicle to determine that it meets the required specifications for emissions levels Valve clearance measurements are conducted per the service manual unless otherwise instructed by the OEM. 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. 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. If any value is below service manual limits, then the technical contact is notified immediately If any of the values is above the 10% threshold, the technical contact is notified immediately Measurement Frequency SOT X X X Every 50 hrs EOT X X X X X X X X X X X

8 8 Engine Service Intervals The figure below illustrates the service intervals for all engines: Engine Checks every 50 hours Engine Fluid Levels X X X X X X X X X X X Oil & Filter Change X X X X X X X X X X X Oil Sample & Keep Oil Filter X X X X X X X X X X X Cylinder Compression X X X X X X X X X X X Cylinder Leak-Down X X X X X X X X X X X Spark Plug Inspection X X X X X Spark Plug Change X X X X X X Air Filter Replacement X X X X X X Valve Clearance Measurement X X

9 9 Set-up of Engines in Test Cells The figure below shows the engine combinations in each of the test cells.. North 2005 Chevy Colorado Ford Edge Dyno 1 Dyno 3 Dyno 2 Dyno Dodge Caliber Scion xa Cell 4 Cell 5

Colorado 164 kw @ 5600 305 Nm @ 2800 Dyno

10 10 Set-up of Engines in Test Cells Test Cell 4 Engine Setup North 2005 Chevy Colorado Dyno Dyno 2009 Dodge Caliber

11 11 Set-up of Engines in Test Cells Test Cell 5 Engine Setup 2007 Ford Edge North Dyno Dyno 2004 Scion xa

12 12 Set-up of Engines in Test Cells The Chevy Colorado, Scion xa, Ford Edge and Dodge Caliber require an umbilical setup for this testing. The vehicle shells are located outside the test cell and wire extensions are made to connect the engine harness to the vehicle harness.

13 13 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) 2009 Dodge Caliber (silver) 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% 100%

14 Current Status 14 Completion Status of the second 4 vehicles shown below: Round 2 Vehicles 2004 Scion xa (silver) 2005 Chevy Colorado (white) 2007 Ford Edge (red) 2009 Dodge Caliber (blue) 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% 100%

15 15 Timeline The current timeline is shown below: Timing Plan for Durability Test Description of Task week # day# Jan Jan Jan/Feb Feb Feb Feb Feb/ Ma Mar Mar Mar Mar / Ap Apr Apr 15 Apr Apr/May May 18 May May May weeks for 500 hr test & checks Dodge Caliber Swap Engines & prep Round 2: 4 weeks for 500 hr test & checks Chevy Colorad o 4 weeks for 500 hr test & checks Swap Engines & prep Round 2: 4 weeks for 500 hr test & checks 4 weeks for 500 hr test & checks Ford Edge Swap Engines & prep Round 2: 4 weeks for 500 hr test & checks Scion xa 4 weeks for 500 hr test & checks Swap Engines & prep Round 2: 4 weeks for 500 hr test & checks

16 16 General Test Summary Some select test results are found on the following pages.

17 17 Engine Specific Data (preliminary) Scion xa (black) The Scion xa has passed all the main checks for the 500 hours without issue. Valve leakage was less than 10% at EOT. Compression was within specification at EOT. Valve clearance measurements were found to be within the specification required in the service manual. No Diagnostic Trouble Codes (DTC) were found related to fuel or other emissions items. The FTP simulation data is currently ongoing, so no evaluation is possible at this time.

18 18 Engine Specific Data (preliminary) Chevy Colorado (red) The Chevy Colorado has passed all the main checks for the 500 hours except for leakage. At 500 hrs, the leakage measurements on cylinders 3 & 5 were 22% and 18%, respectively. All other cylinders were OK. An additional 50 hours was run at EOT. The leakage measurements on cylinders 3 & 5 were 15% and 9%, respectively. LEAKDOWN (%) LEAKDOWN (%) LEAKDOWN (%) Cylinder #1 Cylinder #2 Cylinder # CYCLE LEAKDOWN (%) LEAKDOWN (%) Cylinder #4 Cylinder # CYCLE

19 19 Engine Specific Data (preliminary) Chevy Colorado (red) cont d Compression and valve clearance measurements were found to be within the specification required at EOT No DTC s were found related to fuel or other emissions items. The FTP simulation data showed that the engine would have passed emissions testing at EOT. Engine teardown revealed that in cylinder #3, there was uneven wear and 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 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 SOT to EOT SOT Vehicle Results + Delta CO g/mile THC g/mile NOX g/mile CO g/mile FE mpg

20 20 Engine Specific Data (preliminary) Ford Edge (white) The Ford Edge passed all the main checks for the 500 hours. Leakdown measurements all remained below 10% for all 500 hours. Compression was within specification at EOT. Valve clearance measurements were found to be within the specification required. No DTC s were found related to fuel or other emissions items. The FTP simulation data showed that the engine would have passed emissions testing at EOT 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 to EOT SOT Vehicle Results + Delta CO g/mile THC g/mile NOX g/mile CO g/mile FE mpg

21 21 Engine Specific Data (preliminary) Dodge Caliber (silver) The Dodge Caliber passed all the main checks for the 500 hours except for leakage and the emission results. The emissions results are currently under further investigation. The increase leakage in the beginning of test is likely attributed to the engine not being complete broken in at the start of test. The ring friction stabilized over time and gave consistent compression and leakage results for the second half of testing At 500 hrs, the leakdown measurements on cylinder 4 increased to 11% Cylinder #1 Engine Leakdown (%) (%) Cylinder #2 (%) 10 5 (%) Cylinder #3 5 (%) Cylinder # Cycle

22 22 Engine Specific Data (preliminary) Dodge Caliber (silver) cont d Compression was within specification at EOT. Valve clearance measurements were found to be within the specification required. No DTC s were found related to fuel or other emissions items. The FTP simulation data results are currently being investigated further and will be reported out at a later date.

23 23 Engine Specific Data (preliminary) Dodge Caliber (blue) The Dodge Caliber passed all the main checks for the 500 hours except for the emission; these results are currently under investigation. Leakdown measurements all remained below 10% for all 500 hours. Compression was within specification at EOT. Valve clearance measurements were found to be within the specification required. No DTC s were found related to fuel or other emissions items. The FTP simulation data results are currently being investigated further and will be reported out at a later date.

24 24 General Test Summary The results of the testing are found on the following pages. Summary of Durability Testing Results (V1 = vehicle 1, V2 = vehicle 2): Emissions DTC Valve Clearance Compression Leakage V Scion xa (black) V Chevy Colorado (red) V Ford Edge (white) TBD Pass Pass Pass Pass Pass Pass Pass Pass Fail Pass Pass Pass Pass Pass V Dodge Caliber (silver) TBD (under further investigation) Pass Pass Pass Fail V Scion xa (silver) V Chevy Colorado (white) V Ford Edge (red) V Dodge Caliber (blue) TBD (under further investigation) Pass Pass Pass Pass

25 Next Steps FEV will continue with execution of the program as follows: Finish durability evaluation of Round 2 (second set of 4) engines EOT FTP cycle simulation Periodic engine measurements at FTP correlation points 500 hour durability schedule with standardized maintenance Conduct EOT engine measurements for valve wear Procurement of next vehicles is ongoing. These next vehicles are: 2001 MY Honda CRV 2.0L (add emissions levels) 2007 MY Dodge Ram 5.7L 2009 MY Chevrolet Aveo 1.6L 2002 MY VW Jetta 2.0L Vehicles types that have failed E20 testing will be reference tested on E0 Vehicles types that pass on E0 will be tested on E15 Complete Final Report for delivery to CRC

Study of the Effects of Intermediate Ethanol-Blended Gasoline Fuels (E20, E15) on Engine Durability

Status Update March 2011 Study of the Effects of Intermediate Ethanol-Blended Gasoline Fuels (E20, E15) on Engine Durability March 27, 2012 Henning Kleeberg FEV, Inc. 2 Contents Introduction Project Objective