Client Vehicle Certification Agency Vehicle Light Duty Passenger Vehicles Test In-Service Vehicle Testing Programme 2010-11 Millbrook Report No. MBK11/0162 Millbrook Project No. PT0060-006-01 A. Sale Author: Senior Engineer N. Fulton Approved: Powertrain Manager Approved for Issue: A. Eastlake Date: Head of Laboratories 31 March 2011
Executive Summary European legislation (Directive 70/220/EEC as amended) prescribes exhaust emissions limits for all passenger cars produced for sale within the European Union. These emissions limits have progressively tightened over a number of years and current new vehicles must meet at least Euro 5 emissions standards. The directive also prescribes that passenger vehicles must continue to meet the relevant emissions limits for a duration of In-Service use. Manufacturers are required to carry out In-Service compliance testing of suitable vehicles and to submit this data to their type approval authority. The UK s type approval authority, the Vehicle Certification Agency (VCA), also collect independent information to monitor compliance and, as such, they have completed a number of programmes to gather data on the In-Service compliance of a range of passenger vehicles. The 2010-11 programme was completed at Millbrook Proving Ground in Bedfordshire between December 2010 and March 2011. A total of 10 vehicle models were tested with 6 diesel models and 4 petrol models. Of these a total of 46 vehicles were selected for test, with 30 actually tested. All vehicle models were originally type approved to Euro 4 emissions limits. Regulated Emissions For each regulated pollutant the results, as a percentage of the relevant emissions limit, were categorised into 4 bands according to the procedures defined in Directive 70/220/EEC as amended: Band 0: Less than type approval limit Band 1: Marginally above limit: between 100% and 150% for Euro 4 Band 2: Outlying Emitter, Intermediate Zone: between 150% and 250% for Euro 4 Band 3: Outlying Emitter, Failure Zone: above 250% of the Euro 4 limit values. By relating the level of emissions for each pollutant of each vehicle to the limit values and applying a prescribed statistical assessment a decision for the vehicle model can be made to Pass, Fail, or require more vehicles to be tested, Test More, in accordance with the In-Use Compliance procedures set out in Directive 70/220/EEC as amended. Millbrook Test Report No. 11/0162 Page 2 of 57
Carbon Dioxide Emissions and Fuel Consumption Although there are no mandatory in-use compliance requirements for fuel consumption and Carbon Dioxide (CO 2 ) emissions measurements, these parameters are subject to Conformity of Production requirements for new vehicles. Whilst these requirements do not strictly apply to in-use vehicles, the fuel consumption and CO 2 emissions measurements from this programme have been assessed against the conformity of production requirements to give an indication of whether in-use vehicles differ significantly from the type approval measurements. Whilst there is currently no legal requirement for a Pass, Fail or Test More criteria for CO 2, a threshold of 104% of the declared Type Approval value for the vehicle was used. This value was based on the permitted production tolerance of 4%. Vehicles are highlighted as to their CO 2 status, white for <100% of Type Approval values, green for 100% - 104% and yellow for >104%. Results A range of Petrol and Diesel, Euro 4 certified vehicle models were tested as selected by the VCA and Department for Transport (DfT). Some of these models were continuations of vehicles tested in the 2009/10 programme, where the models achieved a Test More result. For these vehicles the 2009/10 results were added to the 2010/11 results to create an overall result. Four models of Euro 4 Petrol vehicle were tested (Chevrolet Matiz, Fiat 500, Hyundai i10 and Smart Fortwo) and all achieved a Pass decision for regulated In- Service emissions. Of the four Petrol models, 6 vehicles in total were tested and all met emissions limits for all legislated pollutants. Six models of Euro 4 Diesel vehicle were tested (Ford Mondeo, Honda FR-V, Jaguar X-Type, Kia Rio, Vauxhall Corsa and Vauxhall Vectra). Of these, four achieved a Pass, with the Jaguar X-Type and Vauxhall Corsa achieving a Test More condition. The results for the Honda FR-V, Jaguar X-Type and Kia Rio include the results achieved in the 2009/10 programme. Out of the six Diesel models, 24 vehicles in total were tested. Eight of these had at least one legislated pollutant higher than the Euro 4 emissions limits, two of these in the Outlier emissions area. For CO 2 emissions conformity, two vehicle models achieved a result over 104% of the Type Approval Value (Hyundai i10 and Kia Rio). Four models (Chevrolet Matiz, Fiat 500, Honda FR-V and Jaguar X-Type) had a result above 100%, but lower than 104%. The other four models all gave a result of less than 100% of their declared Type Approval CO 2 value. Millbrook Test Report No. 11/0162 Page 3 of 57
Emissions Decision CO 2 Petrol Euro 4 Chevrolet Matiz Pass 100.1% Fiat 500 Pass 100.4% Hyundai i10 Pass 105.8% Smart Fortwo Pass 99.3% Diesel Euro 4 Ford Mondeo Pass 98.6% Honda FR-V Pass 102.8% Jaguar X-Type Test More 100.7% Kia Rio Pass 111.6% Vauxhall Corsa Test More 96.1% Vauxhall Vectra Pass 94.0% Table 1 Emissions and CO 2 decisions summary by vehicle model Millbrook Test Report No. 11/0162 Page 4 of 57
Distribution Organisation Recipient Format Qty Vehicle Certification Agency Mr. A. Molyneux Paper 5 1 The Eastgate Office Centre CD 5 Eastgate Road Bristol BS5 6XX Millbrook Proving Ground Ltd Contract file PDF 1 Millbrook Mr A Sale Paper 1 Bedford MK45 2JQ Report Revision History Rev. Revision Description Date Author Approver Pages 0 Initial release 31 03 2011 A. Sale A. Eastlake All Millbrook Test Report No. 11/0162 Page 5 of 57
Contents Section Page No. Executive Summary... 2 Distribution... 5 Report Revision History... 5 Contents... 6 Appendices... 7 List of Figures... 7 List of Tables... 8 Introduction... 9 Objectives... 11 Test Procedure... 12 Vehicle Sourcing... 12 Vehicle Checks and Test Preparation... 13 Vehicle Testing... 14 Vehicle Completion... 15 Reporting... 15 Test Results and Discussion... 17 Overview... 17 OBD Screening and MOT Testing... 18 Results Petrol Euro 4... 21 Chevrolet Matiz... 21 Fiat 500... 23 Hyundai i10... 25 Smart Fortwo... 27 Results Diesel Euro 4... 29 Ford Mondeo... 29 Honda FR-V... 32 Jaguar X-Type... 35 Kia Rio... 39 Vauxhall Corsa... 42 Vauxhall Vectra... 45 Further Work... 47 Conclusions... 48 Appendices... 52 Appendix A Description of NEDC (New European Drive Cycle)... 52 Appendix B Fuel Analysis Reference Petrol... 54 Appendix C Fuel Analysis Reference Diesel... 55 Millbrook Test Report No. 11/0162 Page 6 of 57
Appendices Description of NEDC cycle Petrol Reference Fuel Analysis Diesel Reference Fuel Analysis Appendix A Appendix B Appendix C List of Figures No Description Page 1 Emission of pollutants, Chevrolet Matiz 21 2 Emission of pollutants, Fiat 500 23 3 Emission of pollutants, Hyundai i10 25 4 Emission of pollutants, Smart Fortwo 27 5 Emission of pollutants, Ford Mondeo 30 6 Emission of pollutants, Honda FR-V 33 7 Emission of pollutants, Jaguar X-Type 36 8 Emission of pollutants, Kia Rio 40 9 Emission of pollutants, Vauxhall Corsa 43 10 Emission of pollutants, Vauxhall Vectra 45 Millbrook Test Report No. 11/0162 Page 7 of 57
List of Tables No Description Page 1 Emissions and CO 2 decisions summary by vehicle model 4 2 Vehicle models tested 13 3 Measurements taken during emissions testing 15 4 Test vehicle summary 17 5 Summary of emissions results 17 6 Summary of CO 2 results 18 7 Petrol OBD screening and MOT emissions test results 18 8 Diesel OBD screening and MOT emissions test results 19 9 Chevrolet Matiz vehicle summary 21 10 Chevrolet Matiz results 22 11 Fiat 500 vehicle summary 23 12 Fiat 500 results 24 13 Hyundai i10 vehicle summary 25 14 Hyundai i10 results 26 15 Smart Fortwo vehicle summary 27 16 Smart Fortwo results 28 17 Ford Mondeo vehicle summary 29 18 Ford Mondeo results 30 19 Honda FR-V vehicle summary 32 20 Honda FR-V results 33 21 Jaguar X-Type vehicle summary (2009/10) 35 22 Jaguar X-Type vehicle summary (2010/11) 36 23 Jaguar X-Type results 37 24 Kia Rio vehicle summary (2009/10) 39 25 Kia Rio vehicle summary (2010/11) 39 26 Kia Rio results 40 27 Vauxhall Corsa vehicle summary (vehicles 1-5) 42 28 Vauxhall Corsa vehicle summary (vehicles 6-10) 43 29 Vauxhall Corsa results 44 30 Vauxhall Vectra vehicle summary 45 31 Vauxhall Vectra results 46 32 Current status of failure investigations (March 2011) 47 33 In-Service conformity test bands 48 34 Euro 4 Petrol results summary 48 35 Euro 4 Diesel results summary 49 36 In-Service emissions decisions, all vehicles 50 37 CO 2 conformance decisions, all vehicles 51 Millbrook Test Report No. 11/0162 Page 8 of 57
Introduction Emissions from vehicles can give rise to poor air quality, leading to environmental and health problems. A number of measures have been adopted by the Government and international bodies to address these problems. These measures have focused in particular on controlling emissions from new vehicles, this being the most cost effective and technically efficient solution to this problem. Such measures are agreed at EU level thus maintaining the single market for motor vehicles in all EU countries. Emission limits are prescribed which all vehicles in a particular category have to meet before they can enter into service. The emissions currently controlled are those which have traditionally given rise to the greatest health concerns, namely carbon monoxide (CO), hydrocarbons (HC), oxides of nitrogen (NOx) and, for diesel engine vehicles, particulate matter (PM). The emission limits to be met have been progressively tightened over a number of years, leading to a substantial reduction per vehicle in emissions of these pollutants. In addition to ensuring that new vehicles meet these standards, measures have been introduced to ensure that new vehicles maintain these standards over a reasonable durability period. Directive 70/220/EEC, as amended, (hereafter referred to as the Directive ), requires that the emissions of regulated pollutants from passenger cars do not exceed specified limits, even after a defined period of use. For type approval of the vehicle model emissions are measured on a new vehicle and an estimate of the emissions deterioration is made using assigned deterioration factors. This deteriorated result is used to confirm the emissions from the vehicle after 100,000km of use still meet the prescribed limits. The Directive also requires vehicle manufacturers to provide test data on In-Service vehicles to be submitted to the type approval authority in order to ensure that vehicles in use are in conformity with the emission limit requirements over the requisite period (100,000km for Euro 4). Euro 4 emission levels became a required standard for all new passenger car models from 1 st January 2006. Several vehicle manufacturers achieved this standard prior to the mandatory requirement. As such, Euro 4 standard vehicles will now have completed a reasonable period of use. It is necessary, for the continued reduction of ambient pollution, to ensure that these vehicles maintain the required emissions levels as specified by the Directive. Although vehicle manufacturers are required to provide data to be submitted to ensure that the vehicle conforms to the In-Service requirements, the VCA also wishes to have an independent view of the level of compliance of Euro 4 vehicles. The VCA has completed several In-Service vehicle testing programmes over previous years in order to build up a picture of the compliance of new vehicles in general with the in-use compliance requirements of the Directive. The VCA is continuing assessment of the compliance of a sample of In-Service Euro 4 passenger car models with the emissions standards to which they were type approved according to the requirements of the Directive. The information obtained is Millbrook Test Report No. 11/0162 Page 9 of 57
to be combined with previous year s results in order to provide an up to date overview of the level of compliance of new cars in general. More detailed analysis of vehicle emissions reveals other species that are of importance to human health and are typically the focus of ambient air quality targets. It is known that some of the new vehicle, catalyst and fuel technologies can exacerbate emissions of specific species under certain operating conditions. With this in mind, the programme was extended to consider the speciation of Oxides of Nitrogen (NOx) with Nitrogen Dioxide (NO 2 ) currently being a major air quality concern. Additionally, there is a requirement to assess the In-Service conformity of CO 2 emissions and calculated fuel consumption as defined in directive 80/1268/EEC as amended. Together with regulated emissions, all vehicles tested had CO 2 emissions measured to allow assessment of the conformity of this aspect of vehicle performance. All test vehicles were sourced from the general public using the DVLA records database to ensure complete impartiality. Selected test vehicles were carefully assessed for service history and current roadworthiness prior to inclusion in the testing programme. The vehicle manufacturers were also invited to witness the testing and review the results of any outliers to assist in determining causes. The detailed test procedure and overall programme methodology is described together with the specific results from each vehicle tested. The conclusions indicate where a vehicle model has passed, failed or if further testing is required ( Test More ). In the case of outliers the causes, where known, have been given and a current status indicated for all investigations still in progress. Millbrook Test Report No. 11/0162 Page 10 of 57
Objectives The overall objective of the programme was to extend an existing programme of testing in order to provide the UK DfT International Vehicle Standards Division (formerly Cleaner Fuels and Vehicles Division) with an objective assessment of the compliance of a sample of in-service passenger car models with the emissions standards to which they were type approved. From this information and from previous years results the DfT intends to maintain a picture of the level of compliance of new cars in general. This programme focussed on passenger cars that had been Type Approved to the Euro 4 emissions standard. The objectives were; 1. To test a range of vehicle models (determined by VCA and DfT) over the New European Driving Cycle (NEDC) using a single batch of appropriate grade reference fuel. 2. Where vehicles of the same model had been tested in previous years, to incorporate those results into the conformity assessment. 3. To calculate for each regulated pollutant the In-Service conformity criteria and determine the vehicle model sample as Pass, Fail or Test More. 4. To aim to get each model to a Pass or Fail conclusion by testing further vehicles and applying the In-Service conformity criteria. 5. To work with the VCA to where possible, determine the cause of any outlier test results should more than one outlier exist in any sample. Millbrook Test Report No. 11/0162 Page 11 of 57
Test Procedure Vehicle Sourcing Millbrook was responsible for sourcing test vehicles from a list of eligible owners provided by the VCA. These owners had initially agreed to take part in the test programme by responding to the questionnaire distributed to owners of eligible vehicles by the VCA. From this list, potential vehicles for testing were selected according to the following criteria: Vehicle had completed between 15,000 and 100,000 kilometres Vehicle was not within 800 kilometres of a scheduled service Preference to vehicles which had completed a higher mileage The vehicles also complied with the requirements of Annex I, Appendix 3, Section 2 of the Directive. The vehicles were also approved to the Row B emissions limits of the Directive and were equipped with on board diagnostic (OBD) systems. When sourcing vehicles, it was necessary before securing the first test vehicle to confirm the availability of two further vehicles should additional testing be required. For the purposes of this programme the need for additional testing was decided on the following criteria: Results above 60% of the relevant Euro limit for any legislated pollutant for Petrol vehicles Results above 70% of the relevant Euro limit for any legislated pollutant for Diesel vehicles The VCA supplied the test laboratory with technical information on ten vehicle models which were to be tested within the programme. All ten models were selected to be included within the VCA In-Service emissions programme for 2010/11 and all but two resulted in a conclusion being achieved. Millbrook Test Report No. 11/0162 Page 12 of 57
These models were: Vehicle Model Fuel Euro Standard Chevrolet Matiz Petrol Euro 4 Fiat 500 Petrol Euro 4 Hyundai i10 Petrol Euro 4 Smart Fortwo Petrol Euro 4 Ford Mondeo Diesel Euro 4 Honda FR-V Diesel Euro 4 Jaguar X-Type Diesel Euro 4 Kia Rio Diesel Euro 4 Vauxhall Corsa Diesel Euro 4 Vauxhall Vectra Diesel Euro 4 Table 2 Vehicle models tested Once the vehicle models were confirmed, vehicles were selected for test and the owners were contacted to arrange the use of their vehicles. An incentive of 250 for three days was provided to owners for the use of their vehicle along with a full tank of fuel on return. All vehicles were transported to and from the test laboratory by car transporters. Vehicle owners received a letter prior to their vehicle collection fully explaining the work that would be carried out on their vehicle whilst on site. Vehicle Checks and Test Preparation Upon securing the vehicle, secondary confirmation was requested from the vehicle manufacturer of the Euro standard. At this time the following information was requested from the manufacturer: Coastdown times Test Inertia Gear shift schedule (for vehicles with 6 speed transmission) Any special requirements for testing The manufacturer was also informed of the scheduled test date and invited to attend. Upon arrival of the vehicle at the test laboratory the following procedure was completed in order to prepare the vehicle for test: Complete vehicle arrival sheet to record any damage present and current mileage Check vehicle service history Ensure vehicle is compliant with In-Service conformity requirements Millbrook Test Report No. 11/0162 Page 13 of 57
Carry out OBD screening log any faults recorded by the ECU Carry out MOT emissions test If requested by the manufacturer, change oil, oil filter and air filter Drain existing fuel from the vehicle Fill with 15 litres of reference fuel from batched supply Operate the vehicle over a distance prescribed by the manufacturer to acclimatise the engine ECU to the new fuel Exhaust leak check Set tyre pressures to either: 1.5 x standard tyre pressure Maximum pressure of tyre if lower than 1.5 x standard Manufacturer s requested pressure, if supplied, for twin roller dynamometer. Fit vehicle to the chassis dynamometer Warm up vehicle New European Drive Cycle (NEDC) Carry out coastdown match to supplied times. Record dynamometer settings Complete preconditioning cycle: 3 x EUDC for Diesel ECE + 2 x EUDC for Petrol Overnight soak at between 20 C and 30 C. Vehicle Testing Each vehicle was tested over the NEDC according to the procedure specified by Directive 70/220/EEC, as amended. A full description of the NEDC is provided in Appendix A. However, the following point of the testing differed to the directive, as requested by the VCA: Raw exhaust gas was sampled for analysis of gaseous pollutants on a second-by-second basis and for NOx species using a Fourier Transform Infra Red (FTIR) analyser. Corrections were made within the calculation of dilute emissions for the removal of this additional exhaust gas. Millbrook Test Report No. 11/0162 Page 14 of 57
The following measurements were made during each test at the tailpipe position: Pollutant Measurement Technique Measurement Frequency Analyser Hydrocarbons Bag Integrated 1Hz FID Modal 1 Hz FID Carbon Monoxide Bag Per phase NDIR Modal 1 Hz NDIR Oxides of Nitrogen Bag Per phase CLD Modal 1 Hz CLD FTIR 1 Hz FTIR Carbon Dioxide Bag Per phase NDIR Modal 1 Hz NDIR Particulate Matter Gravimetric Per phase N/A Optical 1 Hz and per test TSI NO FTIR 1 Hz FTIR NO2 FTIR 1 Hz FTIR N2O FTIR 1 Hz FTIR Table 3 Measurements taken during emissions testing (FID = Flame Ionization Detector, NDIR = Non-Dispersive Infrared, CLD= Chemiluminescent Detector, FTIR Fourier Transform Infrared) Following completion of the cold start NEDC a full coastdown check was carried out upon each vehicle to ensure that the coastdown times remained within the required tolerances. In all cases the checks found the times after test were within an acceptable tolerance of the original coastdown match times, except for the Honda FR-V (1) 2010/11 and the Vauxhall Corsa (1). Vehicle Completion Upon completion of the required testing each vehicle underwent the following procedure: Reset tyre pressures to standard Ensure vehicle is in the condition in which it arrived Fill vehicle with standard pump fuel Complete vehicle departure form and ensure no damage has been sustained during testing Return vehicle to owner with a letter of thanks informing them of the results. Reporting After completion of testing an Individual Vehicle Report was created for each vehicle. This report was in Excel spreadsheet format and contained the following sheets: Vehicle details NEDC summary sheet 1 Hz emissions data Coastdown match and check details Millbrook Test Report No. 11/0162 Page 15 of 57
After the first vehicle of each model was completed the results were assessed to determine whether two further vehicles were required for testing. If further vehicles were required, the procedures described above were again followed. Millbrook Test Report No. 11/0162 Page 16 of 57
Test Results and Discussion Overview During the programme ten vehicle models were tested. It should be noted that 3 diesel vehicles were rejected after the test was conducted and have not been included in the final results. Test Vehicle Summary Petrol Diesel Models Vehicles Models Vehicles Euro 4 4 6 6 24 Table 4 Test Vehicle Summary Table 5 below summarises the legislated emissions results of all vehicles tested: % of relevant Euro Limit HC HC+NOx CO NOx PM Petrol Euro 4 Pass Under 100% 6 6 6 Band 1 Between 100% and 150% 0 0 0 Band 2 Between 150% and 250% 0 0 0 Band 3 Over 250% 0 0 0 Diesel Euro 4 Pass Under 100% 22 24 17 23 Band 1 Between 100% and 150% 0 0 5 1 Band 2 Between 150% and 250% 2 0 2 0 Band 3 Over 250% 0 0 0 0 Table 5 Summary of emissions results Pollutant results within bands 2 and 3 are classed as outliers. The presence of more than one outlier within a vehicle model which could be determined as being due to the same cause would result in a failure of the model within Directive 70/220/EEC s in-use compliance requirements. The presence of any pollutant result within bands 1, 2 or 3 during testing of three vehicles would require manufacturers to increase the sample size and test an additional vehicle. For one vehicle model that was carried over from the previous year s programme as a Test More case (Kia Rio) this reached a total of five vehicles tested this year to achieve a statistical Pass. Two vehicle models reached a Test More condition; Jaguar X-Type after twelve vehicles tested and Vauxhall Corsa after seven vehicles tested. Millbrook Test Report No. 11/0162 Page 17 of 57
Evaluation of the CO 2 emissions of the vehicles was carried out and comparisons were made to the type approval figures for each vehicle. The results are summarised in the table below. % of Type Approval CO 2 Under 100% 16.7% Petrol Euro 4 Over 100% 83.3% Diesel Euro 4 Under 100% 62.5% Over 100% 37.5% Table 6 Summary of CO 2 results OBD Screening and MOT Testing Prior to testing, each vehicle was scanned using a generic or OEM On-Board Diagnostics (OBD) scan tool in order to check for OBD fault codes and also Malfunction Indication Light (MIL) status. Each vehicle then underwent the appropriate MOT test. Table 7 summarises the findings for the petrol vehicles and table 8 for the diesel vehicles. No checks were possible for the Chevrolet Matiz, Hyundai i10 or the Kia Rio due to the generic scan tool not communicating with the vehicle. The manufacturer was also not present to check with the recognised manufacture scan tool. Petrol Euro IV Petrol Vehicles OBD Screening Code Description Chevrolet Matiz (1) not checked off pass Fiat 500 (1) none off pass Hyundai i10 (1) not checked off pass Smart Fortwo (1) none off pass Smart Fortwo (2) none off pass Smart Fortwo (3) none off pass MIL Status MOT Result Comments Judged suitable based on MIL status Judged suitable based on MIL status Table 7 Petrol OBD screening and MOT emissions test results Millbrook Test Report No. 11/0162 Page 18 of 57
Diesel Euro IV Diesel Vehicles Ford Mondeo (1) Ford Mondeo (2) Code P0219, P0313, P0336, P0620, P115A, P1933, P2105 P0299, P0336, P061B, P0620, P1260 OBD Screening Description P0219 Engine Overspeed Condition, P0313 Misfire Detected With Low Fuel, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P0620 Generator Control Circuit, P115A Low Fuel Level - Forced Limited Power, P1933 Fuel Level Signal, P2105 Throttle Actuator Control System - Forced Engine Shutdown P0299 Turbocharger/Supercharger A Underboost Condition, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P061B Internal Control Module Torque Calculation Performance, P0620 Generator Control Circuit, P1260 Theft Detected, Vehicle Immobilized MIL Status MOT Result Comments off pass Static code off pass Static code Ford Mondeo (3) none off pass Honda FR-V (1) 2010/11 61-1 61-1 Battery Voltage Low (ABS) off pass Static code Jaguar X-Type (1) 2010/11 E511H off pass Jaguar X-Type (2) E510H, 2010/11 E511H off pass Jaguar X-Type (3) 2010/11 E511H off pass Jaguar X-Type (4) 2010/11 none off pass Jaguar X-Type (5) 2010/11 none off pass Kia Rio (1) 2010/11 not checked off pass Judged suitable based on MIL status Kia Rio (2) 2010/11 not checked off pass Judged suitable based on MIL status Kia Rio (3) 2010/11 not checked off pass Judged suitable based on MIL status Kia Rio (4) 2010/11 not checked off pass Judged suitable based on MIL status Kia Rio (5) 2010/11 not checked off pass Judged suitable based on MIL status Vauxhall Corsa (1) none off pass Vauxhall Corsa (2) none off pass Vauxhall Corsa (3) none off pass Vauxhall Corsa (4) none off pass Vauxhall Corsa (5) none off pass Vauxhall Corsa (6) none off pass Vauxhall Corsa (7) none off pass Vauxhall Corsa (8) none off pass Not tested Vauxhall Corsa (9) none off pass Not tested Vauxhall Corsa (10) none off pass Not tested Vauxhall Vectra (1) none off pass Vauxhall Vectra (2) none off pass Vauxhall Vectra (3) none off pass Table 8 Diesel OBD screening and MOT emissions test results Millbrook Test Report No. 11/0162 Page 19 of 57
Ford Mondeo (1) returned seven OBD fault codes following an OBD scan: P0219 Engine Overspeed Condition, P0313 Misfire Detected With Low Fuel, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P0620 Generator Control Circuit, P115A Low Fuel Level - Forced Limited Power, P1933 Fuel Level Signal, P2105 Throttle Actuator Control System - Forced Engine Shutdown. Ford Mondeo (2) had five OBD fault codes present: P0299 Turbocharger/Supercharger A Underboost Condition, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P061B Internal Control Module Torque Calculation Performance, P0620 Generator Control Circuit, P1260 Theft Detected, Vehicle Immobilized. Honda FR-V (1) had one OBD fault code present: 61-1 Battery Voltage Low (ABS) At the time of writing no description had been received from Jaguar regarding the codes present on X-Type (1), (2) and (3). In all cases the statuses of the codes were stored as static which means the faults were no longer present and active, therefore the vehicle was deemed suitable for testing. Millbrook Test Report No. 11/0162 Page 20 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Results Petrol Euro 4 Chevrolet Matiz Three vehicles were selected for testing, however only one was tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade petroleum the vehicles were tested as received. It is important to note that the generic OBD scan tool used by the test laboratory could not access fault codes for this vehicle model. However as none of the vehicles displayed a Malfunction Indication Light, they were all deemed suitable for inclusion within the In-Service emissions test programme. 2010/11 Programme Vehicle Chevrolet Matiz (1) Engine 0.8L Transmission Manual Fuel Petrol Euro Level Euro 4 Odometer (km) 20170 Service History Checked, OK MOT Test Pass MIL Off OBD Faults Not Checked Table 9 Chevrolet Matiz vehicle summary 300% 275% Legislated exhaust emissions as a percentage of the Euro 4 limit - Chevrolet Matiz Chevrolet Matiz (1) 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% HC CO NOx Figure 1 Emission of pollutants, Chevrolet Matiz Millbrook Test Report No. 11/0162 Page 21 of 57
Vehicle HC CO NOx CO 2 Fuel Cons Euro 4 0.10 1.00 0.08 Type Approval 40% 64% 25% N/A N/A Chevrolet Matiz (1) 36.5% 38.1% 28.4% 100.1% 97.2% Average 36.5% 38.1% 28.4% 100.1% 97.2% Decision Pass Pass Pass Table 10 Chevrolet Matiz results The first vehicle passed the Euro 4 limit with regard to all legislated pollutants well below the 60% criteria set to negate the need for additional testing. Hence the vehicle met the In-service statistical requirements and the vehicle model reached a Pass decision. The average CO 2 result of the vehicle model was 100.1% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service Emissions Decision = Pass CO 2 Conformance = 100.1% Millbrook Test Report No. 11/0162 Page 22 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Fiat 500 Three vehicles were selected for testing, however only one was tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. Prior to testing the vehicles had various technical checks carried out by Fiat as allowed within EC Directive 70/220/EEC. These included air filter and oil changes. The fuel tanks were fully drained and refilled with reference grade petroleum. The vehicles were then conditioned for twenty minutes on Millbrook s tracks to allow the oil to settle and the engine management system to acclimatise to the new fuel. This consisted of fifteen minutes at 70mph and five minutes at low speed using first and second gear. 2010/11 Programme Vehicle Fiat 500 (1) Engine 1.2L Transmission Manual Fuel Petrol Euro Level Euro 4 Odometer (km) 26223 Service History Checked, OK MOT Test Pass MIL Off OBD Faults None Table 11 Fiat 500 vehicle summary Legislated exhaust emissions as a percentage of the Euro 4 limit - Fiat 500 300% 275% Fiat 500 (1) 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% HC CO NOx Figure 2 Emission of pollutants, Fiat 500 Millbrook Test Report No. 11/0162 Page 23 of 57
Vehicle HC CO NOx CO 2 Fuel Cons Euro 4 0.10 1.00 0.08 Type Approval 55% 18% 43% N/A N/A Fiat 500 (1) 59.0% 25.4% 28.9% 100.4% 99.4% Average 59.0% 25.4% 28.9% 100.4% 99.4% Decision Pass Pass Pass Table 12 Fiat 500 results The first vehicle passed the Euro 4 limit with regard to all legislated pollutants below the 60% criteria set to negate the need for additional testing. Hence the vehicle met the In-service statistical requirements and the vehicle model reached a Pass decision. The average CO 2 result of the vehicle model was 100.4% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service Emissions Decision = Pass CO 2 Conformance = 100.4% Millbrook Test Report No. 11/0162 Page 24 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Hyundai i10 Three vehicles were selected for testing, however only one was tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade petroleum the vehicles were tested as received. Again, it is important to note that the generic OBD scan tool used by the test laboratory could not access fault codes for this vehicle model. However as none of the vehicles displayed a Malfunction Indication Light, they were all deemed suitable for inclusion within the In-Service emissions test programme. 2010/11 Programme Vehicle Hyundai i10 (1) Engine 1.1L Transmission Manual Fuel Petrol Euro Level Euro 4 Odometer (km) 20806 Service History Checked, OK MOT Test Pass MIL Off OBD Faults Not Checked Table 13 Hyundai i10 vehicle summary 300% 275% Legislated exhaust emissions as a percentage of the Euro 4 limit - Hyundai i10 Hyundai i10 (1) 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% HC CO NOx Figure 3 Emission of pollutants, Hyundai i10 Millbrook Test Report No. 11/0162 Page 25 of 57
Vehicle HC CO NOx CO 2 Euro 4 0.10 1.00 0.08 Fuel Cons Type Approval 35% 32% 29% N/A N/A Hyundai i10 (1) 23.9% 33.9% 53.8% 105.8% 106.7% Average 23.9% 33.9% 53.8% 105.8% 106.7% Decision Pass Pass Pass Table 14 Hyundai i10 results The first vehicle passed the Euro 4 limit with regard to all legislated pollutants below the 60% criteria set to negate the need for additional testing. Hence the vehicle met the In-service statistical requirements and the vehicle model reached a Pass decision. The average CO 2 result of the vehicle model was 105.8% of, and therefore above, the approved figures. In-Service Emissions Decision = Pass CO 2 Conformance = 105.8% Millbrook Test Report No. 11/0162 Page 26 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Smart Fortwo Three vehicles were tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade petroleum the vehicles were tested as received. 2009/10 Programme Vehicle Smart Fortwo (1) Smart Fortwo (2) Smart Fortwo (3) Engine 1.0L 1.0L 1.0L Transmission Manual Manual Manual Fuel Petrol Petrol Petrol Euro Level Euro 4 Euro 4 Euro 4 Odometer (km) 52535 41809 39273 Service History Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass MIL Off Off Off OBD Faults None None None Table 15 Smart Fortwo vehicle summary 300% 275% Legislated exhaust emissions as a percentage of the Euro 4 limit - Smart Fortwo Smart Fortwo (1) Smart Fortwo (2) Smart Fortwo (3) 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% HC CO NOx Figure 4 Emission of pollutants, Smart Fortwo Millbrook Test Report No. 11/0162 Page 27 of 57
Vehicle HC CO NOx CO 2 Fuel Cons Euro 4 0.10 1.00 0.08 Type Approval 60% 14% 15% N/A N/A Smart Fortwo (1) 63.4% 25.1% 50.6% 102.6% 103.0% Smart Fortwo (2) 72.4% 26.6% 32.5% 91.7% 92.1% Smart Fortwo (3) 67.0% 17.9% 25.8% 103.5% 103.8% Average 67.6% 23.2% 36.3% 99.3% 99.6% Decision Pass Pass Pass Table 16 Smart Fortwo results All vehicles passed the Euro 4 limit with regard to all legislated pollutants and hence the vehicle model passed the In-Service statistical requirements. The average CO 2 of the three vehicles was 99.3% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service emissions decision = Pass CO 2 conformance = 99.3% Millbrook Test Report No. 11/0162 Page 28 of 57
Results Diesel Euro 4 Ford Mondeo Three vehicles were tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade diesel the vehicles were tested as received. 2010/11 Programme Vehicle Ford Mondeo (1) Ford Mondeo (2) Ford Mondeo (3) Engine 2.2L Duratorque 2.2L Duratorque 2.2L Duratorque Transmission Manual Manual Manual Fuel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Odometer (km) 53781 58578 60616 Service History Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Smoke Result 0.00 0.00 0.01 MIL Off Off Off OBD Faults Yes Yes None Table 17 Ford Mondeo vehicle summary Upon interrogation Ford Mondeo (1) had seven OBD fault codes present: P0219 Engine Overspeed Condition, P0313 Misfire Detected With Low Fuel, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P0620 Generator Control Circuit, P115A Low Fuel Level - Forced Limited Power, P1933 Fuel Level Signal, P2105 Throttle Actuator Control System - Forced Engine Shutdown. Ford suspected the codes were generated from a low level fuel situation. Ford Mondeo (2) had five OBD fault codes present: P0299 Turbocharger/Supercharger A Underboost Condition, P0336 Crankshaft Position Sensor A Circuit Range/Performance, P061B Internal Control Module Torque Calculation Performance, P0620 Generator Control Circuit, P1260 Theft Detected, Vehicle Immobilized. Ford suspected these codes were generated from a stall condition with the exception of P1260 which is because the key is not recognised when the engine is cranked. The owner of this vehicle had reported that the key had to be held directly next to the steering column to be recognised. In both cases Ford accepted that the codes were static fault codes meaning the faults were not present at that time but had occurred before. The faults were deleted and the vehicles were included within the programme. Millbrook Test Report No. 11/0162 Page 29 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 300% 275% Legislated exhaust emissions as a percentage of the Euro 4 limit - Ford Mondeo Ford Mondeo 1 Ford Mondeo 2 Ford Mondeo 3 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% CO NOx HC+NOx PM Vehicle CO NOx Figure 5 Emission of pollutants, Ford Mondeo HC + NOx PM CO2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 53% 88% 87% 4% N/A N/A Ford Mondeo (1) 37.4% 87.6% 87.0% 1.2% 102.4% 102.5% Ford Mondeo (2) 62.0% 86.4% 93.3% 2.8% 98.2% 98.4% Ford Mondeo (3) 38.5% 83.9% 83.5% 2.0% 95.2% 95.2% Average 46.0% 86.0% 88.0% 2.0% 98.6% 98.7% Decision Pass Pass Pass Pass Table 18 Ford Mondeo results Initially, Ford Mondeo (1), (2) and (3) failed the Euro 4 limit with regard to HC+NOx at 102.1%, 102.6% and 113.5% respectively. Vehicle (3) also failed the Euro 4 limit with regard to NOx at 103.5%. Hence the vehicle model reached a Fail condition with three out of three failing HC+NOx. It was agreed with the VCA that Ford could investigate these failures further and retest the vehicles at their own emissions laboratory. Ford were able to procure all three vehicles and conducted various technical checks as allowed within EC Directive 70/220/EEC. Oil and filter replacements were made if it was required. The vehicles were retested at Ford s emissions laboratory in Dunton with an additional ADAC cycle. Ford use this cycle on In-Service vehicles before the start of a preconditioning cycle to minimise the risk of an unexpected particulate filter regeneration. The use of this cycle was accepted by the VCA and it was agreed that Millbrook Test Report No. 11/0162 Page 30 of 57
the results from Ford Dunton would be included in the programme, replacing the results obtained previously. The results from Ford show that Ford Mondeo (1), (2) and (3) passed the Euro 4 limit with regard to all legislated pollutants and hence the vehicle model passed the In-Service statistical requirements. The average CO 2 result of the vehicle model was 98.6% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service Emissions Decision = Pass CO 2 Conformance = 98.6% Millbrook Test Report No. 11/0162 Page 31 of 57
Honda FR-V In the 2009/10 programme, three vehicles were tested and all vehicles passed the requirements for inclusion within the In-Service emissions test programme. Prior to testing the vehicles had various technical checks carried out by Honda as allowed within EC Directive 70/220/EEC. The oil was checked and air filters replaced if it was evident it had not been carried out at service interval. No work was conducted on vehicle (1), while vehicles (2) and (3) had air filters replaced only. The first vehicle failed PM with a result of 157.7%. This result did not show any correlation with the other vehicles therefore Honda were to carry out an investigation on this vehicle. The coastdown check conducted after the test on vehicle (1) was out of specification and one possible cause for this was discussed between Honda and the VCA. Honda believed that a brake may have been dragging during the test which resulted in the high CO 2 result and the coastdown check being out of specification. It was agreed between the VCA and Honda that if the manufacturer could find evidence of an issue with the brake system that the vehicle could be removed from the results. No reply was received from Honda, hence the vehicle was included, leaving the vehicle model in a Test More condition. In the 2010/11 programme, three vehicles were selected for testing, however only one was tested. All vehicles passed the requirements for inclusion within the In- Service emissions test programme. Prior to testing the vehicle had various technical checks carried out by Honda as allowed within EC Directive 70/220/EEC. All three vehicles had an oil change and a new air filter. The fuel tanks were fully drained and refilled with reference grade diesel. It is important to note, instead of the standard NEDC warm-up cycle before the coastdown match the vehicles were driven on the dynamometer for twenty minutes at 40mph. The vehicles were also driven for thirty minutes at 70mph in addition to the standard 3 x EUDC preconditioning cycle. This was agreed with the VCA prior to testing the vehicles. 2009/10 Programme 2010/11 Programme Vehicle Honda FR-V (1) Honda FR-V (2) Honda FR-V (3) Honda FR-V (1) Engine 2.2L I-CDTI 2.2L I-CDTI 2.2L I-CDTI 2.2L I-CDTI Transmission Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 47373 66611 48232 48322 Service History Checked, OK Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Pass Smoke Result 0.36 0.17 0.19 0.39 MIL Off Off Off Off OBD Faults None None None Yes Table 19 Honda FR-V vehicle summary Millbrook Test Report No. 11/0162 Page 32 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Upon interrogation 2010/11 Honda FR-V (1) had one OBD fault code present: 61-1 Battery Voltage Low (ABS). This fault was a static fault code meaning the fault was not present at that time but had occurred before. Honda accepted that the fault code was no longer active and the vehicle went on to complete the test. Legislated exhaust emissions as a percentage of the Euro 4 limit - Honda FR-V 300% 275% Honda FR-V (1) 2009/10 Honda FR-V (2) 2009/10 Honda FR-V (3) 2009/10 Honda FR-V (1) 2010/11 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% CO NOx HC+NOx PM Vehicle CO NOx Figure 6 Emission of pollutants, Honda FR-V HC + NOx PM CO 2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 30% 72% 66% 46% N/A N/A Honda FR-V (1) 2009/10 25.7% 67.8% 61.8% 157.7% 105.7% 105.6% Honda FR-V (2) 2009/10 28.1% 80.6% 72.4% 71.8% 100.8% 100.7% Honda FR-V (3) 2009/10 26.9% 85.1% 75.4% 81.8% 101.8% 101.6% Honda FR-V (1) 2010/11 28.3% 100.5% 88.8% 91.1% 103.0% 102.9% Average 27.2% 83.5% 74.6% 100.6% 102.8% 102.6% Decision Pass Pass Pass Pass Table 20 Honda FR-V results In the 2009/10 programme Honda FR-V (1) failed PM and was classified in the outlying emitter band with 157.7%. Honda FR-V (2) and (3) passed the Euro 4 limits with regard to all legislated pollutants. In the 2010/11 programme the first vehicle passed the Euro 4 limits with regard to all legislated pollutants except NOx, with a result of 100.5%. The vehicle model passed the In-Service statistical requirements with three passes out of four for NOx emissions. Hence it was not necessary to test vehicles (2) and (3). Millbrook Test Report No. 11/0162 Page 33 of 57
The average CO 2 result of the vehicle model was 102.8%. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service emissions decision = Pass CO 2 conformance = 102.8% Millbrook Test Report No. 11/0162 Page 34 of 57
Jaguar X-Type In the 2009/10 programme seven vehicles were tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing, except for vehicle (7) which received oil and oil filter changes and new air and fuel filters, allowed within EC Directive 70/220/EEC. The campaign resulted in a Test More condition where the most common failure for the model was NOx, with five out of seven exceeding the limit. In the 2010/11 programme nine vehicles were selected to be tested. Five vehicles passed the requirements for inclusion within the In-Service emissions test programme. Two vehicles were rejected because they had an automatic gearbox. These vehicles had different type approval figures to the manual model, an issue which had not been highlighted before the procurement process. Another two vehicles were rejected because they had previously been tested in the 2009/10 programme. Prior to testing the vehicles had various technical checks carried out by Jaguar as allowed within EC Directive 70/220/EEC. These included oil, oil filter, air filter and fuel filter changes. The fuel tanks were fully drained and refilled with reference grade diesel. Vehicles (4) and (5) were also conditioned for twenty minutes in fifth gear at 3000rpm on Millbrook s tracks to allow the oil to settle and the engine management system to acclimatise to the new fuel. 2009/10 Programme Vehicle Jaguar X-Type (1) Jaguar X-Type (2) Jaguar X-Type (3) Jaguar X-Type (4) Jaguar X-Type (5) Jaguar X-Type (6) Jaguar X-Type (7) Engine 2.2L TD 2.2L TD 2.2L TD 2.2L TD 2.2L TD 2.2L TD 2.2L TD Transmission Manual Manual Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 67030 50370 70993 43951 44071 60452 46046 Service History Checked, Checked, Checked, Checked, Checked, Checked, Checked, OK OK OK OK OK OK OK MOT Test Pass Pass Pass Pass Pass Pass Pass Smoke Result 1.16 0.45 0.82 0.78 0.57 0.65 0.64 MIL Off Off Off Off Off Off Off OBD Faults None None None None None None None Table 21 Jaguar X-Type vehicle summary (2009/10) Millbrook Test Report No. 11/0162 Page 35 of 57
Vehicle Jaguar X-Type (1) Jaguar X-Type (2) 2010/11 Programme Jaguar X-Type Jaguar X-Type (3) (4) Jaguar X-Type (5) Engine 2.2L TD 2.2L TD 2.2L TD 2.2L TD 2.2L TD Transmission Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 69716 47131 83845 39028 71450 Service History Checked, OK Checked, OK Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Pass Pass Smoke Result 1.09 0.94 1.06 0.49 1.02 MIL Off Off Off Off Off OBD Faults E511H E510H, E511H E511H None None Table 22 Jaguar X-Type vehicle summary (2010/11) Pollutant (% of limit) 300% 275% 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% PASS Band 1 BAND 2 BAND 3 Legislated exhaust emissions as a percentage of the Euro 4 limit - Jaguar X- Type Jaguar X-Type (1) 2009/10 Jaguar X-Type (2) 2009/10 Jaguar X-Type (3) 2009/10 Jaguar X-Type (4) 2009/10 Jaguar X-Type (5) 2009/10 Jaguar X-Type (6) 2009/10 Jaguar X-Type (7) 2009/10 Jaguar X-Type (1) 2010/11 Jaguar X-Type (2) 2010/11 Jaguar X-Type (3) 2010/11 Jaguar X-Type (4) 2010/11 Jaguar X-Type (5) 2010/11 CO NOx HC+NOx PM Figure 7 Emission of pollutants, Jaguar X-Type Millbrook Test Report No. 11/0162 Page 36 of 57
Vehicle CO NOx HC + NOx PM CO 2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 9% 79% 71% 68% N/A N/A Jaguar X-Type (1) 2009/10 37.3% 102.9% 96.0% 65.6% 99.7% 99.8% Jaguar X-Type (2) 2009/10 56.7% 106.2% 106.2% 58.0% 103.3% 103.5% Jaguar X-Type (3) 2009/10 107.9% 79.5% 97.6% 47.6% 100.7% 101.5% Jaguar X-Type (4) 2009/10 46.0% 112.5% 105.7% 43.1% 100.4% 100.8% Jaguar X-Type (5) 2009/10 105.3% 116.6% 131.2% 35.2% 101.2% 101.9% Jaguar X-Type (6) 2009/10 59.6% 102.6% 102.2% 71.7% 103.1% 103.3% Jaguar X-Type (7) 2009/10 40.8% 96.1% 91.2% 56.1% 104.1% 104.4% Jaguar X-Type (1) 2010/11 47.6% 74.3% 76.1% 59.6% 98.9% 99.3% Jaguar X-Type (2) 2010/11 44.0% 79.0% 80.1% 60.8% 100.4% 100.8% Jaguar X-Type (3) 2010/11 35.8% 171.2% 151.6% 64.5% 99.0% 99.1% Jaguar X-Type (4) 2010/11 43.5% 175.4% 157.0% 45.7% 96.2% 96.4% Jaguar X-Type (5) 2010/11 35.5% 88.3% 85.9% 54.8% 102.0% 102.4% Average 55.0% 108.7% 106.7% 55.2% 100.7% 101.1% Decision Pass Test More Test More Pass Table 23 Jaguar X-Type results In the 2009/10 programme Jaguar X-Type (1) failed on NOx at 102.9% of the legislated Euro 4 limit. Jaguar X-Type (2) failed on NOx and HC+NOx both at 106.2%. Jaguar X-Type (3) failed on CO at 107.9% of the legislated Euro 4 limit. Jaguar X-Type (4) failed on NOx and HC+NOx at 112.5% and 105.7% respectively. Jaguar X-Type (5) failed on CO, NOx and HC+NOx at 105.3%, 116.6% and 131.2% respectively. Jaguar X-Type (6) failed on NOx and HC+NOx at 102.6% and 102.2% respectively. Jaguar X-Type (7) passed the Euro 4 limit with regard to all legislated pollutants. All failures were within Band 1. In the 2010/11 programme Jaguar X-Type (1) initially failed on NOx and HC+NOx at 112.1% and 119.1% of the legislated Euro 4 limit respectively. Jaguar X-Type (2) initially failed on NOx and HC+NOx at 137.0% and 123.4% respectively. Jaguar X- Type (3) failed on NOx and HC+NOx at 171.2% and 151.6% respectively. Jaguar X- Type (1) and (2) were both within band 1 and Jaguar X-Type (3) was an outlier within band 2. This left the vehicle model failing the In-Service statistical requirements with eight out of ten failing on NOx emissions. Millbrook agreed with the VCA that Jaguar could investigate these failures and in the meantime Millbrook would continue to test further vehicles. Due to the limited number of questionnaire responses received from Jaguar X-Type owners, Millbrook were only able to procure a further two vehicles. Jaguar X-Type (4) failed on NOx and HC+NOx at 175.4% and 157.0% respectively. Jaguar X-Type (5) initially failed on NOx and HC+NOx at 148.5% and 136.0% respectively. Therefore Jaguar X-Type (4) was an outlier within band 2 and Jaguar X-Type (5) was within band 1. During the test, Jaguar X-Type (4) displayed a flashing glow plug light. Jaguar Engineers believed that this model uses the glow plug light as a secondary engine malfunction indication light for some engine faults. Millbrook Test Report No. 11/0162 Page 37 of 57
VCA and Jaguar agreed that if the manufacturer could find evidence of this that the vehicle could be removed from the results. Following these results, Jaguar had initially planned to procure all five 2010/11 vehicles for their investigation and to resolve the glow plug light situation with vehicle (4). Jaguar were only able to procure vehicle (1), (2) and (5). The vehicles were retested at Jaguar s independent COP emissions laboratory with an alternative conditioning cycle running the vehicles for twenty minutes in fifth gear at 3600rpm. The tests were witnessed by the VCA (and an Engineer from Millbrook Proving Ground) and it was agreed to include the results in the programme, replacing the results obtained previously. At the time of writing, no response had been received regarding the glow plug light in vehicle (4) and the result has been included. The results from Jaguar show that Jaguar X-Type (1), (2) and (5) passed the Euro 4 limit with regard to all legislated pollutants. Including these results leaves the model in a Test More condition with seven out of twelve vehicles failing on NOx. Jaguar have proposed to procure and test further vehicles at their independent COP emissions laboratory, at their own expense, to bring the model to a conclusion. The tests may be witnessed by the VCA and results will be added to the results compiled to date. The average CO 2 result of the vehicle model was 100.7%. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service Emissions Decision = Test More CO 2 Conformance = 100.7% Millbrook Test Report No. 11/0162 Page 38 of 57
Kia Rio In the 2009/10 programme six vehicles were selected and tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. It should be noted that vehicles (1), (2) and (3) were all tested at Cookbook loads due to the manufacturer not supplying any coastdown data for the vehicle. Cookbook loads are generic loads stipulated in the EC Directive 70/220/EEC for a given vehicle mass and are used when the actual road load for a vehicle has not been determined. For vehicles (4), (5) and (6), only dynamometer coefficients were supplied so the correct coastdown match times were calculated from these coefficients. The campaign resulted in a Test More condition on both HC+NOx and PM, with three out of six and four out of six failures respectively. Only one vehicle passed the Euro 4 limit with regard to all legislated pollutants. In the 2010/11 programme five vehicles were tested and all vehicles passed the requirements for inclusion. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade diesel the vehicles were tested as received. Again, the manufacturer had only supplied dynamometer coefficients so the correct coastdown match times were calculated from these coefficients. It is also important to note that the generic OBD scan tool used by the test laboratory could not access fault codes for this model. However as none of the vehicles displayed a Malfunction Indication Light, they were all deemed suitable for inclusion within the In-Service emissions test programme. 2009/10 Programme Vehicle Kia Rio (1) Kia Rio (2) Kia Rio (3) Kia Rio (4) Kia Rio (5) Kia Rio (6) Engine 1.5L TD 1.5L TD 1.5L TD 1.5L TD 1.5L TD 1.5L TD Transmission Manual Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 64305 52975 48691 22582 33496 36193 Service History Checked, OK Checked, OK Checked, OK Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Pass Pass Pass Smoke Result 1.41 0.48 0.35 0.38 0.11 0.44 MIL Off Off Off Off Off Off OBD Faults None None None None None None Table 24 Kia Rio vehicle summary (2009/10) 2010/11 Programme Vehicle Kia Rio (1) Kia Rio (2) Kia Rio (3) Kia Rio (4) Kia Rio (5) Engine 1.5L TD 1.5L TD 1.5L TD 1.5L TD 1.5L TD Transmission Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 49965 47862 70518 45362 57101 Service History Checked, OK Checked, OK Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Pass Pass Smoke Result 0.52 0.10 0.20 0.37 0.28 MIL Off Off Off Off Off OBD Faults Not Checked Not Checked Not Checked Not Checked Not Checked Table 25 Kia Rio vehicle summary (2010/11) Millbrook Test Report No. 11/0162 Page 39 of 57
Pollutant (% of limit) PASS Band 1 BAND 2 BAND 3 Legislated exhaust emissions as a percentage of the Euro 4 limit - Kia Rio 300% 275% 250% Kia Rio (1) 2009/10 Kia Rio (2) 2009/10 Kia Rio (3) 2009/10 Kia Rio (4) 2009/10 Kia Rio (5) 2009/10 Kia Rio (6) 2009/10 Kia Rio (1) 2010/11 Kia Rio (2) 2010/11 Kia Rio (3) 2010/11 Kia Rio (4) 2010/11 Kia Rio (5) 2010/11 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% CO NOx HC+NOx PM Vehicle CO NOx Figure 8 Emission of pollutants, Kia Rio HC + NOx PM CO 2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 52% 80% 77% 84% N/A N/A Kia Rio (1) 2009/10 104.3% 98.1% 108.0% 122.4% 114.9% 115.0% Kia Rio (2) 2009/10 44.6% 97.1% 94.3% 96.5% 117.7% 117.4% Kia Rio (3) 2009/10 64.5% 79.5% 83.5% 116.6% 112.2% 112.1% Kia Rio (4) 2009/10 30.4% 86.3% 81.1% 129.6% 111.0% 110.6% Kia Rio (5) 2009/10 68.3% 120.8% 117.5% 84.2% 106.3% 106.2% Kia Rio (6) 2009/10 60.8% 102.3% 100.7% 105.0% 115.1% 115.0% Kia Rio (1) 2010/11 65.5% 83.3% 84.6% 111.1% 106.9% 106.8% Kia Rio (2) 2010/11 46.6% 98.6% 96.0% 71.8% 112.0% 111.8% Kia Rio (3) 2010/11 75.4% 99.5% 100.0% 92.4% 111.0% 110.9% Kia Rio (4) 2010/11 58.3% 95.2% 98.1% 96.2% 109.6% 109.4% Kia Rio (5) 2010/11 60.8% 93.6% 94.3% 79.8% 111.4% 111.2% Average 61.8% 95.9% 96.2% 100.5% 111.6% 111.5% Decision Pass Pass Pass Pass Table 26 Kia Rio results In the 2009/10 programme Kia Rio (1) failed on CO, HC+NOx and PM at 104.3%, 108.0% and 122.4% of the legislated Euro 4 limit respectively. Kia Rio (2) passed the Euro 4 limit with regard to all legislated pollutants. Kia Rio (3) and (4) failed on PM at 116.6% and 129.6% respectively. Kia Rio (5) failed on NOx and HC+NOx at 120.8% and 117.5% respectively. Kia Rio (6) failed on NOx, HC+NOx and PM at 102.3%, 100.7% and 105.0% respectively. Millbrook Test Report No. 11/0162 Page 40 of 57
In the 2010/11 programme Kia Rio (1) failed on PM at 111.1% of the legislated Euro 4 limit. Kia Rio (2), (3), (4) and (5) all passed the Euro 4 limit with regard to all legislated pollutants. Therefore, the vehicle model then passed the In-Service statistical requirements with six passes out of eleven for PM. The average CO 2 result of the vehicle model was 111.6% of, and therefore above, the approved figures. In-Service Emissions Decision = Pass CO 2 Conformance = 111.6% Millbrook Test Report No. 11/0162 Page 41 of 57
Vauxhall Corsa In the 2010/11 programme eleven vehicles were selected to be tested. The first four vehicles had no additional work performed on them prior to testing and other than refuelling with reference fuel the vehicles were tested as received. Prior to testing vehicles (5), (6) and (7) had various technical checks carried out by Vauxhall as allowed within EC Directive 70/220/EEC. The vehicles received oil and oil filter changes and new air filters. The fuel tanks were fully drained and refilled with reference grade diesel. The vehicles were then conditioned for thirty minutes at 70mph on Millbrook s tracks to allow the oil to settle and the engine management system to acclimatise to the new fuel. Vehicles (8), (9) and (10) were all rejected based on their service history. When sourcing the test vehicles, owners are asked to supply information on the service history and current roadworthiness of their vehicles prior to inclusion in the testing programme. The information received about vehicles (8), (9) and (10) indicated that all scheduled services had been completed and that all had been serviced by a manufacturer s agent. Upon arrival the vehicles were inspected as normal, including a check of their service books revealing that both vehicles (8) and (10) had not had all scheduled services completed by a manufacturer s agent. It was also discovered that vehicle (8) had an oil leak and that the cold air hose was disconnected from the air box. Hence both vehicles were rejected from the programme. Upon inspection of vehicle (9) the service book revealed that it was overdue a scheduled service and therefore was also rejected from the programme. Vehicle (11) was discovered to be a 90PS model upon delivery and was rejected from the programme as only the 75PS variant was required. This left seven vehicles which passed the requirements for inclusion within the In- Service emissions test programme. It should be noted that vehicle (2) was a 90PS model; this was not discovered until after the procurement process and inclusion was agreed by the VCA. Two different sets of type approval figures were supplied by the manufacturer. The type approval revision affected all legislated pollutants and the CO 2 and fuel economy figures for the 90PS model (Vauxhall Corsa (2)). The results correspond to the appropriate figures for each vehicle. 2010/11 Programme Vehicle Vauxhall Corsa (1) Vauxhall Corsa (2) Vauxhall Corsa (3) Vauxhall Corsa (4) Vauxhall Corsa (5) Engine 1.3L CDTi 1.3L CDTi 1.3L CDTi 1.3L CDTi 1.3L CDTi Transmission Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 31902 46597 53034 23978 32158 Service History Checked, OK Checked, OK Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Pass Pass Smoke Result 0.91 0.38 0.29 0.75 0.82 MIL Off Off Off Off Off OBD Faults None None None None None Table 27 Vauxhall Corsa vehicle summary (vehicles 1-5) Millbrook Test Report No. 11/0162 Page 42 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Vehicle Vauxhall Corsa (6) Vauxhall Corsa (7) 2010/11 Programme Vauxhall Corsa Vauxhall Corsa (8) (9) Vauxhall Corsa (10) Engine 1.3L CDTi 1.3L CDTi 1.3L CDTi 1.3L CDTi 1.3L CDTi Transmission Manual Manual Manual Manual Manual Fuel Diesel Diesel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Euro 4 Euro 4 Odometer (km) 66005 18042 18043 18044 18045 Service History Checked, OK Checked, OK Checked, Checked, Checked, Not OK Not OK Not OK MOT Test Pass Pass Pass Pass Pass Smoke Result 0.29 0.45 1.45 2.45 3.45 MIL Off Off Off Off Off OBD Faults None None None None None Table 28 Vauxhall Corsa vehicle summary (vehicles 6-10) 300% 275% 250% Legislated exhaust emissions as a percentage of the Euro 4 limit - Vauxhall Corsa Vauxhall Corsa (1) Vauxhall Corsa (2) Vauxhall Corsa (3) Vauxhall Corsa (4) Vauxhall Corsa (5) Vauxhall Corsa (6) Vauxhall Corsa (7) 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% CO NOx HC+NOx PM Figure 9 Emission of pollutants, Vauxhall Corsa Millbrook Test Report No. 11/0162 Page 43 of 57
Vehicle CO NOx HC + NOx PM CO 2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 46% 88% 80% 80% N/A N/A Type Approval Vehicle (2) 59% 83% 83% 88% N/A N/A Vauxhall Corsa (1) 52.5% 96.9% 90.2% 56.5% 94.9% 95.1% Vauxhall Corsa (2) 63.9% 94.3% 89.9% 65.1% 96.3% 96.7% Vauxhall Corsa (3) 39.4% 107.7% 95.4% 80.2% 97.0% 97.2% Vauxhall Corsa (4) 37.6% 107.7% 96.3% 59.2% 99.3% 99.4% Vauxhall Corsa (5) 63.8% 94.5% 89.0% 90.1% 99.7% 100.0% Vauxhall Corsa (6) 65.6% 105.6% 98.9% 73.8% 97.5% 97.9% Vauxhall Corsa (7) 37.9% 103.7% 92.3% 65.2% 99.5% 99.7% Average 51.5% 101.5% 93.1% 70.0% 96.1% 96.3% Test Decision Pass More Pass Pass Table 29 Vauxhall Corsa results Vauxhall Corsa (1) and (2) both passed the Euro 4 limit with regard to all legislated pollutants. Vauxhall Corsa (3) and (4) failed the Euro 4 limit with regard to NOx both at 107.7%. Vauxhall Corsa (5) passed the Euro 4 limit with regard to all legislated pollutants. Vauxhall Corsa (6) and (7) both failed the Euro 4 limit with regard to NOx both at 105.6% and 103.7% respectively. This leaves the model in a Test More condition with four out of seven vehicles failing on NOx. The average CO 2 result of the vehicle model was 96.1% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service Emissions Decision = Test More CO 2 Conformance = 96.1% Millbrook Test Report No. 11/0162 Page 44 of 57
Pollutant (% of limit) PASS BAND 1 BAND 2 BAND 3 Vauxhall Vectra Three vehicles were selected and tested. All vehicles passed the requirements for inclusion within the In-Service emissions test programme. The vehicles had no additional work performed on them prior to testing and other than draining the fuel tanks and refuelling with reference grade diesel the vehicles were tested as received. 2010/11 Programme Vehicle Vauxhall Vectra (1) Vauxhall Vectra (2) Vauxhall Vectra (3) Engine 1.9L CDTi 1.9L CDTi 1.9L CDTi Transmission Automatic Automatic Automatic Fuel Diesel Diesel Diesel Euro Level Euro 4 Euro 4 Euro 4 Odometer (km) 28785 48826 30639 Service History Checked, OK Checked, OK Checked, OK MOT Test Pass Pass Pass Smoke Result 0.00 0.03 0.00 MIL Off Off Off OBD Faults None None None Table 30 Vauxhall Vectra vehicle summary 300% 275% Legislated exhaust emissions as a percentage of the Euro 4 limit - Vauxhall Vectra Vauxhall Vectra (1) Vauxhall Vectra (2) Vauxhall Vectra (3) 250% 225% 200% 175% 150% 125% 100% 75% 50% 25% 0% CO NOx HC+NOx PM Figure 10 Emission of pollutants, Vauxhall Vectra Millbrook Test Report No. 11/0162 Page 45 of 57
Vehicle CO NOx HC + NOx PM CO 2 Fuel Cons Euro 4 0.50 0.25 0.30 0.025 Type Approval 6% 88% 76% 4% N/A N/A Vauxhall Vectra (1) 8.9% 97.4% 81.2% 5.0% 94.8% 96.7% Vauxhall Vectra (2) 20.6% 81.1% 72.2% 2.5% 92.2% 94.1% Vauxhall Vectra (3) 8.0% 90.6% 78.6% 3.5% 95.2% 97.1% Average 12.5% 89.7% 77.3% 3.7% 94.0% 95.9% Decision Pass Pass Pass Pass Table 31 Vauxhall Vectra results All vehicles passed the Euro 4 limit with regard to all legislated pollutants and hence the vehicle model passed the In-Service statistical requirements. The average CO 2 of the three vehicles was 94.0% of the approved figures. Application of the CO 2 statistical analysis according to Conformity of Production requirements indicated conformity with the type approval figures. In-Service emissions decision = Pass CO 2 conformance = 94.0% Millbrook Test Report No. 11/0162 Page 46 of 57
Further Work Below is a summary of the current status of each manufacturer with regards to further investigations conducted in response to the results presented from this programme: Manufacturer Model Current Status Chevrolet Matiz 0.8L Petrol Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Fiat 500 1.2L Petrol Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Hyundai i10 1.1L Petrol Vehicle reached Pass Criteria on emissions and failed to conform to Type Approval CO 2 figures. Smart Fortwo 1.0L Petrol Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Ford Mondeo 2.2L TDI Diesel Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Honda FR-V 2.2L TDI Diesel Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Jaguar X-Type 2.2L TDI Diesel Vehicle reached Test More criteria on emissions and conformed to Type Approval CO 2 figures. Kia Rio 1.5L TDI Diesel Vehicle reached Pass Criteria on emissions and failed to conform to Type Approval CO 2 figures. Vauxhall Corsa 1.3L TDI Diesel Vehicle reached Test More criteria on emissions and conformed to Type Approval CO 2 figures. Vauxhall Vectra 1.9L TDI Diesel Vehicle reached Pass Criteria on emissions and conformed to Type Approval CO 2 figures. Table 32 Current status of failure investigations (March 2011) Millbrook Test Report No. 11/0162 Page 47 of 57
Conclusions A total of ten vehicle models were tested during the 2010/11 In-Service emissions programme: 4 x Euro 4 approved Petrol models 6 x Euro 4 approved Diesel models Directive 70/220/EEC as amended conformity Regulated emissions In-Service The test results for each vehicle and each regulated pollutant in this programme were categorised as per the In-Service conformity testing criteria defined in the directive: Category Description Euro 3 Definition Euro 4 Definition Pass Pass Result < 100% Result < 100% Band 1 Above type approval limit 100% < Result > 120% 100% < Result > 150 Band 2 Outlying Emitter - Intermediate Band 120% < Result > 250% 150% < Result > 250 Band 3 Outlying Emitter - Failure Band Result > 250% Result > 250% Table 33 In-Service conformity test bands Petrol Euro IV Vehicles Odometer HC CO NOX CO 2 Euro 4 Limit (g/km) (km) 0.10 1.00 0.08 % TA Percentage of limits Chevrolet Matiz (1) 20170 36.5% 38.1% 28.4% 100.1% Fiat 500 (1) 26223 59.0% 25.4% 28.9% 100.4% Hyundai i10 (1) 20806 23.9% 33.9% 53.8% 105.8% Smart Fortwo (1) 52535 63.4% 25.1% 50.6% 102.6% Smart Fortwo (2) 41809 72.4% 26.6% 32.5% 91.7% Smart Fortwo (3) 39273 67.0% 17.9% 25.8% 103.5% Table 34 Euro 4 Petrol results summary. Millbrook Test Report No. 11/0162 Page 48 of 57 % %
Diesel Euro IV Vehicles Odometer HC+NOx CO NOx PM CO 2 Euro 4 Limit (g/km) (km) 0.30 0.50 0.25 0.025 % TA Percentage of limits Ford Mondeo (1) 53781 87.0% 37.4% 87.6% 1.2% 102.4% Ford Mondeo (2) 58578 93.3% 62.0% 86.4% 2.8% 98.2% Ford Mondeo (3) 60616 83.5% 38.5% 83.9% 2.0% 95.2% Honda FR-V (1) 2009/10 47353 61.8% 25.7% 67.8% 157.7% 105.7% Honda FR-V (2) 2009/10 66583 72.4% 28.1% 80.6% 71.8% 100.8% Honda FR-V (3) 2009/10 48213 75.4% 26.9% 85.1% 81.8% 101.8% Honda FR-V (1) 2010/11 48322 88.8% 28.3% 100.5% 91.1% 103.0% Jaguar X-Type (1) 2009/10 67422 96.0% 37.3% 102.9% 65.6% 99.7% Jaguar X-Type (2) 2009/10 50664 106.1% 56.7% 106.2% 58.0% 103.3% Jaguar X-Type (3) 2009/10 70964 97.6% 107.9% 79.5% 47.6% 100.7% Jaguar X-Type (4) 2009/10 43933 105.7% 46.0% 112.5% 43.1% 100.4% Jaguar X-Type (5) 2009/10 44052 131.2% 105.3% 116.6% 35.2% 101.2% Jaguar X-Type (6) 2009/10 60427 102.2% 59.6% 102.6% 71.7% 103.1% Jaguar X-Type (7) 2009/10 46315 91.2% 40.8% 96.1% 56.1% 104.1% Jaguar X-Type (1) 2010/11 69731 76.1% 47.6% 74.3% 59.6% 98.9% Jaguar X-Type (2) 2010/11 47141 80.1% 44.0% 79.0% 60.8% 100.4% Jaguar X-Type (3) 2010/11 83845 151.6% 35.8% 171.2% 64.5% 99.0% Jaguar X-Type (4) 2010/11 39028 157.0% 43.5% 175.4% 45.7% 96.2% Jaguar X-Type (5) 2010/11 71563 85.9% 35.5% 88.3% 54.8% 102.0% Kia Rio (1) 2009/10 52954 108.0% 104.3% 98.1% 122.4% 114.9% Kia Rio (2) 2009/10 64279 94.3% 44.6% 97.1% 96.5% 117.7% Kia Rio (3) 2009/10 48671 83.5% 64.5% 79.5% 116.6% 112.2% Kia Rio (4) 2009/10 22573 81.1% 30.4% 86.3% 129.6% 111.0% Kia Rio (5) 2009/10 33482 117.5% 68.3% 120.8% 84.2% 106.3% Kia Rio (6) 2009/10 36178 100.7% 60.8% 102.3% 105.0% 115.1% Kia Rio (1) 2010/11 49965 84.6% 65.5% 83.3% 111.1% 106.9% Kia Rio (2) 2010/11 47862 96.0% 46.6% 98.6% 71.8% 112.0% Kia Rio (3) 2010/11 70518 100.0% 75.4% 99.5% 92.4% 111.0% Kia Rio (4) 2010/11 45362 98.1% 58.3% 95.2% 96.2% 109.6% Kia Rio (5) 2010/11 57101 94.3% 60.8% 93.6% 79.8% 111.4% Vauxhall Corsa (1) 31092 90.2% 52.5% 96.9% 56.5% 94.9% Vauxhall Corsa (2) 46597 89.9% 63.9% 94.3% 65.1% 96.3% Vauxhall Corsa (3) 53034 95.4% 39.4% 107.7% 80.2% 97.0% Vauxhall Corsa (4) 23978 96.3% 37.6% 107.7% 59.2% 99.3% Vauxhall Corsa (5) 32158 89.0% 63.8% 94.5% 90.1% 99.7% Vauxhall Corsa (6) 66005 98.9% 65.6% 105.6% 73.8% 97.5% Vauxhall Corsa (7) 18042 92.3% 37.9% 103.7% 65.2% 99.5% Vauxhall Vectra (1) 28785 81.2% 8.9% 97.4% 5.0% 94.8% Vauxhall Vectra (2) 48826 72.2% 20.6% 81.1% 2.5% 92.2% Vauxhall Vectra (3) 30639 78.6% 8.0% 90.6% 3.5% 95.2% Table 35 Euro 4 Diesel results summary For each model the test statistic was calculated and compared to the Table for Acceptance (Directive 70/220/EEC as amended, Annex 1, Appendix 4 Section 5). Millbrook Test Report No. 11/0162 Page 49 of 57
Eight of the vehicle models reached a Pass decision and two reached a Test More condition. Of the ten vehicle models tested within the VCA In-Service emissions programme 2010/11, the Vauxhall Vectra was the only model to show compliance with the relevant emissions limits (including CO 2 ) for all pollutants over all vehicles tested of that model. Decision HC HC+NOx CO NOx PM Overall Decision Petrol Euro 4 Chevrolet Matiz Pass Pass Pass Pass Fiat 500 Pass Pass Pass Pass Hyundai i10 Pass Pass Pass Pass Smart Fortwo Pass Pass Pass Pass Diesel Euro 4 Ford Mondeo Pass Pass Pass Pass Pass Honda FR-V Pass Pass Pass Pass Pass Jaguar X-Type Pass Pass Test More Pass Test More Kia Rio Pass Pass Pass Pass Pass Vauxhall Corsa Pass Pass Test More Pass Test More Vauxhall Vectra Pass Pass Pass Pass Pass Table 36 In-Service emissions decisions, all vehicles Directive 80/1268/EC as amended Conformity of production for CO 2 Emissions The Conformity of Production test statistic was calculated and compared to the Table for acceptance (Directive 80/1268/EEC as amended, Annex 1, Section 9.3). Conformity of Production requirements are strictly only applicable to new vehicles, so this assessment is for indicative purposes only. A value of 104% of the vehicle s declared Type Approval CO 2 value was therefore used to determine the vehicle s status. In two cases further tests on additional vehicles would be required to determine whether the model conforms to the new vehicle type approval values. Both of these were diesel models (Jaguar X-type and Vauxhall Corsa). Of the ten vehicle models tested within the VCA In-Service emissions programme 2010/11, eight models showed compliance with the <104% criterion for CO 2. Millbrook Test Report No. 11/0162 Page 50 of 57
Petrol Euro 4 CO 2 Chevrolet Matiz 100.1% Fiat 500 100.4% Hyundai i10 105.8% Smart Fortwo 99.3% Diesel Euro 4 Ford Mondeo 98.6% Honda FR-V 102.8% Jaguar X-Type 100.7% Kia Rio 111.6% Vauxhall Corsa 96.1% Vauxhall Vectra 94.0% Table 37 CO 2 conformance decisions, all vehicles Millbrook Test Report No. 11/0162 Page 51 of 57
Appendices Appendix A Description of NEDC (New European Drive Cycle) Nearly all new car models which are type approved for sale in Europe have to undergo standard tests to determine their fuel consumption and exhaust emissions. Official test procedures have been in use since the 1970 s. EU Directive 70/220/EEC (as amended) defines the test procedures for determination of the exhaust emissions of a vehicle. EU Directive 80/1268/EEC (as amended) defines the test procedures for the determination of the fuel consumption of a vehicle. Emissions requirements are commonly known as Euro standards. The first was Euro 1 introduced in 1994 and then emissions requirements progressively becoming more demanding through Euro 2, 3 and 4. The current Euro 4 limits were introduced for new types of vehicle on 1 st January 2005 and became fully effective from 1 st January 2006 for cars and from 1 st January 2007 for vans. Limit Values (g/km) Fuel CO HC NOx HC+NOx PM Type Approval In-Use Euro 4 Petrol 1.00 0.10 0.08 - - 01/01/05 01/01/06 Diesel 0.50-0.25 0.30 0.025 01/01/05 01/01/06 Testing of vehicles is carried out either by an independent test organisation, by the manufacturer or importers themselves at their own test facilities. Before the results are officially recognised the Department for Transport: Inspects the test laboratories and witnesses some tests being carried out, or Checks that the figures have been certified by a European Government under the agreed arrangements for mutual recognition of test results. The New European Drive Cycle (NEDC), over which the exhaust emissions and fuel consumption of light duty vehicles is evaluated, consists of two phases (Urban (ECE) and Extra-Urban (EUDC)) and is performed on a chassis dynamometer. Millbrook Test Report No. 11/0162 Page 52 of 57
Speed (kph) Urban Cycle The urban test cycle is carried out in a laboratory at an ambient temperature of 20 C to 30 C on a rolling road from a cold start i.e. the engine has not run for several hours. The cycle consists of a series of accelerations, steady speeds, decelerations and idling. Maximum speed is 31mph (50 km/h), average speed 12 mph (19 km/h) and the distance covered is 2.5 miles (4km). The cycle is shown as Part One in the diagram below. Extra-Urban Cycle This cycle is conducted immediately following the urban cycle and consists of roughly half-steady speed driving and the remainder accelerations, declarations and some idling. Maximum speed is 75 mph (120 km/h), average speed is 39 mph (63 km/h) and the distance covered is 4.3 miles (7km). The cycle is shown as Part Two in the diagram below. Results The exhaust emission results are presented as a combined value for the urban and extra-urban cycle together and are given in grams per kilometre (g/km). The results are therefore an average of the two parts of the test, weighted by the distances covered in each part. Fuel consumption results are presented in the same way but the figures are expressed as litres per 100km (l/100km). New European Drive Cycle (NEDC) 140 120 Part One - Urban Part Two - Extra-Urban 100 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Time (secs) Millbrook Test Report No. 11/0162 Page 53 of 57
Appendix B Fuel Analysis Reference Petrol Millbrook Test Report No. 11/0162 Page 54 of 57
Appendix C Fuel Analysis Reference Diesel Millbrook Test Report No. 11/0162 Page 55 of 57
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