450R81102
APPLICATION FORMAT
FOR
CERTIFICATION OF
LIGHT-DUTY MOTOR VEHICLES
—1981 MODEL YEAR-
RECOMMENDED PROCEDURES
ENVIRONMENTAL PROTECTION AGENCY
MOBILE SOURCE AIR POLLUTION CONTROL
DIVISION OF CERTIFICATION
2565 PLYMOUTH ROAD
ANN ARBOR, MICHIGAN 48105
(313) 668-4402
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Preface
The purpose of this document is to facilitate the preparation and
submission of applications for certificates of conformity to the Federal
regulations which govern exhaust and evaporative emissions from 1981 model
year gasoline-fueled and diesel light-duty vehicles and trucks. To achieve
this goal, this document: (1) specifies in detail all information, impli-
cit in 40 CFR 86.081-21, which EPA must analyze and review to determine
compliance with the pertinent regulations; (2) provides a format in which
this information should be submitted to EPA; and (3) outlines a procedure
for submitting this information.
The application and the related inprocess certification documents such
as zero-mile books, vehicle information sheets, etc., serve three equally
important functions. These are: (1) Characterization—much of the
information contained in the application and subsequent documentation is for
purposes of characterizing the vehicles and systems tendered for certifi-
cation; (2) Vehicle selection—this information is also used as a basis
for engineering analyses leading to the selection of durability-data and
emission-data vehicles; and (3) Defeat device identification—the infor-
mation serves as a resource for evaluating the potential for defeat devices
and defeat practices associated with the proposed vehicle and systems.
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TABLE OF CONTENTS
CHAPTER SUBJECT PAGE NUMBER
1. Introduction 1-1
•
2. General Instructions 2-1
•
1. Terminology 2-1
2. Page .Numbering 2-2
3. Revising the Application 2-2
4. Confidentiality 2-4
5. Requesting Deviations 2-5
6. Interchangeable Components 2-5
7. Parameters and Tolerances 2-5
8. Data Carryover 2-6
9. Proposed Vehicle Requirements 2-6
10. Preliminary Engineering Reports 2-6
11. Standardized Engine Family Names 2-6
12. Supplement on Preparation and 2-6
Submission of Certification Data
Forms
3. Sequencing 3-1
4. Indexing 4-1
5. Preparing the Application 5-1
Appendix
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Chapter 1
Introduction
The 1981 application format does not differ significantly from the 1980
version. Changes in regulations, notably concerning parameter adjustments
and Diesel particulates, have necessitated some minor additions to EPA's
needs for information, while new .developments in automotive emission
control technology have influenced a few other requirements. Changes in
EPA policy, such as the development of limited certification review or the
transfer of data-entry responsibilities to the manufacturer, have altered
the recommended formats for presenting certain kinds of information (e.g.,
data for deterioration factor calculations). In general, however, the
1981 application format largely duplicates the structure and content of
the 1980 document.
The extensive changes made to the 1980 version, it should be recalled, were
undertaken with the goal of increasing the use of automated data processing
during certification review. Although the 1981 format could not be compu-
terized without further refinements, the fundamental structure of the 1981
format is expected to be used for many years and to be the basis for
future computerization efforts. Manufacturers are consequently strongly
encouraged to develop their 1981 application in accordance with the format
contained herein, since this will facilitate the transition to additional
computerization and help expedite the review process.
Three central features of the 1981 model year format are indexing, refer-
encing, and sequencing. (These features were developed jointly by the
industry and EPA at a series of workshop and task force meetings.)
Because these terms will be used throughout this document, it is appro-
priate that some introductory discussion of these concepts be provided
here.
1. Indexing
"Indexing" refers to the use of codes or symbols to label each unit or
element of certification information requested by the application format.
Assuming that these codes are used consistently by all manufacturers, and
that the structure of all applications is in accordance with the recom-
mended format, the indexing scheme outlined in Chapter 4 will make possible
the quick location of any unit of application information a certification
engineer might seek.
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Although application formats from model years prior to 1980 have incor-
porated indexing schemes, their coding methods have produced descriptors
which are complicated to manipulate, interpret, and reproduce. In the 1979
model year format, for example, the code assigned to carburetor venturi
diameter for four-stroke engines is Vla.C.l).b).v). The 1980 format developed
an all-numeric coding scheme that should simplify the identification of, or
reference to, particular sections of the application; using this coding
method, carburetor venturi diameter is labelled 11.03.02.05. A short-term
benefit of this scheme is simplified referencing to specific portions of the
application in correspondence. In the long term, adoption of this scheme will
expedite the computerized processing of certification applications.
2. Sequencing
"Sequencing" refers to the submission of blocks of certification infor-
mation which, although "incomplete" relative to the entire application,
are nevertheless sufficient to provide EPA with all information needed to
perform one phase of certification review (e.g., the specification of
durability-data vehicle requirements).
In an effort to reduce the number of revisions and their attendant
paperwork, the present sequencing scheme allows the manufacturer to defer
submission of certification data until the manufacturer is ready to have
those data processed. Briefly stated, the sequencing scheme divides the
application into seven different sections or "sequencing blocks," each of
which corresponds to a particular EPA regulatory activity. The blocks are
as follows:
1 Review of General Information
2. Durability-Data Vehicle Selection
3. Testing Approval
4. Mileage Accumulation Approval
5. Emission-Data Vehicle Selection
6. Information Submitted as Available or Required
7. Certification
Following an internally determined schedule, the manufacturer may
"build up" a complete application by submitting these blocks over a period
of weeks or months. EPA will proceed with the appropriate operation of the
certification review as soon as the pertinent sequencing block is submitted
in good order.
3. Referencing
Referencing seeks to reduce the size of the application by eliminating
duplication and redundancy from the document. In many applications from
previous model years, identical information applying to several engine
families is reproduced in several different places in the application. Other
data, such as descriptions of test facilities and equipment, are often
repeated verbatim from one year's application to the next. "Referencing"
pertains to the use of a single description to cover all instances within the
application where that information may be necessary. The present format
encourages manufacturers to reduce duplication by referring to the location
of a unit of information's first submission whenever access to that infor-
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mation is required, rather than needlessly reproducing identical data. In
essence, the concept of referencing reduces paperwork by encouraging the
manufacturer to submit data one time only.
Manufacturers should be wary, however, of applying the referencing
concept too freely and producing an application whose every page is a be-
wildering network of allusions to other pages of the application. Such
overuse of referencing would generate a document that, although free of
repetition, could not be reviewed without large amounts of inefficient
crosschecking and page-turning. Manufacturers should consequently exercise
good judgment and work cooperatively with their certification teams to
prevent taking the referencing concept to unproductive extremes.
In accordance with 40 CFR 86.081-21, an application for a certi-
ficate of conformity to the regulations applicable to new motor vehicles
shall be made to the Administrator by the manufacturer. Such application
must be made for each set of applicable standards, and clearly identify the
(numerical) standards with which the therein described vehicles are intended
to comply. A separate, complete application is necessary for:
1. Light-duty vehicles which are intended to comply with the 1981 model
year standards applicable to new gasoline-fueled light-duty vehicles;
2. Light-duty vehicles which are intended to comply with the 1981 model
year standards applicable to new Diesel light-duty vehicles;
3. Light-duty trucks which are intended to comply with the 1981 model
year standards applicable to new gasoline-fueled light-duty trucks;
4. Light-duty trucks which are intended to comply with the 1981 model
year standards applicable to new Diesel light-duty trucks.
Each application should clearly identify the class of vehicles (e.g.,
gasoline-fueled light-duty vehicles, Diesel light-duty trucks, etc.)
and the standards with which the vehicles described therein are intended to
comply. A separate application is required for each set of standards and
each class of vehicles. In addition, the projected sales volumes in Cali-
fornia and in the other 49 states must be specified. The regulations do
not allow a certificate of conformity to be issued to cover compliance with
more than one set of standards. This does not prohibit an engine family
which is certified as complying with Federal standards from also containing
some vehicles which are certified by the State of California for sale in
that state. However, separate application must be made for those vehicles
intended to be certified only to the State of California waiver standards
and regulations. Vehicles intended to be certified against both the
California waiver standards and the Federal standards may be included in
the same engine family and application provided all vehicles qualify for
being grouped together in the same engine family as described in 40 CFR
86.080-24 and Advisory Circular No. 20-B.
The application for certification is primarily a declaration of in-
tention by a manufacturer to seek certification of new motor vehicles in
conformance with 40 CFR Part 86 and includes a definitive description of all
the various vehicle models and respective optional power trains to be offered
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for sale by the manufacturer (ref. 40 CFR 86.081-21(b)(1)). The appli-
cation represents the primary source of information regarding a manufac-
turer's intended product line. It is imperative that the application be
as correct and up-to-date as possible.
The manufacturer is responsible for informing the Certification
Division of any changes, additions, or deletions to the application which
occur after the initial submission (ref. 40 CFR 86.081-21(a)).
Sections 01.00.00.00 through 08.00.00.00 of the application (using
the suggested format) should contain general information relating to such
things as the applicant's facility and specifications of test fuels.
For the 1981 model year, the manufacturer must submit Sections 01.00.00.00
through 08.00.00.00, because MSAPC has not developed procedures to accomo-
date referencing of information across model years. To expedite the review
process, however, one of the following statements should accompany these
sections:
"The information contained in Sections 01.00.00.00 - 08.00.00.00
is identical to the information submitted in the analogous
section(s) of the [mfr. name] 1980 Model Year Application
for Certification."
or
"The information contained in Sections 01.00.00.00 - 08.00.00.00
is identical to the information submitted in the analogous
section(s) of the [mfr. name] 1980 Model Year Application
for Certification, with the following exceptions."
Sections 09.00.00.00 through 15.00.00.00 of the application should contain
specific information relating to the product line for a particular model
year and are to be submitted annually.
Section 16.00.00.00 is the Request for Certificate in conformance
with 40 CFR Part 86. It should be submitted to the Certification Division
at least 30 days prior to the date certification is desired. It is a
summary of the data required to substantiate that new motor vehicles
comply with Federal emission standards (ref. 40 CFR 86.079-23).
The application should be submitted as soon as practicable. Each
original application, as well as all subsequent revisions, should be
forwarded with a letter of transmittal to:
Director
Certification Division
Mobile Source Air Pollution Control
U.S. Environmental Protection Agency
2565 Plymouth Road
Ann Arbor, Michigan 48105
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When the manufacturer submits the Request for Certificate, he should
also submit a duplicate copy of the application to the Mobile Source Enforce-
ment Division. This copy should contain all revisions made up to this time
but need not include sections 12.00.00.00 and 14.00.00.00. This duplicate
copy should be forwarded to:
Director
Mobile Source Enforcement Division (EN-340)
U.S. Environmental Protection Agency
401 M Street S. W.
Washington, D.C. 20460
All applications should be presented on 8-1/2 inch by 11 inch paper, or a
reasonable equivalent, and be bound in a looseleaf cover of the same approx-
imate size.
In addition to the above changes, EPA instituted a new policy,
effective with the 1980 model year, with regard to the processing and
review of applications. Prior to the 1980 model year, EPA's certification
staff had spent a considerable amount of time reviewing applications for
their completeness and accuracy. This had included the preparation of
detailed deficiency lists indicating specific areas in need of correction
or revision. Over the years, some manufacturers have begun to rely on
this procedure, thereby causing EPA to assume the responsibility of
proofreading applications and calling attention to substantive, gramma-
tical, and typographical errors.
EPA can no longer provide this service. As in the past, each manu-
facturer shall be responsible for the completeness, quality, and accuracy
of his application. For engine families being certified under the full
certification review procedures or limited certification review procedures,
upon receipt of a preliminary application or application update, the
certification team will conduct a preliminary review to assess its ade-
quacy. If deficiencies are found, the general nature of the deficiencies
will be explained, but a detailed list of problems will not be prepared.
This procedure may be repeated when the manufacturer makes final applica-
tion for certification for families undergoing full certification review or
limited certification review. For engine families being certified under
the voluntary abbreviated certification review procedures, EPA may similar-
ly assess the adequacy of an application and notify the manufacturer of
general deficiencies. This assessment may occur either during an audit or
during review of the manufacturer's final application for certification.
Thus, it is the responsibility of the manufacturer to follow the format
provided and to assure that the application is ready for EPA processing at
the time it is submitted.
This policy was made in an effort to reduce the number of revisions
formerly needed to produce accurate applications and to substantially
decrease the time spent both by EPA and the manufacturer in making such
revisions.
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Chapter 2
General Instructions
To improve the efficiency of application preparation and handling, some
general instructions which help explain both the application and the certifi-
cation process are presented here:
1. Terminology
Certain terms contained in- the format have unique connotations to
assist manufacturers in meeting EPA's requirements for information. The
following list explains the information request associated with each term.
Material - the generic type of substance used (e.g., steel, cast iron).
Composition - the precise substance used (e.g., SAE 1010 steel)
Configuration - the general layout of an item, including the approximate
locations of components and, where appropriate, a labeled sketch or
drawing.
Design - the precise layout and exact locations of components, including
dimensioned engineering drawings.
Calibration - the set of specifications, including tolerances, unique to
a particular design, version, or application of a component or component
assembly capable of functionally describing its operation over its
working range. (When calibration is requested, every calibration should
be specified, not just a "typical" calibration.)
Parameters Sensed and/or Controlled - the engine, vehicle, or ambient
conditions which are sensed and/or controlled, either mechanically or
electrically, and thereby determine or bias the operation of a system
or component.
Method of Operation - a narrative, qualitative description of the
function of a device or system throughout its working range, including
the effect of external variables.
Engine Code - a unique combination within an engine-system combination
(as defined in Part 86) of displacement, carburetor (or fuel injection)
calibration, choke calibration (if automatic), distributor calibration,
auxiliary emission control devices, and all other items described in
Section 10.00.00.00 (any code or number may be used to identify engine
configurations). (Any change to an existing code after production has
begun automatically creates a new code and the original and the modified
codes must be identified separately.)
Car Line - A name denoting a group of vehicles within a make or car
division which has a degree of commonality in construction (e.g., body,
chassis). "Car line" does not consider any level of decor or opulence
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and is not generally distinguished by characteristics such as roof-line
or number of doors, seats, or windows except for station wagons or
light-duty trucks. Station wagons and light-duty trucks are considered
to be in different car lines than passenger cats.
Basic Drive Train Layout - The fundamental special relationship of
engine, transmission, and axle. Examples are "front engine, trans-
mission, rear axle," "mid-engine and transaxle," "front engine and
rear-mounted transaxle," or "transaxle followed by rear-mounted engine."
Auxiliary Emission Control Device - Any element of design which senses
temperature, vehicle speed, engine RPM, transmission gear, manifold
vacuum, or any other parameter for the purpose of activating, modu-
lating, delaying, or deactivating the operation of any part of the
emission control system.
2. Page Numbering
Each page number should include the respective section number, e.g.,
02-2 (section 02.00.00.00 - page 2), 08.01.01-15 (section 08.01.01.00 - page
15), 05.01-9 (section 05.01.00.00 - page 9). The detail of the indexing
system which is used in page numbering should be based upon the amount of
information contained in a given section. In section 02.00.00.00, there is
not a large enough volume of information to support a finer breakdown; however,
in section 08.01.00.00 there may be many pages of carburetor description as
well as fuel injection description so it may be appropriate to use three
levels of indexing in the page number (even four may be appropriate if there
are a number of carburetors to describe). It is up to the manufacturet to
decide what type of detail is appropriate for his application. Some provision,
such as the use of decimal numbers, should be made for adding a new page with
new or supplemental data without disturbing the numbering of the other pages
in a particular section, e.g., 02-2.1. Divider pages should be used between
sections.
For sections that are specific to a particular engine family (e.g.,
10.00.00.00, 16.00.00.00), the page numbering system should include the
name of the appropriate engine family to avoid confusion in handling many
pages of similar format, e.g., 10-ABC-2 (for engine family ABC).
3. Revising the Application
EPA encourages manufacturers to minimize revisions to their appli-
cations. However, it is expected that a certain number of revisions will be
submitted to add or delete material or correct errata. The process of
revising applications has been divided into four elements to assure that
certification personnel have available to them the most recent information
submitted by the manufacturer. The elements are as follows:
1. A revision index;
2. A revision cover letter;
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3. The new or revised material to be inserted in the applica-
tion; and
4. Marked-up copies of the pages of the application which have
been revised to indicate new information, if applicable.
The revision index is a cumulative log of all revisions to the
application. A suggested format is contained on page 27 of the Appendix.
The purpose of the index is to establish a bookkeeping system for the
application which will become essential as we move toward machine proces-
sing.
A suggested format for the revision cover letter is shown on page 1 of the
Appendix.
a. Revision and Review Block
Each page of the application should include a revision block
which provides space for the date of issue as well as the effective date
of each revision.
Issue Date:
Revision Date:
When an application is submitted, each page may be reviewed in
detail by a member of the EPA Certification Division. The reviewer
indicates the acceptability or unacceptability of the page by checking,
initialing, and dating a review block. Each page of the application,
therefore, should include a review block at the bottom as follows:
I-";? !S [1 SflTtSFACTOE*'' fl UMMTR W
.JL.. J
b. Revisions Prior to Certification
Whenever a revision is made to an application, the entire page
containing the revision, including the date of revision in the revision
block, should be submitted along with a marked-up copy of the previously
affected page to indicate the revision.
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c. Revisions After Certification
After the appropriate certificate has been issued, changes which
have no effect on actual hardware, such as a change in the name of a
manufacturer's representative or the correction of a non-substantive
typographical error, may be accomplished by a simple revision of the
application as explained in section 2b. This one-step technique for
changing the application is not appropriate when a revision involves a
change which may have an effect on emission performance or deterioration.
In such cases, the description of the proposed revision must be accom-
panied by a running change request. A suggested format for such a request
is presented on page 23 in the Appendix. Many manufacturers in the past
have followed a practice of identifying successive running changes with a
number which includes the family designation and model year of the engine
being affected. (For example, the number of the first running change in
the 1981 model year for the ABC family might be 81-ABC-l.) This practice
has proved to be quite useful and is highly recommended. Two copies of
each running change should be submitted, so that the Certification
Division may transmit a duplicate of every approved change to the Mobile
Source Enforcement Division.
4. Confidentiality
Section 208(b) of the Clean Air Act requires the Administrator
to disclose to the public all non-trade secret information, requires him
to keep trade secret information confidential, and requires the person who
has submitted the information claimed to be confidential to make a satis-
factory showing that the information in question would divulge trade
secrets, if disclosed.
The EPA General Counsel has issued a Class Determination 1-79 which
sets forth EPA's policy concerning the confidentiality of business infor-
mation submitted in applications for certification of light-duty motor
vehicles. In accordance with the Class Determination, each manufacturer
may make applicable claims of confidentiality and supply justifications in
Section 02.00.00.00 of his application. If a claim of confidentiality is
made, it will be treated in accordance with the Class Determination and
EPA's regulations on confidentiality of business information (40 CFR Part
2 Subpart B, 41 Federal Register 36906, September 1, 1976). If a manufac-
turer fails to make a claim in Section 02.00.00.00, the information in the
application may be made available to the public without further notice to
the manufacturer.
To facilitate reproduction for release purposes, trade secrets
should not be included on the same page as information which is available
for public release. Pursuant to this purpose, Section 10.10.40.00 is
included in the format. Section 10.10.40.00 is identical to Section
10.10.00.00, with the exception that sales information has been deleted.
This section is included because product line descriptions are often
requested by the public, and in past experience, sales information has
been considered confidential information. If the manufacturer chooses not
to request that sales information be considered confidential, Section
10.10.40.00 may be omitted. Section 10.10.40.00 need only be submitted at
the time the Request for Certificate is delivered.
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3. The new or revised material to be inserted in the applica-
tion; and
4. Marked-up copies of the pages of the application which have
been revised to indicate new information, if applicable.
The revision index is a cumulative log of all revisions to the
application. A suggested format is contained on page 27 of the Appendix.
The purpose of the index is to establish a bookkeeping system for the
application which will become essential as we move toward machine proces-
sing.
A suggested format for the revision cover letter is shown on page 1 of the
Appendix.
a. Revision and Review Block
Each page of the application should include a revision block
which provides space for the date of issue as well as the effective date
of each revision.
Issue Date:
Revision Date:
When an application is submitted, each page may be reviewed in
detail by a member of the EPA Certification Division. The reviewer
indicates the acceptability or unacceptability of the page by checking,
initialing, and dating a review block. Each page of the application,
therefore, should include a review block at the bottom as follows:
ff tiNsi
J __ fcPAREF
b. Revisions Prior to Certification
Whenever a revision is made to an application, the entire page
containing the revision, including the date of revision in the revision
block, should be submitted along with a marked-up copy of the previously
affected page to indicate the revision.
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c. Revisions After Certification
After the appropriate certificate has been issued, changes which
have no effect on actual hardware, such as a change in the name of a
manufacturer's representative or the correction of a non-substantive
typographical error, may be accomplished by a simple revision of the
application as explained in section 2b. This one-step technique for
changing the application is not appropriate when a revision involves a
change which may have an effect on emission performance or deterioration.
In such cases, the description of the proposed revision must be accom-
panied by a running change request. A suggested format for such a request
is presented on page 23 in the Appendix. Many manufacturers in the past
have followed a practice of identifying successive running changes with a
number which includes the family designation and model year of the engine
being affected. (For example, the number of the first running change in
the 1981 model year for the ABC family might be 81-ABC-l.) This practice
has proved to be quite useful and is highly recommended. Two copies of
each running change should be submitted, so that the Certification
Division may transmit a duplicate of every approved change to the Mobile
Source Enforcement Division.
4. Confidentiality
Section 208(b) of the Clean Air Act requires the Administrator
to disclose to the public all non-trade secret information, requires him
to keep trade secret information confidential, and requires the person who
has submitted the information claimed to be confidential to make a satis-
factory showing that the information in question would divulge trade
secrets, if disclosed.
The EPA General Counsel has issued a Class Determination 1-79 which
sets forth EPA's policy concerning the confidentiality of business infor-
mation submitted in applications for certification of light-duty motor
vehicles. In accordance with the Class Determination, each manufacturer
may make applicable claims of confidentiality and supply justifications in
Section 02.00.00.00 of his application. If a claim of confidentiality is
made, it will be treated in accordance with the Class Determination and
EPA's regulations on confidentiality of business information (40 CFR Part
2 Subpart B, 41 Federal Register 36906, September 1, 1976). If a manufac-
turer fails to make a claim in Section 02.00.00.00, the information in the
application may be made available to the public without further notice to
the manufacturer.
To facilitate reproduction for release purposes, trade secrets
should not be included on the same page as information which is available
for public release. Pursuant to this purpose, Section 10.10.40.00 is
included in the format. Section 10.10.40.00 is identical to Section
10.10.00.00, with the exception that sales information has been deleted.
This section is included because product line descriptions are often
requested by the public, and in past experience, sales information has
been considered confidential information. If the manufacturer chooses not
to request that sales information be considered confidential, Section
10.10.40.00 may be omitted. Section 10.10.40.00 need only be submitted at
the time the Request for Certificate is delivered.
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5. Requesting Deviations
Unusual conditions may suggest to the applicant that a deviation
from the specifications affecting such areas as test procedures, equipment,
or engine maintenance is necessary. If a request for a deviation is to be
made, it should be included in the letter of transmittal which accompanies
the Part I application.
EPA approval of a request for a deviation will be applicable only
to the model year for which the request was made. Deviations which were
approved for a prior model year will not be considered in effect for the
current model year without specific approval for the current model year.
6. Interchangeable Components
Devices that perform the same function, but differ in design, mat-
erial, or mode of operation should be described separately. For example, if
both a wax pellet and a bimetal thermostat were to be used interchangeably in
production, both devices should be completely described in Section 08.00.00.00,
General Technical Information, of the application.
7. Parameters and Tolerances
Information concerning engine component performance and/or dimen-
sional parameters and associated tolerance bands must be provided in the
application.
The tolerances which are applied to the various parameters will be
examined closely in regard to possible effects on the test requirements
which will be specified by EPA. If the tolerance bands are unusually broad
relative to bands which are traditionally used by the industry, additional
test vehicles may be specified to ensure that the certification vehicles will
adequately represent the final production vehicles.
The Request for Certificate must include, in addition to the production
parameters and tolerance bands, information which will assure EPA that all of
the production vehicles will be within the limits that have been specified by
the applicant. This requirement may be satisfied by either:
a. Providing the production quality control information which is
requested in Section 16.04.00.00, Production Engine Parameters, in the
application or
b. Making an unqualified statement in Section 16.04.00.00 to the
effect that all production engines will be calibrated within the specified
tolerance bands. An example of a statement which will be acceptable to EPA
is presented below (ref. Advisory Circular No. 65-1).
The application for certification identifies and describes
those engines to be covered by the certificate(s) of confor-
mity issued by EPA, and this application for certification
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covers only those new engines to be produced by (Company
Name) which conform, in all material respects, to the
design specifications (including tolerances) which are con-
tained herein.
8. Data Carryover
An applicant may request to use data from a previous model year
(carryover data) to satisfy the 1981 model year certification requirements
(ref. 40 CFR 86.080-24(f)). The request should be made in the cover
letter accompanying the 1981 application. In previous model years, the
manufacturer was required to submit a complete description of the vehicles
(referred to as carryover vehicles), along with the test data, as a
supplement to the application. For the 1981 model year, the manufacturer
need initially only provide a list of the differences between the pro-
jected 1981 model year test vehicles and the proposed carryover vehicles.
It must be emphasized that the responsibility for providing a full
and complete summary of changes lies solely with the manufacturer.
Differences not listed in the summary and subsequently brought to light at
some later stage of the certification process might seriously jeopardize a
manufacturer's program.
9. Proposed Vehicle Requirements
1
With cover letters requesting specification of durability-data or
emission-data vehicle requirements, an applicant may submit suggested or
proposed durability-data or emission-data vehicle requirements to notify
EPA of vehicles already ordered or built. This may reduce delays if the
vehicles already procured are able to be used in certification testing.
10. Preliminary Engineering Reports
40 CFR 86.079-25(a)(10) specifies that a preliminary engineering
report should be submitted to EPA within 3 working days after any malfunc-
tion diagnosis on a test vehicle. Whenever oral discussions regarding
such maintenance take place between EPA and a manufacturer, a written
preliminary engineering report need not be submitted as the necessary
information may be obtained orally.
11. Standardized Engine Family Names
Manufacturers are strongly encouraged to adopt the standardized
engine family naming system transmitted to industry on April 12, 1979. A
copy of this proposal is included in Appendix pages 64-72.
12. Supplement on Preparation and Submission of Certification Data Forms
During the 1981 model year applicants for certification should take
the responsibility for providing the following official Certification
Division data forms (or their machine-readable equivalents):
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2-7
1. Vehicle Information Data Sheet (12.01.02.00)
2. Manufacturer's Test Data Sheet (12.01.07.00)
3. Light-Duty Deterioration Factor Input Sheet (12.02.03.00)
4. Summary Sheet Input Form (16.05.00.00)
Procedures for the processing of these forms are still in the final
stages of development. Rather than delay the publication of the 1981
format while these procedures are finalized, MSAPC has decided to issue
all information pertinent to the preparation and submission of those forms
in a special Data Forms Supplement. This supplement is scheduled for
issue in mid-September.
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Chapter 3
Sequencing
Unlike formats of previous model years, which have encouraged manufac-
turers to provide EPA with a complete application in a single submission,
the present format permits industry to submit the application in sections,
and thus to assemble over a period of several weeks or months, a complete
application from multiple submittals. EPA does not wish to specify the
quantities of data to be contained in these partial submissions—the manufac-
turer certainly remains free to transmit a complete application in one
submission, if he so chooses—but industry will probably find it in their
best interest to relate closely their submissions to the data classifications
represented by EPA's "sequencing blocks."
As was explained in Chapter 1 of this document, EPA has grouped each
element of application information into one of seven categories or "sequencing
blocks," each of which corresponds to a particular EPA regulatory function.
As soon as a manufacturer has correctly submitted all the data specified
within a sequence block, EPA will proceed with the operation associated with
that information.
The seven sequencing blocks are:
1) Review of General Information
2) Durability-Data Vehicle Selection
3) Testing Approval
4) Mileage Accumulation Approval
5) Emission-Data Vehicle Selection
6) Information Submitted as Available or Required
7) Certification
The sequence as listed is not strictly chronological as it is necessary
to loop back in the sequence for mileage accumulation approval for emission-
data vehicles, or if emission-data vehicle selection takes place at the same
time as durability-data vehicle selection.
The precise data which constitute these blocks are specified by the
entries in the "Sequence Block" column found in Chapter 4's Indexing System
table. For example, the following excerpt from this table,
Section of the
Application Sequence Block Title
10.01.04.02 2 Exhaust valve
head diameter
indicates that exhaust valve head diameter belongs to sequence block 2 and so
must be provided before durability-data vehicles can be selected. Similarly,
09.01.03.05 5 Accelerator pump
configuration
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3-2
indicates that the accelerator pump configuration belongs to sequence block
5 and must be provided before emission-data vehicles can be selected. Manufac-
turers will be expected to familiarize themselves thoroughly with the Indexing
System table so that the data requirements of each sequencing block are
clearly understood.
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Chapter 4
Indexing
This chapter assigns a unique eight-digit code to every element or
unit of certification data contained within the application. Each code
consists of four two-digit pairs, such as 10.03.02.05, with each successive
pair indicating a more precise and specific level of description. Hence, in
this example, the 10 refers to engine family descriptions for four-stroke
cycle reciprocating engines; the 03 refers to the fuel system (one of the
individual engine parameters); the 02 refers to carburetor; and the 05 refers
to venturi diameter.
The table below sets forth all codes which can be used within a manu-
facturer's application for certification. Some of these codes, it should be
noted, include two-digit pairs whose value is double zero (00, as in Car-
buretors—08.02.02.00). The presence of the double zero pair indicates that
one available level of the indexing scheme has not been assigned by EPA.
Designations at this level can and should be assigned by manufacturers,
however, if distinctions at this level of precision need to be drawn. If a
manufacturer needed to provide general technical descriptions of two kinds of
carburetor, for example, the pertinent sections of the application could be
labeled 08.02.02.01 and 08.02.02.02.
All submissions of certification data, whether of a few pages, an
entire sequencing block, or a complete application, should be structured
according to the indexing order outlined below. Page numbers should also
reflect this order, as is specified in Chapter 2 on page numbering. It
is not strictly necessary to tag information within the pages of the appli-
cation with their corresponding codes, if it is always clear what kind or
element of data is being presented or described.
Section Sequence
Number Number Title
01.00.00.00 1 COMMUNICATIONS
.01.00.00 Organization Chart
.02.00.00 Mailing Information
.01.00 EPA Liaison
.02.00 Certificate Information
.03.00 Telex & Telecopier Information
.03.00.00 Verbal Contacts - EPA Liaison
.04.00.00 Applicable Emission Standards
02.00.00.00 1 STATEMENT OF CONFIDENTIALITY
03.00.00.00 FUELS AND LUBRICANTS
.01.00.00 3* Tests Fuels - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
* Sequence 2 if fuel type is a family determinator
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4-2
03.02.00.00 4 Service Accumulation Fuels - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
.03.00.00 7 Fuels Recommended to the Owner - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
.04.00.00 4 Lubricants - Specifications
04.00.00.00 FACILITY AND EQUIPMENT
.01.00.00 Facilities
.01.00 3 Low Altitude
.02.00 5 High Altitude
.03.00 5 Secondary Laboratory
.04.00 4 Mileage Accumulation
.02.00.00 3 Equipment
05.00.00.00 TEST PROCEDURES
.01.00.00 3 Emission Testing
.02.00.00 4 Mileage Accumulation
.03.00.00 3 Horsepower Determination
.01.00 Frontal Area
.02.00 Road Load
.03.00 Other
06.00.00.00 MAINTENANCE AND WARRANTY
.01.00.00 Test Vehicle Maintenance
.01.00 Scheduled Maintenance
.01 2 Schedules
.02 4* Procedures
.02.00 4* Unscheduled Maintenance
.01 Diagnostic Procedures
.02 Procedure for Evaluating Driveability
.03 Blanket Approval List
.02.00.00 7 Recommended Customer Maintenance
.01.00 Maintenance Schedules
.02.00 Differences between Certification and In-Use Vehicle
Maintenance
.03.00 Maintenance Cost Estimates
.03.00.00 7 Special Tools
.04.00.00 7 Training Programs
05.00.00 7 Service Literature
.01.00 Shop Manuals
.02.00 Specification Manuals
.03.00 Owners' Manuals
.04.00 Technical Service Bulletins
.06.00.00 7 Emission System Warranty Statement
07.00.00.00 7 LABEL FORMAT
.01.00.00 Sample and Location
*Submit prior to first maintenance point (scheduled or unscheduled)
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Chapter 4
Indexing
This chapter assigns a unique eight-digit code to every element or
unit of certification data contained within the application. Each code
consists of four two-digit pairs, such as 10.03.02.05, with each successive
pair indicating a more precise and specific level of description. Hence, in
this example, the 10 refers to engine family descriptions for four-stroke
cycle reciprocating engines; the 03 refers to the fuel system (one of the
individual engine parameters); the 02 refers to carburetor; and the 05 refers
to venturi diameter.
The table below sets forth all codes which can be used within a manu-
facturer's application for certification. Some of these codes, it should be
noted, include two-digit pairs whose value is double zero (00, as in Car-
buretors—08.02.02.00). The presence of the double zero pair indicates that
one available level of the indexing scheme has not been assigned by EPA.
Designations at this level can and should be assigned by manufacturers,
however, if distinctions at this level of precision need to be drawn. If a
manufacturer needed to provide general technical descriptions of two kinds of
carburetor, for example, the pertinent sections of the application could be
labeled 08.02.02.01 and 08.02.02.02.
All submissions of certification data, whether of a few pages, an
entire sequencing block, or a complete application, should be structured
according to the indexing order outlined below. Page numbers should also
reflect this order, as is specified in Chapter 2 on page numbering. It
is not strictly necessary to tag information within the pages of the appli-
cation with their corresponding codes, if it is always clear what kind or
element of data is being presented or described.
Section Sequence
Number Number Title
01.00.00.00 1 COMMUNICATIONS
.01.00.00 Organization Chart
.02.00.00 Mailing Information
.01.00 EPA Liaison
.02.00 Certificate Information
.03.00 Telex & Telecopier Information
.03.00.00 Verbal Contacts - EPA Liaison
.04.00.00 Applicable Emission Standards
02.00.00.00 1 STATEMENT OF CONFIDENTIALITY
03.00.00.00 FUELS AND LUBRICANTS
.01.00.00 3* Tests Fuels - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
* Sequence 2 if fuel type is a family determinator
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4-2
03.02.00.00 4 Service Accumulation Fuels - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
.03.00.00 7 Fuels Recommended to the Owner - Specifications
.01.00 Leaded
.02.00 Unleaded
.03.00 Diesel
.04.00.00 4 Lubricants - Specifications
04.00.00.00 FACILITY AND EQUIPMENT
.01.00.00 Facilities
.01.00 3 Low Altitude
.02.00 5 High Altitude
.03.00 5 Secondary Laboratory
.04.00 4 Mileage Accumulation
.02.00.00 3 Equipment
05.00.00.00 TEST PROCEDURES
.01.00.00 3 Emission Testing
.02.00.00 4 Mileage Accumulation
.03.00.00 3 Horsepower Determination
.01.00 Frontal Area
.02.00 Road Load
.03.00 Other
06.00.00.00 MAINTENANCE AND WARRANTY
.01.00.00 Test Vehicle Maintenance
.01.00 Scheduled Maintenance
.01 2 Schedules
.02 4* Procedures
.02.00 4* Unscheduled Maintenance
.01 Diagnostic Procedures
.02 Procedure for Evaluating Driveability
.03 Blanket Approval List
.02.00.00 7 Recommended Customer Maintenance
.01.00 Maintenance Schedules
.02.00 Differences between Certification and In-Use Vehicle
Maintenance
.03.00 Maintenance Cost Estimates
.03.00.00 7 Special Tools
.04.00.00 7 Training Programs
05.00.00 7 Service Literature
.01.00 Shop Manuals
.02.00 Specification Manuals
.03.00 Owners' Manuals
.04.00 Technical Service Bulletins
.06.00.00 7 Emission System Warranty Statement
07.00.00.00 7 LABEL FORMAT
.01.00.00 Sample and Location
*Submit prior to first maintenance point (scheduled or unscheduled)
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07.02.00.00
.03.00.00
08.00.00.00
.01.00.00 2
.01.00
.02.00
.03.00
.02.00.00 2
.01.00
.02.00
.03.00.00 2
.04.00.00
.05.00.00 2
.01.00
.02.00
.03.00
.06.00.00 2
.07.00.00
.01.00 2
.02.00 5
.03.00 2
.08.00.00 2
.09.00.00 2
.10.00.00 2
.01.00
.02.00
.11.00.00 2
.01.00
.02.00
.03.00
.12.00.00 2
.01.00
.02.00
.13.00.00
.01.00 5
.02.00 5
.03.00 5
.04.00 2
.14.00.00 2
.15.00.00 6
EPA Approval
Specifications & Tolerances
GENERAL TECHNICAL DESCRIPTION
Fuel Control Systems
Carburetors
Fuel Injection
Closed Loop
Ignition Systems
Distributor
Spark Plugs
Crankcase Control System
Cooling System
Engine
Intake Manifolds
Cylinder Heads
Combustion Chambers
Air Inlet Systems
Exhaust Systems
Exhaust Manifolds
Exhaust System Dimensions (see Example 5)
Heat Riser Valves
Catalyst
EGR Systems
Air Injection Systems
Pump
Valves
Evaporative Emission Control Systems
Fuel Tanks
Fuel Caps
Storage Devices
Valves and Switches
Spark Delay
Temperature Control
General Specifications
Frontal Areas (Sequence 3 for durability-data
vehicles)
Test Horsepower (Sequence 3 for durability-data
vehicles)
Model Identification Charts
Family Identification Charts
System Warning Devices
Mechanisms to Assure Use of Unleaded Fuel
1
Provide labeled drawings for each exhaust system, indicating tubing
diameters, mufflers, and catalyst location(s), if applicable, and
other pertinent dimensions and components such as exhaust pressure or
oxygen sensor(s).
2
If a manufacturer wishes MSAPC's judgment that his vehicles using
unleaded fuel satisfy the requirements of 40 CFR 80.24, he/she should
submit the information indicated by this section (see Advisory Circulars
Nos. 30A, 32B, and 32B-1).
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4-4
.01.00 Unleaded Fuel Labels (Indicate proposed wording,
locations, color, and dimensions)
.02.00 Fuel Tank Filler Inlet (design)
.03.00 Immediate Fuel Shut-off
.01 Design
.02 Method of Operation
.16.00.00 5 Adjustable Parameters
.01.00 Parameter
.02.00 Adjustable Range
.03.00 Production Tolerance of Adjustable Range
.04.00 Nominal Setting
.05.00 Method of Inhibiting Adjustment
.06.00 Justification of Adequacy of Methods of
Inhibiting Adjustment
.17.00.00 Other
09.00.00.00 EVAPORATIVE EMISSION FAMILY DESCRIPTIONS
(See Chapter 5 on preparing the application
for the contents of this section)
10.00.00.00 ENGINE FAMILY DESCRIPTIONS
(See Chapter 5 on preparing the application
for the contents of this section)
11.00.00.00 STARTING AND SHIFTING SCHEDULES
.01.00.00 3 Starting
.02.00.00 3 Shifting
The parameters which are physically capable of being adjusted should be
described. For the 1981 model year, these parameters are limited to (1)
idle mixture on gasoline-fueled vehicles (carbureted or fuel injected),
(2) the choke valve action parameter(s) on carbureted, gasoline-fueled
vehicles, and (3) any parameter on any vehicle (diesel or gasoline—fueled)
which is physically capable of being adjusted, may significantly affect
emissions, and was not present on certified vehicles sold under the appli-
cant's brand name during the previous model year. The description should
include the parameter's adjustable range, the production tolerance for that
range, the nominal setting, and an explanation of the method proposed to
inhibit adjustments, together with a discussion of how this will prevent
adjustments of the parameters on in-use vehicles. Sketches should be used
as necessary in order to provide clarity for the narrative explanations.
It should be noted that, while this information is designated as being
sequence 5, the Administrator needs this information for the purpose of
making his determination of which parameters will be subject to adjustment
for certification testing (86.081-21(b)(1)(ii)(C)). Therefore, manufac-
turers are encouraged to submit this information as early in the certifi-
cation process as possible to avoid any delays in receiving the Admini-
strator's determination.
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4-5
12.00.00.00 TEST VEHICLE INFORMATION
.01.00.00 Vehicle Book
.01.00 4 Vehicle I.D. Sheet (Cover Letter)
.02.00 4 Vehicle Information Data Sheet (see Appendix pages
17-18)2
.03.00 4 Calibrations
.04.00 4 List of Referenced Pages
.05.00 4 Vehicle Test Data Log Sheet(s) (See Appendix page 15)
.06.00 4 Vehicle Maintenance Log Sheet(s) (See Appendix page
16)
.07.00 6 Manufacturer's Test Data Sheet
.02.00.00 Reports and Calculations
.01.00 Engineering Reports (see Appendix page 19)
.02.00 6 Exhaust Emission Deterioration Factors
.03.00 6 Light-Duty Deterioration Factor Input Sheet
13.00.00.00 EVAPORATIVE EMISSION DETERIORATION PROGRAM
.01.00.00 4 Description of Test Program
.02.00.00 5 Procedures
.01.00 Vehicles
.02.00 Bench Test
.03.00 Deterioration Factor Calculation
.03.00.00 7 Data
.01.00 Vehicle Descriptions
.02.00 Vehicle Logs
.03.00 Bench Test Logs
.04.00 Deterioration Factor Calculation Summary
14.00.00.00 6 FORECAST OF TEST VEHICLE AVAILABILITY
15.00.00.00 REVISIONS
.01.00.00 6 Revision Index or Log (see Appendix page 27)
.02.00.00 6 Revisions Prior to Certification
.03.00.00 Revisions After Certification; Certification Change
Request (see Appendix page 23)
16.00.00.00 7 REQUEST FOR CERTIFICATE
.01.00.00 Statement of Compliance
.02.00.00 Emission Data Summary (See Appendix page 21)
.03.00.00 Certificate Information
.04.00.00 Production Engine Parameters
.01.00 Parts List (see Appendix pages 22-22A)
.02.00 Production Tolerance
.05.00.00 Summary Sheet Input Form
17.00.00.00 (Reserved for California)
The assignment of Sequence Block No. 4 to vehicle book items 12.01.01-06
pertains only to vehicle books describing durability-data vehicles. Items
12.01.01-06 in books describing emission-data vehicles belong to Sequence
Block No. 6.
2
See Item 12, pages 2-6 and 2-7, and the forthcoming Data Forms Supplement.
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Chapter 5
Preparing the Application
The use of a format which is comprised of the several sections that
are listed in Chapter 3 is recommended for the application. Use of this
recommended format will greatly expedite the review process. Please ensure
that all required data are submitted.
In the following pages, the sixteen sections of the application
are discussed. Recommendations are presented for preparing each of the
sections in a manner that will ensure that the needs of EPA are met.
01.00.00.00 Communications
Submit an organization and personnel chart showing chain of command
and structure of company and/or divisional group with certification responsi-
bilities (liaison with EPA, vehicle testing, mileage accumulation, etc.).
If the parent company is located in a foreign country, please indicate the
affiliation of the U.S. representative, e.g., home office, U.S. affiliated
company, or U.S. sales organization.
Specify the name(s) and address(es) of the representative(s) to whom
advisory circulars and other technical information should be sent (indicate
the number of copies, if more than one is required). Please indicate if you
regularly receive such information through some organization (e.g., Auto-
mobile Importers of America) so that unnecessary duplicate distribution can
be avoided. Indicate whether information should be mailed or picked up by
courier.
Specify the corporation name and address that should appear on the
certificate(s) of conformity (maximum of four lines). Indicate the name and
address of the person to whom the certificate(s) should be mailed.
Indicate the Telex and telecopier type and telephone numbers and list
those persons who are authorized to communicate orally with EPA and give
their telephone numbers.
02.00.00.00 Statement of Business Confidentiality
Under Class Determination 1-79, issued by the EPA General Counsel, cer-
tain types of information submitted in applications for certification of
light-duty motor vehicles may be entitled to confidential treatment. Infor-
mation of the types identified under Part II of the Class Determination may
be entitled to confidential treatment until the date when the vehicle
model in question is released into the public market. Information des-
cribed under Part III of the Class Determination may be entitled to
confidential treatment beyond the date on which the vehicle is introduced
into commerce.
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5-2
Claims of business confidentiality may be made for data submitted in the
application for certification that fall under Parts II and III of the Class
Determination. Such claims should identify, by specific sections or sub-
sections, the information in the application for certification that is subject
to the claim. Confidentiality claims and substantiating information are to
be included with the data for which confidential status is requested at the
time of submission to EPA. For information for which confidential treatment
is desired, address the following questions:
1. Which information in your 1981 application for certification do you
consider to be entitled to confidential treatment until model introduction,
in accordance with Part II of the Class Determination?
2. Which information in your 1981 application for certification do you
consider to be entitled to continuing confidential treatment after model
introduction, in accordance with Part III of the Class Determination?
3. To what extent has the information been disclosed to others, and
what precautions were taken with respect to these disclosures?
4. Is the information available to the public through legitimate means?
5. Can the information be derived from a detailed engineering inspec-
tion of the motor vehicle model in question or from information already
public once the model is offered for public sale?
6. Would disclosure of the information be likely to result in sub-
stantial harm to your competitive position? If so, discuss in detail what
the harmful effects would be, why the effects would be substantial, and the
nature of the causal relationship between disclosure and the harmful effects.
Please supply complete answers to these questions for all information
claimed to be confidential. The EPA General Counsel will make a final
determination on the entitlement of claimed information to confidential
treatment based in part on your response.
You may claim information submitted in substantiation of your confiden-
tiality claim to be confidential in its own right. If the information pertains
to the confidentiality claim, is not otherwise possessed by EPA, and is
marked, when received by EPA, as "trade secret," "proprietary," or "company
confidential," it will not be disclosed by EPA without your consent unless
disclosure is ordered by a Federal court. If no claim accompanies this
information when it is received by EPA, it may be made available to the
public without further notice to you.
03.00.00.00 Fuels and Lubricants
Submit in this section the information which is necessary to show that
the fuel which will be used for exhaust and evaporative emission testing and
service accumulation will meet the regulatory requirements. The data should
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5-3
be in the form of the range of specifications which will be provided to the
fuel vendor rather than in the form of an analysis of a particular batch of
fuel. Recommended forms for comparing these specifications with the specifi-
cations in the applicable regulations are presented on pages 2 through
5 of the Appendix.
This section should also contain the specification of the fuel recom-
mended to the ultimate purchaser.
Also submit the specifications for lubricants as outlined on pages 6-8
of the Appendix.
04.00.00.00 Facility and Equipment
Submit detailed descriptions of the test equipment, including photo-
graphs, schematic drawings, and narrative explanations, with a statement
concerning the equivalency of equipment prescribed in 40 CFR Part 86. This
information shall be submitted for all facilities which are used in the
certification program.
Description of the facility should include:
1. Name and address of the testing facility
2. Name and title of person in charge of the facility
3. Altitude of testing facility
Description of the test equipment should include:
1. Manufacturer
2. Model number or identification
3. Number of units used in the certification program
4. Pertinent specifications
5. Flow schematics (if applicable)
6. Calibration methods and intervals
7. Scheduled maintenance procedures and intervals
The items of test equipment to be described should include:
1. Constant volume sampler
2. Analysis bench
a. Hydrocarbon analyzer
b . Carbon monoxide analyzer
c. Carbon dioxide analyzer
d. Oxides of nitrogen analyzer
3. Chassis dynamometer
4. Driver's aid
5. Computer data processing system
6. Fuel conditioning equipment (including diurnal)
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5-4
7. Location of cooling fan, fan capacity, and fan type
8. Evaporative emission test equipment
a. Evaporative emission enclosure
b. Enclosure temperature control
c. Analysis equipment
d. Location of mixing fan, fan capacity, and fan type
e. Location of enclosure sample and temperature probes
9. Particulate sampling system including the heated particulate
filter
10. Particulate filter weighing system
11. Filter conditioning system
12. Filters
13. Collection efficiency results from each batch of filters
Include a description of the areas in which vehicle soak, vehicle
preconditioning, vehicle testing, and evaporative emission testing are
performed. Describe the location, temperature controls, humidity controls,
and barometric pressure controls (if so equipped).
Describe the practices and procedures followed relative to calibration
gases used for certification testing. Detail the utilization and identifica-
tion of calibration gases traceability of calibration gases to referenced
standards, and the origin of the referenced standards. If not covered
previously, specify the span gases used for each analyzer.
Please inform EPA if a procedures manual or operational instruction guide
(in English) is available for EPA review. If no such manual exists, please
specify.
If a chassis dynamometer is requested to be used for mileage accumu-
lation, the manufacturer should furnish information describing the dynamo-
meter and associated equipment and verifying that vehicle operation on the
chassis dynamometer is representative of operation on the road (ref. Advisory
Circular No. 35). Such information should include a discussion of:
1. The facility (sketches or photographs showing general layout
and equipment)
a. Dynamometer identification number
b. Controlling unit (block diagram of control circuitry)
c. Absorber and motor (if applicable)
i. type (waterbrake, inductor, D.C. motor absorber, etc.)
ii. specifications (maximum torque, horsepower, and speed)
iii. speed limiting devices (if applicable)
d. Inertia simulation
i. type (mechanical, electrical, etc.)
ii. capability or range
e. Chassis rolls
i. number
ii. diameter
iii. spacing (if applicable)
f. Method used to cool vehicles
i. air flow (constant, proportional to vehicle
speed, etc.)
ii. approximate flow rate (cfm or cfm/mph)
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5-5
g. Use of any equipment used to simulate road vibrations or
conditions
h. Variables monitored
i. variables (engine speed, manifold vacuum, output
power, etc.)
ii. recording method (if applicable)
i. Safety equipment utilized (over-speed, over-temperature,
excessive vibration, vehicle movement, engine malfunction,
vehicle malfunction, etc.)
2. Comparison of road and dynamometer operation
a. Route comparison
i. vehicle used for comparison
ii. preconditioning and warm-up of demonstration vehicle
iii. description of test route (i.e., general terrain)
iv. description of driving schedule (i.e., simulation of
laps 2, 10, and 11 of 40 CFR Part 86 Appendix IV)
b. Data comparison^-
i. underhood temperatures (measured at inlet to
engine compartment)
ii. engine inlet air temperatures (at clean side of
air filter)
iii. engine oil temperatures (in sump, at drain plug,
or at dipstick)
iv. engine coolant temperatures (inlet and outlet of
engine)
v. under-chassis temperatures (longitudinal centerline
of vehicle in front, center, and back)
vi. catalyst temperatures, if applicable (skin at inlet
and outlet)
vii. exhaust manifold(s) temperature (skin at flange
connection - two required for dual exhaust)
viii. manifold vacuum
ix. vehicle speed
x. engine speed
•"•Continuous data plots or recordings should be made utilizing the same
demonstration vehicle and the same instrumentation. The vehicle should be
operated both on the road and on the dynamometer while recording the
suggested data. Comparison of data would be facilitated if like data are
plotted on the same graph ana on the same axis for both road and dynamometer
data. If the data are not on the same graph, submission on transparencies
will facilitate review. Requests for approval of mileage accumulation
dynamometers should be accompanied by a list of all vehicles proposed to be
run on the mileage accumulation dynamometers. If approval of dynamometers
has been granted in previous years, provide a list of those vehicle-engine
family combinations approved for prior certification programs. Include in
the list the temperature ranges, dynamometer specifications, and other
pertinent data necessary to evaluate and approve a mileage accumulation
dynamometer. Submission of these historical data will expedite the review
process.
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5-6
05.00.00.00 Test Procedures
Describe the practices and procedures followed relative to exhaust and
evaporative emission testing and horsepower determination.
Include a description of the mileage accumulation route including
maps, mileages, and driving schedule (i.e., stops, accelerations, cruises,
decelerations, and percent of mileage at various speeds). If test vehicles
are driven to the manufacturer's test facility or the EPA laboratory in Ann
Arbor, mileage accumulated during such delivery is subject to the same
limitations and requirements as normal mileage accumulation schedules.
Therefore, the respective routes which are proposed to be followed must be
specified in this section of the application, along with the approximate
average and maximum speeds. Data must be submitted to substantiate that the
proposed driving schedule and any other mileage accumulation is equivalent to
the Durability Driving Schedule given in Appendix IV of 40 CFR Part 86 (also
see MSAPC Advisory Circular No. 37)(see page 26 of the Appendix for a sample
format)•
Include a description of any method which may be employed to permanently
record or verify the mileage accumulated on test vehicles. Describe the
procedure(s) used for determining dynamometer power absorber setting(s)
(both frontal area and alternative procedures) (ref. 40 CFR 86.129-80 and
Advisory Circular No. 55B).
06.00.00.00 Maintenance and Warranty
Include in this section the information necessary to satisfy the require-
ments of 40 CFR 86.081-21. The information required includes the following:
1. A statement of the recommended maintenance and procedures that are
necessary to assure that the vehicles to be covered by the certificate of
conformity will conform to the regulations when in use.
2. A description of the program for training personnel to do the required
maintenance.
3. A description of any special tools or equipment required for performing
the maintenance. The information should include the data shown in the
suggested table on page 9 in the Appendix.
Also include in this section the information which is required to
satisfy the requirements of 40 CFR 86.079-25, e.g., the scheduled maintenance
which is proposed to be performed on all test vehicles. Mere reference to
the items of maintenance permitted in the regulations is not adequate.
Give specific maintenance operations, respective mileages, and specifications,
indicating which specifications (including any tolerances) will appear on
the label. If the maintenance is the same as in any previous year(s),
include references to the previous year(s) service manual(s). Such reference
will allow EPA to judge whether the regulatory requirements will be met in
regard to the maintenance being conducted in a manner which is consistent
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with the service instructions and specifications which are provided by the
manufacturer for use by the customer service personnel. A request must be
submitted and approved in advance for any scheduled test vehicle maintenance
which is not specifically permitted by the regulations. Such a request will
be evaluated in terms of whether the proposed maintenance is reasonable and
necessary and is likely to be performed on in-use vehicles.
If a warning device (e.g., light, buzzer) is proposed to be used as
a basis for performing maintenance on items such as catalysts or EGR systems,
describe the operation of the warning system as it will relate to maintenance
and include in Section 08.14-00.00 applicable photographs or drawings.
This section should also include a trouble-shooting procedure for
diagnosing performance problems. If desired, a reference may be made to such
a procedure in a service manual which has been supplied to EPA. The submis-
sion of the trouble-shooting procedure is not specifically required in the
regulations but the inclusion of the procedure will ensure that in the event
unscheduled maintenance becomes necessary on a test vehicle, the maintenance
will not have to be delayed until the necessary diagnostic information can be
forwarded to EPA.
If poor driveability is proposed to be one of the criteria for performing
unscheduled maintenance, specify the procedure which will be used for eval-
uating driveability. Include a trouble-shooting procedure for diagnosing
driveability problems. This trouble-shooting procedure may be part of the
service manual.
Submit a proposed list (blanket approval list) of those maintenance
items, repairs, replacements, and/or lubrications which are proposed to be
performed on durability-data vehicles without prior notice to EPA. Also
submit a separate list of those maintenance items which are proposed to be
performed on both durability-data and emission-data vehicles. These lists
should include only exceptions or additions to the list of approved items
contained in Advisory Circular No. 4A-1 to eliminate duplication.
In accordance with 40 CFR 86.079-38, copies of maintenance and use
instructions which will be provided to all ultimate purchasers of vehicles
shall be furnished to EPA no later than the time the Request for Certificate
is submitted. If this information has not been submitted prior to submission
of the Request for Certificate, please include it with the Request for
Certificate. Cost information relating to these various maintenance func-
tions should also be included (ref. Advisory Circular No. 15-A).
If any scheduled maintenance to certification vehicles proposed in
this section differs from the maintenance instructions which will be given to
the ultimate purchaser, these differences and the reason for the differences
should be clearly identified and explained.
Section 86.078-7(b) of 40 CFR Part 86 requires that the vehicle manufac-
turer submit to EPA, at the time of issuance, all explanations regarding the
use, repair, adjustment, maintenance, or testing of a vehicle relevant to the
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5-8
control of crankcase, exhaust, or evaporative emissions issued by the manu-
facturer for use by other manufacturers, assembly plants, distributors,
dealers, and ultimate purchasers. If this requirement can be met by for-
warding to EPA shop maintenance manuals, technical service bulletins, and
vehicle owner's manuals, two copies of relevant documents will be required as
soon as they are available.
Submit two copies of the emission system warranty to be provided to
the ultimate purchaser.
When two copies of these items are required, one should be sent to the
Certification Division in Ann Arbor, the other to the Mobile Source
Enforcement Division in Washington, D.C. (see addresses given in Chapter 1).
07.00.00.00 Label Format
Submit one copy (either the actual label, a photograph, or a drawing)
of each label to be used to comply with 40 CFR 86.079-35. Also include a
photograph or a written description indicating the location of the label on
the vehicle for each model certified.
Prior approval by EPA of the proposed engine label is not a requirement
for issuance of certificates of conformity. If so requested, the Certifica-
tion Division will review the label to determine if the requirements of 40
CFR 86.079-35 are met. If such an evaluation of the label is desired, a
statement to this effect should be included in the letter of transmittal
which accompanies the application.
08.00.00.00 General Technical Description
In this section, provide general technical descriptions regarding
construction and operation of various engine parts such as carburetors,
intake manifolds, and components which comprise the ignition, air inlet,
cooling, and emission control systems, etc. Sketches and cross-section views
should be provided as required to adequately present the necessary infor-
mation.
This section should be a reference book for Sections 9.00.00.00 and
10.00.00.00. Anytime an explanation greater than a few words or a line
is required in these sections, a narrative explanation should be contained in
Section 08.00.00.00. Likewise, anytime the configuration of a component is
requested, the drawing or schematic should be found here.
Information such as Catalyst features (Sec. 10.07.05.00), which does not
differ within or among engine families, will appropriately be listed in
Section 08.08.00.00 and then referenced for each family to eliminate dupli-
cation.
In order to illustrate the degree of detail needed, a number of examples
are being included in the Appendix. These examples are representative of the
type of sketch which should be submitted by a manufacturer.
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5-9
The sketches may not, by themselves, fully explain any particular item, and
the manufacturer is expected to include all pertinent narrative information
necessary to amplify and explain the sketches.
Some descriptions which commonly include a sketch have not been covered by
an example. The examples are only intended for general guidance, and
should not be considered as all encompassing and literal requirements.
09.00.00.00 Evaporative Emission Family Descriptions
The information in this section determines how the applicant's product
line is subdivided into separate evaporative emission families and provides
the data which are used by EPA to select evaporative emission test vehicles.
(The sample Engine Family Description form on page 10 of the Appendix
provides a suitable format for this information.)
Section Sequence
Number Number Title
09.01.00.00 2 Common family parameters
.01.00 2 Vapor storage device
(e.g., canister, crankcase, air cleaner)
.02.00 Device description
.01 2 Number of canisters
.02 2 Design working capacity (grams absorption)
.03 2 Housing material
.04 2 Configuration (see Example 22)
.05 2 Number of air cleaner storage areas
.06 2 Design working capacity (grams absorption)
.07 2 Housing material
.08 2 Configuration
.03.00 Carburetor
.01 2 Number of carburetors
.02 2 Number of Venturis per carburetor
.03 2 Fuel reservoir system (float system) configuration
(see Example 7)
.04 2 Fuel reservoir system location relative to carburetor
.05 2 Fuel reservoir volume
.06 2 Vent system configuration (see Examples 7-11)
.07 2 Accelator pump configuration
.04.00 Fuel Injection
.01 2 Basic type (mechanical, electronic, timed, continuous)
•02 2 Point of injection (e.g., manifold, cylinder, or throttle
body)
.05.00 Fuel tank
.01 2 Material
.02 2 Liner configuration
.03 2 Vapor control (baffles, configuration)
If the parameter is capable of adjustment, indicate "adjustable" at the
appropriate format entry. If the parameter is adjustable and is either (1) the
idle mixture on gasoline-fueled vehicles (carbureted or fuel injected), (2) the
choke valve action parameter(s) on carbureted, gasoline-fueled engines, or (3)
any parameter on any vehicle (Diesel or gasoline-fueled) which is physically
capable of being adjusted, may significantly affect emissions, and was not
present on certified vehicles sold under the applicant's brand name during the
previous model year, provide the information requested in 08.16.00.00.
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5-10 '
.02.00.00 Individual configuration parameters (fuel system)
.01.00 General fuel system
.01 2 Configuration (see Example 21)
.02 5 Fuel pump (electrical or mechanical)
.02.00 Fuel tank
.01 2 Fuel tank configuration (including filler inlet, bladder
or liner, baffles, fuel gauge sending unit, fuel pick-up,
and vents)
09.02.02.02 5 Nominal tank capacity
.03 5 Tank fuel volume (see Example 20)
.04 5 Vapor volume at tank fuel volume
.05 5 Pressure and vacuum relief settings and locations
.06 2 Fuel filler cap configuration (including seal and
retention mechanisms) (see Examples 23 and 24)
.07 2 Fuel tank composition
.03.00 Carburetor
.01 5 Carburetor spacer (heat shield) configuration and
material (see Example 13)
.02 5 Carburetor preheat or warm-up system configuration
.03 2 Fuel reservoir vent system method of
operation
.04 5 Fuel reservoir vent system calibration
.05 5 Carburetor purge port location (if applicable), cali-
bration, and method of operation (e.g., purges at
throttle angles of greater than 3 through a 0.055"
orifice)
.04.00 Fuel injection
.01 5 Fuel injection purge port location (if applicable),
calibration, and method of operation
.03.00.00 Individual configuration parameters (evaporative emission
control systems)
.01.00 2 Overall system configuration (see Examples 20 and 21)
and method of operation
.02.00 Fuel tank vapor control system (fuel tank to storage device)
.01 2 Configuration and method of operation including liquid-
vapor separator, if applicable (include location of maxi-
mum restriction in vapor control system)
.02 2 Parameters sensed and parameters controlled
.03 5 Calibrations
.03.00 Carburetor vapor control system
.01 2 Configuration and method of operation (include location of
maximum restriction in vapor control system)
.02 2 Parameters sensed and parameters controlled
.03 5 Calibrations
.04.00 Storage device
.01 2 Configuration (see Example 22) and method of
operation
.02 2 Storage medium composition
.03 2 Storage medium quantity
.04 2 Parameters sensed and parameters controlled
.05 5 Calibration
.05.00 Purge System
.01 2 Configuration and method of operation (include
location of maximum restriction in purge lines)
.02 2 Parameters sensed and parameters controlled
.03 5 Calibrations
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09.03.06.00 Auxiliary Emission Control Devices - Evaporative
Emissions
.01 2 Device configuration (see Example 34)
.02 2 System configuration and method of operation
.03 2 Parameters sensed and parameters controlled
.04 5 Calibration (including hysteresis)
.05 2 Justification
.07.00 Environmental Control Mechanisms (underhood fans)
.01 2 Configuration and method of operation
.02 2 Parameters sensed and parameters controlled
.03 5 Calibrations
.04.00.00 5 Evaporative emission family sales
(see page 11 of the Appendix)
10.00.00.00 Engine Family Descriptions - Four-Stroke Cycle Reciprocating
Engines
The information submitted in this section determines how the appli-
cant's product line is subdivided into separate engine families and provides
the data which are used by EPA to select test vehicles (see page 10 of the
Appendix for a sample form).
There is a great deal of redundant information submitted when a
manufacturer chooses to run alternate engine families which differ by one
or more engine family determinants with all other information (e.g.,
calibrations, sales, etc.) identical. The submission of much of this
information may be eliminated by referencing the prime engine family. For
example, if a manufacturer wishes to certify prime engine family A and
also runs alternative engine families A-l, A-2, and A-3, each of which
differ by one or more engine family determinants, the manufacturer may
submit all the required information for engine family A and then submit a
single page for engine families A-l, A-2, and A-3, stating that they are
identical to engine family A except for the listed differences.
This concept can be enlarged to where certain sections of an engine
family description may be different and benefit from the use of referencing.
Discretion will have to be used, however, to insure that this procedure is
used in cases where there are few enough differences to make it an effec-
tive tool. (This concept can also be used with evaporative emission
families.)
.01.00.00 Common family parameters
.01.00 2 Deck height (inches) (Dimension "A")2
.02.00 2 Centerline of crankshaft to centerline of camshaft (inches)
(Dimension "B")
.03.00 2 Bore center-to-center (inches) (Dimension "C")
If the parameter is capable of adjustment, indicate "adjustable" at the
appropriate format entry. If the parameter if adjustable and is either
(1) the idle mixture on gasoline-fueled vehicles (carbureted or fuel
injected), (2) the choke valve action parameter(s) on carbureted, gasoline-
fueled engines, or (3) any parameter on any vehicle (Diesel or gasoline-
fueled) which is physically capable of being adjusted, may significantly
affect emissions, and was not present on certified vehicles sold under the
applicant's brand name during the previous model year, provide the infor-
mation requested in 08.16.00.00.
See page 24 in the Appendix for sketch showing dimensions "A," "B," and "C."
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.04.00 Valve head diameters (inches)
.01 2 Intake
.02 2 Exhaust
05.00 2 Valve location
.06.00 Block configuration
.01 2 Type of cooling (air, water)
.02 2 Cylinder arrangement (L-6, 90° V-8, etc.)
10.01.07.00 2 Combustion cycle (Otto cycle, Diesel cycle, etc.)
.08.00 2 Method of aspiration (natural, supercharged, etc.)
.02.00.00 Individual engine parameters (physical)
.01.00 2 Displacement (expressed in cubic inches)
.02.00 2 Bore and stroke (expressed in inches)
.03.00 2 Number of cylinders
.04.00 Compression ratio
.01 5 Nominal
.02 5 Maximum
.03 5 Minimum
.05.00 2 Surface/Volume ratio (surface area expressed in square
inches divided by volume expressed in cubic inches)
.06.00 2 Cylinder head configuration (specify OHV, OHV/OHC, etc.)
.07.00 2 Combustion chamber design (see Example 2)
.08.00 2 Intake port configuration and area (expressed in square
inches) at cylinder head and manifold mating surface
(see Example 1)
.09.00 2 Exhaust port configuration and area (expressed in square
inches) at cylinder head and manifold mating surface
(see Example 1)
.10.00 2 Precombustion chamber design (if applicable)
.11.00 Intake valve
.01 2 Configuration (see Example 2)
.02 2 Material and surface treatment
.03 2 List any special seat preparation (induction hardening,
lapped, etc., and interference angle)
.04 2 Seat angle (in cylinder head)
.05 2 Rotator configuration (see Example 2)
.06 2 Configuration (see Example 2) and composition of stem
seal
.12.00 Exhaust valve
.01 2 Configuration (see Example 2)
.02 2 Material and surface treatment (include any special cooling
methods e.g., sodium filled)
.03 2 List any special seat preparation (induction hardening,
lapped, etc., and interference angle)
.04 2 Seat angle (in cylinder head)
.05 2 Rotator configuration (see Example 2)
.06 2 Configuration (see Example 2) and composition
of stem seal
.13.00 Exhaust port liners
.01 2 Configuration of port and port liner
.02 2 Composition of liner
.03 2 Insulating material and configuration
.14.00 Intake manifold
.01 2 Configuration (including heated passages and EGR passages,
if applicable) (see Example 3)
.02 2 Material
.03 2 Electrically heated areas and material (if different from
intake manifold material)
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10.02.15.00 2 Exhaust manifold configuration (see Ex. 4) (including
heat stoves, shields, and choke heat pickup, and inter-
nal exhaust manifold baffling, if applicable) (see Ex. 16)
.16.00 5 Exhaust manifold material
.17.00 3 Advertised or rated HP @ RPM (include fuel rate if Diesel
.18.00 3 Advertised or rated torque @ RPM (include fuel rate if
Diesel)
.19.00 2 Exhaust system (dual or single)
.20.00 2 General location of catalyst (e.g., in exhaust manifold,
forward underfloor area, etc.)
.21.00 2 Piston and piston ring configuration
.22.00 2 Piston ring material
.23.00 5 Cooling system configuration (see Example 6)
.24.00 5 Thermostat calibration
.25.00 Electronic control devices - for each electronic control
system specify the following
.01 2 Parameters controlled (such as spark, ignition
timing, air/fuel ratio, etc. and calibrations)
.02 2 Parameters sensed (such as engine speed, manifold
vacuum, engine coolant temperature, etc.)
.03 2 General strategy of relationships between sensed and
controlled parameters
.04 5 Complete relationship between sensed and controlled para-
meters, i.e., give graphs and/or decision matrices to
describe relationships between sensed and controlled
parameters
.05 2 Type of system (analog, digital, or hybrid)
.06 2 List those of the following the system contains (timer,
microprocessor, sequential logic)
.07 2 Type(s) of memory used (read-only memory, random access
memory, programmed logic arrays, or other memory devices -
list more than one if applicable) - specify if no memory
is used
.08 5 Size of memory storage (e.g., 3012 12-bit words)
.09 2 Functional logic flow charts of system operation
(see Appendix page 20)
.10 5 Manufacturer
.11 2 For detonation sensors, define location and orientation.^
.03.00.00 Individual engine parameters (fuel system)
.01.00 General fuel system
.01 5 Fuel pump delivery pressure (specify whether
electrical or mechanical pump) (carburetor only)
.02 5 Engine idle speed
.03 4 Idle speed setting procedure (ref. 06.01.01.02)
.04 5 Engine idle mixture
.05 4 Idle mixture setting procedure (ref. 06.01.01.02)
Indicate whether net or gross, and specify method of measurement, e.g.,
128 BHP @ 4000 RPM, SAE net.
For example, orientation of sensors on carbureted engines may be defined rela-
tive to the X and Z planes determined by the base flange of the carburetor and
to the Y plane determined by the crankshaft centerline and camshaft centerline.
If the operation or sensitivity of the sensor could be affected by rotation
within its fixture or mount (assuming that the position of the fixture in the
XYZ space remains constant), identify the correct design configuration or
alignment of sensor and mount.
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10.03.02.00 Carburetor
.01 2 Manufacturer
.02 2 Number of carburetors
.03 2 Configuration (see Examples 7-12) and method of
operation
.04 2 Number of Venturis per carburetor
.05 5 Venturi diameter (nominal)
.06 2 Fuel metering system configuration - type (e.g., fixed
orifice, tapered rod, etc.)
.07 5 Fuel metering system - calibration (e.g., 0.065-inch dia-
meter main metering jet) (see Example 9)
.08 5 Transient enrichment system (e.g., power valve, accelerator
pump, etc.) - configuration (see Examples 10 and 11)
and calibration
.09 5 Idle stop configuration
.10 5 Starting and warm-up enrichment system configuration
(see Example 12)
.11 5 Altitude compensation system configuration and calibration
.12 5 Hot idle compensation system configuration and calibration
.13 5 Air-fuel flow calibration
.03.00 Fuel injection
.01 2 Manufacturer
.02 2 System configuration and method of operation (include
all controlled and sensed parameters and show the general
relationship between them)
.03 5 Calibrations including the design or nominal duration
(expressed in crankshaft degrees) that Diesel fuel is
injected into the combustion chamber at rated speed and
load.
.04 2 Basic type (mechanical, electronic, timed, continuous)
.05 2 Point of injection (e.g., manifold, cylinder, or throttle
body)
.06 5 Fuel shutoff system configuration and calibration
.07 5 Starting and warm-up enrichment system configuration
.08 5 Air-fuel flow calibration
.09 5 Altitude compensation system configuration and
calibration, if applicable
.10 5 Transient enrichment system - configuration and
calibration
.11 5 Injector configuration
.12 5 Operating pressures
.13 5 Injector timing calibration
.04.00 Air inlet system
.01 2 Air cleaner configuration (see Example 15)
.02 5 Air inlet temperature control system configuration
(see Examples 14-16) and calibration
Describe method of operation, location of sensing unit (if automatic), code
or number to indicate choke setting (if applicable), and calibration.
Include a copy of every flow curve referenced, and if different test pro-
cedures are used for flowing different carburetors in the same engine family,
include a description of each procedure used.
Include a copy of every flow curve referenced.
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10.03.04.03 5 Air filter material (e.g., paper, foam, charcoal, etc.)
.04.00.00 Individual engine parameters (ignition and camshaft)
.01.00 Ignition system
.01 2 System configuration (see Example 17) and method
of operation
' .02 2 Distributor manufacturer ,
.03 5 Control parameters and calibrations (include all
controlled and sensed parameters and show the relation-
ship between them)
.04 5 Initial timing setting (degrees BTDC or ATDC @ RPM)
.05 4 Timing adjustment procedure
.06 2 Spark plug electrode composition and design
.07 2 Spark plug gap
.08 5 Spark plug vendor and identification number (e.g.,
RJ10Y, R43S, etc.)
.09 5 Alternate spark plugs
.10 5 Altitude compensation system configuration and cali-
bration, if applicable
.11 2 Secondary ignition wire material
.12 5 Dwell setting, if applicable
.13 4 Dwell adjustment procedure, if applicable
.14 2 Glow plug configuration
.15 2 Glow plug material
.16 5 Glow plug heating output
.17 5 Glow plug control parameters
.18 5 Restrike capability description, if applicable
.02.00 Camshaft timing (crank degrees before or after TDC or BDC)
.01 2 Intake valve opens
.02 2 Intake valve closes
.03 2 Intake valve duration
.04 2 Intake valve maximum lift
.05 2 Exhaust valve opens
.06 2 Exhaust valve closes
.07 2 Exhaust valve duration
.08 2 Exhaust valve maximum lift
.09 2 Valve overlap (degree or degree-inches)
.10 2 Rocker arm ratio
.11 2 Valve lifter (or actuator) type (hydraulic or
mechanical)
.12 5 Valve lash dimension
.13 2 If variable valve timing or geometry is used, describe
the system for varying valve operation and the valve
operation as a function of engine speed and load
.05.00.00 Individual engine parameters (general))
.01.00 Governor
.01 2 Governor type (limiting, variable speed, etc.)
Include a copy of every advance curve (e.g., centrifugal, vacuum, etc.)
referenced.
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10.05.01.02 2 Signal (electronic, mechanical, flow, etc.)
.03 5 Governed speed, RPM (with engine loaded)
.04 2 Manufacturer
.05 2 Configuration
.06 5 Calibration (if applicable)
.02.00 Supercharger/Turbocharger
.01 5 Manufacturer
.02 2 Type (centrifugal, Roots, etc.)
.03 2 Drive (mechanical, exhaust turbine, etc.)
.04 2 Aneroid setting
.05 2 Maximum manifold pressure
.06 5 Wastegate control calibration (include parameters
involved in determining wastegate valve opening and
closing)
.07 2 Configuration
.08 5 Calibration (if applicable)
.06.00.00 Individual engine parameters (emission control)
.01.00 Crankcase emission control system
.01 5 System configuration (see Example 18) and method
of operation
.02 5 Control parameters and calibrations
.03 5 Control valve configuration (see Example 19) and
calibration
.02.00 Exhaust emission control system
.01 2 Indicate usage of the following control systems:
engine modification, mechanical fuel injection,
electronic fuel injection, air injection, exhaust
gas recirculation, thermal reactor, catalyst (specify
type [e.g., oxidation, reduction, 3-way] and number
used on each vehicle), other
02 5 System configuration (see Examples 35 and 36)
.03.00 Auxiliary emission control devices - Exhaust emissions
.01 2 Device configuration (see Example 34)
.02 2 System configuration (see Example 33) and method
of operation
.03 2 Sensed parameter(s)
.04 2 Controlled parameter(s)
.05 2 Calibration (including hysteresis)
.06 2 Justification
.04.00 Emission control related warning system
.01 2 System configuration
.Submit a graph or performance "map" to describe operational characteristics.
If the calibration consists of a curve instead of just one or two points,
include a copy of each curve referenced. Show the complete relationship
between the sensed and controlled parameters.
Such as operation of device substantially included in FTP, vehicle safety,
or engine starting (in accordance with MSAPC Advisory Circular No. 24).
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10.06.04.02 2 Method of operation
.03 2 Parameters sensed and parameters controlled
.04 2 Calibration
.05 2 Component configuration
.06 2 Interval of operation
.07 2 Reset procedure
.07.00.00 Description of emission control systems
(the description of each exhaust emission control system,
as applicable, should include but not be limited to the
following)
.01.00 Engine modification features
.02.00 Air injection features
.01 2 Component configurations (diverter valve, check valve,
pressure relief valve) (see Examples 26 and 27)
.02 2 General location of injected air (exhaust port,
thermal reactor, catalyst, etc.) (see Examples 25 and 28)
.03 2 Parameters sensed and parameters controlled
.04 5 Calibrations
.05 2 Specific features which affect flow characteristics
(nozzle angle, tip design, etc.) (see Example 28)
.06 2 Pulley drive ratio
.07 5 Pump flow calibration
.08 2 Air switching features including locations, timing,
and purpose
.09 2 General method of driving air pump (e.g., constant speed,
proportional to engine speed, clutching)
.03.00 Exhaust gas recirculation features
.01 2 Component configuration (EGR valve, amplifier, modulator,
delay valve) (see Examples 29 and 30)
.02 2 Location of exhaust pick-up (crossover upstream of
muffler, downstream of muffler, etc.)
.03 2 Location of exhaust gas introduction (above throttle
blade, between carburetor and intake manifold,
manifold port, etc.)
.04 2 Special features for filtering or cooling EGR
.05 2 Special features for distribution into the inlet charge
.06 2 Specifications of any EGR cutoff conditions (discuss the
need for these cutoff conditions)
.07 2 Parameters sensed and parameters controlled
.08 5 Calibration
.09 5 EGR valve flow calibration
.04.00 Thermal reactor features
.01 2 Material
.02 2 Lining and/or insulation (reactor and/or vehicle)
.03 2 Cooling (if any)
.04 2 Volume (individually and collectively, if multiple)
.05 2 Light off method (electric ignition, glow plug, self-
inducement, etc.)
The definitions of exhaust emission control systems in Section G of Advi-
sory Circular No. 20-B indicate "that 'engine modification' is a control
system used by itself"; that is, engine modification precludes the use of
major add-on emission control hardware and systems (air pump, catalysts,
exhaust gas recirculation, etc.) and vice-versa.
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10.07.04.06 2 Configuration (show internal baffling)
.05.00 Catalyst features
.01 2 Catalyst supplier and address (e.g., Englehard, UOP, AC,
Matthey-Bishop, etc.)
.02 2 General type of catalyst (e.g., oxidation, reduction, three-
way, etc.) 2
.03 2 Number of each type of catalyst used per vehicle
.04 2 Substrate (e.g., monolithic, pelleted) - give config-
uration construction technique (e.g., extruded, laid-up,
formed, Dravo disk, etc.), composition, supplier and
address, composition of active constituents in substrate
(grams or troy ounces); for monolithic substrates, give
number of cells per square inch of frontal area and
design tolerances, nominal cell wall thickness (e.g., in
mils); for pelleted substrates, give pellet shape and
dimensions, pellet bulk density, specify the use of more
than one type of pellet (e.g., Rh or Pt/Pd), specify any
geometrical distribution of pellets, and, if this is
controlled in production, specify the mean impregnation
depth (e.g., in microns) of active materials and include
production tolerances
.05 2 Washcoat - give composition of active constituents, and total
active material loading (grams or troy-oz) in washcoat
.06 2 Active material - give composition of active constituents,
loading of each active material including design tolerances,
total active material loading including design tolerances
(grams or troy-oz)
.07 2 Container - configuration (see Examples 31 and 32),
dimensions, volume, materials used, technique of containment
and restraint, method of constructing container, canner (if
different from catalyst supplier), and insulation and
shielding (catalyst and/or vehicle)
.08 2 Physical description - dimensions (e.g.,length, width,
height,etc.), weight (Ibs), volume including design
tolerances, active surface area (BET), and total active
surface area including design tolerances
.06.00 Other major exhaust emission control systems
.01 2 Component configuration(s) (see Example 33) and
method of operation
.02 2 Parameters sensed and parameters controlled
.08.00.00 2 Projected engine family sales (see Appendix page 12)
.09.00.00 2 Optional equipment (see Appendix page 13)
.10.00.00 Vehicle description (see Appendix page 14)
.01.00 5 Engine code
Any combination of the listed catalyst features (excluding suppliers'
addresses) is defined as a unique catalyst configuration and should be
identified by a "catalyst code." Some catalyst features determine unique
exhaust emission control systems and/or engine families. See MSAPC Advisory
Circular No. 20-B for additional information.
2
Each individual monolith unit or "biscuit" is considered to be a separate
catalyst.
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5-19
10.10.02.00 2 Engine family
.03.00 2 Exhaust emission control system
.04.00 2 Evaporative emission family
.05.00 2 Evaporative emission control system
.06.00 5 Evaporative emission code
.07.00 2 Catalyst code, if applicable
.08.00 2 Vehicle model (defined as: car line/body style/drivetrain
configuration)
.09.00 2 Car line
.10.00 2 Body style
.11.00 2 Transmission code
.01 Class (manual, automatic, or semi-automatic)
.02 Number of forward gears
.03 Overdrive (specify either "overdrive gear ratio,"
"separate overdrive unit," or "not applicable"; if
a separate unit is used, describe under Special
Features, 10.10.11.10)
.04 Drive gear ratios (including overdrive)
.05 General description (e.g., synchronized countershaft
transmission; fluid coupling; three member, six
element, single phase, three stage torque conver-
ter; etc. Please use terminology recommended by SAE
Recommended Practices J641b and J645b in this and
subsequent subsections.)
.06 Shift calibrations (automatic transmissions only)
.07 Torque converter size (automatic transmissions only)
.08 Torque converter stall torque ratio (automatic
transmissions only)
.09 Torque converter stall speed (automatic transmissions
only)
.10 Special features (e.g., lockup torque converter, split
torque drive, dual range transmission, variable
blade reactor, etc.; provide specifications and
description of operation)
.11 Lockup calibration (converter lockup transmissions
only) (e.g., speed or time or parameters sensed
and/or controlled or equation determining lockup
condition; indicate features inhibiting lockup
condition where applicable)
.12 Lockup gears (converter lockup transmissions only)
(specify for which gears and under what conditions
the lockup feature is employed)
.13 Blade angle shift calibration
"Transmission code" is simply a designation (e.g., 1, A, etc.) used to
identify and refer to each transmission configuration or subconfiguration
within the engine family which may affect exhaust emissions or fuel economy.
Since each combination of the characteristics listed in Section 10.10.11.01-
13 determines a unique transmission code, vehicle descriptions which cover
several codes should, for clarity and economy of presentation, include a
separate page or pages which itemize the characteristics of each code. The
vehicle description page(s) (see Appendix page 14) may then cite the actual
codes.
-------
5-20
10.10.12.00 5 Curb weight
.13.00 2 Inertia weight class
.14.00 2 Equivalent test weight
.15.00 5 Gross vehicle weight (less than 6000, between 6000
and 8500, or greater than 8500 pounds) (applicable to light
duty trucks only)
.16.00 5 Frontal area^(in square feet)
.17.00 Axle ratio2
.01 2 Standard
.02 5 Maximum optional ratio
.03 5 Minimum optional ratio
.18.00 Tires2
.01 2 Standard size and type (e.g., HR78-15)
.02 5 Maximum size^ and type
.03 5 Minimum size-^ and type
.19.00 N/V ratio2
.01 2 Standard
.02 5 Maximum
.03 5 Minimum
.20.00 2 Basic drivetrain layout
.21.00 5 Dynamometer power absorber setting^
.22.00 5 Frontal area horsepower
.23.00 5 A/C factor added (yes or no)
.24.00 5 Altitude (indicate high, low, or all if
optional procedures are to be followed)
.25.00 Projected sales
.01 5 California standards
.02 5 49-state standards
.03 2 Total
.10.40.00 7 Vehicle description - without sales data
.11.00.00 5 Proposed test fleets (optional)
frontal area values should be calculated according to the procedures
specified in 40 CFR 86.129-79. For incomplete trucks (Ref. 40 CFR 86.079-2),
specify the maximum completed curb weight and maximum completed frontal area.
This value may be reported in Section 08.13.01.00 at the manufacturer's
option.
2If vehicles equipped with air conditioning have different standard or
optional axle ratios, tire sizes, or N/V ratio, indicate accordingly. (N/V
ratio is defined as the quotient of engine speed in rpm divided by vehicle
speed in mph measured in the highest, i.e., lowest numerical, transmission
gear.)
•^Maximum and minimum sizes are determined by the circumference. However,
the nominal size (e.g., HR78-15) should be reported.
^Indicate if alternative dynamometer power absorption determination procedure
was used and reference EPA letter of approval.
-------
5-21
10.30.00.00 Engine Family Description - Rotary Engines
.31.00.00 Common family parameters 1
.01.00 2 Major axis (inches) (Dimension "A")
.02.00 2 Minor axis (inches (Dimension "B")
.03.00 2 Eccentricity (inches) (Dimension "E")
.04.00 2 Width of rotor housing (inches) (Dimension "H")
.05.00 2 Generating radius (inches) (Dimension "R")
.06.00 2 Intake port type (side, peripheral, combination, etc.)
.07.00 2 Exhaust port type (side, peripheral, combination, etc.)
.08.00 Housing configuration
.01 2 Type of cooling (air, water)
.02 2 Arrangement (number of rotor housings)
.03 2 Number of spark plugs per rotor
.09.00 Combustion cycle
.10.00 Method of aspiration (natural, supercharged, etc.)
.32.00.00 Individual engine parameters (physical)
.01.00 2 Displacement (inches ) (if different than total
chamber capacity, indicate method of measurement)
.02.00 2 Number of rotors
.03.00 Rotor construction
.03.01 2 Material (including coating, if applicable)
.02 2 Configuration
.04.00 Housing construction
.01 2 Material (including coating, if applicable)
.02 2 Configuration
.05.00 Sealing arrangement
.01 2 Tip seal configuration
.02 2 Tip seal material
.03 2 Tip seal retention
.04 2 Side seal configuration
.05 2 Side seal material
.06 2 Side seal retention
.07 2 Number of seals per rotor
.06.00 Compression ratio
.01 5 Nominal
.02 5 Maximum
.03 5 Minimum
.07.00 2 Surface/volume ratio (surface area expressed in square
inches divided by volume expressed in cubic inches)
.08.00 2 Combustion chamber design including rotor face and
housing, and location of spark plugs
.09.00 2 Precombustion chamber design (if applicable)
.10.00 2 Intake port area (expressed in square inches) at
housing and manifold mating surface
2 See page 25 for sketch showing dimensions "A," "B," "E," "H," and "R."
If vehicles equipped with air conditioning have different standard or
optional axle ratios, tire sizes, or N/V ratio, indicate accordingly. (N/V
ratio is defined as the quotient of engine speed in rpm divided by vehicle
speed in mph measured in the highest, i.e., lowest numerical, transmission
gear.)
-------
5-22
10.32.11.00 2 Intake port design at sliding surface, including location
and any special port preparation
.12.00 2 Exhaust port area (expressed in square inches) at
housing and manifold mating surface
.13.00 2 Exhaust port design at sliding surface, including loca-
tion and any special port preparation
.14.00 2 Intake manifold configuration (including heated passages
and E6R passages, if applicable)(see Example 3)
.15.00 2 Intake manifold material
.16.00 2 Exhaust manifold configuration (see Example 4)
(including heat stoves, shield, and choke heat pickup,
if applicable) (see Example 16)
.17.00 2 Exhaust manifold material
.18.00 5 Advertised or rated HP @ RPM
.19.00 5 Advertised or rated torque @ RPM
.20.00 2 Exhaust system (dual or single)
.21.00 2 General location of catalyst (e.g., in exhaust manifold,
forward underfloor area, etc.)
.22.00 5 Cooling system configuration (see Example 6)
.23.00 5 Thermostat calibration
.24.00 2 Electronic control devices - (ref. 10.02.25.09)
.33.00.00 Individual engine parameters
(ref. 10.03.00.00)
.34.00.00 Individual engine parameters (ignition system)
.01.00 Ignition system (ref. 10.04.01.00)
.02.00 Port timing (eccentric shaft degrees)
.01 2 Intake port opens
.02 2 Intake port closes
.03 2 Intake port duration
.04 2 Exhaust port opens
.05 2 Exhaust port closes
.06 2 Exhaust port duration
.07 2 Port overlap
.35.00.00 Individual engine parameters (general) (ref. 10.05.00.00)
.36.00.00 Individual engine parameters (emission control) (ref.
10.06.00.00)
.37.00.00 Description of emission control systems (ref. 10.07.00.00)
.38.00.00 Projected engine family sales (ref. 10.08.00.00)
.39.00.00 Optional equipment (ref. 10.09.00.00)
.40.00.00 Vehicle description (ref. 10.10.00.00)
.40.40.00 Vehicle description - without sales data (ref. 10.10.40.00)
.41.00.00 Proposed test fleets (optional) (ref. 10.11.00.00)
10.50.00.00 Engine Family Description - Two-Stroke Cycle Reciprocating
Engines
This section is reserved. In the event that a manufacturer wishes to
make application for certification of a two-stroke cycle reciprocating
engine, a copy of this section will be furnished upon request.
•^Indicate whether net or gross, and specify method of measurement, e.g.,
128 BHP @ 4000 RPM, SAE net.
-------
5-23
11.00.00.00 Starting and Shifting Schedules
Provide copies of starting and shifting instructions for each family.
Whenever there are different shifting instructions within the family based
upon model or transmission, include these separately. If variable shift
speeds are to be used, submit a pre-marked driver's aid trace (or a copy) for
each shift schedule.
12.00.00.00 Vehicle Books
Authorization to begin mileage accumulation will not be granted until
a vehicle book containing all of the following items applicable to the
particular vehicle is received:
1. Vehicle information data sheet (see Appendix, pages 17 and 18). (Copies
of the latest version of this form will be available from your certification
team.)
2. Carburetor (or fuel injection) flow curve (and engineering limits for
emission-data vehicles).
3. Distributor advance curve (and engineering limits for emission-data
vehicles).
4. Spark control system specifications (and engineering limits for emission-
data vehicles).
5. PCV valve flow curve (and engineering limits for emission-data vehicles).
6. EGR valve performance curve (and engineering limits for emission-data
vehicles).
7. Air injection pump performance curve (and engineering limits for emission-
data vehicles).
8. Any other emission control device performance specifications or actual
calibration values, if tested (and engineering limits for emission-data
vehicles). Also, if any vehicle is equipped with a thermal or a catalytic
reactor and the thermal or catalytic reactor is subject to any type of
production performance test, then EPA would like to see the results of these
tests.
9. Zero-mile data (use pages 15 and 16 of the Appendix).
10. In order to determine compliance with 40 CRF 86.079-26(a)(7), manufac-
turers shall provide the system miles (system miles = CF X [odometer miles -
1C], where CF = odometer correction factor and 1C = initial correction) and
engine operation time (in minutes) at the initiation of the preconditioning
trip on the dynamometer [see 40 CFR 86. 132-78(a)(2)].
-------
5-24
If the odometer correction factor has not been determined at the time of
submission of the zero-miles book, a value of 1.0 may be used provided there
is a statement that the actual correction factor has not been determined.
(The correction factor must be determined prior to the test at 4,000 miles
for emission-data vehicles or 5,000 miles for durability-data vehicles.)
Note that the requirement to report engine operation time applies only to the
zero-mile test. The zero-mile system miles and engine operation time may be
recorded as a special note on the Vehicle Test Data Log Sheet (page 15 of the
Appendix).
11. Name of individual responsible for assuring that the test vehicle
is in all material respects the same as described.
12. All emission control system components or assemblies for which specifica-
tions have been provided in the application for certification must, when
installed on test vehicles, bear identification relating to the actual
performance characteristics provided in the zero-mile book.
Engine descriptive information (Section 10.00.00.00) and schematics
(Section 08.00.00.00) which are identical to the vehicle being described need
not be submitted, but may merely be referenced except for those items which
are specifically requested on the Vehicle Information Sheet.
All computer input forms needed to enter vehicle test data into EPA's
data base (and the computer outputs generated by the processing of these
forms) are considered part of the Vehicle Book.
13.00.00.00 Evaporative Emission Control Deterioration Program
Submit a complete description of the method used to calculate the
evaporative emission deterioration factor. Describe in detail the proce-
dures used and the data generated.
14.00.00.00 Forecast of Test Vehicle Availability
Submit projections of test vehicle availability weekly (or less frequen-
tly if there is no change in status) covering at least the next four weeks and,
if possible, as much as the next twelve weeks. Longer term projections are
requested to help in long-range planning of laboratory resource requirements
(ref. Advisory Circular No. 54A).
15.00.00.00 Revisions
Provide a cumulative listing of all revisions to the application for
certification (see Appendix page 27 for a sample form). The description
should be as brief as possible while still giving a clear description of the
change.
16.00.00.00 Request for Certificate
Provide a statement of compliance with 40 CFR 86.078-5(b)(1) and (2)
(ref. Advisory Circular No. 46). Also include a statement of compliance with
40 CFR 86.079-23 (this may be submitted once and referenced in the case of
multiple engine families).
-------
5-25
For each engine family/evaporative emission family combination submit:
1. The official emission test results of each emission-data vehicle (submit
using recommended form on page 21 of the Appendix).
2. The vehicle or model names as you wish them to be designated on the
certificate of conformity.
3. The production part numbers for each item listed on page 22 of the
Appendix. At the manufacturer's option, this information may be included in
an earlier sequence of the application.
4. Any production tolerances and any specific point(s) at which production
pieces are checked and/or adjusted. (For example, all carburetors are flow
checked and air/fuel ratio adjusted at 2 and 6 pounds per minute air flow and
checked at 4 and 30 pounds per minute air flow.) Also indicate the percen-
tage of production pieces checked and/or adjusted. Describe sampling tech-
nique, i.e., how "production" tolerances are determined and how tolerance
bands are used, for example, a. 100 percent check with rejection of all pieces
outside of bands, a 2 percent audit of production, or a batch sampling
technique. An unqualified statement as provided in Chapter 2 - Parameters
and Tolerances may be submitted in lieu of the production tolerances requested
above.
5. A completed Summary Sheet Input Form. (Copies of this form will be avail-
able from the certification teams. Instructions for preparation and submission
will be included in the forthcoming Data Forms Supplement described on page
2-7).
17.00.00.00 (Reserved for California)
At the request of the California Air Resources Board (GARB), EPA is
reserving Section 17 of this format for material uniquely required by GARB.
-------
APPENDIX
-------
Revision Cover Letter 1
Fuel Specifications Sheets 2-5
Lubricants 6-8
Use of Special Tools 9
Engine Parameters Data Sheet 10
Evaporative Emission Family Sales 11
Engine Family Sales 12
Optional Equipment 13
Vehicle Description 14
Vehicle Test Data Log Sheet 15
Maintenance Log 16
Vehicle Information Sheet 17-18
Deterioration Factor Calculation 19
Logic Flow Chart (Electronics) 20
Emission Data Summary 21
Parts List 22-22A
Certification Change Request 23
Cylinder Block and Valve Location Dimensions 24
Engine Block Dimensions - Rotary 25
Mileage Accumulation Schedule 26
Revision Index or Log 27
Example Configurations
1 Cylinder Head Intake and Exhaust Ports 28
2 Combustion Chamber Design 29
3 Intake Manifold Configuration 30
4 Exhaust Manifold Configuration 31
5 Exhaust System 32
6 Cooling System 33
7-12 Fuel System 34-39
13 Carburetor Mounting Spacer 40
14-16 Air Inlet System Configuration 41-43
17 Wiring Diagram 44
18-19 Positive Crankcase Ventilation System 45-46
20-24 Evaporative Emission Control System 47-51
25-28 Air Injection System 52-55
29-30 EGR Valve 56-57
31-32 Catalytic Converter 58-59
33-34 Auxiliary Emission Control Devices 60-61
35-36 Exhaust Emission Control System 62-63
Standardized Engine Family Names 64-72
-------
1
Revision Cover Letter
TO: Chief, Light-Duty Vehicle Certification Branch
FROM:
RE: 1981 LDV1 Application for Certification: Engine Family2
(Family Name or
Application Sec-
tion Number)
This letter transmits the latest revision(s) described on the attached revision
log.3
The purpose of this revision (these revisions) is
4
Enter either LDV (Light-Duty Vehicle); LOT (Light-Duty Truck); LDDV (Light-Duty
Diesel Vehicle); or LDDT (Light-Duty Diesel Truck).
2
Enter either Engine Family, Evaporative Emission Family, or Section Number.
3
A sample revision log is shown on Appendix page 27.
4State succinctly the purpose of this revision: e.g., to avert a possible
dieseling condition; to reflect a change in marketing strategy; etc.
-------
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Section 06.03.00.00 - Special Tools
Special tool
or equipment
Use of
Tool
Was this tool
used in previous
model years?
Justification for
use of tool I/
I/ Ref. 40 CFR 86.079-25(a)(12;
-------
10
Section 10.00.00.00
Information Required
Engine Family Description
Family Identification
1
Engine
Code
Eng ine
Code
Engine
Code
e.g.
10.01.01.00 Deck height
10.01.02.00 Centerline of crankshaft
to centerline
of camshaft
10.01.03.00 Bore center to center
If optional procedures for high-altitude certification are to be followed,
indicate whether engine code is intended for sale at high altitude,
low altitude, or all.
-------
Section 09.04.00.00 Evaporative Emission Family Sales
Family Identification
11
1
Evaporative Emission Projected
Control Systems Sales % of Family
Family Totals
_!/ Submit a separate sheet for each family, outlining all control systems
available.
-------
12
I/
Section 10.08.00.00 Engine Family Sales—'
Job 1 date
Introduction date
Family Identification
Sales by CID
Engine
Displacement
Exhaust Emission
Control System
Projected Sales
% of Family
Hi Alt. 49 States Cal. Hi Alt. 49 State Cal.
Sales by Test Weight and Transmission Configuration
Transmission Test Projected
Configuration Weight Lbs. Sales
% of Family
Sales by Test Weight
Test Projected
Weight Sales
% of Family
Sales Weighted Average
Test Weight
Family Totals
I/
Submit a separate sheet for each family, outlining all displacement - control system
combinations available.
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14
Section 10.10.00.00 Vehicle Description
Engine Family Identification Displacement
Exhaust Emission Control System Evaporative Emission Family
Evap. Emission Control System No. and Location of Driving Wheels
Engine Code
Evaporative Emission Code
Vehicle Model
Carline
Body Style
Transmission Code
Curb Weight
Inertia Weight Class
Equivalent Test Weight
Gross Vehicle Weight
Frontal Area
Axle Ratio^-' ,
Tire Size & Type^-'
N/V Ratio^-'
Basic Drivetrain Layout
Dynamometer Power Absorber Setting
A/C Factor Added (yes or no)
Altitude (high, low, or all)
Projected Sales
California Standards
49 State Standards
Total
-See discussion on page 5-19. *
Sales need not be provided for each axle ratio/tire size combination; however,
standard, maximum, and minimum axle ratio, tire size, and N/V values should be
provided.
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Section 12.01.02.00 - Vehicle Information Data Sheet
17
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Section 12.01.02.00
hFR CODE. VEHICLE ID.
AMD VI VERSION «)
NEV
CHANGE (ft)
INFORMATION SPECIFIED f>Y VERSION «.
ONLY TrtE KEY FULL'S AND CHANGING
CARRYOVER 1C)
INFORMATION SPECIFIED PY VERSION 1.
1EAK KING CARMEE* OVtR TO S^ET.IFlEIi
CORRECTION (H)
EXCEPT KEY FIELPS. OW.Y THE FIELDS
HANF CODE (COLS 1-3)
10 AHC
20 CMRYtLER
20 (CHRYS) PLYMOUTH
H 'ft »*Q roi rfa*
40 0ENERAL MOTORS
40 (OH) BUICK
44 (OH) PONTIAC
40 (2M> CMC
30 AfARTM
40 AC CARS
44 AICHI
AS ALBANY
83 AUTO SPORT
»0 AL'A KOiFO
93 AH DENIS4L
OS AUSURN
15 fLM
20 t>nu
23 80LUELL
30 BRISTOL
33 »RICKLIN
40 CHECKER
SO CITROEN
*0 COMHER
73 DAC1* (ARO)
180 -OAF
1TO DAIHATSU
193 DELORtAN
203 OE TQHASO
210 DUAL GHAI
220 FERRARI
223 FASCINATION
230 FIAT
240 FORD OF ENGLAND
230 HIND
2 0 HONDA
2 S HYUNDAI
2 0 IMC
2 3 INDR*
2 0 ISO
2 0 ISUZU
3 0 JAGUAR (BLPC)
110 JENSEN
335 KAUASAKI
340 LANCIA
330 LOTUS
340 HASERATI
3*3 HO
343 RONS
370 MORGAN
380 NISSAN
383 NORTON
3VO NSU
4OO OPEL
403 PANTHER
413 PIAGGIO-VESPA
30 RENAULT
4« ROLLS-ROYCE
40 ROVER OLIO
80 SHELBY
»0 MITSUBISHI
95 SATRA
310 SKODA
320 EXCALIIUR AUTOflOHLE
325 SQUIRE
330 TRIUMPH (BLHO
333 STUTZ
340 SUZUKI
5*0 TOYO KOGYO
370 TOYOTA
310 VAUXHALL
3VO VOLKSVAOCN
400 VOLVO
403 WHITE
413 YAMA«A
*ro TVR
630 SU5t E.N3IONS iNf (01EQA)
440 AUDI
TOO HARCOS
710 ARHY
730 CATERPILLAR
740 CUNMINS
750 HERCULES
740 RACK
780 SCANIA-VAftlS
810 CASE
820 DIAMOND RED
»9? EXPERIMENTAL
THE 3 DIGIT CODE
1 HI TUN
3 VAN
4 UASON
3 MOTORCYCLE
o: HERT; DETROCT
03 htRT": L.
03 DIESEL
04 OAS TURBINE
05 RANKINE
04 STIRLINO
07 HYBRID*
99 OTHER
01 IN-LINE
03 OPPOSED
04 (COT ART
09 ONE SHAFT
04 TUO SHAFT
Of DATTERY
99 OTHER
FUEL INJECTION (COL 4O)
t - YES
A - AFTER
8 - IEFORE
OCA* (COL 7U
K - NEUTRAL
P - F-fll-K
N - N1LC8
T - TCI
3 SINGLE RIGHT REAR
3 DUAL REAR
S SINGLE RISHT SIDE
4 DUAL SIDES
1 CLOSED
2 M-3
1 «-4
3 I-*
8 A-4
10 AIR PUMP
19 CLOSED LOOP
98 NONE
99 OTHER
ni CRAMKCASE
02 CANISTER
03 TANK
99 OTHER
FU£L TYPE (COLS 33-34>
03 LPO
04 PROPANE
09 *1 FUEL OIL
10 NATURAL CAS
tl ALCOHOL
12 INDOLENE 10
13 INDOLENE 20
14 JP-4
0 - 8ALLQNS
3 DO NOT SHIFT MANUALLY
TIHINfl 6EAR
N - MEUTfiAL
D - I'RIVE
p - PAr,K
TIM CONSTRUCTION (COL 40)
3 BIAS
(COLS 42 i 44 >
A ARAHID
f FIBERGLASS
P POLYESTER
• RAYON
* 3TEEL
CARD Vl-3
ALTERNATE HFR CODE
-------
19
Section 12.02.02.00 - Exhaust Emission Deterioration Factors
1
Engine Family_
_Durability-Data V.I.D. No.
Interpolated Values:
4,000-Mile: HC = .
NOx = .
50,000-Mile: HC = .
NOx =
CO
CO =
Deterioration Factors:
Engine-System CO Factor = .
2
Engine-System HC Factor = .
Engine-System NOx Factor = . Engine-System Part. Factor" = .
Submit a separate sheet for each engine family/exhaust emission control
system combination. The data used to calculate the deterioration factors
should be supplied on the "Light-Duty Deterioration Factor Input Sheet"
(Section 12.02.03.00), whose preparation and submission will be described in
the forthcoming Data Forms Supplement. See Item 12, pages 2-6 and 2-7.
2
Particulate deterioration factors pertain to Diesel engines only.
-------
20
Section 10.02.25.09 - Logic Flow Chart (Electronics)
c
LITON
LITE 1
Y7
Display Warning
Light
LITE 2
Set Spark
Advance to
15°
LITE 3
-------
Section 16.02.00.00 Emission Data Summary 21
Engine Family
Vehicle
Model
I.D. Number
Selection Criteria—
Exhaust System
Engine Code
Evaporative Em. Family
Transmission (Type/Code)
Displacement
Inertia Weight Class
Equivalent Test Weight Category
Axle Ratio
N/V Ratio
EPA 4000-Mile Results2/
Test Number
HC (g/mi)
CO (g/mi)
NO (g/nd) , _
Particulates (g/mi)-
Evap. (g/test)
Deterioration Factors
HC
CO
NOX 3/ _
Particulates—
Evap.
Certification Levels
HC (g/mi)
CO (g/mi)
N0x(g/mi)
Particulates (g/mi)—
Evap (g/test)
Estimated Emission Levels
HC (g/mi)
CO (g/mi)
NO (g/mi) _
Particulates (g/mi)-'
Evap. (g)
—, Reference the applicable section in 40 CFR 86.080-24(b).
—, If not tested by EPA, give the EPA-determined manufacturer's test number.
—, Diesel engines only.
— To be provided only for engine families whose emission-data vehicles have
been selected according to the procedures outlined in EPA's May 15, 1979
guidelines on "Exhaust Emission-Data Vehicle Selection Criteria," Section
II.B.I, pp. 5-7.
-------
22
Section 16.04.01.00 - Parts List
Fuel pump part number
Carburetor assembly part number
Fuel injection control unit
part number
Supercharger or Turbocharger:
Assembly
Turbine
Compressor housing
Wastegate valve
Spark plug identification
number
Alternate spark plugs
Distributor assembly part number
Crankcase emission control system:
component part number
Evaporative emission canister
part number
Auxiliary emission control devices:
identification (color, production
code, number, etc.) of calibrated
components
Air injection system:
Air pump part number
Diverter valve part number
Check valve part number
Pressure relief valve part number
Exhaust Gas Recirculation System:
EGR valve
Amplifier
Modulator
Delay Valve
Catalyst assembly part number
Other major exhaust emission and evap-
orative emission control systems: part
numbers of calibrated component(s)
Engine
Code
Engine
Code
Engine
Code
Note: In each case, both the manufacturer's part number and any vendor's
part number should be included and identified. For parts labelled
or identified by color-coding in addition to or instead of parts
numbers, explain the color coding system used.
-------
Section 16.04.01.00 - Parts List
Major exhaust emission-related
devices: part number(s) of cali-
brated or non-calibrated compo-
nents
Emission control related warning
system: part number(s) of cali-
brated components(s)
22-A
Engine
Code
Engine
Code
Engine
Code
-------
Section 15.03.00.00 - Certification Change Request
This draft form will soon be circulated to industry for comments.
form will be finalized and distributed as soon as possible.
23
The
YEAR
'RFQursr NO.
1?EKG!NE FAMILY NAME
'"OISPIACEMFNTS
"EXHST CONTROL SYS**
**l'je codes on VI
2"ENGINE CODES
2'CATALYST CODES
"TRANSMISSIONS
23EVAP-EMISS FAMILY
2"EVAP CONTROL SYS
25EVAP CODE
26MODELS AFFECTED
WR.CGDE
cAMEND NO.'
"REQUEST DATE
'AMEND DATE*
CERTIFICATION CHANGE REQUEST
LIGHT-DUTY VEHICLES AND TRUCKS
ADDITION OF VEHICLE
FIELD FIX
RUNNING CHANGE
AMEND
11'jV.S-
AC1 ION
cooe.*
Add
.[.eletp
.Change
SALES
LOC
CODE:
1 50 St
2.VJ St
3. Calif
EUEL
TlPE
COOE.
l.Gas
2. Dies
VTH
l>r'E
CODE:
1 . Vch
2 Trk
3.HC I
AMEND
T'-'-.S-
ACI1CN
COUE.*
l.Add
2 Delete
3 Clidr.jo
SALES
LOC
CODE.
l.tj St
FUEL
TiFl
CODf
1.C?5 j l.Vch
2.Dies ! 2 l-l
DESCRIPTION OF CHANGE/REASON FOR CHANGE
MFR'S TEST DATA SUBMITTED FOR:
29VID
30
VERSION* 31TEST#
CHANGE27
CATEGORY
CODES
REASOti2
CODES:
1
j;HAS THIS CHANGE BEEN IMPLEMENTED CONCURRENTLY WITH THIS REQUEST TO EPA?
IF
SIGNATURES: (As required bij i
NAME:
DATE:
J'juct be at Ivast one signature on this form.)
NAME: DATE:
-------
Section 10.01.00.00 - Cylinder Block Dimensions
24
X
X.
1
Cylinder Block Dimensions "A," "B, and "C
Valve Location:
front of engine
Cylinder Head
Valve Location Dimensions
Intake
Valve
(Four-stroke
cycle engine?
Exhaust
Valve
X4
1
yj
i
)
a.
i
6±3
X
ye
e
e*3
Units
inches
J ..-,1*4* A
inches
degrees
degrees
inches
inches
degrees
Cylinder Number 1
li2 12. 11
NOTE: Comparable drawings of equal detail should be supplied for other than
V-block cylinder arrangements.
1 If all dimensions are the same for all cylinders, they may be specified
for one cylinder and others may be indicated as "same."
2 Use additional columns as necessary.
3 For V-block engines, measure angles of left cylinder banK (when facing
toward front of engine).
-------
25
Section 10.31.00.00 - Engine Dimensions - Rotary Engines
-------
Section 05.02.00.00 - Mileage Accumulation 26
Percent of Mileage Accumulation — at Speed
2/
Speed, MPH - Percent
30
35
40
45
50
55
60
70
Transient
total
Driving Mode Number per Cycle — Per Mile — Accel Rate —
Stops
Normal Accelerations
(from stop)
Wide open throttle
accelerations (from
stop)
Idle time (seconds)
Light Accels (from 20 mph)
Average Speed of Cycle y.
Total Mileage of Cycle —
I/ This assumes a repetitive, cyclic type of schedule. If the mileage
is accumulated on a non-repetitive route, estimates obtained from a
"representative" portion of route are acceptable.
2_l Include other speeds, in 5 mph increments, if applicable.
_3/ If drivers are instructed to accelerate or decelerate at a prescribed
rate, please specify rate.
-------
Section 15.01.00.00 - Revision Index or Log (Sample)
Engine Family BBK350V4FA7
Revision // Revision Date Page Nos. Affected
27
Description of
Revision
001
002
003
June 30, 1979
July 18, 1979
Aug. 1, 1979
1-40
10.07.03.08-33
10.03.02.13-21
Dropping of engine
code
EGR valve recali-
bration
R/C #39: Timing
setting change
[A "revision log" is to be maintained for each engine family application,
evaporative emission family application, and general section(s) of the
manufacturer's application. As indicated in the example above, the following
information should be included: (1) the appropriate engine family name (in
MY 1981 this should be the standardized EPA engine family name), evaporative
emission family name, or general section number; (2) the revision number (a
consecutive three digit number, starting with 001, for each engine family,
evap family, or general section each year); (3) the date the revision is
issued (i.e., the date of the letter transmitting the revision); (4) the page
numbers affected by the revision; and (5) a terse but characterizing descrip-
tion of the revision. Revision logs are to be cumulative and updated at the
time of each revision. An updated copy should accompany each revision
submitted to EPA. For families undergoing full certification, a revision log
must be supplied with each revision to the application. For families under-
going abbreviated certification review, the revision log will include all
revisions made to the engine family. This log will be maintained by the
manufacturer as one of the application records and submitted as part of the
application. Following the submission of the ACR application, an updated
revision log will be submitted with each subsequent revision.]
-------
EXAMPLE 1
28
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fig
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-------
EXAMPLE 2
COMBUSTION CHAMBER DESIGN
VALVE, VALVE STEM SEAL AND ROTATOR CONFIGURATION
PISTON AND PISTON RING CONFIGURATION
29
1.48 R-
EXHAUST VALVE
ROTATOR CONFIGURATION
(WHERE APPLICABLE)
SEAL CONFIGURATION
INTAKE EXHAUST
SEAL
SEAL
EXHAUST
VALVE
GASKCT .033
.025 PISTON TO TOP
OF CASE
PLUG
1.50 DIA.
EXHAUST
-------
EXAMPLE 3
30
EXHAUST GAS
CROSSOVER -i
FRONT
PRIMARY BORE DIA - 1.40
AREA - 1.53
SECONDARY BORE DIA - 2.32
AREA - 4. 22
EXHAUST
CROSSOVER
PASSAGE
VIEW
0.96
EGR VALVE
MOUNTING PAD
CARBURETOR
MOUNTING PAD
i
1.56
T
PORT CONFIGURATION
NOMINAL PORT
AREA - 1. 46 (ALL 8 PORTS SAME)
INTAKE MANIFOLD CONFIGURATION
NOTE: Dimensions in inches.
-------
EXAMPLE 4
31
EXHAUST MANIFOLDS
1.88 DIA
Take Down
Area = 2.77 In/
RIGHT SIDE
PORT AREA
End Ports = 1.80 In.2
C«nter Ports = 1.80 In.'
End Ports = 1.80 In.
i
Center Porti = 1.80 In.'
^-1.84 DIA.
Take Down
Area = 2.66 In.
-------
EXAMPLE 5
32
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EXAMPLE 6
33
THERMOSTAT
WATER PUMP
RADIATOR
COOLING SYSTEM
8CYL ENGINE
(ARROWS SHOW DIRECTION OF WATER FLOW)
-------
34
EXAMPLE 7
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35
EXAMPLE 8
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EXAMPLE 9
36
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EXAMPLE 10
37
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EXAMPLE 11
38
-------
EXAMPLE 12
39
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EXAMPLE 13
40
44 OIA
PCV PASSAGE
NOTE:
All Dimensions Are In Inches Unless
Otherwise Noted.
EGR MOUNTING PAD
SIDE VIEW
EGR PASSAGE
CARBURETOR MOUNTING SPACER
BOTTOM VIEW
.50 X .75 HOLE
68 OIA.
-------
EXAMPLE 14
41
AIR CLEANER CONFIGURATION - TEMPERATURE CONTROL
THERMAL AIR
CLEANER ASSEMBLY
SENSOR
VACUUM MOTOR
LINKAGE
DAMPER
ASSEMBLY
AIR BLEED VALVE
VACUUM HOSE TO
MANIFOLD VACUUM
SNORKEL
SNORKEL
HOT AIR DELIVERY
MODE
COLD AIR INLET
CLOSED
DAMPER ASSEMBLY
DIAPHRAGM -,
JPRING
t
AIR BLEED VALVE
CLOSED
VACUUM HOSES
DIAPHRAGM
t
HOT AIR DUCT FULLY OPEN
REGULATING MODE
COLD AIR INLET
OPEN
AIR BLEED VALVE
PARTIALLY OPEN
AIR DUCT OPEN
COLD AIR DELIVERY
MODE
COLD AIR INLET
FULLY OPEN
AIR BLEED VALVE
FULLY OPEN
HOT AIR DUCT
CLOSED
-------
EXAMPLE 15
42
COLD AIR INLET SYSTEM CONFIGURATION
RADIATOR
RADIATOR
SUPPORT
RADIATOR
SUPPORT
22222222213^ RADIATOR
AIR CLEANER
— ENGINE
•AIR
CLEANER
-ENGINE
•L.H. FENDERj
FRONT
FRONT
-AIR CLEANER
-ENGINE
-AIR
CLEANER
— ENGINE
-------
EXAMPLE lt>
43
HOT AIR INLET SYSTEM CONFIGURATION
AIR CLEANER
HERMAC ASSEMBLY
HEAT TUBE
-R.H. EXHAUST
MANIFOLD
HEAT STOVE
-------
EXAMPLE 17
44
WIRING DIAGRAM - Breaker less- ignition System
IGNITION
SWITCH
o
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BAT.
IGfS O )
COILV ^~J-
JL
DIST.
MODULE
TYPICAL INSTALLATION DIAGRAM
•ELECTRONIC
SWITCH
DISTRIBUTOR
IGNITION
COIL
FRONT of ENGINE
-------
EXAMPLE 18
45
POSITIVE CRANKCASE VENTILATION
SYSTEM SCHEMATIC
-va-
ROCKER COVER
AIR CLEANER
INTAKE MANIFOLD
PCV CONTROL VALVE
ROCKER COVER
CRANKCASE
OIL PAN
CLEAN AIR
VOLATILE OIL FUMES
MIXTURE OF AIR AND FUMES
-------
EXAMPLE 19
46
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-------
EXAMPLE 22
EVAPORATIVE EMISSION CANISTER CONFIGURATION
49
NOTE: All dimensions are given
in inches.
VAPOR TO CARB
VAPOR FROM FUEL TANK
BODY COVER
FILTER
CARBON
BODY
FILTER
GRID
FILTER
RETAINER
AIR UNDER VACUUM
5.1 DIA.
-------
EXAMPLE 23
50
FUEL FILLER CAP
,63
2,180+,010 DIA
DIAPHRAGM
7^\\T\ A>-7.
.60
1
Ml
r- - i -v L*— 1 * '"^ s—+*- -"*.
. O
(PRESSURE CONDITION)
IP.
GASKET
SPRING
- SPRING
•—CASE
-------
EXAMPLE 24
51
FUEL TILLER CAP
2,180+,010 DIA
DIAPHRAGM
GASKET
£•" ''*"L^li0'>-7 \ V.-"
Ifr^'T^^r
(VACUUM CONDITION)
-------
EXAMPLE 25
52
CHECK VALVE
AIR INJECTED INTO
EXHAUST PORTS
\
r
DIVERTER
VALVE
AIR PUMP
-L_L
CHECK VALVE
MANIFOLD
VACUUM
SIGNAL
AIR SYSTEM SCHEMATIC
— V8 ENGINE - MANIFOLD INJECTION —
-------
EXAMPLE 26
53
A.I.R. DIVERTER VALVE
Inlet From
Air Pump
Vacuum signal from
carburetor activates
spool
Normal Air Flow
to Manifold
Vacuum connection on
case top not shown in
this section.
Excess Pressure Relief
Diverted Air Through
Integral Silencer
Air Bleed (Unrestricted flow
out of vacuum chamber, re-
stricted flow into vacuum
chamber)
-------
EXAMPLE 27
54
A.I.R. CHECK VALVE
DISC VALVE -
SPRING WASHER
VIEW 1 (NO FLOW)
DIRECTION
OF FLOW
VIEW 2 (FLOW)
-------
EXAMPLE 28
55
A.I.R. INJECTION CONFIGURATION
AT EXHAUST PORT
.258 01A
LINEAR DIMENSIONS IN INCHES.
-------
EXAMPLE 29
56
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57
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EXAMPLE 31
UNDERFLOOR CONVERTER - FULL FLOW
260 CU. IN. BED VOLUME
58
CONVERTER SHELL
INSULATION
OUTER WRAP
FILL PLUG
INSULATION
CATALYST
BED SUPPORT
CATALYTIC PELLET COMPOUND
Overall Length
Overall Width
Overall Thickness
Diameter
Nominal Converter Dimensions - Inches
Converter Shell
18.7
12.4
3.5
Inlet Pipe
2.5
Catalyst Bed
11.8
11
2
Outlet Pipe
2.5
-------
EXAMPLE 32
59
CATALYTIC CONVERTER ASSEMBLY
TYPICAL«SINGLE .SUBSTRATE CONVERTER
SUBSTRATE-
EXHAUST CONVERTER
CATALYST (HC/CO)
SUPPORT
SHELL ASSEMBLY
TYPICAL»DUAL SUBSTRATE CONVERTER
•SPACER
SUPPORT
f
-SHELL ASSEMBLY
SUPPORT
SUBSTRATE-
EXHAUST CONVERTER
CATALYST (HC/CO)
-------
EXAMPLE 33
60
EFE VALVE CONFIGURATION
VACUUM ACTUATOR WITH
INTEGRAL RETURN SPRING
ACTUATOR ROD
VALVE CLOSED BY VACUUM
OPENED BY RETURN SPRING
EFE VALVE
'VACUUM SIGNAL
RIGHT EXHAUST
MANIFOLD OUTLET
EXHAUST PIPE
-------
EXAMPLE 34
61
Name
DISTRIBUTOR SPARK ADVANCE TVS
Part No.
Device Type
WAX PELLET THERMAL VACUUM SWITCH
Activation Value
Deactivation value
Comment on Operation
Below the calibration valve the O ring is seated by the spring.
As the temperature of the wax power element is raised, the expanding
wax forces the piston upward.
Above Calibration Value
Below Calibration Value
1
1
Ports
Connected
X
X
Ports
Connected
Ports
Sealed
Ports
Sealed
Device Crosaection
PORT #2
PORT #1
ORING
O RING SEAT
WAX POWER ELEMENT
THERMAL VACUUM SWITCH
TYPE 1
-------
EXAMPLE 35
62
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EXAMPLE 36
63
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64
EPA STANDARDIZED ENGINE FAMILY NAMES
BACKGROUND
A number of recent circumstances—governmental hiring freezes, reorgani-
zation of MSAPC, increased agency emphasis on inspection and maintenance
programs, increasingly stringent emission standards, new emission control
technology—have resulted in a smaller number of certification engineers
having to review an increasingly greater number of applications for certi-
fication. Not only has the number of engine families per team member
increased, but the number of manufacturers each engineer must deal with has
(in most cases) increased as well; thus each team member must spend addi-
tional time mastering the idiosyncrasies of format and terminology of the
various manufacturers he/she must regulate. Even with the development of
limited and abbreviated certification review to streamline the process, the
capacities of the certification staff are being severely overtaxed.
Given these pressures, close cooperation between the Certification Division
and industry is needed to assure and improve the timeliness of certifica-
tion processing. One area where increased efficiency seems possible is the
day-to-day maintenance of the data base containing descriptive and test-
related data on all light-duty certification vehicles. The tasks of data
entry and validation may not be as visible as the selection of test vehi-
cles or the approval of unscheduled maintenance, but a well kept data base
is essential to the accomplishment of the Division's mission: virtually
every step in the processing of certification depends on the reception,
storage, and retrieval of correct and correctly identified certification
data.
The development and use of consistent, standardized formats and nomencla-
ture will go far to promote this desirable level of accuracy. While more
rigorous formats and terminology may be somewhat more restricting to
manufacturers, they will reduce input errors, permit verification by
automated error-checking routines, and encourage easy manipulation by the
certification teams. The proposed system for naming engine families (ef)
is a first step toward an increased (and more practicable) degree of
standardization. The error-checking potentials of this coding scheme should
eliminate errors of transposition (1.23 for 1.32), shifted decimals (01.23
for 1.230), and character misinterpretations (the number zero for the
letter 0, the number 1 for the letter I, the letter V for the letter U)
whenever an engine family name must be entered or retrieved. Further, the
adoption of this naming system would enable any certification engineer to
glance at the name of any engine family and know at once the family's
manufacturer, model year, vehicle class, displacement, fuel metering
system, and catalyst type. The adoption of this system by all manufac-
turers, consequently, would increase the operating efficiency of the
Certification Division, and might well accelerate CD's processing of
applications.
PROPOSED STANDARDIZED EF NAME
The proposed format for future ef codes was developed after examining
manufacturers' coding formats, obtaining feedback from Certification
personnel, and dicussing a preliminary draft of the proposal with manufac-
-------
65
turers on March 21, 1979. Its design is a compromise between length and
content. Although it was advantageous to make the code as short as possible,
EPA sees merit in providing some basic information on the engine family
(e.g., displacement). The code is to be alpha-numeric since alphabetical
characters have mnemonic value and they provide for more alternatives per
digit than numerical characters. The use of alphabetic characters such as
I, 0, and Q that are easily confused with numbers will be prohibited. The
code is to include a check-sum digit (CSD) for error checking. The method
of determining the CSD is discussed at the end of this paper.
The proposed ef codes are formatted as follows:
first character
character 2 and 3
character 4, 5, and 6
character 7
character 8
character 9
character 10
character 11
Model Year (see Table 1)
Letter code describing manufacturer
(see Table 2 for list of proposed
codes)
Displacement in cubic inches (e.g.,
350) or liters (e.g., 5.7). If
more than one then larger
displacement. The decimal place
is the equivalent of a digit.
Vehicle class (see Table 3)
Numeric code describing fuel metering
system (see Table 4)
Letter code describing type of catalyst
(see Table 5)
Letter code to make the first 9
digits unique. This character
makes it possible to have up to
22 families for each combination
of displacement, fuel metering
system, type catalyst, and certifi-
cation class.
Check-sum digit (CSD)
Character 10 is provided to ensure that the ef code is unique. Any
alphabetic character (except for I, 0, Q, and V) can be used. Although
this character does not have any inherent meaning, and so could be selected
randomly, a manufacturer is free to choose a letter that can be readily
associated with certain emission control technologies.
For example, suppose that two engine families are identical except that one
has regular air injection whereas the other has radial-air tubes
(R.A.T. air). For the former case character 10 could be A and for the
latter character 10 could be R. Consequently, it would be possible to
associate the A with regular air injection and R with R.A.T. air.
-------
66
In the rare event that there are more than 22 engine families in a combi-
nation of displacement, vehicle class, fuel metering system, and catalyst
type, it will be necessary to use both character 9 and 10 to make the code
unique. In this case, character 9 would be selected with the same limita-
tions as character 10 and without regard to catalyst type.
Examples
A 1979 GM family 910L4RU might be designated by the proposed format as:
9CV5.0V4ARX
1) 9 indicates MY 1979 (Table 1 starts with MY 1980)
2) CV indicates that the engine is built by Chevrolet (Table 2)
3) 5.0 indicates displacement in liters
4) V indicates light-duty vehicle (gasoline) (Table 3)
5) 4 indicates a 4 barrel carburetor (Table 4)
6) A indicates an oxidation catalyst (Table 5)
7) R hypothetically chosen
8) X is the CSD (see explanation on pages 67-68)
The advantage of the proposed ef code over GM's code is not obvious since
GM uses a concise method to generate their ef codes. However, at a glance
the proposed code does tell the displacement, manufacturer, vehicle class,
fuel metering system, and type of catalyst. Someone unfamiliar with GM's
engine families would have difficulty extracting this information out of
GM's code. In addition, the code has a CSD and avoids the use of alpha-
betic characters that are confused with numbers, both of which will reduce
transcription errors.
The advantage from a data processing standpoint of the proposed codes is
better illustrated by showing how the following Ford engine family might be
designated.
Ford's code l^.lWlV_i2.^1_9_5X__9_5)
Proposed code 1I.M5__L8.V2_G_A11
1) 9 indicates MY 1979 (Table 1 starts with MY 1980)
2) FM indicates Ford Motor Company (Table 2)
3) 5.8 indicates displacement in liters
4) V indicates light-duty vehicle (gasoline; Table 3)
5) 2 indicates a 2 barrel carburetor (Table 4)
6) G indicates three-way plus other catalyst(s) (Table 5)
7) A is hypothetically chosen
8) 1 is the CSD (see explanation on pages 67-68)
As mentioned earlier, the proposed code is a compromise between length
and content. Consequently, some of the new codes will be considerably
longer than the existing counterparts that contain no internal information
(e.g., Honda's "A" engine family). On the other hand, the Ford example
shows how the new code can be shorter than the existing counterpart at the
expense of some internal information (e.g., for Ford's case the information
-------
67
on catalyst size was dropped in the proposed code). It should be noted
that by indicating the manufacturer in the proposed code there will be no
need to use 2 parameters to identify data records (the second parameter
being manufacturer). Therefore, it should be easier for EPA to retrieve
information pertinent to all manufacturers.
Check-Sum Digit (CSD)
A check-sum digit is used in codes as a means of checking that the charac-
ters entered are correct. For example, in university courses, the regis-
tration code for Math 321 Section 4 might be 456-321-4-5 (Math). The
check-sum digit of 5 is simply the remainder obtained after the sum of all
the preceding digits is divided by some arbitrary number, in this case 10
(i.e., 4+5+6+3+2+1+4= 25, which when divided by 10 leaves a
remainder of 5.) Thus a transcription error such as 466-321-4-5 would be
flagged by an error-checking computer program.
Error checking with a CSD can be made more effective if different weights
are applied to each digit before they are added together. For example, the
value of the first digit can be multiplied by 9, the value of the second
digit by 8, and so forth. This method will catch transposition errors that
could be accepted by the previous method. In the example shown, if the
number were entered as 456-312-4-5 (the 1 and 2 being switched), the
computer would accept it since the sum is still equal to 25. The use of
different weights on each digit would help prevent this type of error. The
following discussion will better illustrate the weighting method proposed.
Method of Determining CSD
Step 1. Assign to each number in the ef code its actual mathematical
value and assign to each letter the value specified below:
A = 1 J = 1 T = 3
B = 2 K = 2 U = 4
C = 3 L = 3 V = 5
D = 4 M = 4 W = 6
E = 5 N = 5 X=7
F = 6 P = 7 Y = 8
G = 7 R = 9 Z = 9
H = 8 S = 2 decimal pt. = 1
Step 2. Multiply the assigned value for each character in the ef code by
the weight factor specified for it below:
Weight Factor
1st 10
2nd 9
3rd 8
4th 7
5th 6
6th 5
7th 4
8th 3
9th 2
10th 1
-------
68
Step 3. Add the resulting products and divide the total by 11. The
remainder is the CSD. If the remainder is 10, the CSD is X.
Example 1: Determine the CSD if the first 10 characters are 9CV5.0V4AR
(GM example).
9CV5.0V4AR
Assigned Value 9355105419
Weighted Value 10 987654321
Products 90 27 40 35 6 0 20 12 2 9
Sum of Products =241
Divide by 11 = 21 + 10/11
CSD = X
Therefore, ef code is 9CV5.0V4ARX.
Example 2; Determine the CSD for the Ford example 9FM5.8V2GA.
9FM5.8V2GA
Assigned Value 9645185271
Weighted Value 10 987654321
Products 90 54 32 35 6 40 20 6 14 1
Sum of Products = 298
Divide by 11 = 27 + 1/11
CSD = 1
Therefore, ef code is 9FM5.8V2GA1.
-------
69
TABLE 1. PROPOSED SUBCODES FOR MODEL YEAR
Code
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
V
W
X
Y
1
2
3
4
5
6
7
8
9
A
B
C
Year
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
-------
70
TABLE 2. PROPOSED SUBCODES FOR MANUFACTURERS
Code
Manufacturer
AR
AM
AS
AD
AV
BM
BR
BK
CA
CK
CV
CR
EX
FE
FT
FM
FJ
GC
HN
HY
HC
SZ
JA
JR
LT
MA
MB
MG
MT
NS
LD
PA
PE
PN
PR
RE
RC
RR
RV
SA
SH
SR
SB
TK
TY
TR
TV
VW
W
Alfa Romeo
American Motors
Aston Martin
Audi
Avanti
BMW
Bristol
Buick (CMC)
Cadillac
Checker
Chevrolet (CMC)
Chrysler
Excalibur Autos
Ferrari
Fiat
Ford
Fuji
CMC Division (CMC)
Honda
Hyundai
International Harvester Company
Isuzu
Jaguar
Jaguar Rover Triumph Ltd.
Lotus
Maserati
Mercedes
MG
Mitsubishi
Nissan
Oldsmobile (CMC)
Panther
Peugeot
Pontiac
Porsche
Renault
Replicar
Rolls Royce
Rover
Saab
Shetley
Satra
Steelbro
Toyo Kogyo
Toyota
Triumph
TVR
Volkswagen
Volvo
-------
TABLE 3. PROPOSED SUBCODES FOR VEHICLE CLASS
71
«•
Code
Vehicle Class
V
T
D
K
Light-Duty Vehicle (Gasoline)
Light-Duty Truck (Gasoline)
Light-Duty Diesel Vehicle
Light-Duty Diesel Truck
TABLE 4. PROPOSED SUBCODES FOR FUEL METERING SYSTEM
Code
Fuel Metering System
1
2
3
4
5
6
9
Multiple carburetors
(e.g., four two-barrel)
1 BBL
2 BBL
3 BBL
4 BBL
Electronic fuel injection
Mechanical fuel injection
Other
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72
TABLE 5. PROPOSED SUBCODES FOR CATALYST TYPES
Code Catalyst Type
A Single oxidation
N
B More than one oxidation
I
C Single reduction /
D More than one reduction
E Three-way; no feedback control of
fuel/air ratio
F Three-way with feedback control of
fuel/air ratio
G Three-way plus other catalyst(s); no
feedback control of fuel/air ratio
H Three-way plus other catalyst(s) and
feedback control of fuel/air ratio
J No catalyst
K Other "
f
it
U. S. GOVERNMENT PRINTING OFFICE: 1979-0-650-029/1
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