EPA/AA/CTAB/TA/84-4
Technical Report
Interim Report on Durability Testing
of Low Cost Catalysts for Methanol-Fueled Vehicles
By
Robert D. Wagner
Larry C. Landman
August, 1984
NOTICE
Technical Reports do not necessarily represent final EPA
decisions or positions. They are intended to present
tecnnical analysis of issues using data which are
currently available. The purpose in the release of such
reports is to facilitate tne excnange of technical
information and to inform the public of technical
developments whicn may form the basis for a final EPA
decision, position or regulatory action.
U. S. Environmental Protection Agency
Office of Air and Radiation
Office of Mobile Sources
Emission Control Technology Division
Control Technology and Application Brancn
2565 Plymouth Road
Ann Arbor, Michigan 48105
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Background
The use of puce methanol as an automotive fuel could allow
the use of less expensive exhaust catalysts. Two important
benefits are expected from the use of methanol compared to
unleaded gasoline. Those benefits are reduced levels of
catalyst poisons, such as lead and sulfur, and reduced exnaust
gas temperatures at the catalyst inlet. Therefore, both major
mechanisms of catalyst deactivation, poisoning and thermal
degradation, could be less of a problem with metnanol.
The purpose of this program is to evaluate the durability
of various low cost catalysts on a fleet of methanol-fueled
venicles. This durability program is being conducted in
cooperation with the California Energy Commission, Ford Motor
Company, and Toyota Motor Company. Durability catalysts were
tested at EPA for efficiency at zero miles on a methanol-fueled
Toyota (described in Appendix 1A) . The catalysts were then
shipped to California where they will be run for about 10,000
miles on methanol-fueled Escorts. After mileage is
accumulated, the catalysts will be returned to EPA for
additional efficiency testing on the Toyota. The initial low
mileage (i.e., zero-mile) data generated thus far in this
program are included in Appendix 2.
The selection of catalysts for this program is based on
tne results of an ongoing, in-house program to evaluate
catalysts at low mileage.[1J* The criteria for identifying low
cost catalysts for tnis program were that all candidate
catalysts should have provided the capability to meet the 0.41
HC and 3.4 CO levels with substantial margins of safety at low
mileage in that previous program. Additionally, three-way
catalysts should have provided emissions well below the 1.0 NOx
level.
Test Vehicle Description
Two types of test vehicles are being used in this
program. The first is a 1982 model year Toyota Cressida wnich
is being used at the EPA to generate exnaust emission (HC, CO,
NOx, and aldehyde) and catalyst efficiency data. The Cressida
was modified by Toyota to operate on metnanol fuel (using
gasoline for cold starts). This venicle is described in
Appendix 1A.
The second type of vehicle in this program is a group of
1983 model year Ford Escorts (both sedans and station wagons)
Mumoers in brackets are references listed at the end of
this report.
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which Ford has modified to operate on a mixture of 90 percent
methanol and 10 percent unleaded, winter-grade gasoline. The
Escorts (described in Appendixes IB and 1C) are part of a fleet
of methanol-fueled vehicles in operation in Los Angeles County
as part of tne California Energy Commission programs. These
Escorts are being used to accumulate about 10,000 miles on each
of eignt (8) catalysts which EPA shipped to California. These
vehicles are part of a fleet which is based at the Los Angeles
airport. The venicles are driven by state employees. The
fleet is operated by Thrifty Car Rental.
Descriptions of the Catalysts
Two types of catalysts have been selected thus far for
this program. Both catalysts have a loading of 20 grams of
noble mecai per cubic foot. The first contains platinum (Pt)
ana palladium (Pd) in a ratio of 3:2. The second is an all
palladium. Tney are denoted oy 3Pt:2Pd(20) and Pd(20),
respectively. The substrates are 400 cells per square inch
witn a wall thickness of 6 mils.
Both catalysts are monoliths. Each is composed of two
separate biscuits in a single container. Each biscuit has an
oval cross section measuring 3.15 by 4.75 inches. The front
biscuit is 2.98 inches long and the rear biscuit is 4.3 inches
long. This yields a total substrate volume of 92.8 cubic
inches (38.0 for the shorter oiscuit plus 54.8 for the longer
biscuit) . Biscuits of this size and shape were selected so
that they would be identical in both size and shape to those
used in tne Escort's standard catalysts. Thus, we could easily
substitute our catalysts for standard Escort catalysts. These
units, at 92.8 cubic inches, are thus 23 percent larger than
the corresponding 75.4 cubic inch units which were used in the
low-mileage evaluation program.[Ij
Four of each of those two catalysts were produced (i.e.,
canned). Three of tne four units of each catalyst were shipped
to California on January 6, 1984. The remaining unit of each
type stayed at EPA for zero-mile testing (Appendix 2) . Those
two units were each tested as three-way catalysts (by not
adding any air to the exhaust and running the engine at
stoichiometry) and subsequently as oxidizing catalysts (by
running the engine at stoichiometry and adding air to che
exhaust, just upstream of the catalyst). After completion of
the zero-mile testing, those two remaining units were also
shipped (April 26, 1984) to California.
Of tne four catalysts of each type which were shipped to
California for mileage accumulation, two were installed as
oxidation catalysts and two as tnree-way catalysts. For each
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Escort using the catalysts as oxidizing catalysts, the
downstream air tube was flush mounted with the exnaust pipe to
put air (from the air pump) into the exhaust at least six
inches upstream of the catalyst. For each Escort using the
catalysts as three-way catalysts, the belt to the air pump was
removed, and the downstream air tube was capped. A listing of
those eight catalysts appears in Table 1.
Thus, durability mileage is currently being accumulated on:
Two 3Pt:2Pd(20) catalysts being run as oxidizing
catalysts;
two 3Pt:2Pd(20) catalysts being run as three-way
catalysts;
two Pa(20) catalysts being run as oxidizing
catalysts; and
two Pd(20) catalysts being run as three-way
catalysts.
As more catalysts complete the low-mileage evaluation program,
additional catalysts may be selected for durability evaluation
in this program.[i]
Table 1
Listing of Durability Catalysts
Designation
3Pt:2Pd(20)
Serial Number
Zero-Mile
Test at
EPA
9K-8583 EP4-2650
9K-8580 EP4-2649
9K-8584 EP4-2651
9K-8579 EP4-2648
Pa(20)
NPN,
NPN,
NPN,
NPN,
8-17
3-12
6-15
6-17
No
NO
NO
Yes
No
NO
NO
Yes
Mileage
Accumulation AS
Three-Way Catalyst
Oxidizing Catalyst
Oxidizing Catalyst
Three-way Catalyst
Three-way Catalyst
Oxidizing Catalyst
Oxidizing Catalyst
Three-way Catalyst
Test Sequence, Instrumentation, and Fuel
The initial plan included testing of the Toyota in the
no-catalyst configuration over the following sequence:
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1975 Federal Test Procedure (FTP)
Highway Test Procedure (HWY)
Idle
10 mph steady state
20 mph steady state
30 mpn steady state
With the catalysts installed, the vehicle was operated over
only the FTP and HWY.
The sequence was performed three times for each catalyst
at each of two exhaust oxygen levels. The higher of the two
exhaust oxygen levels was measured at the catalyst inlet using
a Sun oxygen analyzer and was obtained at 30 miles per hour
steady state. The two oxygen levels were stoichiometry (or
near 0 percent) and about 6 percent. The air pump was
installed (March 9, 1984) in order to provide the 6 percent
oxygen level. By testing at different exhaust oxygen levels,
we could, therefore, evaluate eacn catalyst as a three-way
catalyst and also as an oxidation catalyst.
As the project proceeded, the idle test point was
deleted. HC, CO, NOx, MPG, methane, and aldehydes were
initially measured over each test in the sequence. Measurement
for aldehydes was deleted during steady states in the more
recent testing.
Exnaust HC emissions, as reported here, were measured with
a flame ionization detector (FID) from Beckman (model 400). No
corrections in tne results were made for either the FID
response to methanol or the difference in tne exhaust HC
composition (i.e., the hydrogen to carbon ratio) with methanol
(instead of gasoline) as the fuel. NOx emissions were measured
with a cnemiluminescent NO/NOx analyzer from Beckman (Model No.
951A) . CO was measured with infrared analyzers from MSA and
Bendix. Methane was measured with a gas chromatograpn (Bendix
8205 methane analyzer). Aldehydes were measured by high
pressure liquid chromatography (HPLC) and are reported as
formaldehyde. (See Appendix 2 of Reference 1 for more details
on how formaldehyde is measured.) The emissions (in
grams/mile) of HC, CO, and CC>2 were used to calculate fuel
economy (in miles/gallon) using the following formula:
1124
Fuel Economy
0.866(HC) + 0.429(CO) -I- 0.273(C02)
The primary test fuel which has been used in this program
is pure metnanol. Five batches of methanol have been consumed,
and one has been analyzed. The fuel analysis is presented in
Appendix 5. The gasoline used in the cold-start system of the
Toyota is Indolene Clear (unleaded) and meets the EPA
specifications for that fuel (40 CFR 86.307-82).
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Summary of the Test Results
Tables 2 and 3 present average zero-mile FTP and highway
(HWY) emissions, respectively. (These averages appear in more
detail in Appendix 4.) In light of the substantial shift in
emissions which followed the replacement of the fuel injectors
(March 9, 1984) , these averages are based only on those tests
following the change of injectors. The average FTP HC, CO, and
NOx emissions are satisfactory. HC and sometimes CO are higher
than the target levels of our earlier screening tests. This is
the result of two things: 1) engine-out HC and CO emissions
from the Toyota are very low, and 2) the catalyst volumes are
appropriate for Escorts with 1.6-liter engines and have been
tested on the Toyota with a much larger engine. Over every
driving cycle, at both oxygen levels, and both with and without
a catalyst, there is virtually no methane in the exhaust
(Appendixes 2 or 4) .
Emissions of alaehydes, HC, CO, and NOx for each catalyst
are shown as functions of exhaust oxygen level in Figures 1
through 4, respectively. CO, NOx, and aldehydes are all
affected by oxygen level. CO decreased and both NOx and
alaehydes increased as the oxygen level increased.
When the aged catalysts are returned to EPA, they will be
tested again using the Toyota vehicle. Tne purpose of this
second series of tests will be to determine the efficiency loss
due to mileage accumulation.
Zero-mile (i.e., baseline) catalyst efficiencies were
calculated for each catalyst at each oxygen level using the
average emission data from Appendix 4. Tne results of these
calculations are presented in Tables 4 and 5 for the FTP and
HWY driving cycles, respectively. Zero-mile catalyst
efficiencies were also calculated for each "Bag" of the FTP and
are presented in Taole 6. "Catalyst efficiency," as used here,
is defined as the average tailpipe emissions with no catalyst
minus the average tailpipe emissions with a catalyst, that
difference divided by the average tailpipe emissions with no
catalyst and then multiplied by 100 percent.
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Table 2
Summary of Average Zero-Mile FTP Emissions
at Different Oxygen Levels
Catalyst
None
3Pt:2Pd(20)
Pd(20)
Catalyst
None
3Pt:2Pd(20)
Pd(20)
HC (g/mi)
--Oxygen-
0% 6+%
.99
.24 .27
.29 .28
Summary of
at
HC (g/mi)
--Oxygen-
0% 6+%
.42
.01 .01
.01 .01
Aldy (rag/mi)
Oxygen--
0% 6+%
283.6
37.3 264.6
41.0 236.5
Table 3
Average Zero-Mile
Different Oxygen
Aldy (mg/rai)
Oxygen
0% 6+%
167.2
5.4 40.4
7.3 31.9
CO (g/mi)
- -Oxygen -
0% 6%
8.85
2.80
1.97
—
0.34
0.72
NOx (g/mi)
--Oxygen-
0% 6%
2.08
0.51 1.35
0.32 1.32
HWY Emissions
Levels
CO (g/mi)
— Oxygen-
0% 6%
6.33
0.74
0.74
0.00
0.02
NOx (g/mi)
— Oxygen —
0% 6%
1.88
0.26 1.06
0.06 1.06
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Table 4
Zero-Nile Catalyst Efficiency (percent) over FTP
at Different Oxygen Levels*
HC Effic. Aldy Effic.
Run As
3WY
3Pt:2Pd(20) 76
Pd(20)
71
Zero-Mile
: Run As:
QC 3WY QC
73 87 7
72 86 17
Table 5
Catalyst Efficiency
at Different Oxygen
HC Effic. Aidy Effic.
3Pt:2Pd
Pd(20)
Run As
3WY
(20) 98
98
Zero-Mile
by
: Run As:
PC 3WY QC
97 97 76
97 96 81
Table 6
Catalyst Efficiency
CO Effic.
Run
3WY
68
78
As:
PC
96
92
NOx Effic.
Run
3WY
75
85
As:
OC
^^H^^BH
35
36
(percent) over HWY
Levels*
CO Effic.
Run
3WY
88
88
As:
PC
99+
99+
NOx
Effic
Run As:
3WY
86
97
OC
44
43
(percent) over FTP
Bag at Different Oxygen Levels*
HC Effic. Aldy Effic.
3Pt:2Pd
Bag
Bag
Bag
Pd(20)
Bag
Bag
Bag
Run As
3WY
(20)
1 49
2 97
3 88
1 38
2 97
3 84
: Run As:
PC 3WY PC
48 67 8
94 96 5
78 90 8
44 65 1
97 96 39
81 85 -24
CO Effic.
Run
3WY
54
73
74
54
90
78
As:
PC
87
100
98
77
99
93
NOx
Run
3WY
65
82
77
72
92
87
Effic
As:
OC
> •^H^MH
19
50
31
18
53
34
'3WY' denotes a three-way catalyst (0 percent oxygen
level), and 'OC' denotes an oxidizing catalyst (6+ percent
oxygen level).
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FIGURE 1. Comparison of FTP Aldehyde Emissions
by Oxygen Level for Each Catalyst
400
9
6
300-
$
u 1 U> ; 1 ; Q
200-
C
a
u
oa
.^4
100-1
I &
Ho C^Pd Op\,2?
Catalyst
FIGURE 2. Comparison of FTP HC Emissions
by Oxygen Level for Each Catalyst
1.2-
H-
£ 0.8-
£
u
V
a o.e-
n
e
2
O 0.4-
?'
I . T :
• •> r >•
6%' ?dO%'
Catalyst
-------
-10-
FIGURE 3. Comparison of FTP CO Emissions
by Oxygen Level for Each Catalyst
13
o
11-
10-f - < • <••
9-
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References
1. "Low Mileage Catalyst Evaluation with a
Methanol-Pueled Raobit Second Interim Report," R. Wagner and L.
Landraan, EPA Report No. EPA/AA/CTAB/TA/84-3, May 1984.
-------
-12-
APPENDIX 1
Test Vehicle Description
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Appendix 1A
Emission Test Vehicle Description
1982 Toyota Cressida (methanol-fueled)
Venicle Identification Number: MX62-083780
Engine;
Type 4 Stroke Otto cycle,
In-Line 6
Bore x Stroke 83.0 x 85.0 nun
Displacement 2759 cc (168 CID)
Compression Ratio 10.0:1
Fuel Metering Two separate fuel
injection systems.
(The main fuel
injection system uses
pure methanol; a
separate cold-start
fuel injection system
uses pure gasoline.)
Drive Train;
Transmission Type 4-speed automatic with
overdrive
Axle Ratio 3.73
Cnassis;
Type 4-Door Sedan
Tires Dunlop 185/70SR14 steel
belted radials
Curb Weight 2,855 pounds
Test Weight (ETW) 3,000 pounds
Actual Dynamometer Horsepower .... 10.3
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Appendix IB
Mileage Accumulation Vehicle Description
1983 Ford Escorts (methanol-fueled)
Engine;
Type 4-stroke Otto cycle,
In-Line 4
bore x Stroke 80.0 x 79.5 mm
Displacement 1.6 liters (98 CID)
Compression Ratio 11.8:1
Fuel Metering 2-barrel carburetor
urive Train;
Transmission Type 3-speed automatic
transaxle
Chassis;
Type 4-door station wagon
or 4-aoor sedan
Vehicle Identification Numbers*. . . . 1FABP1373DW237349
1FABP137XDW237350
1FABP1376DW237359
1FABP137XDW237378
1FABP1379DW237386
1FABP1379DW237405
The iaentification numbers, of tne two vehicles which were
equipped in April 1984 with the catalysts, are not yet
available.
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Appendix 1C
Modifications Made to the 1983 Model Year Gasoline-
Fueled Escorts to Convert Them to Methanol-Fueled
Fuel System
Fuel Tank:
Same design as gasoline-fueled Escort, but it is made of
stainless steel for corrosion protection.
Fuel Tank Sending Unit:
Same design as standard unit, but it is nickel plated to
prevent corrosion and has a nickel plated brass float.
Fuel Tank Straps:
Same design as standard model, but the straps are coated
with nylon to prevent dissimilar metal corrosion with the
stainless steel methanol fuel tank.
Fuel Lines:
Same routing as standard Escort, but the lines are
fabricated from stainless steel to prevent corrosion.
Fuel Pump:
Same design as standard unit, but all metallic parts have
been made corrosion resistant through nickel plating, and
all plastic and rubber parts are made from a material
which will withstand methanol.
Carburetor:
The carburetor is base 740 model modified and recalibrated
to meet the higher fuel-flow requirements of the methanol
engine. All parts have been nickel plated or manufactured
from a material which is compatible with fuel methanol.
For example, idle adjusting needles and throttle shafts
are made of stainless steel. The float unit is an acetal
hollow design and replaces the standard unit.
Carburetor Spacer:
A rectangular spacer plate is installed oetween the
carburetor base and intake manifold. This plate uses a
round electrical beating unit which replaces the square
heating unit used on the gasoline-fueled engine.
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Appendix 1C (cont'd)
Modifications Maae to the 1983 Model Year Gasoline-
Fueled Escorts to Convert Them to Methanol-Fueled
Engine
Basic Engine:
Tne engine that powers the methanol vehicle is the same
basic design as the Escort's gasoline-fueled 1.6L
high-output (HO) engine.
The compression ratio has been increased from 8.8:1 to
11.8:1. This was accomplished by installing the piston
from a European 1.3L Ford engine in the 1.6L block. Each
piston has been fitted with a special top compression ring
whicn is oarrel faced and hard chromed steel. Piston
rings two and three are standard.
A iy84 head gasket that will withstand higher compression
pressures is used to replace the standard gasoline head
gasket. This nead gasKet uses a stainless steel fire ring
and special bacKing material.
The base 1.6L camshaft (pink color code) is used in place
of the HO camshaft (yellow color code).
Engine Oil:
A unique engine oil containing a special additive must be
used witn methanol-fueled engines. The recommended oil is
marked for methanol engines only.
Ignition
Distributor:
The distributor is a modified, solid-state unit. Its
operation is the same as the standard unit; the advance
curves nave been modified. The major difference is less
mechanical advance.
Spark Plugs:
Tne spark plugs used in tne methanol-fueled engine are two
heat ranges colder than the spark plugs in the gasoline
powered 1.6L engine. This is necessary to prevent engine
damage due to preignition.
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APPENDIX 2
Initial, Low Mileage Data from the Catalyst
Durability Evaluation Program
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APP«ndlx 2A
Eatsslons (bv Baa) during the FTP
Test
Nunber
842014
842020
842026
842032
842037
842042
842283
842288
842293
842295
02 TMt DOOM
% CAT* Date Jkm)
OT*«V ^»^— — WM^fa^H^^V* ^B^B^— ^^^
TOYOTA CATALYST:
0.0 STOCK 1-19-84 872.0:
Bag 1:
Bag 2:
Bag 3:
Weighted:
0.0 STOCK 1-20-84 959.3:
Bag 1 :
Bag 2:
Bag 3:
weighted:
0.0 STOCK 1-24-84 1044. O:
Bag 1 :
Bag 2:
Baa 3:
weighted:
STRAIGHT PIPE, NO CATALYST
0.0 NONE 1-31-84 1130.7:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 NONE 2-01-84 1220.3:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 NONE 2-02-84 1305.8:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
STRAIGHT PIPE, NO CATALYST
0.0 NONE 2-22-84 1632.6:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 NONE 2-23-84 1717.0:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
3Pt:2Pd(20) CATALYST:
0.0 (iM) 2-24-84 1799.2:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 (*1) 2-25-84 1860.9:
Bag 1 :
Bag 2:
Bag 3:
Alde-
hyde Ml In /
(mq/mt) Gallon
42.67
5.08
o.oo .
11.51
43.95
6.46
1 .42
12.86
50.89
5.45
1 .89
13.87
364. 14
266.94
156.26
256. 16
385.22
263.49
157.37
259.28
375.00
298.47
177.63
281 .30
(AFTER
238.70
237.07
146. 19
212.62
315.71
239.49
151 .42
230.92
91 .66
8.25
6.25
24.78
88.72
12.67
8.56
10.
1 1 ,
12.
1 1 .
10.
1 1 ,
12,
1 1 .
10.
1 1 .
12
1 1 .
10.
1 1
12
1 1
9
1 1
12
1 1 .
10
1 1
12
1 1
0
3
5
2786
.3
2
. 7
.3806
.0
.9
9
,6617
.2
.6
.6
.5303
.8
6
.8
,4941
.2
.6
._B
.5534
RETURN
10
12
13
1 1
10
12
13
1 1
10
12
13
12
10
1 1
12
.4
. 1
.2
.9362
.3
. 1
J2
.951 1
.4
.3
.3
.0699
.0
.7
.6
HC
(g/reO
.501
.010
.004
0. 1 105
.458
.006
. 002
0.0984
.556
.013
.003
0. 1219
2.099
1 . 122
.864
1 .2519
3.220
1.316
.865
1 .5837
2.408
1 .421
.951
1 .4964
DP* vlr>«
CO
(g/ml)
2.788
.814
.286
1.0790
2.496
.646
•272
0.9272
3. 151
.628
.287
1 .0558
19. 107
25.581
18.702
22.3398
22.947
28. 108
20.395
24.9270
21 .254
28.792
21 .360
25.2086
Cycle
C02
(o/mD
407.
363.
742
,04O
328 . 335
362,
393
366
324,
360
406
345
317
350
368
31O
293
317
372
306
285
314
364
305
284
312
,78
294
.137
.241
.25
.415
880
.885
.74
.763
.085
.568
.59
.883
.440
.921
.47
.471
.868
.713
. 19
NOx
(a/ml)
.165
-.003
.021
0.0388
. 156
.OOO
•°37
0.0426
. 173
.003
.029
0.0452
2.741
1.248
2.000
1.7638
2.701
1 .218
1.954
1.7253
2.738
1.257
1.806
1 .7124
Non-Metn-
an* HC METHANE
(a/ml) (a/ml)
.493
.008
002
0. 1076
.452
.004
•001
0.0967
.550
.011
.002
0 . 1 202
2.O88
1.117
.860
1.2462
3.208
1 .310
.861
1.5775
2.398
1.414
.946
1 .4896
.007
.002
•QQ1
0 . OO290
.005
.001
•001
0.00172
.006
.001
.OQ1
O.OO170
.010
.005
.OO4
O.OO567
.012
.005
.004
O.OO618
.010
.007
.005
O.OO680
FROM TOYOTA):
2. 174
1 . 134
.821
1.2629
2. 1 16
1.272
.881
1 .3383
.715
.022
.017
0. 1621
.694
.012
.015
19.285
24.644
17.482
21.5905
21 .386
26.780
19.635
23.7052
4.507
1 .794
1 .581
2.2912
4.973
1 .825
2.096
358
299
282
306
359
294
277
303
385
333
306
336
399
350
323
.399
.080
.521
.78
. 115
.270
.875
. 1 1
. 169
. 151
.816
.65
.732
.030
.555
2.835
1 . 150
1 .892
1 .6994
2.685
1 . 106
1 -783
1.6.174
.624
.099
.319
0.2661
.661
. 103
.306
2. 173
1 . 131
.820
1.2612
2.113
1 .268
.879
1.3355
.705
.018
.015
0. 1581
.688
.009
.011
.001
.002
.001
0.00174
.003
.003
.002
O.OO282
.010
.003
,001
O.OO403
.006
.003
.003
Weighted: 27.23 11.5169 0.1531 2.5464 353.03 0.2733 0.1497 O.OO340
-------
-19-
APoendlx 2A (Cont.)
Emissions (bv Baa) during the FTP
Test 02 Teet DOOM
Number Jt CAT* _8aJe (kmL
842297 0
842299 0
842301 0
842303 0
842305 0.
842307 0.
842309 0.
842331 0.
Based on
prior to
842336 0.
.0 (*D 2-26-84 1923.7:
Bag 1:
Bag 2:
Bag 3:
Weighted:
Pd(20) CATALYST:
.0 (*2) 2-27-84 1985.5:
Bag 1 :
Bag 2:
Bag 3:
weighted:
.0 (*2) 2-28-84 2052.2:
Bag 1 :
Bag 2:
Bap 3:
Weighted:
.0 (#2) 2-29-84 2113.1:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
,O U2) 3-01-84 2173.9:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0 (#2) 3-02-84 2252.8:
Bag 1 :
Bag 2:
Bag 3:
weighted:
STRAIGHT PIPE. NO CATALYST
0 NONE 3-04-84 2330.9:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0 NONE 3-O5-84 2414.5:
Bag 1 :
Bag 2:
Baa 3:
weighted:
the change in emissions fol
March 10. 1984, may not be
STRAIGHT PIPE. NO CATALYST
0 NONE 3-14-84 2629. 1 :
Bag 1 :
Bag 2:
Baa 3:
Weighted:
Alde-
hyde Miles / HC
(ma/ml) Gallon (a/mi)
88.24
8.58
6.99
24.50
88.99
11 .20
6.82
26.23
99.28
6.46
6.26
25.61
91.53
7.06
6.97
24.43
105. 17
10. 11
8-70
29.32
75.09
6.82
2.21
19.61
:
343.23
342.26
211 .77
306 . 79
290.00
358.49
197.41
300.22
lowing
10.
11 ,
12,
1 1 ,
9
1 1 ,
12
1 1 .
10
12,
13,
1 1 ,
10
1 1 ,
12,
1 1
10,
12
13.
1 1 ,
10,
12,
13,
1 1 ,
10
1 1 ,
13,
1 1 ,
10
1 1
13,
1 1
the
,4
8
.5742 0.
.7
.5
.9
.4268 0.
.4
. 1
.3
.9869 0.
.4
.7
J :
.6842 0.
.4
. 1
L2. :
.9883 0.
.2
. 1
. 1
.9O61 0.
.3 2.
.8 2.
.0 1 .
.7326 1.
.3 2.
.7 2.
^ Ii
.7195 2.
621
017
015
141 1
645
011
014
1424
788
008
010
1694
745
020
015
1680
734
017
013
1637
728
008
015
1583
403
223
225
9871
577
545
252
1965
replacement
representative of
(NEW
504 . 26
392.94
220.73
369. 11
INJECTORS .
10.
12
13,
12,
.5 1 .
.4
. 1692 0.
the
AIR
944
735
626
9550
Driving
CO
(a/ml)
4.366
2. 176
2.522
2.7212
3.462
1 .304
1 . 586
1.8250
4. 134
1 .571
.734
1 .8717
4.210
2.924
2-539
3.0836
4.386
5.482
2-353
4.4004
5.462
1 .706
2.655
2.739O
23.294
31.238
22. 163
27. 1212
23.839
33.015
22.428
28.2208
of the
vehicle'
Cycle
C02
(a/mn
388.521
344.657
334 . 46 1
350.90
415.203
355.695
316.683
357.29
386.956
338.062
309 . 52 1
340.35
387.318
346.670
316.306
346.72
385.075
331 .734
307.428
336.08
393.226
336.805
311 .222
341 .42
356.766
292.406
278.547
301 .86
353.813
290. 70O
278. 348
30O.30
NOx
ja/ml)
0,
0
0
0
0
0
2
1
1
1
2
1
1
1
injectors,
.558
095
341
.2575
.305
OO6
.070
.0852
.268
.003
. 109
.0869
.315
.012
. 101
.0991
.342
.009
. 107
. 1044
.282
.012
. 103
. O925
.375
.090
.620
.4996
.440
. 138
.761
.5772
the
ane HC
(a/ml)
.616
.013
• 012
0. 1375
N/A
N/A
N/A
N/A
.781
.004
.007
0. 1659
.737
.015
•O11
0. 1632
.728
.012
.010
0 . 1 594
.720
.005
. 01 1
0. 1546
2.395
2.212
1 .222
1 .9796
N/A
N/A
N/A
N/A
METHANE
(a/mi)
.005
.004
• 002
0.00359
N/A
N/A
N/A
N/A
.006
.003
.002
0.00354
.008
.005
•903
O.OO484
.005
.004
•093
0.00429
.007
.002
.004
0.00370
.007
.010
.OO2
0.00754
N/A
N/A
N/A
N/A
data generated
s performance from then
on.
PUMP INSTALLED):
1 1 . 548
8.803
7.804
9 . 0980
368.820
315.355
295.764
32 1 . 06
3
1
2
2
. 155
.615
.411
. 1493
1 .939
.732
.624
0.9522
.005
.002
.002
0.00277
-------
-20-
Aoo«nd1x 2A (Cont.)
T«St
Hunt*r
842691
842696
842701
842703
8430OO
8430O2
843004
8430O6
Emissions
02 TMt DOOM
% CAT* Data (km)
0.0 NONE 3-15-84 2711.4:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 NONE 3-16-84 2793.7:
Bag 1 :
Bag 2:
Bag 3 :
Weighted:
Pd(20) CATALYST:
0.0 (*2) 3-17-84 2873.8:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 (*2) 3-18-84 2934.9:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 (#2) 3-19-84 2996. 1 :
Bag 1 :
Bag 2:
Bag 3:
Weighted:
6.4 (#2) 3-20-84 3061.9:
Bag 1 ;
Bag 2:
Bag 3:
Weighted:
6.4 (#2) 3-21-84 3123.3:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
6.4 (,*2) 3-22-84 3184.4:
Bag 1 :
Bag 2:
Bag 3:
Weighted:
(bv Baa) durtna the FTP
Alda-
hyd* M11M / HC
(ma/m\) gallon (q/»
-------
-21-
Apeandlx 2A (Cent.)
TMt
Muntear
843018
843156
843161
843163
843165
843167
843169
843171
Testing
843173
Citissions
02 TMt ODOM
% CAT* Data (KJB)
0.0 NONE 4-11-84 3538.4
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 NONE 4-12-84 3618.3
Bag 1 :
Bag 2:
Baa 3:
weighted:
3Pt:2Pd(20) CATALYST:
0.0 (/M) 4-13-84 3701 .3
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 (*D 4-17-84 3762.7
Bag 1 :
Bag 2:
Bag 3:
Weighted:
0.0 (*D 4-18-84 3823.6
Bag 1 :
Bag 2:
Bag 3:
Weighted:
6.2 (*1) 4-19-84 3890.6
Bag 1 :
Bag 2:
Bag 3;
Weighted:
6.2 (
-------
-22-
TMt 02
CAT*
843178 0.0 NONE
843183 0.0 NONE
tail s« tons
T««t
Data
4-26-84
DOOM
(to)
4160.0:
Bag 1 :
Bag 2:
Bag 3:
W«1gnt*d:
4-27-84
4245.4:
Bag 1 :
Bag 2:
Bao 3:
WBlgnted:
AoMndlx 2A
(by Baa) durlna
A1d«-
hyd*
Lmg/reO
363.90
263.20
2 1 1 . 94
269.83
355.25
288.49
200.46
278. 15
Mi
S£.
10
12
13
12
10.
12.
13.
12.
Us /
lion
.6
.7
.J
.3968
6
7
_6
4051
(Cont.
th« FTP
HC
(g/rel)
2.053
.790
.716
1 .0292
2. 110
.810
.746
1 .0612
)
Driving Cvc1«
CO C02
(g/mn (a/ni)
10. 109
7.807
7.426
8.1757
10.402
8.436
7.580
8 . 607 1
365.832
309.087
290. O78
315.54
364.791
309.532
287.629
314.93
NOx
Ca/inn
3
1
2
2
3
1 ,
2^
2.
.060
. 49O
.270
.0261
.100
,473
L367
0546
Non-M«th-
•n« HC METHANE
(a/mn (.a/mi)
2.038
.783
1 .0214
2.094
.803
1.0530
.014
.006
/V\£
•°°° —
0.00775
.016
.006
•006
0.00817
-------
-23-
Appandtx M
Emissions during tha HWY DMvlna Cyela
TMt
02 Tact DOOM nyde Miles / HC
% CAT* Data (KB) (ing/ml) Gallon (g/nH)
CO
C02
XftU
Non-Math-
NOx ana HC METHANE
(a/ml) (a/mn (a/mO
TOYOTA CATALYST:
842015 0.0 STOCK 1-19-84 892.5 1.44
842021 0.0 STOCK 1-20-84 992.8 1.97
842027 0.0 STOCK 1-24-84 1077.9 2.61
15.0852 0.0044
15.0284 0.0037
15. 1913 0.0039
1 .2184 271.27
1 .2398 272.24
1.2759 269. 18
STRAIGHT PIPE. NO CATALYST:
842033 0.0 NONE 1-31-84 1164.6 170.71 15.1574 0.4770 16.6208 244.50
842038 0.0 NONE 2-01-84 1254.0 153.35 15.1448 0.4821 17.3859 243.44
842282 0.0 NONE 2-02-84 1339.8 N/A 15.2675 0.50O8 17.8730 240.33
STRAIGHT PIPE. NO CATALYST (AFTER RETURN FROM TOYOTA):
842284 0.0 NONE 2-22-84 1650.0 222.21 15.2960 0.4699 16.3412 241.54
842289 0.0 NONE 2-23-84 1750.5 183.28 15.3904 0.4990 17.1448 239.44
O.OO43 0.0034 O.OO098
O.OO31 O.OO31 O.OOO61
O.OO32 O.OO16 O.OO227
1.5857 0.4741 O.OO288
1.4956 0.4783 O.OO383
1.4491 0.4976 0.00324
1.4347 0.4687 0.00119
1.4196 0.4975 O.OO154
3Pt:2Pd(20):
842294
842296
842298
842300
842302
842304
842306
842308
842310
842332
0.0 (#1)
0.0 (#1)
0.0 (#1)
Pd(20):
0.0 (*2)
0.0 (/C2)
0.0 (*2)
0.0 (#2)
0.0 (*2)
STRAIGHT
0.0 NONE
0.0 NONE
2-24-84
2-25-84
2-26-84
2-27-84
2-28-84
2-29-84
3-01-84
3-02-84
PIPE, NO
3-04-84
3-05-84
1833.5
1895. 1
1956.7
2023.8
2085 . 5
2146.6
2207.8
2302.3
CATALYST
2364.4
2448. 1
4.92
4.86
5.25
5.28
3.80
4.00
4.27
4.36
218.21
217.85
15
15
15
14
15
15
15
15
15
15.
.6318
. 1883
.4812
.2389
.5006
.5833
.5045
.3437
.3732
. 1763
O.OO62
O.OO62
O.OO50
0.0084
0.0126
0.0135
0.0124
0.0113
0.5847
0.6472
0,
1 .
1 ,
1 ,
4
5,
4
5
18
19,
,8689
.3052
,2346
.9874
8205
,8254
,781 1
.2828
.4316
.8818
261.76
268.61
263.93
285.97
258 . 30
255. 12
258.41
260.02
237.21
237.50
0.0757
0.0585
0 . 0508
0.0103
0.0280
0.0410
0.0465
0.0395
1 .3226
1 .3163
0.0059
N/A
O.OO42
O.OO84
0.0097
0.0104
0.0104
0.0090
0.5827
N/A
0.00025
N/A
0.00075
O.OO002
0.00294
O.O0311
O.OO198
O.OO228
0.00197
N/A
Based on the change in emissions following the replacement of the injectors, the data generated
prior to March 10, 1984, may not be representative of the vehicle's performance from then on.
842337 0
842692 0
842697 0
842702 0
842704 0.
843O01 0
843003 6.
843005 6
843007 6,
843009 0,
843014 0.
843019 0.
843157 0,
843162 0,
843164 0,
843166 0.
843168 6,
843170 6.
843172 6.
843174 0.
843179 0.
843184 0,
.0 NONE
.0 NONE
.0 NONE
Pd(20):
.0 (#2)
,0 (*2)
.0 (*2)
.4 (*2)
,4 (#2)
,4 (*2)
STRAIGHT
.0 NONE
STRAIGHT
0 NONE
.0 NONE
.0 NONE
3-14-84
3-15-84
3-16-84
3-17-84
3-18-84
3-19-84
3-20-84
3-21-84
3-22-84
PIPE. NO
3-23-84
PIPE, NO
4-10-84
4-1 1-84
4-12-84
3Pt:2Pd(20):
.0 (#1) 4-13-84
,0 (#1-) 4-17-84
,0 (*D 4-18-84
,2 (#1)
2 (/M)
2 (#1)
STRAIGHT
,0 NONE
0 NONE
0 NONE
4-19-84
4-20-84
4-24-84
PIPE, NO
4-25-84
4-26-84
4-27-84
2662.9 214
2744.0 182
2826.9 162
2907 .3 11
2968.3 5
3029 . 7 4
3095.5 27
3156.8 30
3221.5 37
CATALYST :
3283.6 188
.21
.31
.73
.44
.72
.79
.74
.09
.80
.97
CATALYST (NEW
3495.0 196.87
3558.0 112.38
3651.9 111.24
3734.9 6
3795.9 5
3856.7 4
3923.8 37
3984.5 42
4045.7 41
CATALYST :
4112.0 210
4193.8 132
42~?.6 159
.61
.47
. 16
. 10
.95
.22
.56
.86
.91
15.6993
15.8065
16.0496
15.8821
15.88OO
15.8314
15.9542
15.8312
15.7102
15.9044
0.3871
0.3812
0.3780
0.0134
O.OO88
O.OO89
0.0152
0.0118
0.0130
0.4247
INJECTORS):
15.5619 0.4494
15.5388 0.4340
15.7147 0.4071
15.8854
15.9463
16.0087
15.8331
15.7722
15.7121
16.0719
16.0516
16. 1802
0.0106
0.0092
0.0069
0.0122
0.0126
0.0129
0.4384
0.4458
0.4285
6.3752
7. 1679
7.2062
0.7602
0.7919
0.6552
0.0080
0.0217
0.0245
7.9711
5.8188
6 . 096 1
5.5353
0.7278
0.7391
0. 7444
0.0047
O.OOOO
0.0000
5.5883
5 . 7804
5.7876
251.03
247.65
243.87
258. 13
257.69
258.81
258.49
259.86
262.38
244.99
254.48
253.96
251.70
258.41
256.67
256. 18
260. 14
261 .01
261 .60
245.75
246.43
243.67
1 .9304
1 .8580
1 .7970
0.0602
0.0619
0.0382
1 .0547
1.0782
1 .0594
1 .7416
1 . 9205
1 .9513
1.9298
0.2503
0.2774
0.2550
1 . 0095
1 . 05 1 7
1 . 1078
1 .8966
1 .8798
1 .8785
0.3856
N/A
0.3775
0.0123
0.0087
0.0084
0.0143
0.0113
0.0129
N/A
0.4447
0.4294
0.4024
0.0070
0.0059
0.0035
0.0079
0.0080
0.0082
0.4338
0.4412
0.4245
O.OO153
N/A
O.OO054
0.00106
O.OO013
0.00048
O.OO090
O.OO041
0.00006
N/A
0.00471
0.00464
0.00469
0.00361
0.00325
0.00336
0.00432
0.00456
0.00469
0.00465
0.00463
0 . 00402
Testing completed. Both catalysts were shipped to Calif for mileage accumulation (April 26. 1984)
-------
-24-
Appendtx 2C
Test 02 Test
Number % CAT* Date
TOYOTA CATALYST:
842016 0.0 STOCK 1-19-84
842022 0.0 STOCK 1-20-84
842028 0.0 STOCK 1-24-84
Emissions during Idle
A 1 04A
DOOM hyde Wins / HC CO C02 NOx "Sne^HC** MFTMAMB
_ikml_ (mg/mln) a.non (g/mln) Ca/mln) (q/m1n) (g/mln) (a/mln) "g^T
895.2
1008.4
1094.0
0.566 94.0 0.0015 0.0135 43.9187 O.OOO8 0 0008 0 OOO7
0.149 91.0 0.0003 0.0457 44.9817 O.OOOO 00002 o'ooo
0.00 102.0 0.0007 0.0054 40.3118 O.OOOO 0 OOO6 o'oOOl
-------
-25-
Appendix 2D
Emissions during Steady State Driving at 10 MPH
Ald*-
Non-M*th-
TMt 02
NUHO«r X CAT*
TOYOTA
842017 0.0 STOCK
842023 0.0 STOCK
842029 0.0 STOCK
842034 0.
842039 0.
Test
Oat*
CATALYST:
1-19-84
1-20-84
1-24-84
STRAIGHT PIPE, NO
0 NONE 1-31-84
0 NONE 2-01-84
ODOM
(Km)
898.4
1008.5
1094.0
CATALYST
1181 .0
1270.6
hyd*
(ma/rat)
2.54
1.85
2.26
584.58
557.85
Mll«s / HC CO C02
Gallon (a/ml) Igyml) (o/»n
7.8 0.006 0.897 524.012
7.9 0.010 2.239 518.317
13.0 0.005 0.111 317.197
8.7
8.9
3.585
6.569
52.889
53 . 996
379. OOO
358.515
NOx
(a/ml)
0.005
O.OOO
O.OOS
0.668
0.634
•n* HC
(a/»n
0.0030
0.0092
0.0042
3.5698
6 . 5480
METHAI
. W"
0.003
0.001
O.001
0.019
0.020
STRAIGHT PIPE, NO CATALYST (AFTER RETURN FROM TOYOTA):
842285 0.0 NONE 2-22-84 1670.2 343.61 8.9 4.786 52.632 366.075 0.557 4.7792 0.007
842290 0.0 NONE 2-23-84 1767.0 321.40 8.9 8.565 54.298 347.667 0.650 8.5553 0.010
3Pt:2Pd(20):
Pd(20):
STRAIGHT PIPE. NO CATALYST:
842311 0.0 NONE 3-04-84 2383.4 N/A
842333 0.0 NONE 3-05-84 2468.8 N/A
8.9 9.728 48.269 357.579 0.698 9.7181 0.010
8.3 10.325 53.035 379.688 0.837 N/A N/A
Based on the change m emissions following the replacement of the injectors, the data generated
prior to March 10, 1984, may not be representative of the vehicle's performance from then on.
STRAIGHT PIPE, NO CATALYST
842338 0.0 NONE 3-14-84 2680.0
842693 0.0 NONE 3-15-84 2764.5
842698 0.0 NONE 3-16-84 2844.0
Pd(20):
STRAIGHT PIPE, NO CATALYST:
843010 0.0 NONE 3-23-84 3300.1
STRAIGHT PIPE, NO CATALYST
843O15 O.O NONE 4-10-84 3507.0
843153 0.0 NONE 4-11-84 3588.0
843158 0.0 NONE 4-12-84 3670.9
3Pt:2Pd(20):
STRAIGHT PIPE. NO CATALYST:
843175 0.0 NONE 4-25-84 4129.0
843180 0.0 NONE 4-26-84 4213.0
843185 0.0 NONE 4-27-84 4246.9
(NEW INJECTORS, AIR PUMP INSTALLED):
N/A 9.6 0.590 11.036 408.019 0.432 0.5859 0.004
N/A 9.3 0.591 11.642 420.458 0.573 N/A N/A
N/A 13.9 0.560 7.465 282.155 0.258 0.5603 O.OOO
N/A
9.6
1.14O 21.971 389.323 0.431
N/A
N/A
(NEW
N/A
N/A
N/A
N/A
N/A
N/A
INJECTORS):
9
9
a
14
9
15
.7
.9
.5
.9
.7
.6
O.
0,
0.
0,
0,
1
639
.656
625
,616
685
.254
10.
1 1 .
9,
5
1 1
1
188
.869
.856
.731
.819
.940
4O6
396
417
265
403
256
.570
.946
.580
.829
.688
.768
O.485
0.429
0.577
0.244
0.470
0.236
0.6229
0.6366
0.6097
0 . 6084
0.6673
1 .2527
0.016
0.019
0.016
0.008
0.018
0.001
Testing completed. Both catalysts were shipped to Calif for mileage accumulation (April 26, 1984).
-------
-26-
T««t 02
Numb«r % CAT*
APtxndlx 2E
E»1t«-
Tnt DOOM hyde Mflcs / HC CO COS NOx
P«t« (km) (mq/reO Gallon (a/m<) (q/mO (o/ml) (q/qH)
TOYOTA CATALYST:
842018 0.0 STOCK 1-19-84 935.0 1.42 15.5 0.012 0.394
842024 0.0 STOCK 1-20-84 1016.6 7.17 15.3 0.009 0.397
842030 0.0 STOCK 1-24-84 1106.2 3.88 16.0 0.012 0.517
STRAIGHT PIPE, NO CATALYST:
842035 0.0 NONE .1-31-84 1194.0 185.26 16.6 0.761 23.438
842040 0.0 NONE 2-01-84 1278.0 161.18 17.4 0.771 22.159
208.052
199.560
STRAIGHT PIPE. NO CATALYST:
842312 0.0 NONE 3-04-84 2387.0 N/A 16.6
842334 0.0 NONE 3-05-84 2472.0 N/A 16.2
Non-M*th-
ane HC METHANE
(g/ml) (g/ml)
265.116 0.002
268.274 O.OOO
255.909 0.000
0.554
0.586
STRAIGHT PIPE. NO CATALYST (AFTER RETURN FROM TOYOTA):
842286 O.O NONE 2-22-84 1686.6 149.57 17.6 0.767 21.896 196.660 0.514
842291 0.0 NONE 2-23-84 1770.0 153.54 17.1 1.248 26.105 195.193 0.501
3Pt:2Pd(20):
Pd(20):
3.660 27.249 194.183 0.697
4.515 28.673 195.064 0.764
0.7543
0.7642
0.7641
1.2443
0.0076 O.OO5
O.OO61 0.003
0.0086 0.004
3.6558
N/A
0.007
0.006
0.003
0.003
O.OO4
N/A
Based on the change in emissions following the replacement of the injectors, the data generated
prior to March 10. 1984, may not be representative of the vehicle's performance from then on.
STRAIGHT PIPE, NO CATALYST
842689 0.0 NONE
842694 0.0 NONE
842699 0.0 NONE
Pd(20):
3-14-84 2683.5
3-15-84 2768.0
3-16-84 2847.0
STRAIGHT PIPE, NO CATALYST:
843011 0.0 NONE 3-23-84 3303.2
STRAIGHT PIPE, NO CATALYST
843016 0.0 NONE 4-10-84 3510.0
843154 0.0 NONE 4-11-84 3592.0
843159 0.0 NONE 4-12-84 3674.5
3Pt:2Pd(20):
STRAIGHT PIPE, NO CATALYST:
843176 0.0 NONE 4-25-84 4132.0
843181 0.0 NONE 4-26-84 4216.0
843186 0.0 NONE 4-27-84 4299.5
(NEW INJECTORS, AIR PUMP INSTALLED):
N/A 18.4 0.394 5.217 214.361
N/A 18.0 0.390 6.021 217.961
N/A 18.5 0.395 5.763 212.249
0.656 0.3917 0.002
0.706 N/A N/A
0.621 0.3946 O.OOO
N/A
18.7 0.456 8.348 205.866 0.496 N/A
(NEW INJECTORS):
N/A 18.2 0.462
N/A 18.5 0.419
N/A 18.3 0.424
N/A
N/A
N/A
18.5
18.8
19.8
0.445
0.447
0.704
4.246 217.811
4.660 213.953
4.632 216.258
4.766 213.071
4.804 210.406
1.231 203.645
N/A
0.692 0.4575 0.005
0.666 0.4129 O.OO6
0.703 0.4184 0.006
0.655 0.4407 0.004
0.648 0.4421 0.005
0.392 0.7043 O.OOO
Testing completed. Both catalysts were shipped to Calif for mileage accumulation (April 26, 1984).
-------
-27-
Tnt
D«t«
Aepandlx 2F
T«*t 02
Njfifisr JL
TOYOTA CATALYST
842019 0.0 STOCK 1-19-84
842025 0.0 STOCK 1-2O-84
842031 0.0 STOCK 1-24-84
STRAIQ
842036 0.0 NONE 1-31-84
842041 0.0 NONE 2-01-84
STRAIGHT PIPE, NO CATALYST (AFTER RETURN FROM TOYOTA):
842287 0.0 NONE 2-22-84 1696.4 101.47 18.8 0.522 16.757 191.521 0.933 0.5198 0.002
842292 0.0 NONE 2-23-84 1778.7 103.28 18.4 0.612 19.037 192.127 0.912 0.6088 0.003
3Pt:2Pd(20):
Pd(20):
STRAIGHT PIPE, NO CATALYST:
842313 0.0 NONE 3-04-84 2393.0 N/A 18.5 0.741 22.073 185.537 0.773 0.7383 O.OO3
842335 0.0 NONE 3-05-84 2478.2 N/A 7.5 3.405 63.514 441.030 1.896 N/A N/A
Emissions during Steady State Driving at
Ald*-
ODOM hydc
_ (km) (mq/mi)
14 950.0 0.00
14 1023.6 1.88
14 1115.0 1.26
NO
14
14
CATALYST:
1200.0 1
1288.0 1
16.90
19. 17
MIlM /
Gallon
23. 1
18. 1
18.6
18.8
18.0
' HC
. (g/ml)
O.OO5
O.OO4
0.004
0.522
0.508
30 MPH
CO C02
(g/mt) (g/ml)
0.309 177.729
0.272 226.462
0.361 220.231
19.
19.
,512
807
186
195,
. 108
,673
NOx
(g/ml)
O.OO3
O.OOO
0.000
0.799
0.941
fcA»«k ftAA+a*
UQV1 PJVlrl
ane HC
(g/ml)
0.0041
0.0028
0.0018
0.5164
0.5036
i-
METHANE
(g/mi)
0.001
O.OO2
O.OO2
O.O06
0.005
Based on the Chang* m emissions following the replacement of the Injectors, the data generated
prior to March 10. 1984, may not be representative of the vehicle's performance from then on.
STRAIGHT PIPE, NO CATALYST
842690 0.0 NONE 3-14-84 2691.3
842695 0.0 NONE 3-15-84 2773.8
842700 O!Q NONE 3-16-84 2853.0
Pd(20):
STRAIGHT PIPE, NO CATALYST:
843012 0.0 NONE 3-23-84 3310.0
STRAIGHT PIPE, NO CATALYST
843017 O.O NONE 4-1O-84 3517.O
843155 0.0 NONE 4-11-84 3598.0
843160 0.0 NONE 4-12-84 3680.5
3Pt:2Pd(20):
STRAIGHT PIPE, NO CATALYST:
843177 0.0 NONE 4-25-84 4140.0
843182 0.0 NONE 4-26-84 4225.0
843187 0.0 NONE 4-27-84 4310.0
(NEW INJECTORS, AIR PUMP INSTALLED):
N/A 18.8 0.388 5.434 209.538
N/A 19.8 0.359 6.120 197.433
N/A 20.1 0.355 6.296 193.586
1.269 0.3868 O.OO1
1.086 O.OOOO O.OOO
0.987 0.3541 O.OO1
N/A
19.7 0.400 6.378 197.907 1.155 N/A
(NEW INJECTORS):
N/A 19.6 0.459
N/A 19.7 0.423
N/A 19.9 0.401
N/A
N/A
N/A
20.0
19.5
19.7
0.531
0.454
0.43B
4.824 2O0.872
5.129 199.336
4.932 198.231
1.218 202.226
5.670 200.501
5.664 198.326
N/A
1.250 O.4545 O.OO4
1.225 0.4180 0.005
1.167 0.3974 0.004
0.977 0.5302 O.OOO
1.268 0.4499 0.004
1.180 0.4338 0.005
Testing completed. Both catalysts were shipped to Calif for mileage accumulation (April 26, 1984).
-------
-28-
APPENDIX 3
Unscheduled Maintenance
on the Toyota Cressida
-------
-29-
Appendix 3
Unscheduled Maintenance on the Toyota Cressida
Date
Feo. 1, 1984
Feb. 1, 1984
Feb. 17, 1984
Mar. 9, 1984
Mar. 26, 1984
Apr. 5, 1984
May 1, 1984
May 23, 1984
June 13, 1984
Problem
Excessive cranking
to start in prior
testing—no gasoline
injection.
Noise in engine
compartment.
Fuel gauge not
reading full.
Low coolant level,
None
Increase in HC and
CO.
None
Lack of acceleration
and metallic par-
ticles in fuel.
Prior injector
plugging.
Prior injector
plugging.
Screw found missing
in pulsating damper
valve.
Repair
New thermal switch to cold
start injector installed.
Vacuum switch disabled,
later replaced on April
15, 1.984.
Replaced sender unit, cor-
rosion noted.
Coolant added, new tube in
overflow reservoir.
Air pump installed.
New fuel injectors in-
stalled.
Installed a new thermal
switch witn revised
calibrations.
Installed new fuel in-
jectors, flushed fuel
tank of foreign mater-
ials, and cleaned fuel
strainer in tank.
New stainless steel
fuel tank and new
fuel filter at engine.
Installed new fuel
inlet pipe to the fuel
tank (nickel plated),
fuel pump (nickel plated),
fuel injectors, and fuel
log to main injectors
(nickel plated).
Valve replaced.
-------
-30-
Appendix 3 (cont'd)
Unscheduled Maintenance on the Toyota Cressida
Date Problem Repair
June 28, 1984 High HC New injectors/ new
gasoline-type pul-
sating aamper valve.
June 29, 1984 Prior problem Pulsating damper valve
replaced with methanol-
compatible unit.
-------
-31-
APPENDIX 4
Statistics with the Data
Stratified by Oxygen Level,
Test Cycle, and Individual Catalyst
(Data generated prior to March 10, 1984,
are omitted from these analyses since they
cannot be duplicated due to the shift in
emissions which followed the replacement
of the fuel injectors.)
-------
-32-
Emission Statistics for FTP Driving Cycle
For Catalyst: 3Pt:2Pd(20)
Tested As a 3-Way Catalyst (0% Exhaust Oxygen)
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 33.420
3 12.214
3 .22960
3 2.7308
3 .49650
3 .22000
3 .00810
MAXIMUM
42.510
12.289
.25400
2.8905
.52060
.24380
.01025
Tested As an Oxidizing Catalyst (6.2%
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 236.75
3 11.951
3 .25900
3 .30450
3 1.2971
3 .25090
3 .00804
MAXIMUM
283.01
12. 133
.28970
.37290
1.4140
.28050
.00920
MEAN
37.293
12.248*
.23827
2.7972
.51133
.22897
.00931
Exhaust Oxygen
MEAN
264.57
12.048*
.27233
.33580
1.3513
.26387
.00845
STD DEV
4.6915
.01365
.08320
.01298
.01294
.00110
)
STD DEV
24.517
.01574
.03457
.05891
.01514
.00065
The mean Fuel Economy is a harmonic average.
-------
-33-
Emission Statistics for HWY Driving Cycle
For Catalyst: 3Pt:2Pd(20)
Tested As a 3-Way Catalyst (OX Exhaust Oxygen)
VARIABLE
Aldehyde
Fuel EC on (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 4.1600
3 15.885
3 .00690
3 .72780
3 .25030
3 .00350
3 .00325
MAXIMUM
6.6100
16.009
.01060
.74440
.27740
.00700
.00361
Tested As an Oxidizing Catalyst (6.2%
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 37.100
3 15.712
3 .01220
3 0.
3 1.0095
3 .00790
3 .00432
MAXIMUM
42.950
15.833
.01290
.00470
1.1078
.00820
.00469
MEAN
5.4133
15.947*
.00890
.73710
.26090
.00547
.00341
Exhaust Oxygen
MEAN
40.423
15.772*
.01257
.00157
1.0563
.00803
.00452
STD DEV
1.2260
.00187
.00848
.01448
.00179
.00018
)
STD DEV
3.0053
.00035
.00271
.04931
.00015
.00019
The mean Fuel Economy is a harmonic average.
-------
-34-
Emission Statistics for FTP Driving Cycle
For Catalyst: Pd(20)
Tested As a 3-Way Catalyst (OX Exhaust Oxygen)
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 34.710
3 11.906
3 .27420
3 1.8313
3 .30010
3 .27310
3 .00034
MAXIMUM
47.420
12. 171
.31580
2.0766
.33990
.31300
.00279
Tested As an Oxidizing Catalyst (6.4%
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 209.62
3 11.794
3 .25930
3 .68920
3 1 .31 15
3 .25910
3 .00024
MAXIMUM
250.73
12.003
.29320
.75680
1 .3317
.29170
.00152
MEAN
40.977
12.026*
.29317
1.9654
.32123
.29177
.00140
Exhaust Oxygen
MEAN
236.50
1 1 .91 1*
.27703
.71810
1.3217
.27637
.00070
STD DEV
6.3568
.02104
.12424
.02001
.02007
.00126
)
STD DEV
23.289
.01700
.03485
.01010
.0163°
.00071
The mean Fuel Economy is a harmonic average.
-------
-35-
Emission Statistics for HWY Driving Cycle
For Catalyst: Pd(20)
Tested As a 3-Way Catalyst (0% Exhaust Oxygen)
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 4.7900
3 15.831
3 .00880
3 .65520
3 .05820
3 .00840
3 .00013
MAXIMUM
11.440
15.882
.01340
.79190
.06190
.01230
.00106
Tested As an Oxidizing Catalyst (6.4%
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 27.740
3 15.710
3 .01180
3 .00800
3 1.0547
3 .01130
3 .00006
MAXIMUM
37.800
15.954
.01520
.02450
1.0782
.01430
.00090
MEAN
7.3167
15.864*
.01037
.73577
.06010
.00980
.00056
Exhaust Oxygen
MEAN
31.877
15.831*
.01333
.01807
1.0641
.01283
.00046
STD DEV
3.6011
.00263
.07155
.00185
.00217
.00047
)
STD DEV
5.2626
.00172
.00883
.01244
.00150
.00042
The mean Fuel Economy is a harmonic average.
-------
-36-
Emission Statistics for 'No Catatyst' (i.e., Baseline)
at a OX Exhaust Oxygen Level:
FTP Driving Cycle
VARIABLE N__ MINIMUM MAXIMUM
9 219.45
Aldehyde
Fuel Econ (mpg) 10 12.116
HC
CO
NOx
Non-Methane HC
Methane
VARIABLE
369.11
12.406
1.0719
12.276
2. 1949
1.0692
.00909
HWY Driving Cycle
N MINIMUM MAXIMUM
10 .89790
10 7.6501
10 1.9574
9 .89730
9 .00056
Aldehyde 10 111.24 214.21
Fuel Econ (mpg) 10 15.539 16.180
HC 10 .37800 .44940
CO 10 5.5353 7.9711
NOx 10 1.7416 1.9513
Non-Methane HC 8 .37750 .44470
Methane 8 .00054 .00471
MEAN
283.55
12.295*
.99440
8.8533
2.0776
.99766
.00629
MEAN
167.20
±
15.855*
.41742
6.3327
1.8783
.41739
.00368
STD DEV
43.597
.06665
1.3836
.07223
.06182
.00330
STD DEV
38.096
— — —
.02710
.83393
.06542
.02564
.00167
* The mean Fuel Economy is a harmonic average.
-------
-37-
Emission Statistics for Steady State Driving Cycles
For No Catatyst & for a 0% Exhaust Oxygen Level:
10 MPH Steady State Driving Cycle
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
0 N/A
10 9.3000
10 .56000
10 1.9400
10 .23600
8 .56030
8 0.
MAXIMUM
N/A
15.600
1.2540
21.971
.57700
1.2527
.01900
20 MPH Steady State
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
K MINIMUM
0 N/A
10 18.000
10 .39000
10 1.2310
10 .39200
8 .39170
8 0.
MAXIMUM
N/A
19.800
.70400
8.3480
.70600
.70430
.00600
30 MPK Steady State
VARIABLE
Aldehyde
Fuel Econ (mpg)
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
0 N/A
10 18.800
10 .35500
10 1.2180
10 .97700
9 0.
9 0.
MAXIMUM
N/A
20. 100
.53100
6.3780
1.2690
.53020
.00500
MEAN
N/A
10.947*
.73560
10.352
.41350
.69297
.01025
Driving Cycle
MEAN
N/A
18.559*
.45360
4.9688
.62350
.45777
.00350
Driving Cycle
MEAN
N/A
19.674*
.42080
5. 1665
1.1564
.38052
.00267
STD DEV
N/A
.24720
5.1888
.12727
.22841
.00791
STD DEV
N/A
.09189
1.7635
.10118
.10228
.00251
STD DEV
N/A
.05276
1.4903
.10807
.15114
.00212
The mean Fuel Economy is a harmonic average.
-------
-38-
Emission Statistics for 3Pt:2Pd(20) Catalyst
Tested As a 3-Way Catalyst (0% Exhaust Oxygen)
Bag 1 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 2 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 3 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
N MINIMUM
3 107.13
3 .967
3 4.602
3 1.031
HC 3 .949
3 .016
FTP Driving Cycle
N MINIMUM
3 10.87
3 .016
3 2.249
3 .264
HC 3 .007
3 .006
FTP Driving Cycle
N MINIMUM
3 19.43
3 .078
3 1.986
3 .534
HC 3 .071
3 .006
MAXIMUM
143.29
1.069
5.313
1.108
1.053
.017
•
•
MAXIMUM
12.42
.021
2.455
.276
.011
.010
•
•
MAXIMUM
23.91
.083
2. 104
.568
.077
.007
MEAN
123.00
1.0017
4.8953
1.0657
.98500
.01633
MEAN
11.683
.01767
2.3567
.27033
.00900
.00800
MEAN
21.287
.08133
2.0513
.55067
.07500
.00633
STD DEV
18.482
.05832
.37145
.03907
.05892
.00058
STD DEV
.77784
.00289
.10332
.00603
.00200
.00200
STD DEV
2.3363
.00289
.06001
.01701
.00346
.00058
-------
-39-
Emission Statistics for 3Pt:2Pd(20) Catalyst
Tested As an Oxidizing Catalyst (6.2% Exhaust Oxygen)
Bag 1 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 2 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 3 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
N MINIMUM
3 287.83
3 .968
3 1.294
3 2.317
HC 3 .952
3 .016
FTP Driving Cycle
N MINIMUM
3 235.99
3 .039
3 -.008
3 .723
HC 3 .032
3 .006
FTP Driving Cycle
N MINIMUM
3 171.53
3 .134
3 .136
3 1.563
HC 3 .128
3 .005
MAXIMUM
428.82
1.054
1.574
2.566
1.037
.017
•
•
MAXIMUM
298.97
.053
.000
.817
.045
.008
•
•
MAXIMUM
204.56
.160
.171
1.675
. 154
.006
MEAN
339.65
1 .0100
1.4277
2.4807
.99367
.01633
MEAN
273.04
.04567
-.00267
.76233
.03867
.00667
MEAN
191 .91
.14600
.15467
1.6182
.14000
.00533
STD DEV
77.562
.04304
.14043
.14178
.04252
.00058
STD DEV
32.931
.00702
.00462
.04884
.00651
.00115
STD DEV
17.818
.01312
.01762
.05601
.01312
.00058
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-40-
Emission Statistics for Pd(20) Catalyst
Tested As a 3-Way Catalyst (0% Exhaust Oxygen)
Bag 1 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 2 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
Bag 3 of the
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane
Methane
N MINIMUM
3 98.33
3 1.132
3 4.796
3 .835
HC 3 1.126
3 .001
FTP Driving Cycle
N MINIMUM
3 11.50
3 .020
3 .668
3 .098
HC 3 .020
3 .000
FTP Driving Cycle
N MINIMUM
3 28.29
3 .070
3 1.456
3 .282
HC 3 .069
3 .000
MAXIMUM
153.21
1.283
5.248
.865
1.280
.005
•
•
MAXIMUM
13.55
.026
1.021
. 158
.026
.004
•
•
MAXIMUM
32.30
.139
1.880
.329
.138
.001
MEAN
127.01
1.2187
5.0167
.84933
1.2150
.00300
MEAN
12.423
.02400
.88967
. 12333
.02267
.00133
MEAN
30.397
.10633
1.7073
.29967
. 10533
.00033
STD DEV
27.523
.07794
.22619
.01504
.07976
.00200
STD DEV
1.0400
.00346
.19306
.03107
.00306
.00231
STD DEV
2.0127
.03465
.22268
.02558
.03465
.00058
-------
-41-
Emission Statistics for Pd(20) Catalyst
Tested As an Oxidizing Catalyst (6.4% Exhaust Oxygen)
Bag 1 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 338.00
3 1.008
3 2.351
3 2.504
3 1.007
3 .001
MAXIMUM
379.64
1.190
2.535
2.513
1.187
.003
MEAN
362.89
1.1020
2.4613
2.5100
1. 1000
.00200
STD DEV
21.983
.09115
.09733
.00520
.09015
.00100
Bag 2 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
Bag 3 of the FTP
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
3 154.29
3 .025
3 .080
3 .717
3 .024
3 .000
Driving Cycle
MAXIMUM
198.42
.028
.145
.735
.028
.001
•
•
N MINIMUM MAXIMUM
3 217.83
3 . 124
3 .482
3 1.528
3 . 123
3 .000
303.91
.135
.584
1 .582
.134
.001
MEAN
175.98
.02633
.12233
.72400
.02567
.00033
MEAN
256.32
.13100
.53600
1.5617
.13000
.00033
STD DEV
22.074
.00153
.03669
.00964
.00208
.00058
STD DEV
43.755
.00608
.05126
.02937
.00608
.00058
-------
-42-
Emission Statistics for No Catalyst (i.e., Baseline)
Bag 1 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
Bag 2 of the FTP
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
9 284.24
10 1.811
10 9.899
10 2.898
9 1.793
9 .001
Driving Cycle
N MINIMUM
10 224.41
10 .668
10 7.285
10 1.439
9 .668
9 .000
MAXIMUM
504.40
2.110
13.427
3.238
2.094
.018
•
•
MAXIMUM
392.94
.909
13.090
1.615
.909
.007
MEAN
367.44
1.9600
10.853
3.0724
1.9526
.01267
MEAN
287.64
.77760
8.6334
1.5376
.78311
.00456
STD DEV
83.667
.08639
1.1638
.10954
.08851
.00577
STD DEV
47. 140
.07567
1.7517
.05849
.07128
.00300
Bag 3 of the FTP Driving Cycle:
VARIABLE
Aldehyde
HC
CO
NOx
Non-Methane HC
Methane
N MINIMUM
10 173.54
10 .584
10 6.635
10 2.203
9 .582
9 .000
MAXIMUM
237.87
.746
9.872
2.595
.740
.007
MEAN
207.49
.67760
7.7636
2.3526
.68344
.00433
STD DEV
20.103
.06154
.94252
. 1 1160
.05405
.00260
-------
-43-
APPENDIX 5
Fuel Analysis
-------
-44-
Appendix 5
Analysis of One Batch of Test Fuel
The following analysis was performed by Southwest Research
Institute in November 1982 and were reported to EPA in May 1983:
Test
Heat of Combustion (ASTM D-240)
Gross
Net
Water Content by Karl Fischer Titration
(ASTM D-1744) wt. percent
API Gravity (ASTM D-287)
Density (ASTM D-287)
Flash Point (ASTM D-93)
Acid Number (ASTM D-664) equiv. mg KOH/g sample
Leaa by A.A. (ASTM D-3237)
Sulfur by Dohrmann Microcoulometer
Phosphorous by A.A.
Higher Alcohols by G.C.
Results
10,292 Btu/lb
9,143 Btu/lb
0.055 %
46.9° @ 60°F
0.7928 @ 15°C
71.9°F
0.00
3 ppm
N.D. (<0.001 %)
1.7 ppm
N.D. (<0.1% ea.)
N.D. = none detected.
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