<>EPA
United States
Environmental Protection
Agency
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
2565 Plymouth Road
Ann Arbor, Michigan 48105
EPA 460/3-88-006
May 1988
Air
Intake System Deposits
and Gasoline/Alcohol Blends
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EPA 460/3-88-006
Intake System Deposits and
Gasoline/Alcohol Blends
by
Sherrill F. Martin
Southwest Research Institute
6220 Culebra Road
San Antonio, Texas 78284
Contract No. 68-03-3353
Work Assignment B-2
EPA Project Officer: Craig A. Harvey
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Mobile Source Air Pollution Control
Emission Control Technology Division
2565 Plymouth Road
Ann Arbor, Michigan 48105
May 1988
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This report is issued by the Environmental Protection Agency to report technical
data of interest to a limited number of readers. Copies are available free of charge
to Federal employees, current contractors and grantees, and nonprofit organizations
- in limited quantities - from the Library Services Office, Environmental Protection
Agency, 2565 Plymouth Road, Ann Arbor, Michigan 48105.
This report was furnished to the Environmental Protection Agency by Southwest
Research Institute, 6220 Culebra Road, San Antonio, Texas, in fulfillment of Work
Assignment No. B-2 of Contract 68-03-3353. The contents of this report are
reproduced herein as received from Southwest Research Institute. The opinions,
findings, and conclusions expressed are those of the author and not necessarily those
of the Environmental Protection Agency. Mention of company or product names is
not to be considered as an endorsement by the Environmental Protection Agency.
Publication No. EPA 460/3-88-006
ii
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FOREWORD
This report covers the effort under Work Assignment No. B-2 of EPA Contract
68-03-3353, performed for the Emission Control Technology Division, Environmental
Protection Agency, 2565 Plymouth Road, Ann Arbor, Michigan 48105. The EPA
Contracting Officer was Mr. E. M. Hennessey, and the Project Officer was Mr.
Craig A. Harvey.
The Southwest Research Institute Project Leader was Sherrill F. Martin.
Charles T. Hare, Project Manager, was involved in fiscal negotiations concerning
this work assignment, and Charles M. Urban was involved in technical development
of the test plan. The project was performed during the period September, 1986
through August, 1987 and was identified as SwRI Project 08-1193-002.
111
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ABSTRACT
Six vehicles, four of them ethanol blend-fueled and two gasoline-fueled, were
examined for intake system deposits. The engines were partially disassembled,
photographs were taken, and deposits were evaluated by a professional rater.
Elemental analysis was made of the intake valve deposits.
IV
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TABLE OF CONTENTS
Page
FOREWORD iii
ABSTRACT iv
LIST OF FIGURES vi
LIST OF TABLES vii
I. SUMMARY 1
IL INTRODUCTION 3
IIL TEST PLAN 5
A. Test Plan 5
1. Task 1 - Arrange for Test Vehicles and Inspection
Capability 5
2. Task 2 - Inspection and Parts Replacement 6
a. Task 2 A - Engines 6
b. Task 2B - Fuel Tank 6
3. Task 3 - analysis
B. Vehicles 7
C. Blend Fuel 8
IV. DISASSEMBLY AND INSPECTION 9
V. DEPOSIT RATINGS 17
A. Engine Components 20
1. Intake Valves
2. Combustion Chambers
3. Intake Manifold Runners and Intake Ports 18
4. Piston Crowns 19
5. Carburetor Bores 19
6. Miscellaneous Items 19
B. Fuel Tanks 20
VL ANALYSIS OF VALVE DEPOSITS 21
VH. DISCUSSION OF PROGRAM RESULTS 23
APPENDICES
A. Vehicle Information
B. Rater's Reports
C. Fuel Additive Analysis
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LIST OF FIGURES
Figure gage
1 Intake Valves, Ford Escorts 10
2 Intake Valves, Plymouth Reliants 11
3 Cylinder Heads, Plymouth Reliants 12
4 Typical Cylinder Head, Ford Escorts 13
5 Intake Manifolds, Plymouth Reliants 14
6 Carburetor Bores, Plymouth Reliants 15
7 Fuel Tanks, Ford Escorts 16
VI
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LIST OF TABLES
Table Page
1 Deposit Rating Summary 1
2 Test Vehicles 7
3 Ratings of Intake Valves 17
4 Ratings of Combustion Chambers 18
5 Ratings of Manifold Runners 18
6 Ratings of Intake Ports 18
7 Ratings of Piston Crowns 19
8 Ratings of Carburetor Bores 19
9 Ratings of Miscellaneous Items 20
10 Elemental Analysis of Valve Deposits 22
VII
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L SUMMARY
Six vehicles, three Ford Escorts and three Plymouth Reliants, were borrowed
from the State of Minnesota for examination of their intake system deposits. Two
vehicles of each make had been operated almost exclusively on a 10% ethanol blend
available at fleet headquarters, while the third had been fueled with gasoline
purchased on the road. The average age of the vehicles was five years, and the
average odometer reading was 63,000 miles.
The vehicles were transported to Southwest Research Institute, San Antonio,
Texas, for examination. Cylinder heads, intake manifolds, and valves were removed.
Fuel tanks were also removed and cut open for inspection.
Preliminary observations showed that one of the blend-fueled Reliants had
extreme deposits on the intake valves. The other blend-fueled Reliant also showed
very heavy valve deposits, but not to the extreme extent of the first. The gasoline-
fueled Reliant had deposits which were typical of a vehicle of its age and mileage.
One of the blend-fueled Escorts had heavier intake valve deposits than the other two
Escorts. Other components showed either the same trend to a lesser degree or
minimal differences. The rater's report is summarized in Table 1. Higher numerical
ratings mean better condition or less severe deposits.
TABLE 1. DEPOSIT RATING SUMMARY
Vehicle/Fuel Valves
Ford Escort
Gasoline 7.6
Blend, avg. 6.7
Plymouth Reliant
Gasoline 6.3
Blend, avg. 4.2
Manifold
Runners
8.2
8.6
8.0
7.5
Intake
Ports
8.0
8.3
9.2
7.0
EGR
Line
8.0
8.0
6.0
5.2
Carburetor
7.3
6.8
7.0
4.2
An elemental analysis of the deposits found on the intake valves was
conducted. Sulfur, iron, copper, and zinc appear to correlate with type of fuel.
Magnesium, aluminum, phosphorus, potassium, iron, and nickel showed correlation
with vehicle make.
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IL INTRODUCTION
On September 11, 1986, Work Assignment No. B-2, entitled, "Intake System
Deposits and Gasoline/Alcohol Blends," was authorized by the EPA Contracting
Officer for contract 68-03-3353. The objective of this work assignment was to
determine any differences in deposit-forming tendencies of gasoline versus
gasoline/alcohol blends, in vehicles that have use these fuels over an extended
period of time in typical everyday driving.
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BO. TEST PLAN
This section provides the test plan that was to be followed and describes the
vehicles used in the work assignment. It also describes what is known about the fuel
used in the vehicles.
A. Test Plan
The test plan was divided into three major parts. They are described in
the following three sub-sections.
1. Task 1 - Arrange for Test Vehicles and Inspection Capability
Each of the potential candidate fleets of vehicles listed in Table 1 of
the Appendix A "Statement of Work" (S.O.W.) will be contacted. Contact will also
be made with other potential sources of vehicles, primarily local sources, if any such
fleets are located. Vehicle selection (automobiles, small vans, or pickups) will be
based on the criteria given under Task 1 in the S.O.W. Following identification of
potentially available vehicles that apparently meet the required criteria,
verification of their operating history will be obtained. It is anticipated that such
verification will require on-site visits to inspect the vehicles and the records. Only
vehicles having adequate operating records as required in Tasks 1 and 2A of the
S.O.W. will be considered for final selection. As required, a maximum of 40 hours
will be expended in identifying potentially available vehicles and in making
preliminary provisions for performing the Task 2 inspections. At that time, the
status will be reported verbally to the Project Officer. If conditions are such that a
Project Officer decision on continuation appears appropriate, this decision will be
requested.
In the event that all required information concerning the vehicles is
readily provided by the vehicle sources, it will be included in the verbal report to
the Project Officer. As previously stated, however, it is anticipated that a visit will
be required to each of the sources of the tentatively selected vehicles. Such site
visits are not included in and will be in addition to the previously stated 40 hours.
Visits to each source of vehicles could be required, two are assumed for planning
purposes.
It is planned to arrange for transport of the vehicles to SwRI for
inspection, but potential for on-site vehicle inspection will be discussed with the
sources. Conducting the inspections at SwRI will generally be more efficient,
provide for better technical control, and enable better safety precautions when
working with the fuel tanks. In summary, more reliable data will be obtained at
lower costs. Other than reimbursing the vehicle supplier for the cost of renting a
replacement vehicle, no provisions are included for any compensation or financial
incentives to the suppliers of the vehicles.
The Project Officer will be notified of the vehicles selected, and his
approval will be obtained prior to continuation of the project. If we are dealing with
fleets operated by government organizations, limited assistance by EPA personnel
(introductions to fleet managers, interagency cooperation requests, etc.) may also
be requested to find vehicles.
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This planned effort is based on a total of six vehicles, two having
operated on gasoline and four on gasoline-alcohol blends. Depending on the actual
effort involved in locating, obtaining, and evaluating the vehicles, the total number
of vehicles could increase or decrease from the planned number.
2. Task 2 - Inspection and Parts Replacement
Information listed under Task 2A of the S.O.W. will be recorded for
each vehicle inspected. The information related to source and operation of the
vehicles will generally be obtained in Task 1, prior to final selection of the vehicles.
Component inspections will be conducted by a qualified rater in accord with CRC
rating procedures, where applicable. For any components or requirements not
covered by a procedure, an existing procedure considered most appropriate will be
adapted. Tentative inspection methods for use in this work assignment are listed in
Appendix B.
a. Task 2 A - Engines
Engine components listed under Task 2A of the S.O.W. will be
inspected. These inspections will include the following criteria, as appropriate:
deposits, wear, cracks, surface texture and discoloration.
It is planned to remove the carburetor, intake manifold, and the
cylinder head(s). In addition, it will generally be necessary to remove the EGR valve
and the intake and exhaust valves to conduct the requested inspections. Any valves
with an "unusual" amount of deposit build-up or erosion will be replaced, as
described under Task 2A of the S.O.W. Any "unusual" deposit build-up or other
characteristics apparent on other components will be photographed and/or samples
taken as appropriate and practical. Replacement of components, other than valves
as previously described, will be done only when necessary, or when deemed
appropriate based on the severity of deposits or other characteristics.
b. Task 2B - Fuel Tank
The fuel tank will be removed from each vehicle and replaced
with a new fuel tank. The procedure to be followed for inspecting the in-use fuel
tanks will be as follows:
(1) Drain fuel tank and remove from vehicle (if inspection
preparation is not to proceed at that time, replace several
gallons of the drained fuel and seal all fuel tank openings).
(2) Drain, or otherwise remove, all liquid fuel from the tank.
(3) Purge the tank with nitrogen, or other appropriate inert
gas, until essentially all fuel vapors are removed from the
tank.
(4) While still flowing the purge gas, cut open the fuel tank.
(5) Inspect the tank in accord with the requirements under
Task 2B of the S.O.W.
NOTE: Steps 2 through 5 will normally be completed during an
8-hr work shift, and in no case will the elapsed time
exceed 24 hours.
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3. Task 3 - Analysis
Selected deposit samples will be analyzed to determine amount,
composition, and physical characteristics. The number of samples and the specific
analyses will be determined in coordination with the Project Officer. The allocation
in this work plan is for a reasonable number of analyses on up to four samples,
assuming that a total of six vehicles are inspected in detail.
The data collected under all tasks will be reviewed for any apparent
relationship between the fuel(s)/additive(s) used and the observed condition of the
inspected components.
B. Vehicles
The six vehicles used in the program were obtained from the Minnesota
Department of Administration. Basic information is listed in Table 2. The blend-
fueled vehicles were from the Capitol District of the Minnesota DOA. They were
principally fueled at the fleet headquarters at St. Paul. Occasional "on-the-road"
fueling would have occurred, which would cause a small percentage of operation on
very low ethanol content fuel.
TABLE 2. TEST VEHICLES
Number
SC239
SC205
SC453
C83
C202
C232
Make
Ford
Ford
Ford
Plymouth
Plymouth
Plymouth
Model
Escort
Escort
Escort
Reliant
Reliant
Reliant
Year Mileage Fuel
1982
1981
1981
1983
1983
1982
62,000
61,000
68,000
57,000
75,000
55,000
Gasoline
Blend
Blend
Gasoline
Blend
Blend
Engine
1.6L
1.6L
1.6L
2.2L
2.2L
2.2L
The gasoline-fueled vehicles were headquartered in other cities without
fleet fueling facilities. Therefore, their fueling history would be typical of other
vehicles operating in Minnesota, with gasoline being purchased at retail from a
variety of suppliers.
The vehicles were taken from service with an average of 63,000 miles on
the odometer. Most, if not all, of the vehicles were about to be auctioned by the
fleet. The Ford Escorts were 1981 and 1982 models, while the Plymouth Reliants
were of 1982 and 1983 vintages.
Examination of the maintenance records showed no work which would
affect the purposes of this assignment. One of the Ford Escorts, number SC205, had
undergone a camshaft repair at 39,000 miles. Because this vehicle has an overhead
cam engine, it is possible to remove the camshaft without disturbing the valves. No
fuel tanks had been replaced. No specific oil consumption records were kept.
However, excessive oil use would have been reported.
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C. Blend Fuel
The blend fuel supplied to the Minnesota DOA is provided on a yearly
contract basis. Gasoline and ethanol are purchased by the contractor from different
suppliers and blended in the tank truck. The target blend is 10% ethanol. No
corrosion inhibitor or detergent package is added to the blend by the contractor.
However, analysis of the fuels indicates that an additive package was present in the
blend fuels.
The producer of most of the ethanol used in the Minnesota Fleet blend
confirmed that a detergent package was added to the ethanol starting early in the
summer of 1986. It had been standard practice to include a corrosion inhibitor prior
to that time. Therefore, the blend fueled vehicles would only have been exposed to
the additional detergent for roughly nine months prior to this study. This would not
be expected to clean up deposits existing before that time.
The additive analysis is included as Appendix C. Note that the blend fuels (the last
four listed) all indicated higher additive content than the two gasoline samples.
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IV. DISASSEMBLY AND INSPECTION
In order to perform the inspections required by the test plan, the carburetor,
manifolds, cylinder head, and EGR lines were removed from each engine. In
addition, the valves were removed from the heads to allow inspection and rating of
the stem side of the valve heads. All fuel tanks were removed, drained, and cut
open for inspections.
Figures 1 through 7 are photographs of the major components which were
inspected. First shown are the intake valves. The R.eliants showed the widest
variation in deposits, ranging from normal to extremely heavy. Valve deposits on
the Escorts ranged from light to moderate. In both cases, the vehicles which had
been fueled on gasoline had the lightest deposits. The carburetors, particularly in
the area under the secondary throttle, showed similar trends. Other components on
the Reliants fell in line. The remaining components on the Escorts showed no clear
correlation with the deposits on the valves and carburetors.
Five of the fuel tanks looked like new inside. The sixth, from one of the
blend-fueled Escorts, was free of corrosion, but had a dull gray film inside.
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SC 239
SC 205
SC453
FIGURE 1. INTAKE VALVES, FORD ESCORTS
10
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JLJLXJL
C83
C202
C232
FIGURE 2. INTAKE VALVES, PLYMOUTH RELIANTS
11
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FIGURE 3. CYLINDER HEADS, PLYMOUTH RELIANTS
12
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FIGURE 4. TYPICAL CYLINDER HEAD, FORD ESCORTS
13
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SC232 CLOSE UP
FIGURE 5. INTAKE MANIFOLDS, PLYMOUTH RELIANTS
14
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C83
CZ02
C232
FIGURE 6. CARBURETOR BORES, PLYMOUTH RELIANTS
15
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FIGURE 7. FUEL TANKS, FORD ESCORTS
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V. DEPOSIT RATINGS
This section discusses the report of the rater on his examination of the engine
components (Tables 3 through 9). These ratings involve subjective comparisons of
the components to photographs and charts in the CRC Manual. Ratings are on a
scale of 0 to 10, with 10 being the highest quality (best condition) rating. Quality
control is maintained by regular attendance of the rater at CRC rating symposiums.
A. Engine Components
1. Intake Valves
Within each vehicle make grouping, the lightest deposits occurred
on the gasoline-fueled vehicle. In addition to being heavier, the valve deposits were
quite variable in the blend-fueled vehicles. For instance, among the Escorts, vehicle
C239 (gasoline) and vehicle C453 (blend) had almost identical valve deposit ratings,
but vehicle C205 (blend) was significantly worse. For the Reliants, vehicle C202
(blend) had deposits which were intermediate between those of vehicle C83
(gasoline) and C232 (blend).
It is inconceivable that the deposits on the intake valves in vehicle
C232 had no effect on performance. The fleet manager confirmed, that one vehicle
had difficulty climbing the ramps onto the vehicle carrier, and we suspect that it
was C232.
TABLE 3. RATINGS OF INTAKE VALVES
Cylinder
Vehicle Fuel 123
SC239 Gasoline 7.6 7.6 7.6 7.6
SC205 Blend 5.7 5.5 7.0 6.0
SC453 Blend 7.4 7.6 7.1 7.4
C83 Gasoline 5.7 6.9 6.8 5.7
C202 Blend 5.8 5.8 4.8 5.1
C232 Blend 3.5 3.5 2.0 3.5
2. Combustion Chambers
All of the Escort cylinder heads were visually similar in the
combustion chamber areas, therefore only one photograph is shown. The ratings
confirm this similarity. The Reliant heads displayed slight visual differences, but
the rater's report indicates minimal practical differences. Note that in the head
from vehicle C232, some deposits can be seen caked in the area behind the intake
valve, which is not part of the combustion chamber.
17
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TABLE 4. RATINGS OF COMBUSTION CHAMBERS
Cylinder
Vehicle
SC239
SC205
SC453
C83
C202
C232
Fuel
Gasoline
Blend
Blend
Gasoline
Blend
Blend
Intake Manifold
1
9.0
8.9
8.5
8.5
8.3
8.0
Runners
2
8.8
8.9
8.3
8.1
8.2
7.9
and Intake
3
8.4
8.2
8.8
8.1
8.1
7.8
Ports
4
8.6
7.9
8.7
8.2
8.0
7-9
7.9
3.
With the exception of Reliant C232, the intake manifold runners and
intake ports showed no correlation with fuel or vehicle. Vehicle C232 rated
comparatively low, in line with the valve ratings.
TABLE 5. RATINGS OF MANIFOLD RUNNERS
Vehicle
SC239
SC205
SC453
C83
C202
C232
Cylinder
Fuel
Gasoline
Blend
Blend
Gasoline
Blend
Blend
1
8.4
8.0
9.0
8.0
9.0
7.4
2
8.4
8.0
9.1
8.0
9.1
6.2
3
8.0
8.0
9.1
8.0
8.9
5.5
4
8.0
8.0
9.2
8.0
8.6
5.6
TABLE 6. RATINGS OF INTAKE PORTS
Vehicle
SC239
SC205
SC453
C83
C202
C232
Fuel
Cylinder
Gasoline
Blend
Blend
Gasoline
Blend
Blend
1
8.0
8.2
9.4
9.2
7.9
6.5
2
8.0
8.2
8.4
9.0
8.6
4.6
3
8.0
7-9
7.8
9.0
8.2
3.5
4
8.0
8.0
8.5
9.4
8.8
7.9
8.0
8.
8.
9.2
8.4
5.6
18
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4. Piston Crowns
Piston crowns showed very little variation from vehicle to vehicle.
Vehicle C232 again deviated on the low rating side compared to the others.
TABLE 7. RATINGS OF PISTON CROWNS
Cylinder
Vehicle Fuel
SC239 Gasoline 7.8 8.2 8.2 8.5
SC205 Blend 8.0 8.3 8.0 7.9
SC453 Blend 8.0 8.4 8.5 8.0
C83 Gasoline 8.3 8.5 8.5 8.0
C202 Blend 8.2 8.2 8.1 8.1
C232 Blend 7.8 7-9 8.0 7.5
5. Carburetor Bores
The rater was asked to evaluate only the area of the carburetor
bores below the throttle plate. All were fairly normal except for C232. The
extremely low rating of the C232 carburetor requires some explanation. From the
photograph, Fig. 6, there appears to be very heavy deposits in the bores of the
spacer below the throttle body. This material is actually a rubber-like lining which
was present in this 1982 Reliant, but not in either of the others, which were both
1983 models. The rater treated this liner material as a deposit.
TABLE 8. RATINGS OF CARBURETOR BORES
Barrel
Vehicle Fuel 1 \
SC239 Gasoline 7.5 7.1
SC205 Blend 6.2 6.4
SC453 Blend 7.2 7.4
C83 Gasoline 7.5 6.5
C202 Blend 7.5 5.4
C232 Blend 3.1 0.8
6. Miscellaneous Items
For the Escorts, the intake manifold inlet, EGR port, and EGR line
showed no trends with respect to fuel. In the Reliants, C232 again showed the
heaviest deposits, while the other blend-fueled Reliant had heavier deposits than the
gasoline-fueled vehicle in the EGR port and line.
19
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TABLE 9. RATINGS OF MISCELLANEOUS ITEMS
Vehicle
SC239
SCZ05
SC453
C83
C202
C232
Fuel
Gasoline
Blend
Blend
Gasoline
Blend
Blend
Intake
Manifold
Inlet
8.9
8.5
9.2
9.5
9.5
7.7
EGR
Line
8.0
8.0
8.0
6.0
5.5
5.0
B. Fuel Tanks
The rater's reports on the fuel tanks (see Appendix B) confirmed the
evidence of the photographs. All were in good to very good condition, with one of
the Escort blend-fueled tanks (SC453) having a gray film in the bottom half.
20
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VL ANALYSIS OF VALVE DEPOSITS
One "average" looking intake valve was selected from each of four engines.
These engines included two of each vehicle and two of each fueling history. An
elemental analysis was made of deposit samples removed from each of these four
valves (Table 10). Elements other than hydrogen, carbon, and nitrogen were
determined by the X-ray fluorescence method.
The ratio of hydrogen to carbon was highest in the engine with the extreme
deposits, indicating the presence of more organic material. Nitrogen, magnesium,
aluminum, phosphorus, potassium, iron, and nickel appear to correlate more with the
make of vehicle than with fuel type. Sulfur, iron, copper, and zinc show some
correlation with fuel type. The difference between 100% and the total shown would
be mostly oxygen.
21
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TABLE 10. ELEMENTAL ANALYSIS OF VALVE DEPOSITS
Vehicle
Escort
SC239
SC205
Reliant
C83
C232
Fuel
Gasoline
Blend
Gasoline
Blend
H
4.2*
4.5
4.9
6.5
C
53.4*
63.8
62.1
65.4
N
0.95*
1.80
3.19
3.47
Mg
1.7
2.6
2.9
4.2
Al
0.12
0.10
0.04
0.04
Si
0.19
0.13
0.10
0.16
P
1.8
2.0
5.4
3.5
S
5.7
4.6
5.8
4.4
YL
0.57
0.29
0.08
0.12
Ca Cr
1.2
0.9 0.04
0.9 --
1.5
Fe
1.0
0.51
0.24
0.21
Cu
0.30
0.13
0.22
0.10
Ni Zn
0.08 2.4
0.04 2.0
— 4.5
— 2.7
Pb
1.2
0.5
0.50
0.71
Total
74.8
84.0
90.9
93.0
All values percent by mass.
* Marginal sample quantity.
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VIL DISCUSSION OF PROGRAM RESULTS
On the basis of a limited sampling from one fleet of vehicles, there is evidence
that vehicles being operated on ethanol-gasoline blends can develop heavier deposits
in the intake system than those operated on generally-available gasolines. The
reason for these heavier deposits is not clear from the present study. The ethanol
producer began adding a detergent package shortly before these vehicles were pulled
from service. This would not have been expected to clean up pre-existing deposits.
The effect on deposits is mainly limited to the intake system, because the effect
observable in the combustion chambers was minimal. There was no corrosion
evident in the fuel tanks of any of the vehicles examined.
23
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APPENDICES
A. VEHICLE INFORMATION
B. RATER'S REPORTS
C. FUEL ADDITIVE ANALYSIS
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APPENDIX A
VEHICLE INFORMATION
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VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
SCZ39
Ford Escort
1982
62194
2FABPO62XCX240987
1.6Lx4
Label Missing
Automatic
E2EEL1A 2E17
EGR/PMP/OXD/3WY
Gasoline
A-2
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VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
SC205
Ford Escort Wagon
1981
61307
1FABPO82BW276552
1.6Lx4
1.6AP
Automatic
E1EE NA 1F2
EGR/PMP/OXD/3WY
10% Ethanol Blend
A-3
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VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
SC453
Ford Escort Wagon
1981
68185
1FABPO820BW275464
1.6Lx4
1.6 AP
Automatic
E1EE NA 1F1
EGR/PMP/OXD/3WY
10% Ethanol Blend
A-4
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VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
C83
Plymouth Reliant
1983
57470
1P3BP26CXDF195447
2.2Lx4
Label Missing
Automatic
40010-2 42807086 0263
EGR/PMP/ODX/3CL
Gasoline
A-5
-------
VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
C202
Plymouth Reliant
1983
74626
1P3BP26C6DF195423
2.2Lx4
DCR2.2V2HAC3 DCRKA
Automatic
40010-2 4287086 0203
EGR/PMP/ODX/3CL
10% Ethanol Blend
A-6
-------
VEHICLE INFORMATION
Fleet ID No.
Make and Model
Model Year
Odometer Reading
V.I.N.
Engine Size & Cylinders
Engine Family
Transmission Type
Carburetor No.
Emission Controls
Fuel
C232
Plymouth Reliant
1982
54927
1P3BP26B3CF218590
2.2Lx4
CCR2.2V2HNLX CCRKA
Automatic
R9019 4227293 1042
EGR/PMP/OXD/3 CL
10% Ethanol Blend
A-7
-------
APPENDIX B
RATER'S REPORTS
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: SC-239 DATE: 05-26-87 RATER: G. TSCHIRHART
COMBUSTION CHAMBERS
No. 1
Area
50%
30%
20%
Rate
9.5
9.0
8.0
Merit
4.75
2.70
1.60
No. 2 Area
20%
50%
30%
Rate
9.5
9.0
8.0
Merit
1.90
4.50
2.40
Total 9.05 Total 8.80
No. 3
Area
10%
20%
70%
Rate
9.5
9.0
8.0
Merit
0.95
1.80
5.60
No . 4 Area
30%
20%
50%
Rate
9.5
9.0
8.0
Merit
2.85
1.80
4.00
Total 8.35 Total 8.65
Comments; Avg. 8.71
VALVES
INTAKE VALVES
No._ Rate No. Rate No. Rate
_i_ 7.6 2 7.6 3 7.6
4 7.6
Comments: Avg. 7.60
EXHAUST VALVES
No- Rate No. Rate No. Rate
1_ 8.0 2 7.8 3 7.9
4 7.8
Comments: Avg. 7.90
B-2
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: SC-239
DATE: 05-26-87
RATER: G. TSCHIRHART
MANIFOLD RUNNERS
No. 1
Total. ..
Area
40%
60%
Rate
9.0
8.0
Merit
3.60
4.80
...8.40
No. 2 Area
40%
60%
Total
Rate
9.0
8.0
•
Merit
3.60
4.80
...8.40
No. 3
Area
Rate
Merit
No. 4
Area
Rate
Merit
100%
8.0
8.00
100%
8.0
8.00
Total 8.00
Total 8.00
Comments: 8.20
HEAD PORTS - INTAKE
No. 1
Area
Rate
Merit
No. 2
Area
Rate
Merit
100%
8.0
8.00
95%
5%
8.0
7.5
7.60
0.38
Total 8.00
Total 7.98
No. 3
Area
Rate
Merit
No. 4
Area
Rate
Merit
95%
5%
8.0
7.5
7.60
0.38
100%
8.0
8.00
Total 7.98
Total 8.00
Comments: Avg. 7.99
B-3
-------
TEST NO. SC-239
INTAKE MANIFOLD; 8.9 Carbon Rating
EGR PORT INTO INTAKE SYSTEM; 7.5 Carbon Rating
EGR LINE; 8.0 Carbon Rating
PISTON CROWN; 1 - 7.8
2 - 8.2
3 - 8.2
4 - 8.5
Avg. 8.18
CYLINDER BORE; 1
2
3
4 -
Good condition, no apparent distress.
Good condition, no apparent distress.
Good condition, no apparent distress.
Good condition, no apparent distress.
FUEL TANK:
Fuel tank is in very good condition. No signs of rust or varnish.
Trace amount of foreign material in bottom of tank.
9.80 Sludge Rating
9.80 Varnish Rating
B-4
-------
CARBURETOR MAKE.
. BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
Appendix C
RECOMMENDED CARBURETOR RATING FORM
_ DATE 05-26-87 TEST # SC-239 RATERG. Tschirhart
SECONDARYBBLS
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0 to 9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
*6.0to< .001 "thick
Deposit < .015" > .001" thick
Deposit > .015" thick
(1)
Linkage Barrel
% Area x
(2)
Left
Side
1007o
100%
(1)
Right
Side
100%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.50
0
7.50
Right
Side
7.50
0
7.50
Non-Linkage Barrel
% Area x
Left
Side
95%
5%
1 00%
Right
Side
70%
30%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.12
0.25
0
7.37
Right
Side
5.25
1.50
0
6.75
M
I
Ul
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = %; % Right Side = 100 x Right Depth = %
Left + Right Left + Right
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 7.12
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = 7 '.43
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x ) = ( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
.2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40% Left Side Available Area, 60% Right Side Available Area.
*CRC Varnish Rating Scale
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: SC-205 DATE: 05-26-87 RATER: G. TSCHIRHART
COMBUSTION CHAMBERS
No. 1
Area
20%
60%
20%
Rate
9.5
9.0
8.0
Merit
1.90
5.40
1.60
No. 2 Area
20%
60%
20%
Rate
9.5
9.0
8.0
Merit
1.90
5.40
1.60
Total 8.90 Total 8.90
No. 3 Area Rate Merit No. 4 Area Rate Merit
30% 9.0 2.70 80% 8.0 6.40
60% 8.0 4.80 20% 7.5 1.50
10% 7.5 0.75
Total 8.25 Total 7.90
Comment s; Avg. 8.49
VALVES
INTAKE VALVES
No. Rate No. Rate No. Rate
1 5.7 2 5.5 3 7.0
4 6.0
Comments: Avg. 6.0
EXHAUST VALVES
No. Rate No. Rate No. Rate
1 7.5 2 7.5 3 7.5
4 7.5
Comments: Avg. 7.5
B-6
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: SC-205 DATE: 05-26-87 RATER: G. TSCHIRHART
MANIFOLD RUNNERS
No. 1 Area Rate Merit No. 2 Area Rate Merit
1007o 8.0 8.00 1007= 8.0 8.00
Total 8.00 Total 8.00
No. 3 Area Rate Merit No. 4 Area Rate Merit
1007., 8.0 8.00 1007= 8.0 8.00
Total 8.00 Total 8.00
Comments: Avg. 8.00
HEAD PORTS - INTAKE
No. 1 Area Rate Merit No. 2 Area Rate Merit
207o 9.0 1.80 207o 9.0 1.80
807o 8.0 6.40 807= 8.0 6.40
Total 8.20 Total 8.20
No. 3
Total . . .
Area
907o
57=
57=
Rate
8.0
7.5
7.0
Merit
7.20
0.38
0.35
...7.93
No. 4 Area
957»
57=
Total ,
Rate
8.0
7.5
Merit
7.60
0.38
...7.98
Comments: Avg. 8.08
B-7
-------
TEST NO. SC-205
INTAKE MANIFOLD; 8.5 Carbon Rating
EGR PORT INTO INTAKE SYSTEM; 7.0 Carbon Rating
EGR LINE; 8.0 Carbon Rating
PISTON CROWN; 1 - 8.0
2 - 8.3
3 - 8.0
4 - 7.9
Avg. 8.05
CYLINDER BORE; 1 - Good condition, no apparent distress.
2 - Good condition, no apparent distress.
3 - Good condition, no apparent distress.
4 - Good condition, no apparent distress.
FUEL TANK; Fuel tank is in very good condition. No signs of rust or varnish.
Trace amount of foreign material in bottom of tank.
9.80 Sludge Rating
9.80 Varnish Rating
B-8
-------
CARBURETOR MAKE.
BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
Appendix C
RECOMMENDED CARBURETOR RATING FORM
_ DATE 05-26-87 JEST # SC-205 RATER G. Tschirhart
SECONDARY BBLS.
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0 to 9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
* 6.0 to < .001 "thick
Deposit < .015" > .001 "thick
Deposit > .01 5" thick
(1)
Linkage Barrel
% Area x
(2)
Left
Side
100%
100%
0)
Right
Side
95%
5%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
5.00
0
5.00
Right
Side
7.12
.25
0
7.37
Non-Linkage Barrel
%Area x
Left
Side
60%
40%
100%
Right
Side
50%
50%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
4.50
2.00
0
6.50
Right
Side
3.75
2.50
0
6.25
to
I
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = %; % Right Side = 100 x Right Depth = %
Left + Right Left + Right
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 6.81
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = 5.75
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x ) = ( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40% Left Side Available Area, 60% Right Side Available Area.
v
*CRC Varnish Rating Scale
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: SC-453 DATE: 05-26-87 RATER: G. TSCHIRHART
COMBUSTION CHAMBERS
No. 1
Area
10%
30%
60%
Rate
9.5
9.0
8.0
Merit
0.95
2.75
4.80
No. 2 Area
30%
70%
Rate
9.0
8.0
Merit
2.70
5.60
Total 8.50 Total 8.30
No. 3
Area
80%
20%
Rate
9.0
8.0
Merit
7.20
1.60
No. 4 Area
10%
50%
40%
Rate
9.5
9.0
8.0
Merit
0.95
4.50
3.20
Total 8.80 Total 8.65
Comments; Avg. 8.56
VALVES
INTAKE VALVES
No. Rate No. Rate No. Rate
1 7.4 2 7.6 3 7.1
4 7.4
Comments: Avg. 7.4
EXHAUST VALVES
Rate No. Rate No. Rate
7.5 2 7.5 3 7.5
7.5
Comments: Avg. 7.5
B-10
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.
No. 1
Total. . .
No. 3
No. 1
Tnl-fll
No. 3
Total
: SC-453 DATE: 05-26-87
MANIFOLD RUNNERS
Area Rate Merit No. 2
100% 9.0 9.00
9 . 00 Total
Area Rate Merit No. 4
30% 9.5 2.85
70% 9.0 6.30
9 . 15 Total
Comments: 9.12
HEAD PORTS - INTAKE
Area Rate Merit No. 2
1007o 9.4 9.40
9.40 Total
Area Rate Merit No. 4
807=, 8.0 6.40
107o 7.5 0.75
107o 6.5 0.65
7 . 80 Total . .
RATER: G.
Area Rate
307c 9.5
707o 9 . 0
Area Rate
407, 9 . 5
607o 9 . 0
Area Rate
5070 9.0
4070 8 . 0
107= 7 . 0
Area Rate
107o 9.5
507o 9.0
307o 8 . 0
10% 7 . 0
TSCHIRHART
Merit
2.85
6.30
9 15
Merit
3.80
5.40
. ..9.20
Merit
4.50
3.20
0.70
...8.40
Merit
0.95
4.50
2.40
0.70
...8.55
Comments: Avg. 8.54
B-ll
-------
TEST NO. SC-453
INTAKE MANIFOLD: 9.2 Carbon Rating
EGR PORT INTO INTAKE SYSTEM; 7.8 Carbon Rating
EGR LINE; 8.0 Carbon Rating
PISTON CROWN; 1 - 8.0
2 - 8.4
3 - 8.5
4 - 8.0
Avg. 8.22
CYLINDER BORE; 1
2
3
4
Good condition, no apparent distress,
Good condition, no apparent distress,
Good condition, no apparent distress,
Good condition, no apparent distress,
FUEL TANK; Fuel tank has trace amount of foreign material in bottom of tank.
Tank is in good condition. Bottom of tank has film like substance
that is in the 4.5 range on the CRC Varnish rating scale.
Top of tank - 9.8 Sludge
Bottom of tank - 9.8 Sludge
B-12
-------
*Non linkage throttle plate has light rust existence.
Appendix C
CARBURETOR MAKE
. BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
RECOMMENDED CARBURETOR RATING FORM
_ DATE 05-26-87 JEST # SC-453 RATER G. Tschirhart-
SECONDARY BBLS
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0 to 9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
*6.0 to < .001 "thick
Deposit < .015" > .001 "thick
Deposit > .015" thick
(1)
Linkage Barrel
% Area x
(2)
Left
Side
100%
100%
(1)
Right
Side
80%
20%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.50
0
7.50
Right
Side
6.00
1.00
0
7.00
Non-Linkage Barrel
% Area x
Left
Side
90%
10%
100%
Right
Side
100%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
_ Deposit
No.
Left
Side
6.75
0.50
0
7.25
Right
Side .
7.50
0
7.50
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = %; % Right Side = 100 x Right Depth = %
Left + Right Left + Right
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 7 . 25
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = 7 '.38
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x )=( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40% Left Side Available Area, 60% Right Side Available Area.
*CRC Varnish Rating Scale
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: C-83 DATE: 05-25-87
COMBUSTION CHAMBERS
No. 1 Area Rate Merit No. 2
50% 9.0 4.50
50% 8.0 4.00
Total 8.50 Total. . .
No. 3 Area Rate Merit No. 4
107o 9.0 0.90
90% 8.0 7.20
Total 8.10 Total . . .
Comments: Avg. 8.22
VALVES
INTAKE VALVES
No. Rate No. Rate
1 5.7 2 6.9
4 5.7
Comment s : Avg . 6.3
EXHAUST VALVES
No. Rate No. Rate
1 7.5 2 7.5
4 7.5
RATER: G. TSCHIRHART
Area Rate Merit
10% 9.0 0.90
90% 8.0 7.20
8.10
Area Rate Merit
20% 9.0 1.80
80% 8.0 6.40
. 8 20
No. Rate
3 6.8
No. Rate
3 7.5
Comments: Avg. 7.5
8-14
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: C-83
DATE: 05-25-87
RATER: G. TSCHIRHART
MANIFOLD RUNNERS
No. 1
Area
Rate
Merit
No. 2
Area
Rate
Merit
100%
8.0
8.00
100%
8.0
8.00
Total 8.00
Total 8.00
No. 3
Area
Rate
Merit
No. 4
Area
Rate
Merit
100%
8.0
8.00
100%
8.0
8.00
Total 8.00
Total 8.00
Comments: 8.00
HEAD PORTS -
No. 1
T0f-.jl
No. 3
Total
Area
80%
20%
Area
70%
20%
10%
Rate
9.5
8.0
Rate
9.5
8.0
7.0
Merit
7.60
1.60
. . .9.20
Merit
6.65
1.60
0.70
...8.95
INTAKE
No. 2 Area Rate
70% 9.5
30% 8.0
Total
No. 4 Area Rate
80% 9 . 5
20% 9 . 0
Total
Merit
6.65
2.40
... 9 . 05
Merit
7.60
1.80
...9.40
Comments: Avg. 9.15
B-15
-------
TEST NO. C-83
INTAKE MANIFOLD; 9.5 Carbon Rating
EGS PORT INTO INTAKE SYSTEM; 8.0 Carbon Rating
EGR LINE; 6.0 Carbon Rating
PISTON CROWN; 1 - 8.3
2 - 8.5
3 - 8.5
4 - 8.0
Avg. 8.32
CYLINDER BORE: 1 - Good condition, no apparent distress.
2 - Good condition, no apparent distress.
3 - Good condition, no apparent distress.
4 - Good condition, no apparent distress.
FUEL TANK: Fuel tank is in very good condition. No signs of rust,
Top of tank - 9.7 Varnish, 9.9 Sludge
Bottom of tank - 9.0 Varnish, 9.9 Sludge
B-16
-------
*Non linkage throttle plate has 100% rust.
Appendix C
RECOMMENDED CARBURETOR RATING FORM
CARBURETOR MAKE .
BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
.DATEQ5-25-87 TEST # C-83
SECONDARY BBLS.
.RATER G. Tschirhart
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0to9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
* 6.0 to < .001 "thick
Deposit < .015" > .001 "thick
Deposit > .015" thick
(D
Linkage Barrel
% Area x
(2)
Left
Side
100%
100%
(1)
Right
Side
100Z
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.50
0
7.50
Right
Side
7.50
0
7.50
Non-Linkage Barrel
% Area x
Left
Side
100%
100%
Right
Side
20%
80%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.50
0
7.50
Right
Side
1.50
4.00
0
5.50
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = %; % Right Side = 100 x Right Depth = %
Left + Right Left + Right
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 6.50
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = 7:50
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x ) = ( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40%left Side Available Area, 60% Right Side Available Area.
*CRC Varnish Rating Scale
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: C-202 DATE: 05-26-87 RATER: G. TSCHIRHART
COMBUSTION CHAMBERS
No. 1 Area Rate Merit No. 2 Area Rate Merit
30Z 9.0 2.70 20% 9.0 1.80
707o 8.0 5.60 807o 8.0 6.40
Total 8.30 Total 8.20
No. 3 Area Rate Merit No. 4 Area Rate Merit
107o 9.0 0.90 1007» 8.0 8.00
907o 8.0 7.20
Total 8.10 Total 8.00
Comment s: Avg. 8.15
VALVES
INTAKE VALVES
Rate No. Rate No. Rate
1 5.8 2 5.8 3 4.8
4 5.1
Comments: Avg. 5.4
EXHAUST VALVES
No. Rate No. Rate No. Rate
1 7.5 2 7.5 3 7.5
4 7.5
Comments: Ayg. 7.5
B-18
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.:
No. 1
Total
No. 3
Total
No. 1
Tnf-al
No. 3
Total
C-202
Area
507=
50%
Area
407o
60%
Area
107o
807.,
57o
5%
Area
307o
507,
107.
10%
DATE: 05-26-87
MANIFOLD RUNNERS
Rate Merit No. 2
9.5 4.75
8.5 4.25
9.00 Total . . .
Rate Merit No. 4
9.5 3.80
8.5 5.10
8 . 90 Total
Comments: 8.90
HEAD PORTS - INTAKE
Rate Merit No. 2
9.5 0.95
8.0 6.40
6.0 0.30
5.0 0.25
7.90 Total
Rate Merit No. 4
9.0 2.70
8.0 4.00
7.0 0.70
7.5 0.75
8.15 Total..
RATER: G. TSCHIRHART
Area Rate Merit
707o 9.5 6.65
3070 8.5 2.55
9 10
Area Rate Merit
1070 9.5 0.95
907, 8.5 7.65
8.60
Area Rate Merit
7070 9.0 6.30
2070 8.0 1.60
107o 7.0 0.70
8.60
Area Rate Merit
807o 9.0 7.20
207o 8.0 1.60
8.80
Comments: Avg. 8.36
B-19
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TEST NO. C-202
INTAKE MANIFOLD: 9.5 Carbon Rating
EGR PORT INTO INTAKE SYSTEM; 6.0 Carbon Rating
EGR LINE; 5,5 Carbon Rating
PISTON CROWN; 1 - 8.2
2 - 8.2
3 - 8.1
4 - 8.1
Avg. 8.15
CYLINDER BORE; 1 - Good condition, no apparent distress.
2 - Good condition, no apparent distress.
3 - Light scratch marks, possible stuck or broken ring.
4 - Good condition, no apparent distress.
FUEL TANK; Fuel tank is in very good condition. No signs of foreign material.
Top of tank - 9.9 Varnish, 9.9 Sludge, 9.0 Rust Rating
Bottom of tank - 9.9 Varnish, 9.9 Sludge
B-20
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CARBURETOR MAKE .
BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
Appendix C
RECOMMENDED CARBURETOR RATING FORM
_ DATE 05-26-87 TEST # C-202 RATER _jG Is-C-h-irhart
SECONDARYBBLS
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0to9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
*6.0to< .001 "thick
Deposit < .015" > .001 "thick
Deposit > .015" thick
(1)
Linkage Barrel
% Area x
(2)
Left
Side
100%
100%
(1)
Right
Side
100%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
7.50
0
7.50
Right
Side
7.50
0
7.50
Non-Linkage Barrel
% Area x
Left
Side
30%
70%
100%
Right
Side
100%
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
2.25
3.50
0
5.75
Right
Side
5.00
0
5.00
w
%
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = _ %; % Right Side = 100 x Right Depth =
Left + Right Left + RighT"
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 6.25
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = 6.62
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x ) = ( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40%'Left Side Available Area, 60% Right Side Available Area.
*CRC Varnish Rating Scale
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: C-232 DATE: 05-25-87 RATER: G. TSCHIRHART
COMBUSTION CHAMBERS
No. 1 Area Rate Merit No. 2 Area Rate Merit
100% 8.0 8.00 80% 8.0 6.40
20% 7.5 1.50
Total 8.00 Total 7.90
No. 3 Area Rate Merit No. 4 Area Rate Merit
50% 8.0 4.00 80% 8,0 6.40
50% 7.5 3.75 207» 7.5 1.50
Total 7.75 Total 7.90
Comment s; Avg. 7.89
VALVES
INTAKE VALVES
No. Rate No. Rate No. Rate
1 3.5 2 3.5 3 2.0
4 3.5
Comments: Avg. 3.1
EXHAUST VALVES
No. Rate No. Rate No. Rate
1 7.5 2 7.5 3 7.5
4 7.5
Comments: Avg. 7.5
B-22
-------
INDUCTION SYSTEM RATING SHEET
TEST NO.: C-232
No. 1 Area
807=
207o
Total
No. 3 Area
1007o
No . 1 Area
507»
507»
Tofal
No. 3 Area
507»
507c
Total
DATE: 05-25-87
MANIFOLD RUNNERS
Rate Merit No. 2
7.5 6.00
7.0 1.40
7.40 Total...
Rate Merit No. 4
5.5 5.50
5 . 50 Total
Comments: 6.18
HEAD PORTS - INTAKE
Rate Merit No. 2
8.0 4.00
5.0 2.50
6.50 Total...
Rate Merit No. 4
4.0 2.00
3.0 1.50
3 . 50 Total . .
RATER: G.
Area Rate
307o 6.5
707» 6.0
Area Rate
307» 6 . 0
707» 5.5
Area Rate
107, 8.0
307, 6.0
207= 4.0
407o 3 . 0
Area Rate
907» 8 . 0
10% 7.0
TSCHIRHART
Merit
1.95
4.20
6 15
Merit
1.80
3.85
5 . 65
Merit
0.80
1.80
0.80
1.20
4.60
Merit
7.20
0.70
7.90
Comments: Avg. 5.62
B-23
-------
TEST NO. C-232
INTAKE MANIFOLD: 7.7 Carbon Rating
EGR PORT INTO INTAKE SYSTEM; 5.0 Carbon Rating
EGR LINE; 5.0 Carbon Rating
PISTON CROWN: 1 - 7.8
2 - 7.9
3 - 8.0
4-7.5
Avg. 7.80
CYLINDER BORE: 1 - Good condition, no apparent distress.
2 - Good condition, no apparent distress.
3 - Good condition, no apparent distress.
4 - Good condition, no apparent distress.
FUEL TANK; Fuel tank is in very good condition. No signs of foreign material
Top of tank - 9.9 Sludge, 9.9 Varnish Rating
Bottom of tank - 9.9 Sludge, 9.9 Varnish Rating
-------
CARBURETOR MAKE
.BBLS.
USE SEPARATE SHEET FOR: PRIMARY BBLS.
Appendix C
RECOMMENDED CARBURETOR RATING FORM
_ DATE 05-25-87 TEST # C-232 RATER r,. TSr-hirhart
SECONDARY BBLS
DEPOSIT DESCRIPTION
Clean (no visible deposits)
* 10.0 to 9.0
Light discoloration
* 9.0 to 6.0
Definite (dark) discoloration
* 6.0 to < .001 "thick
Deposit < .015" > .001" thick
Deposit > .01 5" thick
(D
Linkage Barrel
°/oArea x
(2)
Left
Side
15%
5%
807c
100%
(1)
Right
Side
57»
57o
907o
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
1.12
0.25
2.00
0
3.37
Right
Side
0.38
0.25
2.25
0
2.88
Non-Linkage Barrel
% Area x
Left
Side
10%
907o
100%
Right
Side
207o
807»
100%
Depth
Factor
10.0
7.5
5.0
2.5
0
Total
Deposit
Number
Deposit
No.
Left
Side
0.50
0
0.50
Right
Side
1.00
0
1.00
ra
% OF TOTAL AREA BELOW THROTTLE PLATE AVAILABLE FOR DEPOSIT (CRC Test Sleeves (3): 40% Left; 60% Right)
% Left Side = 100 x Left Depth = %; % Right Side = 100 x Right Depth = %
Left + Right Left + Right
FOR 2/4 BBL CARBURETORS: AVG RIGHT DEPOSIT NO. = 0.5 x (RIGHT LINKAGE BARREL + RIGHT NON-LINKAGE BARREL) = 1 ._94
AVG LEFT DEPOSIT NO. = 0.5 x (LEFT LINKAGE BARREL + LEFT NON-LINKAGE BARREL) = i T 94
CARBURETOR MERIT RATING = (Avg. Left Dep. No. x % Available Area) + (Avg. Right Dep. No. x % Available Area)
Carburetor Merit Rating = ( x ) + ( x ) = ( ) + (
NOTES
1. The right side of the carburetor/sleeve is the one with idle fuel ports, transfer slot, and vac. ports.
The linkage barrel is the barrel adjacent to the carburetor linkages.
2. The left side of the carburetor/sleeve has no holes.
3. The CRC Carburetor Cleanliness Test Aluminum sleeve is considered to have 40% Left Side Available Area, 60% Right Side Available Area.
^
*CRC Varnish Rating Scale
-------
APPENDIX C
FUEL ADDITIVE ANALYSIS
-------
SOUTHWEST RESEARCH INSTITUTE
INTER-DEPARTMENTAL MEMORANDUM
TO: Sherrill Martin
FROM: Michelle Miller
SUBJECT: Additive Analysis of samples C-83, SC-239, SC-453, SC-205
C-202 and C-232
October 6, 1987
The following are the results from the analysis:
Additive A*
Sample # Unwashed Gum (mg/50ml) (ppma)
C-83 2.2 4.1
SC-239 1.5 0.0
SC-453 6.3 17.9
SC-205 9.8 28.7
C-202 11.3 155.6
C-232 13.7 11.0
Sample C-202 has normal amount of additive A added. In this
particular test procedure a high unwashed gum content correlates with
the amount of additive added. With this in mind, the high unwashed
gum value for C-232 could mean there is an additive that was undetected
by our procedure.
*Additive A's name cannot be given out. This is confidential
information between the sponsor and Southwest Research Institute.
MM:chl
C-2
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
•1. REPORT NO. 2.
EPA 460/3-88-006
4. TITLE AND SUBTITLE
Intake System Deposits and Gasoline/Alcohol Blend
7. AUTHOR(S)
Sherrill F. Martin
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Southwest Research Institute
Department of Emissions Research
6220 Culebra Road
Ann Arbor, Michigan 48105
12. SPONSORING AGENCY NAME AND ADDRESS
Environmental Protection Agency
2565 Plymouth Road
Ann Arbor, Michigan 48105
15. SUPPLEMENTARY NOTES
3. RECIPIENT'S ACCESSION-NO.
5. REPORT DATE
s May 1988
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-03-3353
13. TYPE OF REPORT AND PERIOD COVERED
Final (Sept. 1986 - Aug. 1987
14. SPONSORING AGENCY CODE
16. ABSTRACT
Six vehicles, four of them ethanol blend-fueled and two gasoline-fueled, were
examined for intake system deposits. The engines were partially disassembled,
photographs were taken, and deposits were evaluated by a professional rater.
Elemental analysis was made of the intake valve deposits.
i
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS b.lDENTIFI
Deposits Engine Valves Gasohc
Blends Intake Systems Blend
Fuel Tanks Intake
Fuel Additives
Ehtanol
18. DISTRIBUTION STATEMENT 19. SECURI
Release Unlimited Unclas
20. SECURI
Unclas
ERS/OPEN ENDED TERMS C. COS AT I Field/Group
)1
Fuels
2 Deposits
TY CLASS (This Report) 21. NO. OF PAGES
ssified 40
TV CLASS (This page) 22. PRICE
;sif ied
EPA Form 2220-1 (9-73)
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