2009-2011 Compliance Report
nsfine
ompimn
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ctivities
&EPA
United States
Environmental Protection
Agency
EPA-420-R-13-006
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2009-2011 Compliance Report
Vehicle Eneine
Complian
Activities
United States Environmental Protection Agency
Office of Transportation and Air Quality
1200 Pennsylvania Avenue, NW
Washington, DC 20460
EPA-420-R-13-006
December 2013
www.epa.gov/otaq
Contributors
Phil Carlson Holly Pugliese
Emily Chen Lynn Sohacki
Karen Danzeisen TrinaVallion
Chris Nevers Carl Wick
Bill Pidgeon Ching-Shih Yang
Editors
Amy Bunker MarkWolcott
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Table of Contents
List of Figures iv
I. Forward by the Compliance Division Director 1
Compliance Report Organization 6
II. Scope of EPA's Vehicle, Engine, Equipment, and Fuel Compliance Programs 8
A. Statutory Authority for EPA Regulation of Vehicles, Engines, Equipment, & Fuels 8
B. Scope of EPA Vehicle, Engine, & Equipment Regulations 8
C. Scope of EPA Fuel Regulations 12
III. Compliance Programs and Processes 13
A. Overview 13
1. Preproduction Programs 15
2. Production Programs 18
3. Postproduction Programs 19
4. Regulatory Flexibility Programs 19
5. Exemption Programs 20
B. Light-Duty Vehicles 21
C. Highway Motorcycles 34
D. Heavy-Duty Highway Engines 38
E. Nonroad Compression Ignition (NRCI) Engines 44
F. Nonroad Spark Ignition Engines 48
G. Recreational Vehicles 52
IV. Industry Statistics 57
Alternative Fuel and Alternative Fuel Conversions 57
Manufacturer Locations.... .... 64
in
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List of Figures
Figure F-l - Certificates of Conformity by Model Year 3
Figure F-2 - MY 2009-2011 Tier 2 Bin 5 NOx Certification Levels and Compliance Margins by Manufacturer 4
Figure F-3 - MY 2009-2011 Highway Motorcycle Engine Families by Manufacturer 5
Figure F-4 - MY 2009-2011 Construction and Agricultural Engine Families by Manufacturing Location 5
Figure 1 - Industry Sectors and Examples 6
Figure 2 - Environmental Statutes 8
Figure 3 - Vehicle and Engine Regulations and Implementation Dates 9
Figure 4 - Fuels Regulations and Implementation Dates 12
Figure 5 - Compliance Schedule Examples 14
Figure 6 - Certificates of Conformity by Model Year 16
Figure 7 -Vehicle and Engine Exemptions 20
Figure 8 - MY 2009-2011 Light-Duty Vehicle Test Groups by Manufacturer 22
Figure 9 - MY 2009-2011 Light-Duty Production Volume by Manufacturer 22
Figure 10 - Vehicles Tested in EPA's In-Use Testing Program in 2009-2011 25
Figure 11 - Example of IUVP Testing Process for a MY 2010 Vehicle 27
Figure 12 - Light-Duty Vehicle In-Use Verification Program Test Volumes and Failure Rates 27
Figure 13-2009-2011 CY Light-Duty Vehicle Defect Reports by Manufacturer 28
Figure 14 - 2009 - 2011 CY Light-Duty Vehicle Defect Reports by Problem Category 29
Figure 15-2009-201 ICY Light-Duty Vehicle Recalls by Manufacturer 30
Figure 16 - 2009-2011 CY Light-Duty Vehicle Recalls by Problem Category 31
Figure 17 - MY 2009-2011 Light-Duty Test Group Distribution by Tier 2 Emissions Bins 32
Figure 18 - MY 2009-2011 Tier 2 Bin 5 NOx Certification Levels and Compliance Margins by Manufacturer 32
Figure 19 - MY 2009-2011 Tier 2 Bin 5 NMOG Certification Levels and Compliance Margins by Manufacturer...33
Figure 20 - MY 2009-2011 Tier 2 Bin 5 CO Certification Levels and Compliance Margins by Manufacturer 33
Figure 21 - MY 2009-2011 Highway Motorcycle Engine Families by Class 34
Figure 22 - MY 2009-2011 Highway Motorcycle Manufacturers by Class 35
Figure 23 - MY 2009-2011 Highway Motorcycle Engine Families by Manufacturer 35
Figure 24- MY 2009-2011 Highway Motorcycle Production Volumes by Manufacturer 36
Figure 25-2009-2011 Highway Motorcycle Defect Reports by Problem Category 37
Figure 26 - MY 2009-2011 Heavy-Duty Highway Compression Ignition Engine Families by Service Class 39
Figure 27 - MY 2009-2011 Heavy-Duty Highway Spark Ignition Engine Families by Service Class 39
Figure 28 - MY 2009-2011 Heavy-Duty Highway Compression Ignition Engine Families by Manufacturer 39
Figure 29 - MY 2009-2011 Heavy-Duty Highway Spark Ignition Engine Families by Manufacturer 40
Figure 30 - 2009-2011 Heavy-Duty Highway Engine Defect Reports by Manufacturer 41
Figure 31 - 2009-2011 Heavy-Duty Highway Engine Defect Reports by Problem Category 41
Figure 32 - 2009-2011 Heavy-Duty Highway Engine Recalls by Manufacturer 42
Figure 33 - 2009-2011 Heavy-Duty Highway Engine Recalls by Problem Category 43
Figure 34 - MY 2009-2011 Marine Diesel Engine Certificates by Tier 44
Figure 35 - MY 2009-2011 Marine Diesel Engine EPA and IMO Certificates by Manufacturer 45
Figure 36 - MY 2009-2011 Locomotive and Engine Certificates by Manufacturer 45
Figure 37 - MY 2009-2011 Construction and Agricultural Engine Families by Service Class 46
Figure 38 - MY 2009-2011 Construction and Agricultural Engine Families by Manufacturer 47
Figure 39 - MY 2009-2011 Small Spark Ignition Engine Families by Class 48
Figure 40 - MY 2009-2011 Small Spark Ignition Engine Families by Manufacturer 49
Figure 41 - MY 2009-2011 Marine Spark Ignition Engine Families by Manufacturer 49
iv
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Figure 42 - MY 2009-2011 Large Spark Ignition Engine Families by Manufacturer 50
Figure 43 - MY 2009-2011 Nonroad Spark Ignition Evaporative Component Families by Manufacturer 51
Figure 44 - MY 2009-2011 Recreational Vehicle Engine Families by Manufacturer 53
Figure 45 - MY 2009-2011 ATV and UTV Engine Families by Manufacturer 53
Figure 46 - MY 2009-2011 Off-Highway Motorcycle Engine Families by Manufacturer 54
Figure 47 - MY 2009-2011 Snowmobile Engine Families by Manufacturer 54
Figure 48 - MY 2009-2011 Recreational Vehicle Two-Stroke Engine Families 54
Figure 49 - 2009-2011 Recreational Vehicle Defect Reports by Manufacturer 55
Figure 50 - 2009-2011 Recreational Vehicle Defect Reports by Problem Category 56
Figure 51 - 2009-2011 Recreational Vehicle Recall Reports by Manufacturer 56
Figure 52 - 2009-2011 Recreational Vehicle Recall Reports by Problem Category 56
Figure 53-MY 2009 Light-Duty Vehicle Production Volume by Fuel Type 58
Figure 54-MY 2010 Light-Duty Vehicle Production Volume by Fuel Type 58
Figure 55-MY 2011 Light-Duty Vehicle Production Volume by Fuel Type 59
Figure 56 - MY 2009-2011 Light-Duty OEM Diesel and Alternative Fuel Test Groups by Manufacturer 59
Figure 57 - MY 2009-2011 Light-Duty Alternative Fuel Conversion Certificates by Manufacturer 60
Figure 58 - MY 2009-2011 Highway Motorcycle OEM Alternative Fuel Engine Families by Manufacturer 62
Figure 59 - MY 2009-2011 Heavy-Duty Highway Engine OEM Alternative Fuel Engine Families by Manufacturer
Figure 60 - MY 2009-2011 Heavy-Duty Highway Engine Alternative Fuel Conversion Certificates by Manufacturer 62
Figure 61 - MY 2009-2011 Small Spark Ignition Engine OEM Alternative Fuel Engine Families 63
Figure 62 - MY 2009-2011 Large Spark Ignition Engine OEM Alternative Fuel Engine Families 64
Figure 63 - MY 2009-2011 Recreational Vehicle OEM Diesel Engine Families by Manufacturer 64
Figure 64 - MY 2009-2011 Light-Duty Vehicle Production Volume by Manufacturer's Country of Origin 65
Figure 65 - MY 2009-2011 Heavy-Duty Highway CI and SI Engines by Manufacturing Location 65
Figure 66 - MY 2009-2011 Marine Diesel Engine Families by Manufacturing Location 66
Figure 67 - MY 2009-2011 Locomotive Engine Families by Country of Origin 66
Figure 68 - MY 2009-2011 Construction and Agricultural Engine Families by Manufacturing Location 67
Figure 69 - MY 2009-2011 Small Spark Ignition Engine Families by Manufacturing Location 67
Figure 70 - MY 2009-2011 Marine Spark Ignition Engine Families by Manufacturing Location 68
Figure 71 - MY 2009-2011 Large Spark Ignition Engine Families by Manufacturing Location 68
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L Forward by the Compliance Division Director
I
3
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LU
2009 - 2011 Compliance Report
This is the third in a series of vehicle and engine compliance reports issued by
the U.S. Environmental Protection Agency (EPA) Office of Transportation and Air
Quality (OTAQ). These reports offer a convenient reference to the data that
OTAQ collects in implementing emissions regulations for vehicles, engines, and
other motorized equipment. The environmental programs OTAQ implements
apply to virtually every vehicle, engine and gallon of transportation fuel sold in
the United States. It is our job to make sure that these regulated mobile sources
comply with emissions and fuel economy requirements. OTAQ's role in ensuring
comprehensive compliance is essential to realizing national air quality and public
health goals.
This report updates and builds upon the data and information presented in the
first two reports, the "2007 Progress Report on Vehicle and Engine Compliance
Activities" (2007 Compliance Report) and the "2008 Progress Report on Vehicle
and Engine Compliance Activities" (2008 Compliance Report). The 2009-2011
Progress Report on Vehicle and Engine Compliance Activities (2009-2011
Compliance Report) presents certification data and other types of information
OTAQ collected for model years (MY) 2009 through 2011 and for calendar years
2009-20111.
OTAQ oversees a broad set of compliance activities to ensure that vehicle and
engine manufacturers satisfy their regulatory obligations. These activities
extend from pre- to post-production and range from issuing certificates of
conformity before vehicles and engines enter commerce to monitoring in-use
testing and reporting after they enter customer service. In addition to regulating
vehicles and engines, EPA regulates motor vehicle fuels, including gasoline,
diesel and renewable fuels such as ethanol and biodiesel. Please see EPA's fuels
web site, http://epa.gov/otaq/fuels/, for further information about OTAQ's fuel
compliance program.
We recommend that readers who are unfamiliar with EPA's mobile source
emission control programs refer to the 2007 Compliance Report for additional
background information, including descriptions of the vehicle, engine, and fuel
categories EPA regulates.
The 2009-2011 Compliance Report includes data from the following mobile
source sectors: light-duty vehicles, highway motorcycles, heavy-duty highway
engines, nonroad compression ignition engines, nonroad spark ignition engines
and recreation vehicles.
Some information is reported by model year while other types of information
(e.g., recalls and defects) are reported by calendar year.
US-EPA | Compliance Scope
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The purpose of the compliance reports is to offer a snapshot of compliance
activity over a given time frame. The years covered by the 2009-2011
Compliance Report represent a period of significant transition in the mobile
source program. Stringent new emission standards took effect for many
vehicle and engine categories, including motorcycles, heavy-duty highway
engines, nonroad compression-ignition and marine diesel engines,
locomotives, small spark-ignition and marine spark-ignition engines, and
recreational vehicles. In addition, EPA promulgated the first-ever mobile
source greenhouse gas emission standards, beginning with a light-duty vehicle
greenhouse gas rule in 2010. Heavy-duty highway greenhouse gas standards
followed in 2011. The greenhouse gas regulations do not take effect until
future years but manufacturers were already taking steps in the 2009-2011
timeframe to accrue early credits and to prepare for compliance mandates
starting in the 2012 model year. The 2009-2011 time period was also notable
for a rapid expansion of new certification and compliance activity in the
recreational vehicle, and small nonroad and marine engines sectors, as well
as an accelerating international dimension to EPA compliance oversight.
This report is also one of our deliverables on the President directives regarding
the need for and importance of transparency. From the President's memo on
Transparency and Open Government on www.whitehouse.gov: "Transparency
promotes accountability and provides information for citizens about what
their Government is doing. Information maintained by the Federal Government
is a national asset." This report provides a broad range of partners and stake-
holders access to the data collected and generated as part of the vehicle and
engine certification and compliance program.
The highlights that follow provide additional examples of information that is
available today and that is explained in more detail in the report.
Byron Bunker
Director, Compliance Division
Office of Transportation and Air Quality
USEPA National Vehicle and Fuel Emissions Laboratory
2565 Plymouth Road
Ann Arbor, Ml 48105
US-EPA | Compliance Scope
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Highlight 1 - Certification
EPA issued nearly 4,000 certificates of conformity in each of model years 2009-2011. While it is typical for
the number of certificates to fluctuate from year to year, the overall trend has been one of growth. EPA issued
2,520 certificates of conformity in 2000. Certification activity has increased significantly over the last decade.
Figure F-l
Certificates of Conformity by Model Year
Industry Sector
Light- Duly Vehicles
Highway
Motorcycles
Heavy-Duty Highway
Engines
Nonroad
Compression
Ignition Engines
Nonroad Spark
Ignition Engines
Recreational
Vehicles
Total
Category
Passenger cars and trucks
Independent commercial importers
Alternative fuel conversions
On-highway motorcycles
Compression ignition (mostly diesel)
Spark ignition (mostly gasoline)
Alternative fuel conversions
Evaporative emissions
Diesel powered equipment, such as tractors, generators,
construction equipment, forklifts, welders
Diesel boats and ships
Oceangoing vessels per International Maritime Organization
requirements
Locomotives
Small SI: Small nonroad gasoline powered equipment, such
as lawnmowers, string trimmers, chain saws, small
compressors, pumps, utility vehicles < 25 mph, snow
blowers, rammers, and floor cleaners
Marine SI: Gasoline boats and personal watercraft
Large SI: Large nonroad gasoline powered equipment, such
as forklifts, compressors, generators, and stationary
equipment
Evaporative components (mostly intended for small nonroad
gasoline and marine gasoline equipment)
All-terrain vehicles
Utility vehicles
Off-highway motorcycles
Snowmobiles
MY 2009
507
21
74
460
90
9
11
13
616
152
28
70
1,160
124
89
161
229
13
62
38
3,927
MY 2010
489
15
55
399
44
9
13
15
648
170
37
47
1,020
117
124
195
182
15
58
37
3,689
MY 2011
464
11
227
337
52
9
34
17
568
210
53
60
985
124
140
424
143
23
46
35
3,962
Highlight 2 - Light-Duty Manufacturers Design to Exceed Standards
EPA confirmatory test results show high compliance margins among light-duty pre-production vehicles,
meaning that their emission levels were significantly below the level the standards allow. For example, light-
duty vehicle NOx emissions were aboutone half of the applicable 0.07 grams per mile NOx standard.
US-EPA | Compliance Scope
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Figure F-2
MY 2009-2011 Tier 2 Bin 5 NOx Certification
Levels and Compliance Margins by Manufacturer
Ford
Volkswagen/ Audi
Mercedes-Benz
Mazda
Chrysler
Mit
General
subishi
Honda
Subaru
BMW
Nissan
Motors
Hyundai/Kia
Porsche
Toyota
Others
Tier 2 Bin 5 NOx Certification Levels
NOx Standard: 0.07
grams per mile
12011
12010
12009
-0.01 2.3E-16 0.01
0.02 0.03 0.04 0.05
NOx (grams per mile]
0.06
0.07
0.08
Highlight 3 - In-Use Surveillance, Defect Reporting, and Recall Requirements Prevent Potential
Problems in Millions of Vehicles and Engines
Manufacturers reported emission defects for a variety of components. The most prevalent defects reported
involved onboard diagnostic systems, catalysts, particulate filters, turbochargers, and fuel delivery and
exhaust systems. Manufacturers corrected a significant number of these defects through voluntary recalls.
From 2009 through 2011 manufacturers voluntarily recalled some 12 million cars (about 5% of registered
light-duty vehicles) and, 900,000 heavy-duty highway engines (more than 20% of heavy-duty registered
vehicles).
Highlight 4 - The Characteristics of Mobile Source Industries are Changing
The car and truck manufacturing sectors are dominated by relatively few very large companies. The more
recently regulated nonroad, small engine, and recreational vehicle industries are different, with literally
hundreds of very small manufacturers comprising the market. In the motorcycle industry, for example, about
US-EPA | Compliance Scope
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one half of the model year 2009 - 2011 certificates were issued to manufacturers who produced a small
number of engine families (grouped below as "Other").
Figure F-3
MY 2009-2011 Highway Motorcycle Engine Families by Manufacturer
Manufacturer
Piaggio Group Americas, Inc.
Yamaha Motor Corporation
American Suzuki Motor Corporation
American Honda Motor Co., Inc.
Kawasaki Motors Corp., U.S.A.
Carter Brothers Manufacture Co., Ltd.
Kymco USA
Harley-Davidson Motor Company
Ducati North America, Inc.
BMW
QlinkL.P.
Triumph Motorcycles America Ltd
Cobra Scooters
Big Bear American Made Choppers, Inc.
Xingyue USA, Inc
Other
Total
Number of Engine Families
MY 2009
30
31
30
18
16
9
10
12
7
7
7
6
6
5
5
261
460
MY 2010
31
27
23
13
15
12
11
8
9
8
7
6
5
5
5
214
399
MY 2011
26
28
14
14
13
9
11
7
10
5
4
7
3
0
3
183
337
Furthermore, while the set of vehicle and engine manufacturers historically subject to EPA regulation had
their headquarters and/or production facilities in the United States, today's manufacturers are based all over
the world.
Figure F-4
MY 2009-2011 Construction and Agricultural Engine Families by Manufacturing Location
Country
Japan
Germany
China
Italy
England
USA
Korea
India
Mexico
Sweden
Switzerland
France
Czech Republic
Austria
Number of Engine Families
MY 2009
193
83
60
46
47
43
31
23
8
8
7
8
2
1
MY 2010
195
83
65
49
47
47
36
25
7
2
11
7
2
1
MY 2011
179
75
43
50
32
21
27
22
8
9
3
2
2
-
US-EPA | Compliance Scope
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Country
Brazil
Belgium
Slovakia
Multiple countries1
Number of Engine Families
MY 2009
1
0
-
50
MY 2010
1
0
4
59
MY 2011
-
-
4
43
COMPLIANCE REPORT ORGANIZATION
This summary is followed by three chapters that cover the following topics:
• Chapter II, Scope of EPA's Vehicle, Engine, Equipment, and Fuel Compliance Programs, describes
the laws that authorize EPA's mobile source compliance activity.
• Chapter III, Compliance Programs and Processes, describes the compliance programs and processes
in more detail and provides compliance data and other information organized by industry sector.
Please refer to Figure 1 for examples of the vehicles, engines, and equipment that are included in
each industry sector.
• Chapter IV, Industry Statistics, presents some interesting statistics that are contained within the
compliance information that EPA collects.
Figure 1 - Industry Sectors and Examples
Industry Sector
Examples
Key
Light-Duty
Vehicles
Passenger cars, vans, SUVs, small trucks
Highway
Motorcycles
On-highway motorcycles, cruisers, choppers, scooters,
touring bikes, mopeds, street bikes
Heavy-Duly
Highway
Engines
Tractor-trailers (semi-trucks), buses, delivery and work
trucks
"Multiple countries" means that engines within an engine family are manufactured in more than one country.
US-EPA | Compliance Scope
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Nonroad
Compression
Ignition Engines
(Nonroad CI)
Construction and agricultural equipment, such as tractors,
generators, construction and road-work equipment,
welders
Marine diesel boats and ships, oceangoing vessels
Locomotives
Nonroad Spark
Ignition Engines
(Nonroad SI)
Small SI: lawnmowers, string trimmers, chain saws, small
compressors, pumps, snow blowers
Marine SI: inboard and outboard motorboats, jet-skis
Large SI: forklifts, large compressors, generators
Evaporative components: hoses, fuel tanks
All-terrain vehicles (ATVs), utility vehicles (UTVs), sand
cars, dune buggies, go karts
Recreational
Vehicles
Off-highway motorcycles
Snowmobiles
US-EPA | Compliance Scope
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IL Scope of EPA's Vehicle, Engine,
Equipment, and Fuel Compliance Programs
A. STATUTORY AUTHORITY FOR EPA REGULATION OF VEHICLES, ENGINES,
EQUIPMENT, & FUELS
EPA derives authority to do its work through a variety of environmental statutes enacted by Congress. Figure
2 outlines the primary environmental statutes that give EPA the authority to develop and implement its
mobile source clean air programs.
Figure 2 - Environmental Statutes
Statute
Clean Air Act (CAA)
Energy Policy and
Conservation Act (EPCA)
Energy Policy Act (EPAct)
Energy Independence and
Security Act (EISA)
Authority
Emission standards for highway & nonroad vehicles and their
Fuel economy information programs for consumers, including
fuel economy labels
fuels
vehicle
Annual volume standards for renewable fuel content
From locomotives to lawnmowers, EPA's Office of Transportation and Air Quality (OTAQ) has the authority
to regulate nearly all engines and vehicles that emit pollutants into the environment The statutory authority
also covers the fuels that power these mobile sources, and includes responsibility for emissions compliance
oversight that extends from initial product design to performance on the road or in the field.
B. SCOPE OF EPA VEHICLE, ENGINE, & EQUIPMENT REGULATIONS
Compliance programs play an essential role in achieving the benefits of statutes and regulations. OTAQ
oversees a comprehensive set of compliance activities to ensure that vehicle and engine manufacturers and
fuel refiners and producers satisfy their regulatory obligations. EPA regulation of motor vehicles began in the
1970s; Figure 3 lists vehicle and engine regulations that were proposed or established since 2004. For a
comprehensive list of EPA mobile source emission standards, refer to EPA's online Emission Standards
Reference Guide, available atwww.epa.gov/otaq/standards/index.htm. Please see Section II.C of this report
for a list of regulations applicable to motor vehicle fuels.
US-EPA | Compliance Scope
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Figure 3 - Vehicle and Engine Regulations and Implementation Dates
Affected Industry
Sector/Category
Program/Rulemaking Description
Effective
Model
Year2
Light-Duty Vehicles
Tier 2 Emission Standards and Gasoline Sulfur Fuel Control -
Strengthened emission standards for light-duty vehicles and
significantly reduced sulfur levels in gasoline
On-Board Diagnostics (OBD) -
Established new emissions system monitoring requirements for
light-duty diesel vehicles
Revisions to Motor Vehicle Fuel Economy Labeling -
Updated EPA method for determining fuel economy label values
to better represent typical driving patterns and more accurately
estimate actual consumer fuel economy
Mobile Source Air Toxics -
Set standards to lower gasoline benzene content, reduce cold
temperature exhaust emissions, and reduce evaporation and
permeation from portable fuel containers
Clean Alternative Fuel Vehicle and Engine Conversions3-
Updated anti-tampering provisions applicable to manufacturers
of clean alternative fuel conversion systems for highway vehicles
and engines
Light-Duty Greenhouse Gas (GHG) Emission Standards -
Established the first mobile source emission standards for
greenhouse gases including carbon dioxide, methane, and nitrous
oxide
Revisions and Additions to Motor Vehicle Fuel Economy Label -
Redesigned label provides new information on vehicle fuel
economy, energy use, fuel costs, and environmental impacts for
conventional and advanced technology vehicles
2004
2005
2008
2010
All*
2012
2013
2 Effective model year refers to the first year of a new program. Many programs are phased in over multiple model years.
3 This rule also applies to heavy-duty highway clean alternative fuel conversions.
4 .Although the regulation took effect with its promulgation in 2011, because it applies to tampering, it applies to any model year that
is subject to any emissions standard.
US-EPA | Compliance Scope
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Affected Industry
Sector/Category
Program/Rulemaking Description
Effective
Model
Year
Highway Motorcycles
Highway Motorcycle Exhaust Emissions-
Class I and II: Established more stringent HC and added new
optional hydrocarbons + oxides of nitrogen (HC+NOx) standards;
Added Class la (<50cc)
Class III: Established new Tier 1 HC+NOx standard
Class III: More stringent Tier II HC+NOx standard
Highway Motorcycle Permeation Emissions-
Established new evaporative/permeation standards for fuel
tank(s) and lines.
2006
2006
2010
2008
Heavy-Duty Highway
Engines and Vehicles
Light Heavy-Duty OBD -
Established OBD monitoring requirements for heavy-duty
chassis certified vehicles, and for engines certified for use in
heavy-duty vehicles between 8,500 and 14,000 pounds gross
vehicle weight rating (GVWRJ
Heavy-Duty Highway Rule -
Established more stringent exhaust emission standards for
heavy-duty vehicles and engines; required Ultra Low Sulfur
Diesel (ULSD) fuel (15 ppm sulfur maximum]
Heavy-Duty Engines OBD Rule -
New OBD monitoring requirements for engines certified for use
in heavy-duty vehicles above 14,000 pounds GVWR
Heavy-Duty GHG Standards -
Established first emission standards for greenhouse gas
pollutants from heavy-duty engines and heavy-duty vehicles
2004
2007
2010
2014
Nonroad
Compression
Ignition
Engines &
Equipment
Construction &
Agricultural
Tier 3/Interim Tier 4 -
Established more stringent emission standards for engines
between 37 and 560 kilowatts (50 and 750 hp)
Tier 4 Nonroad Diesel Rule -
Established more stringent emissions standards for all engines
greater than 19 kilowatts (25 hp) and lowered nonroad diesel
fuel sulfur to 15 ppm maximum
2006
2010
Marine
Diesel
Engines
Tier 3 and Tier 4 Emission Standards for Marine Diesel Engines -
Established more stringent emission standards for newly built
and remanufactured engines
2009
Locomotives
Tier 3 and Tier 4 Emission Standards for Locomotive Diesel
Engines -
Established more stringent emission standards for newly built
and remanufactured engines
2011
10
US-EPA | Compliance Scope
-------
Affected Industry
Sector/Category
Program/Rulemaking Description
Effective
Model
Year
Nonroad
Spark Ignition
Engines &
Equipment
Small Spark
Ignition
Engines
[Small SI]
Control of Emissions From Nonroad Spark Ignition Engines and
Equipment -
Established more stringent exhaust emission standards for Class
I [MY2012] and Class II [MY2011] engines below 19 kilowatts
and fuel permeation standards for all engines below 19 kilowatts
2011
2012
Marine Spark
Ignition
Engines
(Marine SI]
Control of Emissions From Nonroad Spark Ignition Engines and
Equipment -
Established first federal exhaust emission standards for
sterndrive and inboard Marine SI engines and increased the
stringency of exhaust emission standards for outboard and
personal watercraft engines. Established new evaporative
emission standards for all Marine SI engines
2010
Large Spark
Ignition
Engines
[Large SI]
New Emissions Standards for Large SI Engines -
Established new emission standards, diagnostic capability and
portable emission testing provisions
Tierl
Tier 2
2004
2007
Recreational Vehicles
New Exhaust Emission Standards for RVs -
Off-highway motorcycles, ATVs and UTVs
Snowmobiles
Tierl
Tier 2
Tire 3
New permeation standards for fuel components
2006
2006
2010
2012
2008
Aircraft5
Control of Air Pollution from Aircraft and Aircraft Engines;
Emission Standards and Test Procedures -
Established more stringent NOx exhaust emission standards for
aircraft engines
NOx Emission Standards for Aircraft Gas Turbine Engines -
Established new NOx emission standards for aircraft, engines
consistent with international standards
2005
2012
5 The Federal Aviation Administration has primary oversight responsibility for aircraft emissions compliance.
II
US-EPA | Compliance Scope
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C. SCOPE OF EPA FUEL REGULATIONS
In addition to regulating vehicles and engines, EPA regulates motor vehicle fuels, including gasoline, diesel,
and renewable fuels such as ethanol and biodiesel. Figure 4 describes both historical and current fuels
programs and implementation dates. For a comprehensive list of ongoing fuels regulations, please visit
http://www.epa.gov/otaq/fuels/publications.htm. Additional information can be found on the OTAQ website
at http://www.epa.gov/otaq/fuels/index.htm. Please see Section II.B of this report for recent regulatory
actions applicable to vehicles and engines.
Figure 4 - Fuels Regulations and Implementation Dates
Affected Fuel Type-
Applicable Fuel Producer or
Importer
Program/Rulemaking Description
Effective
Imple-
mentation
Date
Motor vehicle fuels and fuel
additives -
Gasoline and diesel refiners and
importers, renewable fuel
producers and importers, fuel
additive producers and
Fuels and Fuel Additives Registration System (FFARS) -
Mandatory registration program for motor vehicle
gasoline, diesel, and their additives sold in the U.S.
Requires all fuel and fuel additive manufacturers to
report the chemical composition of their products and
other technical, sales and health effects information
1975
Gasoline -
Gasoline Refiners and Importers
Volatility Standards -
Limits the vapor pressure of gasoline sold at retail
stations during the summer ozone season to reduce
evaporative emissions from gasoline, which contribute to
ground-level ozone formation
Oxygenated Fuel Requirements -
Establishes fuel oxygen standards to reduce carbon
monoxide emissions from motor vehicles during the
winter season
Reformulated Gasoline (RFC) -
Reduce smog-forming and toxic pollutants in U.S. cities
with worst smog pollution
Tier 2 Emission Standards and Gasoline Sulfur Regulations
Establishes stringent exhaust emission standards for all
fuel types and limits fuel sulfur levels to an average of 30
ppm
Mobile Source Air Toxics Regulations -
Limits the benzene content of gasoline and reduces toxic
emissions from passenger vehicles and gas cans
1989
1992
1995
2004
2011
Diesel -
Diesel Producers and Importers
Highway, Nonroad, Locomotive, and Marine Regulations -
Suite of rules for highway, nonroad, locomotive, and
marine diesel engines that requires ultra-low sulfur diesel
(ULSD), 15 ppm maximum
2006
12
US-EPA | Compliance Scope
-------
Affected Fuel Type-
Applicable Fuel Producer or
Importer
Program/Rulemaking Description
Effective
Imple-
mentation
Date
Renewable Fuels (e.g.
ethanol, biodiesel) -
Gasoline Refiners and Importers,
Renewable Fuel Producers,
Importers, Exporters, Marketers,
and Blenders
The Renewable Fuel Standard (RFS) -
RFS1-
Regulations established under the Energy Policy Act
(EPAct) of 2005 required 7.5 billion gallons of renewable
fuel to be blended into gasoline by 2012.
RFS2-
Regulations established under the Energy Independence
and Security Act (EISA) of 2007 expanded upon RFS1.
The RFS2 regulations require renewable fuel to be
blended into both gasoline and diesel fuel, as well as jet
fuel and heating oil in volumes that increase from 9
billion gallons in 2008 to 36 billion gallons in 2022.
2007
2010
IIL Compliance Programs and Processes
A. OVERVIEW
EPA uses a variety of testing and reporting programs to monitor compliance with emissions regulations.
The programs may apply to vehicles and engines before they are produced (preproduction), while they are
in production and after they are in customer service (postproduction). EPA has the authority and flexibility
to choose compliance strategies that best fit an industry sector at any given time. Factors that influence the
use of a particular compliance approach include regulatory requirements affecting a given industry sector,
the technology being used to meet the emission standards, industry-specific production processes and
cycles and sector or manufacturer size. This report describes compliance programs and activities that
OTAQ conducted in 2009 - 2011. Specifically, the report presents data we collected and analyzed pertaining
to MY 2009 - 2011 vehicles and engines, as well as test results and other types of information OTAQ
obtained during calendar years 2009-2011.6
EPA regulations typically give manufacturers some flexibility about how they will achieve emissions
compliance. Examples include emissions standards phase-ins, averaging, banking and trading (ABTJ
programs and several types of exemptions. This regulatory flexibility enables manufacturers to align their
business model with emissions requirements and sometimes allow manufacturers to earn credit for
introducing new technologies early. At the same time, some regulatory flexibilities introduce challenges to
compliance oversight because vehicles and engines subject to one regulation and set of standards may
legally certify to different emissions levels. This report includes some discussion of flexibility provisions
and presents data showing how manufacturers are using them.
6 This report presents the data we have received and compiled as of the date of publication. In some cases data sets may be
incomplete due to agency workload constraints, manufacturer under-reporting or error, and/or other issues. EPA continues to work
with manufacturers to improve compliance with all requirements. Failure to comply with the applicable regulations, including failure
to comply with all reporting requirements represents a violation of law that may result in enforcement action.
13
US-EPA |Compliance Overview
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EPA mobile source compliance programs allow for vehicle and engine testing and other compliance activity
that can generally be parsed into three life-cycle categories:
Preproduction activities include certification testing and reporting and other compliance processes
conducted before vehicles and engines are produced.
Production activities include audits and other compliance testing conducted on vehicles and engines
coming off the production line, but before they enter customer service.
Postproduction activities include in-use testing and reporting and other compliance processes conducted
after vehicles and engines enter customer service.
Figure 5 provides how EPA's compliance programs are related to one another.
Figure 5 - Compliance Schedule Examples
EPA's mobile source compliance processes seek to ensure that the vehicles and engines are fully
compliant with emissions standards throughout their full useful life. This is accomplished with a
variety of testing programs and other requirements that occur over the life of vehicles and engines.
This figure shows example compliance schedules for certain sectors. Other mobile source sectors
may differ with regard to the timing but generally follow similar protocols.
Compliance Schedule for Light-Duty Vehicles
EPA Confirmatory
Testing, Random
and Targeted
EPA Reviews
Final
Manufacturer
Application
EPA In-Use Surveillance Testing
EPA Action
Manufacturer Action
EPA Reviews Initial
Manufacturer
Application Vehicle Design
and Build
EPA Issues Certificate of
Conformity
0 Miles 10,000 Miles 20,000 Miles 50,000 Miles 90,000 Miles 120,000 Miles
Manufacturer Prototype
Vehicle Emissions and
Durability Testing
[Representative of
Production]
Low-Mileage In-Use
Verification Testing
Performed by Manufacturer
High-Mileage In-Use
Verification Testing
Performed by Manufacturer
End of Useful Life
(per CAA)
[Emission Levels
Predicted Via Certifica-
tion Durability Testing]
14
US-EPA |Compliance Overview
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Compliance Schedule for Certain Heavy-Duty Highway and Nonroad Engines
EPA Confirmatory Testing
EPA Selective Enforcement
Audit
EPA Action
Manufacturer Action
EPA
Reviews Initial
EPA Issues Certificate
EPA
Reviews Final
al Manufacturer
ication Application E
t
Manufacturer
Testing of F
Prototype Engine
Representative
of Production
1
of Conformity J EPA In-Use End of Useful Life
Begin Useful Testing 435,000 Miles or
Life 1 50 to 10,000 Hours Depending
ngine Design 0 Miles Engine/ Application
and Build /_ 0 Hours |
1
T " I
Manufacturer End of Useful Life (per CAA)
'reduction Line Manufacturer In-Use Emission Levels Predicted via
Testing Testing Certification Durability Testing
1. Preproduction Programs
CERTIFICATES OF CONFORMITY
Section 206 of the Clean Air Act (CAA) requires all engines and vehicles to be covered by a certificate of
conformity before they can enter commerce. A certificate of conformity is a license to produce products for
one model year constant with the vehicle description and any terms of the certificate. Certificates of
conformity are generally issued to a group of vehicles or engines having similar design and emission
characteristics. For light-duty vehicles, certificates are issued for each unique combination of exhaust test
group7 and evaporative family. For heavy-duty vehicles and nonroad equipment subject to engine
standards, the unit of certification is called an engine family. Test groups and engine families may include
multiple models. Conversely, different versions within a given model may be included in different engine
families or test groups.
Figure 6 shows the number of certificates that EPA issued in MY 2009 - 2011. It is typical for the number of
certificates to fluctuate from year to year. The drop in total certificates in model year 2010 may have
reflected the downturn in the global economy at that time. Overall the trend has been one of growth:
certification activity has increased significantly over the last decade. (In 2000 EPA issued 2,520 certificates
of conformity.)
7 An exhaust test group is a group of vehicle models with similar engines, drive trains and emission control systems. It represents a
group of vehicles or engines that have a similar design and emission characteristics.
15
US-EPA |Compliance Overview
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Figure 6 - Certificates of Conformity by Model Year
Industry Sector
Light- Duly Vehicles
Highway
Motorcycles
Heavy-Duty Highway
Engines
Nonroad
Compression
Ignition Engines
Nonroad Spark
Ignition Engines
Recreational
Vehicles
Total
Category
Passenger cars and trucks
Independent commercial importers
Alternative fuel conversions
On-highway motorcycles
Compression ignition (mostly diesel)
Spark ignition (mostly gasoline)
Alternative fuel conversions
Evaporative emissions
Diesel powered equipment, such as tractors, generators,
construction equipment, forklifts, welders
Diesel boats and ships
Oceangoing vessels per International Maritime Organization
requirements
Locomotives
Small SI: Small nonroad gasoline powered equipment, such
as lawnmowers, string trimmers, chain saws, small
compressors, pumps, utility vehicles < 25 mph, snow
blowers, rammers, and floor cleaners
Marine SI: Gasoline boats and personal watercraft
Large SI: Large nonroad gasoline powered equipment, such
as forklifts, compressors, generators, and stationary
equipment
Evaporative components (mostly intended for small nonroad
gasoline and marine gasoline equipment)
All-terrain vehicles
Utility vehicles
Off-highway motorcycles
Snowmobiles
MY 2009
507
21
74
460
90
9
11
13
616
152
28
70
1,160
124
89
161
229
13
62
38
3,927
MY 2010
489
15
55
399
44
9
13
15
648
170
37
47
1,020
117
124
195
182
15
58
37
3,689
MY 2011
464
11
227
337
52
9
34
17
568
210
53
60
985
124
140
424
143
23
46
35
3,962
16
US-EPA |Compliance Overview
-------
STA TIONARY SOURCES-
OTAQ assists EPA's Office of Air Quality Planning and Standards with certification procedures for
stationary engines. Stationary engines are used either in a fixed application or in a portable (or
transportable) application where the engine resides at a single site for at least one year. A given engine
may be certified as a mobile engine, stationary engine, or both. In 2009, of the 89 certificates of
conformity for the nonroad large spark ignition engine sector, 16 were for mobile-stationary applications
and 17 were for static nary-only applications. The remaining 56 certificates were for mobile-only
applications. In 2010, of the 124 certificates of conformity for the nonroad large spark ignition engine
sector, 21 were for mobile-stationary applications and 56 were for stationary-only applications. The
remaining 47 certificates were for mobile-only applications. In 2011, of the 140 certificates of conformity
for the nonroad large spark ignition engine sector, 37 were for mobile-stationary applications and 64
were for stationary-only applications. The remaining 39 certificates were for mobile-only applications. Of
the certificates of conformity issued for engines in the nonroad compression ignition diesel powered
equipment sector (616 in MY 2009, 648 in MY 2010 and 461 in MY 2011), 128 in MY 2009, 209 in MY
2010 and 189 in MY 2011 were for mobile-stationary engines. In both 2009 and 2010 only 5 engines were
certified as stationary-only engine families while 43 engines were certified as static nary-only engine
families in 2011.
APPLICATION FOR CERTIFICATION
The certification process begins when a manufacturer submits an application for certification to EPA.
Applications cover an exhaust test group or engine family that represents a group of vehicles or engines
having similar design and emission characteristics. EPA requires manufacturers to provide detailed
information in the certification application to show that the vehicles or engines meet all of the applicable
emissions requirements and to describe the vehicles or engines to be covered by the certificate of
conformity. Each certificate covers only those vehicles or engines specifically described in the application.
The list below summarizes the general types of information and data that manufacturers submit to begin
the application process:
• A description of the basic engine design and list of distinguishable configurations to be covered by the
certification application.
• An explanation of how the emission control system operates
• A description of the vehicle or engine being used to represent the group for certification testing.
• A description of the test procedures and equipment used to test the vehicle or engine
• All emission data obtained on each test vehicle or engine
• The emission deterioration characteristics for each regulated pollutant over the useful life of the vehicles
and engines covered by the certification application
The predicted production volumes of each configuration to be covered by the certificate
17
US-EPA |Compliance Overview
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• An unconditional statement attesting that vehicles or engines covered by the certification application
comply with all requirements of the applicable regulation and the CAA
• Manufacturer representative and official company contact information
• Durability groupings (i.e., groups of vehicles/engines with similar emission deterioration and emission
component durability]
• Durability test procedures
• Description of each test group or engine family which is represented by the durability test vehicle or
engine
• Description of vehicles or engines used to demonstrate emissions and emission control component
durability
• List of all test results, official certification levels, and the applicable emission standards for each vehicle or
engine tested
• Statement of compliance with the applicable emission standards for all other configurations not tested
but represented by the test vehicles or engine and covered by the certification application
• Evaporative emissions system information
• Description of the evaporative, permeation or refueling families covered by the certification application
and test results demonstrating compliance with the applicable standards
• Information on emission control diagnostic systems, where applicable
CONFIRMATORY CERTIFICATION TESTING
Manufacturers conduct the initial testing to support an application for a certificate of conformity and report
the results to EPA. Subsequent certification testing, called confirmatory testing, occurs after an application
has been submitted. Confirmatory tests are performed by either the manufacturer or by EPA and serve to
validate the manufacturer's initial emissions or fuel economy test results.
2. Production Programs
The objective of compliance activities that occur during production is to confirm that vehicles and engines
coming off production lines match specifications set forth in the certificate of conformity. In other words,
production programs are designed to verify that manufacturers are actually producing the same vehicle or
engine that they certified. Some mobile source regulations call for routine production line testing. EPA
may also audit production vehicles and engines without prior notice using selective enforcement audits.
IS
US-EPA |Compliance Overview
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3. Postproduction Programs
IN-USE COMPLIANCE PROGRAMS
In-use compliance programs track emissions performance of production vehicles or engines after they
enter customer service. In-use testing programs are conducted by both EPA and manufacturers.
DEFECT REPORTING PROGRAMS
Manufacturers are required to report emission-related defects to EPA. An emission-related defect is a
defect in design, materials or workmanship in a device, system or assembly, as described in the approved
application for certification. Manufacturers must report a defect even if it does not increase emission
levels. EPA regulations generally establish minimum numbers of confirmed defects that trigger defect
information reporting requirements. An emission-related defect does not necessarily lead to an emission
recall because not all defects in emission-related parts increase emissions.
RECALL PROGRAMS
An emissions recall is a repair, adjustment or modification program conducted by a manufacturer to
remedy an emission-related problem. Vehicle and engine manufacturers are required to design and build
their products to meet emission standards for the useful life of the vehicle or engine specified by law.
Under Section 207(c)(l) of the CAA, if EPA determines that a substantial number of vehicles or engines in
a category or class do not meet emission standards in actual use, even though they are properly
maintained and used, EPA can require the manufacturer to recall and fix the affected vehicles and engines.
EPA may use a variety of data sources including EPA and manufacturer test results to determine that a
recall is necessary. The purpose of a recall is to make sure the problem gets fixed and thereby prevent
excessive pollution from vehicles or engines that are already in customer service. When an emissions
recall occurs, the manufacturer must notify vehicle owners and provide instructions about how to have
their vehicle repaired. Most recalls are initiated voluntarily by manufacturers once potential
noncompliance is discovered; however, EPA also has the authority to order the manufacturer to recall and
fix noncompliant vehicles or engines if the manufacturer declines to implement a voluntary recall.
4. Regulatory Flexibility Programs
EPA builds flexibility into its emissions regulations to increase compliance efficiency, decrease costs and
encourage manufacturers to introduce new technologies.
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
Average Banking and Trading (ABT) provisions allow manufacturers to meet an overall fleet average
standard instead of an individual vehicle or engine standard. Manufacturers may comply with ABT
provisions by certifying some vehicles and engines at levels above the emission standard, provided that
these emission "deficits" are offset by positive credits from vehicles and engines certified below the
standard. Compliance is determined by calculating the manufacturer's fleet-wide average of each exhaust
test group's production or sales volume and emission level. The flexibility to meet fleet average emission
standards by ABT credits can facilitate earlier introduction of clean technology into the market.
19
US-EPA |Compliance Overview
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TRANSITION PROGRAM FOR EQUIPMENT MANUFACTURERS
The Transition Program for Equipment Manufacturers (TPEM) recognizes a potential challenge that can
face equipment manufacturers when new emission standards take effect If engines, of which there are
relatively few designs, must be redesigned to achieve the required emission reductions, equipment
powered by those engines, of which there could be 10,000 or more designs, may also need to be
redesigned. TPEM permits equipment manufacturers a transition period during which they may continue
to use a limited number of engines meeting previous standards while they update product designs to
accommodate engines meeting the new standards.
5. Exemption Programs
Vehicles and engines imported into the United States may be eligible for an exemption from federal
emission requirements. For example, vehicles belonging to military personnel or nonresidents may be
eligible for exemption. Vehicles that are being imported for testing or display may also be exempt.
Depending on the type of exemption, importers must request written EPA approval in advance. EPA works
with the Department of Homeland Security U.S. Customs and Border Protection to ensure that proper
approvals have been issued before vehicles and engines may enter the United States. The majority of the
1,469 import exemptions EPA issued in 2009, the 1,778 exemptions issued in 2010 and the 1,732
exemptions issued in 2011 were for light-duty vehicles (less than 0.02%). The majority of exemptions EPA
issued for heavy-duty highway and nonroad engines or equipment were for test programs. EPA issued 90
heavy-duty or nonroad exemptions in 2009,158 in 2010 and 245 in 2011 (less than 0.05%). An
exemption may cover multiple vehicles and/or engines. Figure 7 summarizes the exemptions that EPA
issued in calendar years 2009 - 2011.
Figure 7 - Vehicle and Engine Exemptions
800
700
600
500
400
300
200
100
589
12009
12010
12011
445
131 123>
Mil
Military
Nonresidential Repair or
Alteration
Testing
Display Racing Competition
20
US-EPA |Compliance Overview
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B. LIGHT-DUTY VEHICLES
SECTOR PROFILE:
• The light-duty vehicle sector includes passenger vehicles such as cars, vans, SUVs, and light-
trucks
• Light-duty vehicles have been subject to increasingly stringent emissions and fuel economy
standards since the 1970s
• Primary emission standards in effect for MY 2009-2011 are Tier 2 emission standards for HC,
CO, NOx, and PM
PRIMARY COMPLIANCE ACTIVITIES IN 2009 -2011:
• Certification and fuel economy
• EPA and manufacturer confirmatory and in-use testing
• Defect reporting
• Recall
• Early credit for reducing greenhouse gas emissions described here.
CERTIFICATION
EPA issued about 500 certificates to light-duty vehicle8 original equipment manufacturers (OEMs) each
year in MY 2009 - 2011 (see Figure 6). Figure 8 shows the number of certified test groups for MY 2009 -
2011 by manufacturer.9
PRODUCTION VOLUME
Figure 9 presents by manufacturer the number of MY 2009-2011 cars and light-duty trucks produced for
sale in the United States.10 A comparison of Figures 8 and 9 shows that there is not always a correlation
between the number of test groups a manufacturer certifies and the number of vehicles the manufacturer
produces. Manufacturers with the most certified test groups do not necessarily produce the most vehicles.
8 Some heavy-duty vehicles that are between 8,500-14,000 pounds GVWRare chassis-certified and are included in the light-duty
vehicle certificate count.
9 Each light-duty vehicle certificate covers a unique combination of exhaust test group and evaporative emissions family. Therefore
the number of light-duty certificates and test groups is usually different. Manufacturers may create test groups that include both cars
and trucks.
10 These production data only include vehicles subject to Corporate Average Fuel Economy standards.
US-EPA |Light-Duty Vehicles
-------
Figure 8 - MY 2009-2011 Light-Duty Vehicle Test Groups by Manufacturer11
2011 Truck
2011 Car
2010 Truck
2010 Car
2009 Truck
2009 Car
Figure 9 - MY 2009-2011 Light-Duty Production Volume by Manufacturer
3,000,000
2,500,000
2,000,000
1,500,000
2011 Truck
• 2011 Car
2 010 Truck
• 2010 Car
2009 Truck
• 2009 Car
1,000,000
500,000
11 In MY 2010, two manufacturers created test groups that included both cars and trucks. One General Motors car/truck test group
and two BMW car/truck test groups are counted under the "MY 2010 Car" category in Figure 8.
US-EPA |Light-Duty Vehicles
-------
CONFIRMATORY TESTING
EPA and manufacturers test pre-production vehicles and engines prior to their introduction into commerce
to confirm initial manufacturer emission test results. When a vehicle fails a confirmatory test, the
manufacturer is allowed one retestto confirm or refute the failure. If the vehicle passes on retest, the retest
is deemed the official certification test and the results from the retest stand as the official emission levels
for that vehicle. Sometimes a confirmatory test failure can be attributed to problems that render the test
vehicle unrepresentative of production vehicles. In those situations, the manufacturer corrects the problem
in the test vehicle and retests. In still other cases, failures over the confirmatory test reflect actual
engineering problems. These types of failures usually result in manufacturer action to change the vehicle
calibration and update the certification application accordingly, resulting in a quantifiable emissions
reduction for the vehicles that are ultimately produced. Regardless of whether a confirmatory test failure is
due to problems with the test vehicle or problems with the calibration, the problems must be corrected and
the vehicle must pass confirmatory testing before EPA will issue a certificate.
FUEL ECONOMY TESTING
EPA and manufacturers perform confirmatory testing for both emissions and fuel economy validation
purposes. Fuel economy test results are the source for information that appears on new vehicle fuel
economy labels and that EPA and the U.S. Department of Transportation use to assess compliance with
corporate average fuel economy (CAFE) standards.
On May 7, 2010, EPA and the National Highway Safety Administration (NHTSA) published a final rule to
regulate carbon dioxide (CCh) and other GHG emissions from light-duty vehicles. The greenhouse gas and
fuel economy standards apply to passenger cars, light-duty trucks and medium-duty passenger vehicles,
covering model years 2012 through 2016. The program design enables manufacturers to use a single data
set to satisfy both greenhouse gas and CAFE compliance requirements. EPA has been working with
manufacturers to implement these regulations and expects to begin reporting greenhouse gas data as the
program matures.
EPA reports fuel economy test data in an annual Fuel Economy Trends Report12 which includes both
laboratory test value results and results adjusted for real-wo rid driving conditions.
12 See http://www.epa.gov/oms/fetrends.htm for the latest Light-Duty Automotive Technology, Carbon Dioxide Emissions, and Fuel
Economy Trends Report.
US-EPA |Light-Duty Vehicles
-------
DURABILITY TESTING
The CAA requires EPA emission standards to apply for the full useful life of the vehicle. Since emissions
may degrade as vehicles age and accrue miles, manufacturers must perform durability testing to
demonstrate that a vehicle will remain compliant for its full useful life, despite any deterioration that may
occur over time. EPA regulations establish processes by which manufacturers may demonstrate durability
using standard or custom methods. All the other manufacturers chose to use proprietary methods to
estimate. Manufacturers who use their own durability aging procedures must provide EPA with an
"equivalency factor" that enables comparison between the proprietary method and the published, standard
EPA method. This allows a third party who relies on the EPA method to replicate the manufacturer's
method.
IN-USE COMPLIANCE TESTING
Both EPA and manufacturers conduct testing to monitor in-use vehicle emissions. EPA conducts in-use
vehicle surveillance testing at the National Vehicle and Fuel Emissions Laboratory in Ann Arbor, Michigan.
The purpose of the EPA surveillance program is to assess emissions performance a few years after vehicles
enter the fleet EPA typically recruits two- or three-year-old vehicles from volunteers in southeast
Michigan. EPA selects vehicles for surveillance both randomly and based on certification data,
manufacturer in-use verification data, vehicle production volume, new technology, and public complaints
and inquiries. In both 2009 and 2010, EPA selected about 45 classes per year for surveillance and generally
tested three vehicles from each selected class. In 2011 EPA selected 50 classes and tested two vehicles per
class. If any of the initial vehicles within a class failed a test, EPA recruited additional vehicles from that
class for follow-up testing to determine whether an emissions problem was likely to exist and was not an
artifact of the small sample size (or even a single defective vehicle).
EPA also conducts an in-use confirmatory testing program for vehicle classes that merit closer scrutiny.
These classes may be indentified through failures in either EPA in-use surveillance or manufacturer in-use
testing programs.
Figure 10 on the next page shows the vehicle model year, manufacturer, and carline selected for EPA
surveillance testing in 2009-2011.
US-EPA |Light-Duty Vehicles
-------
Figure 10 - Vehicles Tested in EPA's In-Use Testing Program in 2009-2011
Model
Year
Manufacturer
Model
Surveillance Classes
2005
2005
2006
2006
2006
2006
2006
2006
2006
2006
2006
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2008
2008
2008
2008
2008
2008
2008
2008
2008
Hyundai
Volkswagen
BMW
Chrysler
Ford
General Motors
Honda
Mercedes Benz
Porsche
Toyota
Volkswagen
Audi
BMW
DaimlerChrysler
Ford
GM-Daewoo
General Motors
Honda
Hyundai
Jaguar
Kia
Mazda
Mercedes Benz
Mitsubishi
Nissan
Subaru [Fuji]
Toyota
Volvo
Audi
BMW
Chrysler
Ford
General Motors
GM-Daewoo
Honda
Hyundai
Kia
Elantra (2.0)
Touareg [3.2]
M3, M3 CONVERTIBLE [3.2]
Jeep Liberty 2WD/4WD [3.7]
Freestar Wagon FWD [4.2]; F150 2WD [5.4]
Trailblazer, Rainier, Envoy (6.0); Chevrolet Colorado, Canyon,
Isuzu 1280 [2.8]
Pilot 2WD [3.5]
E320CDI[3.2]
Carrera (3.8)
Scion XB [1.5]
Jetta [1.9]
Audi Q7 and Touareg [4.2]
328i, 328xi [3.0]; Mini Cooper [1.6]
Dodge Caliber [2.4]; Pacifica [4.0]; Wrangler 2WD,4WD [3.8];
Nitro 2WD [3.7]
Expedition 2WD, Navigator 2WD [5.4]; Lincoln-Mercury, MKZ
AWD/FWD [3.5]; 500 FWD [3.0]
Aveo [1.6]
Saturn Outlook 4WD & AWD [3.6]; Several 5. 3L vehicles;
Chevrolet Malibu [2.4]; Chevy Impala [3.5]; Saab 9-3 [2.3];
Fit [1.5]
Tucson [2.7]
Jaguar S-type, VDP, XJ8, XK [4.2]
Sedona, Hyundai Entourage [3.8]
CX-7 [2.3]; Mazda 3 [2.3];
HL450 4Matic [4.6]
Outlander 2WD 4WD [3.0]; Galant [2.4]
Altima [2.5]; Frontier 2WD & 4WD [4.0]; Versa [1.8]; Frontier
[2.5]
Impreza AWD, Wagon/Outback [2.5]
Camry Hybrid [2.4]; Corolla [1.8]; Lexus: LS 460, LS 460L [4.6];
Sienna [3.5]
XD 90 AWD, XC 90 FWD [3.2]
Audi A6 [3.1]; Passat, Gtt, Jetta Passat [2.0]
335 [3.0]
Jeep Liberty 4WD [3.7]; Dodge Dakota 2WD & 4WD [3.7];
Charger [5.7]
F150 [5.4]; Focus [2.0]; Escape Hybrid [2.3]; F150 XL FFV [5.4];
Explorer 4WD [4.0]
GM Chevrolet Cobalt [2.4]; CIS Silverado 2WD [4.3]; Saturn Astro
[1.8]; Yukon Denali + XL [6.2];
Suzuki Forenza Reno [2.0]
Accord [2.4]; Civic Hybrid [1.3]; Odyssey [3.5]
Tucson 2WD, 4WD [2.7]
Kia Rondo [2.4]
US-EPA |Light-Duty Vehicles
-------
Model
Year
Manufacturer
Model
Surveillance Classes
2008
2008
2008
2008
2008
2008
2008
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
Land Rover
Mazda
Mercedes Benz
Mitsubishi
Nissan
Subaru [Fuji]
Toyota
Audi
BMW
Chrysler
Ford
General Motors
Honda
Hyundai
Kia
Land Rover
Mazda
Mercedes Benz
Mitsubishi
Nissan
Subaru [Fuji]
Suzuki
Toyota
Volkswagen
Volvo
LR2 (3.2)
CX-9 2WD, 4WD (3.7)
C300,C350,CLK350,E350 (3.5)
Lancer (2.0)
Versa (1.8)
Impreza (2.5)
Toyota Lexus GX470 (4.7); Lexus IS 250 (2.5); Camry (2.4)
A4,A5, Quattro(2.0)
335 CI, 335 I (3.0)
Dodge Caravan (3.8); Dodge Ram 1500 (5.7); Dodge Journey
(4.0); Dodge Charger (3.5); Dodge Ram 1500 (4.7)
F150 FFV (5.4); Escape Hybrid (2.5); Escape (2.5); Focus (2.0);
Fusion (3.0); F150 (5.4)
Saab 9-3 (2.3); Chevrolet Malibu (2.4); Saturn Vue Hybrid (2.4);
Chevrolet HHR (2.4); Chevrolet CIS Silverado (5.3); Envoy,
Trailblazer (4.2)
Pilot (3.7); CR-V (2.4); Civic (1.8); Accord (2.4)
Sonata (2.4); Santa Fe (2.7)
Optima (2.4); Rio (1.6); Sportage (2.0)
LR3, Range Rover Sport (4.4)
Mazda 5 (2.3)
Smart for 2 (1.0)
Galant (2.4); Eclipse and Eclipse Spyder (2.4)
350Z (3.5); Murano (3.5); Versa (1.8)
Subaru Forester (2.5); Outback Wagon (3.0)
SX4 (1.9)
Sienna (3.5); Highlander Hybrid (303); Yaris (1.5); Corolla (1.8);
Camry Hybrid (2.4)
Jetta (2.5)
C30, C70, S40, V50 (2.4)
In addition to its own in-use testing, EPA uses data from the mandatory manufacturer run In-Use
Verification Program (IUVP) to monitor in-use light-duty vehicle emissions performance. IUVP tests are
required at low mileage (between 10,000 and 50,000 miles) and high mileage (greater than 50,000 miles).
Manufacturers must complete low mileage IUVP testing one year after the end of production and complete
high mileage IUVP testing five years after the end of production. Figure 11 on the next page shows a sample
IUVP test schedule for a MY2010 vehicle.
US-EPA |Light-Duty Vehicles
-------
Figure 11 - Example of IUVP Testing Process for a MY 2010 Vehicle
2009
2010
2011
2012-2013
2014
2015
Ql Q2 Q3 Q4 Ql Q2
Q3 Q4 Ql Q2
Q3 Q4 Ql
Q4 Ql Q2
Q3 Q4 Ql Q2
Q3 Q4
Production
period
Low Mileage
Testing JL
High Mileage
Testing JL
= Testing is due for completion on or before this date
Figure 12 shows the total number of vehicles tested over each test procedure and their corresponding
failure rates by vehicle model year for all IUVP testing conducted and reported through January 2011.
Figure 12
Light-Duty Vehicle In-Use Verification Program Test Volumes and Failure Rates
Model
Year
FTP
Vehicles
Tested
Failure
Rate
US06
Vehicles
Tested
Failure
Rate
2-Day Evap
Vehicles
Tested
Failure
Rate
ORVR«
Vehicles
Tested
Failure
Rate
High-Mileage Testing
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
481
1147
1135
1185
1173
1103
935
1115
264
23
6.4%
4.2%
5.2%
4.2%
3.8%
3.5%
4.9%
2.9%
8.0%
0.0%
0
18
91
254
819
782
671
781
209
16
N/A
5.6%
3.3%
2.0%
1.5%
1.2%
0.8%
1.9%
0.0%
6.3%
38
103
105
121
158
142
114
120
43
6
0.0%
3.9%
3.8%
5.0%
4.4%
4.2%
1.8%
4.2%
7.0%
0.0%
20
76
77
101
142
140
121
127
53
7
10%
6.6%
9.1%
7.9%
4.9%
5.7%
0.8%
6.3%
7.6%
14.3%
Low-Mileage Testing
2004
2005
2006
2007
2008
2009
2010
2011
670
654
654
724
649
530
556
480
4.8%
4.6%
3.8%
3.9%
4.3%
3.8%
3.1%
2.5%
621
589
569
602
557
479
489
425
1.5%
0.9%
0.9%
0.3%
0.2%
0.4%
0.0%
1.2%
167
156
152
143
128
116
141
125
5.4%
3.9%
2.0%
1.4%
1.6%
6.9%
2.1%
0.8%
150
145
154
149
130
127
149
130
7.3%
3.5%
5.2%
4.0%
4.6%
0.8%
0.7%
2.3%
Overall, the test results from this program show that the majority of the in-use fleet continues to comply
with the emission standards. However, when IUVP testing identifies potential emissions concerns, EPA and
manufacturers work together to implement solutions which may involve voluntary manufacturer action to
fix the problem, or, if necessary, an EPA-ordered emissions recall. This process is described in greater
detail in the 2007 Compliance Report.
i3 Onboard refueling vapor recovery (ORVR) is a vehicle emission control system that captures fuel vapors from the vehicle gas tank
during refueling. This requirement was phased-in from 1998 through 2006. It appears that the failure rate is generally decreasing.
US-EPA |Light-Duty Vehicles
-------
DEFECT REPORTING
Figures 13 and 14 present2009 - 2011 calendaryear light-duty vehicle emission defect report information.
Defects reported in 2009 -2011 potentially affected more than 57 million vehicles. A single defect incidence
may affect multiple model years of a given vehicle.
Light-duty vehicle manufacturers are required to notify EPA when they learn of emission-related defects in
25 or more vehicles of the same class (e.g., exhaust test group) and category (e.g., manufacturer, model
year).
Figure 13 - 2009-2011 CY Light-Duty Vehicle Defect Reports by Manufacturer
Manufacturer
Bentley
BMW
Chrysler
Cummins
Ford
General Motors
Honda/Acura
Hyundai
Jaguar
Kia
Lamborghini
Land Rover
Mazda
Mercedes-Benz
Mitsubishi
Nissan/Infiniti
Porsche
Rolls Royce
Rousch
Subaru
Suzuki
Toyota/ Lexus
Volkswagen/ Audi
Volvo
Total
Reported in CY2009
Number of
Defect
Reports
5
10
33
1
12
10
21
8
3
9
1
2
8
5
5
23
53
-
-
5
-
3
28
2
247
Number of
Affected
Vehicles
22,109
184,143
2,647,013
157
2,936,701
849,594
5,488,140
963,385
18,619
572,562
139
53,237
761,000
954,611
45,386
2,576,199
253,990
-
-
454,814
-
1,705,800
1,024,318
231,355
21,743,272
Reported in CY2010
Number of
Defect
Reports
-
17
18
2
11
11
9
12
4
10
-
4
13
7
1
21
17
2
-
1
1
4
13
1
179
Number of
Affected
Vehicles
-
342,059
2,170,741
211,305
1,816,928
684,655
3,711,978
469,805
70,828
620,411
-
208,491
807,700
292,246
157,314
3,341,602
56,220
595
-
384,984
11,819
892,300
619,951
6,971
16,878,903
Reported in CY2011
Number
of Defect
Reports
2
21
16
-
14
12
20
14
4
9
-
8
12
12
3
15
5
-
2
4
1
3
26
5
208
Number of
Affected
Vehicles
2,369
497,010
2,109,506
-
2,123,801
2,091,073
2,871,321
1,435,048
131,357
475,043
0
371,850
1,180,484
936,202
1,661
2,255,282
62,550
-
1,415
478,217
4,174
668,680
762,073
737,627
19,196,743
Figure 13 shows the number of defect reports submitted for each manufacturer in 2009 - 2011 calendar
year and the number of affected vehicles. The vehicle model years that are covered by the defect reports
US-EPA |Light-Duty Vehicles
-------
submitted in 2 009 - 2011 calendar years range from MY 2001 through 2 011.14 Manufacturers are required
to report defects up to five years after the end of production.
Figure 14 shows the number of defects by defect category for all the vehicles covered by defect reports in
2009-2011 calendar years.
Figure 14 - 2009 - 2011 CY Light-Duty Vehicle Defect Reports by Problem Category
Problem Category
Air Inlet/Intake System
Catalyst System
Computer Related (other than
OBD)
Crankcase Ventilation System
Drivability Problem
EGR System
Electrical, Mechanical &
Cooling Systems
Emission Control Information
Evap Emissions System
Exhaust System
Fuel Delivery System
Fuel Tank System
Hybrid Vehicle System
Ignition System
Intake/Exhaust Manifold
Internal Engine Component
Monitoring/Measuring
Sensor/System
OBD System
Other
Oxygen Sensor
Selective Catalytic Reduction
Turbocharger/Supercharger
Total
Reported in CY2009
Number
of Defect
Reports
25
21
3
2
2
19
3
14
6
23
14
2
11
10
24
58
1
9
247
Number of
Affected
Vehicles15
1,651,327
4,615,410
187,429
2,116,987
485,755
2,878,703
13,606
1,033,398
309,888
1,861,491
2,177,608
25,840
378,428
1,362,544
6,460,405
5,566,516
157
3,238,400
34,363,892
Reported in CY2010
Number
of Defect
Reports
11
19
1
1
2
13
3
12
3
18
11
1
7
3
27
36
-
11
179
Number of
Affected
Vehicles
1,643,927
2,473,670
1,991,813
88,063
621,929
1,540,914
36,619
968,646
123,221
1,529,698
2,235,022
25,810
1,876,995
155,205
3,415,266
2,500,612
-
511,651
21,739,061
Reported in CY2011
Number
of Defect
Reports
6
7
22
3
0
3
29
4
20
4
10
22
0
6
3
1
15
40
1
7
2
3
208
Number of
Affected
Vehicles
752,695
267,647
2,754,463
97557
0
480,845
3,188,305
2,936
2,252,586
409,419
185,005
3,150,623
0
575,421
204,248
612,518
1,086,995
2,330,438
8,314
608,779
18,219
209,730
19,196,743
14 Defect and recall reports can be submitted in the calendar year prior to the designated model year because vehicles can be certified
and introduced into commerce starting January 2 of the prior year. For example, MY 2014 vehicles can be certified and introduced
into commerce starting January 2,2013.
15 Vehicles that have defects in more than one category are counted in each problem category. Thus, the total number of affected
vehicles can be higher in Figure 16 than the total number of affected vehicles in Figure 15.
US-EPA |Light-Duty Vehicles
-------
RECALL REPORTING
Figure 15 shows the number of light-duty vehicle recalls by vehicle manufacturer in 2009 - 2011 calendar
years. Because a recall usually covers a single, specific condition, a vehicle with multiple emissions
problems may be subject to multiple recalls. Thus the total number of affected vehicles includes vehicles
that have been recalled more than once. Similarly, there is no direct correlation between the number of
defect reports, recalls, and the number of vehicles that are recalled. A manufacturer may identify a lot of
defects that are not significant enough to warrant a recall. On the other hand, a manufacturer could have a
few major defects that evolve into major recalls affecting large portions of their product line. Historically,
emissions recalls affect about three million vehicles annually although the number may vary in any given
year.
Figure 15 - 2009-2011 CY Light-Duty Vehicle Recalls by Manufacturer
Manufacturer
Aston Martin
Bentley
BMW
Chrysler
Cummins
Ford
General Motors
Honda/Acura
Hyundai
Jaguar
Kia
Land Rover
Lamborghini
Mazda
Mercedes-Benz
Mitsubishi
Nissan/Infiniti
Porsche
Rolls Royce
Rousch
Subaru
Suzuki
Toyota/Lexus
Volkswagen/ Audi
Volvo
Total
Recalls in CY2009
Number
of
Recalls
-
1
5
11
-
-
4
2
1
1
1
1
-
1
1
3
-
4
-
2
4
-
42
Number of
Affected
Vehicles18
-
11,800
354,935
212,363
-
-
89,312
518,181
65,614
98,581
6,680
6,615
-
-
16,623
6,882
379,688
-
-
-
428,578
-
265,600
520,657
-
2,982,109
Recalls in CY2010
Number
of
Recalls
-
-
2
1
2
1
10
1
-
1
-
-
-
1
1
2
7
1
-
-
2
1
2
3
1
39
Number of
Affected
Vehicles
-
-
47,534
31,797
160,582
215,764
543,308
95,611
-
3,122
-
-
-
16,200
65,444
56,113
1,454,813
71,792
-
-
28,156
11,692
962,661
561,433
6,971
4,332,993
Recalls in CY2011
Number
of
Recalls
1
-
7
2
1
2
8
7
-
-
1
2
-
1
-
-
3
1
-
2
1
1
3
9
1
53
Number of
Affected
Vehicles
3,977
-
348,305
112,076
28,978
4,632
1,497,203
1,304,845
-
-
45,635
10,316
-
52,000
-
-
41,523
226
-
1,415
834,045
311
1,581,700
1,046,881
1,597
6,915,665
Figure 16 lists categories of defects that were corrected by recalls in 2009 - 2011. EPA established
the defect categories primarily for internal tracking purposes to identify potential, industry-wide
problems with a particular component or technology. Recalls in 2009 -2011 calendar years affected
vehicles spanning 2001 through 2011 modelyears.
US-EPA |Light-Duty Vehicles
-------
Figure 16 - 2009-2011 CY Light-Duty Vehicle Recalls by Problem Category
Problem Category
Catalyst System
Computer Related (other than OBD)
Crankcase Ventilation System
Drivability Problem
Electrical, Mechanical & Cooling Systems
Emission Control Information Label
Evap Emissions System
Exhaust System
Fuel Delivery System
Fuel Tank System
Hybrid Vehicle System
Ignition System
Intake/Exhaust Manifold
Monitoring/Measuring Sensor/System
OBD System
Other
Oxygen Sensor
Total
Recalls in CY2009
Number
of
Recalls
7
7
1
1
-
2
-
-
8
3
1
3
1
2
5
-
1
42
Number of
Affected
Vehicles
392,664
638,641
2,470
51,000
-
737
-
-
674,363
30,175
18,353
501,739
359,665
26,069
156,033
-
130,200
2,982,109
Recalls in CY2010
Number
of
Recalls
7
5
-
-
-
2
1
1
4
5
1
2
-
3
6
1
1
39
Number of
Affected
Vehicles
241,617
22,807
-
-
-
231,964
643
4,156
723,103
1,330,691
566,745
572,864
-
117,362
412,669
36,580
71,792
4,332,993
Recalls in CY2011
Number
of Recalls
3
8
1
-
4
2
3
1
8
6
1
1
2
6
7
-
-
53
Number
of
Affected
Vehicles
178,701
2,413,259
115,829
-
330,740
1,735
96,935
135,740
363,507
1,158,906
46,400
237,610
129,015
1,549,407
157,881
-
-
6,915,665
AVERAGING, BANKING AND TRADING (ABT) PROGRAMS
The 2007 Compliance Report provided an overview of EPA's Tier 2 program. The Tier 2 standards are the
current set of emission standards that apply to cars and light-duty trucks. The Tier 2 regulations offer
manufacturers a choice of eight emission bins to which they can certify. Lower bin numbers reflect more
stringent emission standards. The Tier 2 ABT program allows manufacturers to use sales-weighted
averaging to certify groups of vehicles to different bin levels, as long as the fleet as a whole on average
meets Bin 5 standards each year.
Figure 17 shows the percentage of exhaust test groups by emission certification bin for MY 2 009 - 2011.
For MY 2009, about 97 percent of test groups were certified to Bin 5 or better. For MY 2010 about 95
percent of test groups were certified to Bin 5 or better. And for MY 2 Oil about 90 percent of test groups
were certified to Bin 5 or better.
US-EPA |Light-Duty Vehicles
-------
Figure 17
MY 2009-2011 Light-Duty Test Group Distribution by Tier 2 Emissions Bins
Tier 2 Bin
1
2
3
4
5
6
7
8
Percenta
MY 2009
0.3%
1.8%
2.4%
10.6%
82.2%
-
-
2.7%
ge of Light- Duty Test Groups16
MY 2010
0.3%
2.6%
5.7%
15.4%
71.5%
0.3%
0.3%
3.9%
MY 2011
1.9%
3.9%
4.6%
18.0%
61.5%
0.8%
0.2%
9.1%
Figures 18-20 present the average certification levels for NOx, NMOG, and CO respectively along with the
standards for Tier 2 Bin 5 for each major manufacturer for 2009 - 2011. The lower the certification levels
relative to the standard, the greater the compliance margin.17
Figure 18
MY 2009-2011 Tier 2 Bin 5 NOx Certification Levels and Compliance Margins by Manufacturer
Ford
Volkswagen/ Audi
Mercedes-Benz
Mazda
Chrysler
Mitsubishi
Honda
Subaru
BMW
Nissan
General Motors
Hyundai/Kia
Porsche
Toyota
Others
Tier 2 Bin 5 NOx Certification Levels
NOx Standard: 0.07
grams per mile
2011
2010
12009
0.01
0.02
0.03 0.04 0.05
NOx (grams per mile]
0.06 0.07
0.08
16 Sum of rounded values may not equal 100 percent.
17 In Figures 20-22, the order from left to right is determined by the 2011 compliance margin, from lowest to highest.
US-EPA |Light-Duty Vehicles
-------
Figure 19
MY 2009-2011 Tier 2 Bin 5 NMOG Certification Levels and Compliance Margins by Manufacturer
Tier 2 Bin 5 NMOG Certification Levels
Mitsubishi
Subaru
Ford
General Motors
Chrysler
Volkswagen/ Audi
Mazda
Hyundai/Kia
Porsche
Nissan
Honda
Mercedes-Benz
BMW
Toyota
Others
NMOG Standard: 0.09
grams per mile
2011
2010
12009
0.04 0.06
NMOG (grams per mile]
Figure 20
MY 2009-2011 Tier 2 Bin 5 CO Certification Levels and Compliance Margins by Manufacturer
Tier 2 Bin 5 CO Certification Levels
CO Standard: 4.2
Subaru
General Motors
Ford
Chrysler
Mazda
Mitsubishi
Volkswagen/ Audi
Mercedes-Benz
Nissan
Hyundai/Kia
Porsche
BMW
Honda
Toyota
Others
3p%
30%
0.5
1.5 2 2.5 3
CO (grams per mile]
3.5
2011
2010
12009
4.5
US-EPA |Light-Duty Vehicles
-------
C. HIGHWAY MOTORCYCLES
SECTOR PROFILE:
• Highway and off-highway motorcycles are subject to different sets of regulations and
emission standards. This section covers the highway motorcycles. Information about off-
highway motorcycles is reported in the Recreational Vehicles section, starting on page 55
• Highway motorcycles have been subject to HC and CO emissions standards since 1978
• A second set of more stringent emission standards took effect in MY2006. Although the
CO emission standard remained unchanged at 12.0 g/km, the HC emission standard was
reduced from 5 g/km to 1.0 g/km for Class 1 and 2 motorcycles. In addition, an optional
HC + NOx 1.4 g/km standard was added.
PRIMARY COMPLIANCE ACTIVITIES IN 2009 - 2011:
• Certification
Production vehicle testing
Defect reporting
CERTIFICATION
Figure 21 presents the number of certified highway motorcycle engine families by class.
Figure 21 - MY 2009-2011 Highway Motorcycle Engine Families by Class
Highway Motorcycle Category
Class la (<50cc)
Class Ib (50 -169cc)
Class II (170-279CC)
Class III (>279cc)
Battery electric motorcycles
Total
Number of Engine Families
MY 2009
91
96
73
196
4
460
MY 2010
77
80
68
167
7
399
MY 2011
48
55
44
135
8
290
For MY 2009,141 manufacturers certified highway motorcycles and 115 manufacturers certified
highway motorcycles in MY 2010. For MY 2011, 89 manufacturers certified highway motorcycles. Figure
22 on the next page presents the number of motorcycle manufacturers in MY 2009 - 2011 for each
highway motorcycle class.
34
US-EPA [Industry Statistics
-------
Figure 22 - MY 2009-2011 Highway Motorcycle Manufacturers by Class
Highway Motorcycle Category
Class la (<50cc)
Class Ib (50 -169cc)
Class II (170-279CC)
Class III (>279cc)
Battery electric motorcycles
Number of Manufacturers Holding Certificates
MY 2009
68
69
41
52
4
MY 2010
52
51
37
44
5
MY 2011
47
44
39
41
6
Figure 23 presents the number of certified highway motorcycle engine families by manufacturer for MY
2009-2011. The manufacturers that certified a small number of engine families across the three model
years are grouped together as "Other".
Figure 23 - MY 2009-2011 Highway Motorcycle Engine Families by Manufacturer
MY 2009
Manufacturer
Yamaha
Suzuki
Piaggio
Honda
Kawasaki
Harley-Davidson
KYMCO
Carter Brothers
BMW
Other
Total
Top Manufacturers
Number of
Engine
Families
31
30
30
18
16
12
10
9
7
297
460
35.4%
MY 2010
Manufacturer
Piaggio
Yamaha
Suzuki
Kawasaki
Honda
KYMCO
Carter Brothers
Ducati
BMW
Other
Total
Top Manufacturers
Number of
Engine
Families
30
27
23
15
13
11
10
9
8
253
399
36.6%
MY 2011
Manufacturer
Yamaha
Piaggio
Honda
Suzuki
Kawasaki
KYMCO
Ducati
Carter Brothers
Harley-Davidson
Triumph
Other
Total
Top Manufacturers
Number of
Engine
Families
28
26
14
14
13
11
10
9
7
7
199
338
41.1%
PRODUCTION VOLUME
More than 150 highway motorcycle manufacturers certified products in MY 2009 - 2011, butthe vast
majority of bikes sold in the United States were produced by just a few companies. Figure 24 shows
reported production volumes for the five highest sales volume motorcycle manufacturers in model years
2009 - 2011.25 The production volume for lower-volume manufacturers is shown in aggregate. The
aggregated volume is based on available data manufacturers have reported to EPA. As with light-duty
vehicles, a comparison of Figures 23 and 24 show that there is not always a correlation between the
number of engine families a manufacturer certifies and the number of vehicles the manufacturer
is For MY 2009 Kawasaki Heavy Industries produced 1,555 Class Ib motorcycles; For MY 2010 Suzuki Motor Corporation
produced 1,033 Class II and 245 Class III motorcycles; for MY 2010, Yamaha produced 516 Class la and 228 Class Ib motorcycles.
These low volumes are difficult to discern on the scale of this chart.
35
US-EPA [Industry Statistics
-------
produces.19 Manufacturers with the most certified engine families do not necessarily produce the most
vehicles.
Figure 24 - MY 2009-2011 Highway Motorcycle Production Volumes by Manufacturer
0)
_3
"o
C
O
T3
O
300000
250000
200000
150000
100000
50000
.'MY2011 Class la
MY 2011 Class Ib
MY 2011 Class II
• MY2011 Class III
MY 2009 Class la
MY 2009 Class Ib
MY 2009 Class II
• MY 2009 Class III
••MY 2010 Class la
MY 2010 Class Ib
MY 2010 Class II
• MY 2010 Class III
PRODUCTION VEHICLE TESTING
EPA may require a manufacturer to supply production vehicles for emissions testing on demand. EPA has
found, via inspections at ports and other enforcement related activities, that some imported production
motorcycles are not built to the certified configurations. To follow up on this concern, EPA is
collaborating with Environment Canada to test production motorcycles at an Environment Canada
emissions testing facility. Through July 2011, the agencies had tested or were in the process of testing 29
MY 2008-2010 EPA certified engine families and have identified several engine families that may
potentially exceed applicable standards. So far, one manufacturer has initiated a voluntary recall for
thousands of motorcycles sold in both the United States and Canada based on this testing. EPA is
continuing to follow up with other manufacturers.
19 The economic slowdown may have contributed to the MY 2010 drop in production volume.
36
US-EPA [Industry Statistics
-------
DEFECT REPORTING
Figure 25 presents 2009 - 2011 emission defect report information for highway motorcycles. These
reports can include multiple model years of a given vehicle and can span more than one problem
category. Highway motorcycle manufacturers are required to notify EPA when they learn of the existence
of emission-related defects in 25 or more vehicles of the same class (e.g., engine family) and category
(e.g., manufacturer, model year).
Figure 25 - 2009-2011 Highway Motorcycle Defect Reports by Problem Category
Problem Category
Oxygen sensor
Electrical, mechanical & cooling
systems
OBD system
Crankcase ventilation
component/ system
Computer related (other than OBD)
Carburetor
Fuel Delivery Component
Other
Total
Reported in 2009
Number
of Defect
Reports
1
-
1
1
-
-
-
-
3
Number of
Affected
Vehicles
12,015
-
2,447
2,447
-
-
-
-
16,909
Reported in 2010
Number
of Defect
Reports
-
1
-
-
1
-
-
1
3
Number of
Affected
Vehicles
-
2,782
-
-
1,452
-
-
59
4,293
Reported in 2011
Number
of Defect
Reports
-
-
-
-
-
1
1
-
2
Number of
Affected
Vehicles
-
-
-
-
16,856
314
17,170
In calendar years 2009-2011, manufacturers submitted defect reports that affected highway
motorcycles in model years ranging from MY 2008-2011.
RECALL REPORTING
There was one highway motorcycle recall in 2009 for 5,858 MY 2010 Honda motorcycles with a problem
categorized as "defective/incorrect crankcase ventilation component/system." There were no highway
motorcycle recalls in calendar year 2010. There was one highway motorcycle recall in 2011 for 314 MY
2011 Bombardier motorcycles with a problem categorized as "defective/incorrect intake/exhaust
manifold".
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
The 2006 regulations added provisions allowing highway motorcycle manufacturers to use an EPA
specified emission averaging approach to show compliance with the applicable HC+NOx standards. For
MY 2009 - 2011 about 6-9 percent of manufacturers availed themselves of this provision.
Class III motorcycles (>279cc) represent the majority of motorcycle sales, and many Class III
manufacturers with large sales volumes take advantage of the fleet averaging flexibility for HC+NOx. For
model year 2009 about 13 percent of Class III manufacturers used this fleet averaging flexibility. For
model year 2010 about 21 percent of Class III manufacturers used the fleet averaging flexibility. And for
model year 2011 about 17 percent of Class III manufacturers used the fleet averaging flexibility.
37
US-EPA [Industry Statistics
-------
D. HEAVY-DUTY HIGHWAY ENGINES
SECTOR PROFILE:
• Heavy-duty highway engines are used in highway vehicles such as trucks and buses
that are more than 8,500 pounds GVWR
• EPA has regulated heavy-duty highway engine emissions since 1982
• Primary emission standards in effect for MY 2009-2011 were NMHC, CO, NOx, and
PM, with final phase-in of a more stringent NOx standard starting in MY2010.
Reductions in diesel sulfur content prior to 2007 enabled significant advances in
emission controls.
PRIMARY COMPLIANCE ACTIVITIES IN 2009 - 2011:
• Certification
• In-use testing
• Defect reporting
CERTIFICATION
As shown in Figure 6, EPA issued 123 heavy-duty highway certificates for MY 2009, 81 heavy-duty
highway certificates for MY 2010 and 112 heavy-duty certificates for MY 20II.20 These include
alternative fuel conversion and evaporative emissions certificates. Most certificates were for diesel
engines.
Figures 26 and 27 on the next page present the number of MY 2009 - 2011 engine families certified in
each intended service class for compression ignition and spark ignition heavy-duty highway engines.21
20 Some vehicles that are between 8,500-14,000 pounds GVWR are chassis-certified and are included in the light-duty vehicles data.
21 The number of engine families has is not directly correlated to engine production volumes.
38
US-EPA [Industry Statistics
-------
Figure 26
MY 2009-2011 Heavy-Duty Highway Compression Ignition Engine Families by Service Class
Service Class
Light heavy-duty diesel
Medium heavy-duty diesel
CA only medium-duty
Heavy heavy-duty diesel
Urban Bus
CA only urban bus
Number of Engine Families
MY 2009
14
31
2
39
4
-
MY 2010
3
12
-
25
3
1
MY 2011
8
12
1
28
3
-
Figure 27
MY 2009-2011 Heavy-Duty Highway Spark Ignition Engine Families by Service Class
Service Class
Heavy-duty gasoline 1 (<=14klbs)
Heavy-duty gasoline 2 (>14k Ibs)
Urban bus
Number of Engine Families
MY 2009
5
3
1
MY 2010
5
3
1
MY 2011
5
4
-
Figures 28 and 29 present the number of MY 2009 - 2011 compression ignition and spark ignition engine
families by each heavy-duty highway manufacturer.
Figure 28
MY 2009-2011 Heavy-Duty Highway Compression Ignition Engine Families by Manufacturer
MY 2009
MY 2010
MY 2011
39
US-EPA (Industry Statistics
-------
Figure 29
MY 2009-2011 Heavy-Duty Highway Spark Ignition Engine Families by Manufacturer
I MY 2009
MY 2010
MY 2011
Ford Motor Company
General Motors
ISE Corporation
IN-USE COMPLIANCE TESTING
As is the case for light-duty vehicles, EPA relies on both internal and manufacturer testing programs to
assess heavy-duty vehicle compliance with in-use emission standards. Heavy-duty in-use testing differs
significantly from light-duty in-use testing. For light-duty vehicles, identical test procedures are used to
measure emissions in both certification and in-use testing. The heavy-duty vehicle regulations do not
require manufacturers to test in-use engines on a laboratory dynamometer, as they must for
certification. Heavy-duty manufacturers may use portable equipment to measure in-use emissions while
a vehicle is being driven over the road, instead of removing the engine from an in-use vehicle for
laboratory testing. The regulations require manufacturers to measure the percentage of time that a
vehicle exceeds certain emission thresholds under real-world driving conditions using devices that
monitor emissions of hydrocarbons, carbon monoxide, nitrogen oxides, and particulate matter.
EPA also conducts its own heavy-duty in-use surveillance program, currently focusing on engines with
2010-level emission control systems. Beginning in late 2011 and lasting through 2012, this program
focused on testing the most common engines currently used in heavy-duty line-haul tractors and
vocational vehicles. This testing included engines from all of the major heavy-duty on-high way diesel
engine manufacturers and the engine families tested represent 84% of the estimated large heavy-duty
on-high way diesel engine production volume (MY2012 estimate].
All of the engines tested in this program were found to be in compliance with in-use emission standards
when evaluated using the prescribed procedures. Emissions performance over non-prescribed
conditions, such as extended idle and cold-starting, differed significantly by manufacturer, revealing key
differences in calibration philosophy and limitations of current emission control technologies. These
findings have been shared with the affected manufacturers and are driving system improvements for
future model years.
40
US-EPA [Industry Statistics
-------
Currently this testing program is focusing on small and medium sized heavy-duty diesel engine
segments.22
DEFECT REPORTING
Figure 30 shows the number of defect information reports heavy-duty highway engine manufacturers
submitted in 2009 - 2011 calendar years. Figure 31 shows the number of defect reports manufacturers
submitted for each problem category reported in 2009 - 2011 calendar years. Defect reports can include
multiple model years of a given engine.
Figure 30 - 2009-2011 Heavy-Duty Highway Engine Defect Reports by Manufacturer
Manufacturer
Caterpillar
Cummins
Detroit Diesel Corporation
Ford
FTP Industrial S.p.A
General Motors
Hino
Isuzu
John Deere
Navistar
Paccar
Roush Industries, Inc.
UD Trucks Corporation
Volvo
Number of Defect Reports
Reported in CY2009
21
1
2
1
2
-
1
-
1
-
3
Reported in CY2010
14
10
4
-
2
1
3
1
8
3
5
Reported in CY2011
11
2
4
4
1
2
-
1
-
18
6
2
1
15
Figure 31 - 2009-2011 Heavy-Duty Highway Engine Defect Reports by Problem Category
Problem Category
Fuel delivery component / system
Turbocharger /supercharger
Passive diesel particulate filter (DPF)
Active diesel particulate filter [DPF]
Electrical, mechanical & cooling systems
VECI label
EGR system
Exhaust system
Crankcase ventilation component/system
NOx absorber system
NOx sensor
OBD system
Number of Defect Reports
Reported in CY2009
9
5
5
4
4
2
2
2
2
1
-
Reported in
CY2010
4
6
5
4
2
4
2
1
-
-
1
6
Reported in
CY2011
8
7
5
1
-
5
12
2
1
1
1
2
22 Smith, ]., Greuel, ]., Ratkos, B., and Schauer, E., "In-Situ Emissions Performance of EPA2010-Compliant On-Highway Heavy-Duty
Diesel Engines/'SAE Int. J. Engines 6(3):1490-1499, 2013, doi: 10.4271/2013-01-2430.
41
US-EPA [Industry Statistics
-------
Problem Category
Selective catalytic reduction [SCR] system
Monitoring/measuring sensor/system
Computer related [other than OBD]
Diesel oxidation catalyst [DOC]
Ignition component
Defective / Incorrect Catalyst System [non-diesel
engine]
Oxygen sensor
Number of Defect Reports
Reported in CY2009
_
-
_
-
-
-
-
Reported in
CY2010
5
4
3
1
1
Reported in
CY2011
8
2
5
-
1
3
1
RECALL REPORTING
Figure 32 shows the number of heavy-duty highway engine recalls issued in 2009 - 2011 calendar years.
Figure 33 shows the number of recalls for each problem category reported in 2009 - 2011 calendar years.
Recalls can include multiple model years of a given engine. Recalls in the 2009 calendar year affected
engines from 2004 - 2009 model years, while recalls in the 2010 calendar year affected 2006 - 2010
modelyears. Recalls in 2011 affected 2006 - 2012 model year engines.
Figure 32 - 2009-2011 Heavy-Duty Highway Engine Recalls by Manufacturer
Manufacturer
Caterpillar
Cummins
Detroit Diesel
Ford
FPT Industrial S.p.A.
General Motors
Hino
Isuzu
International-Navistar
IVECO S.pA
Mitsubishi Fuso Truck
PACCAR Inc.
Roush Industries, Inc.
Volvo
Total
Recalls in CY2009
Number
of
Recalls
4
1
3
1
1
1
1
12
Number of
Affected
Engines
153,771
182
47,639
29,909
7,065
128,514
616
367,696
Recalls in CY2010
Number
of
Recalls
1
6
1
2
1
11
Number of
Affected
Engines
7,488
101,072
868
21,679
1,065
132,172
Recalls in CY2011
Number
of
Recalls
2
1
1
2
1
1
8
Number of
Affected
Engines
25,719
1,197
3,531
88,794
1,800
31
121,072
42
US-EPA [Industry Statistics
-------
Figure 33 - 2009-2011 Heavy-Duty Highway Engine Recalls by Problem Category
Problem Category
Crankcase ventilation
component/ system
Active diesel particulate filter
(DPF)
EGR system
Electrical, mechanical & cooling
systems
Turbocharger/supercharger
Fuel delivery component
Exhaust system
OBD system
VECI label
Selective catalytic reduction (SCR)
system
Computer related (other than
OBD)
NOx Sensor
Monitoring/measuring
sensor/system
Catalyst system
Total
Recalls in CY2009
Number
of
Recalls
1
2
1
1
1
2
2
1
1
12
Number of
Affected
Engines
147,245
133,964
29,909
19,954
19,954
14,796
965
616
293
367,696
Recalls in CY2010
Number
of
Recalls
1
1
5
1
2
1
11
Number of
Affected
Engines
7,488
1,117
95,439
21,006
6,254
868
132,172
Recalls in CY2011
Number
of
Recalls
2
1
3
1
1
8
Number of
Affected
Engines
25,719
31
82,446
3,531
9,345
121,072
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
In MY 2009,100 percent of heavy-duty highway compression ignition engine manufacturers participated
in ABT programs. Approximately 25 and 45 percent of heavy-duty highway compression ignition engine
manufacturers participated in ABT programs in MY 2010 and 2011, respectively.23
1 In MY 2010 a regulatory change took effect that eliminated split engine family accounting.
43
US-EPA [Industry Statistics
-------
E. NONROAD COMPRESSION IGNITION [NRCI) ENGINES
SECTOR PROFILE-
• EPA regulates several categories of nonroad compression ignition engines
including marine diesel engines, locomotives, and compression ignition engines
used in construction and agricultural equipment.
• EPA has regulated emissions from nonroad compression ignition engines since 1996
• Primary emission standards in effect for MY 2009-2011 were NMHC, CO, NOx, and
PM
PRIMARY COMPLIANCE ACTIVITIES IN 2009 - 2011:
• Certification
• Compliance programs
CERTIFICATION
Figure 34 presents the number of marine diesel certificates issued by certification Tier and classification.
Figure 35 presents the number of marine diesel certificates by manufacturer. Marine diesel engine
manufacturers applying for engine certification may request an International Maritime Organization
[IMO) certificate in addition to an EPA certificate of conformity for the same engine family. The IMO
program, in general, is different from EPA's program, but certain jurisdictions require operators to
display an EPA-issued IMO certificate. For the purposes of this compliance report, only one certificate for
each engine family was included in the counts listed below.
New marine diesel standards were phased in at different times for different engine sizes. In general, Tier
2 began to take effect around 2005; Tier 3 began in about 2009. Tier 3 will not be in place for all engines
until 2018.
Figure 34 - MY 2009-2011 Marine Diesel Engine Certificates by Tier
Certification Tier
Tierl
Tier 2
TierS
Remanufacture
IMO
Total
Number of Certificates
MY 2009
8
116
26
2
28
180
MY 2010
4
131
26
9
38
208
MY 2011
0
164
27
19
53
263
44
US-EPA [Industry Statistics
-------
Figure 35 - MY 2009-2011 Marine Diesel Engine EPA and IMO Certificates by Manufacturer
Manufacturer24
AB Volvo Penta
Alaska Diesel Electric
Caterpillar Inc.
Cummins Inc.
Detroit Diesel Corporation
Electro-Motive Diesel, Inc.
IHI Shibaura Machinery Corporation
Iveco N.V.
John Deere Power Systems Group
MAN Nutzfahrzeuge AG
Mitsubishi Heavy Industries, Ltd.
MTU Detroit Diesel, INC.
Perkins Engines Co Ltd
Transportation Systems Business Operations of GE
VM Motori S.P.A.
Yanmar CO., Ltd
Other
Total
Number of Certificates
MY 2009
16
5
32
22
3
3
10
10
3
3
5
7
2
5
4
19
31
180
MY 2010
28
4
41
23
3
9
11
10
7
3
6
6
4
5
3
17
28
208
MY 2011
17
5
29
18
6
15
11
11
46
4
6
9
11
6
3
25
41
263
Figure 36 shows locomotive certificates. Some engine manufacturers obtain a locomotive
certificate of conformity, if a locomotive uses its engine.
Figure 36 - MY 2009-2011 Locomotive and Engine Certificates by Manufacturer
Manufacturer
HMD
GE
CSX
Advanced Global
Engineering
National Railway
Equipment Co.
Motive Power
Kansas City
Southern
MY 2009
Locomotive
Certificates
23
19
6
4
2
3
3
Engine
Manufacturer
2
-
-
-
2
-
-
Total
23
19
6
4
4
3
3
MY 2010
Locomotive
Certificates
10
5
2
8
2
3
Engine
Manufacturer
2
-
-
-
2
-
Total
12
5
2
8
4
3
MY 2011
Locomotive
Certificates
11
10
8
11
2
2
-
Engine
Manufacturers
2
-
-
-
2
-
-
Total
13
10
8
11
4
2
0
24 Manufacturers that certified only a few Marine CI engine families in MY 2009 2011 are aggregated under "Other". For MY 2009
"Other" represents 13 manufacturers; for MY 2010 "Other" represents 15 manufacturers; and for MY 2011 "Other" represents 30
manufacturers.
45
US-EPA [Industry Statistics
-------
Manufacturer
Cummins
MY 2009
Locomotive
Certificates
Burlington North
Santa Fe
HK Engine
Components
OceanAir
Haynes
Progressive Rail
Brookeville
Equipment Corp.
RJ Corman
Railpower
Bombardier
Transport
Total
-
Engine
Manufacturer
2
2
1
-
-
-
-
65
2
-
-
-
1
-
-
-
7
Total
2
MY 2010
Locomotive
Certificates
2
2
1
1
-
-
-
70
-
Engine
Manufacturer
-
-
3
-
3
1
1
38
4
-
-
-
1
-
-
-
9
Total
4
-
-
3
1
3
1
1
47
MY 2011
Locomotive
Certificates
-
-
1
3
-
3
-
-
1
52
Engine
Manufacturers
4
-
-
-
-
-
-
-
-
8
4
0
1
3
0
3
0
0
1
60
Nonroad compression ignition engines intended for use in construction and agricultural equipment can
be certified for use in one or multiple service classes. Figure 37 presents the number of certificates that
were issued covering each power category. There were more than 100 different nonroad compression
ignition engine families certified in both the 19-37 kW and the 37-75 kW power ranges. Figure 38 shows
the number of engine families certified by each manufacturer for MY 2009 - 2011. There were
approximately 90 different manufacturers that certified nonroad compression ignition engines intended
for use in construction and agricultural equipment in MY 2009 2011.
Figure 37 - MY 2009-2011 Construction and Agricultural Engine Families by Service Class
Service Class (Power Category)
0-8 kW
<130kW
8-19 kW
8-37 kW
19-37 kW
37-56 kW
37-75 kW
56-75 kW
75-130 kW
75-225 kW
75-450 kW
130-225 kW
130-450kW
130-560 kW
>=130kW
225-450 kW
225-560 kW
450-560 kW
560-900 kW
>560 kW
Number of Engine Families
MY 2009
60
-
73
2
120
20
107
9
52
2
27
5
11
2
49
2
9
61
MY 2010
59
2
74
-
121
27
107
11
59
2
31
4
13
6
48
2
11
64
MY 2011
41
2
70
-
Ill
27
106
14
67
1
-
9
1
23
-
23
2
2
2
19
US-EPA [Industry Statistics
-------
Service Class (Power Category)
Total25
Number of Engine Families
MY 2009
611
MY 2010
641
MY 2011
520
Figure 38 - MY 2009-2011 Construction and Agricultural Engine Families by Manufacturer
Manufacturer26
Kubota Corporation
Cummins Inc.
Deutz AG
Yanmar Co., Ltd.
Caterpillar Inc.
John Deere Power Systems
Motornfabrik Hatz
Mitsubishi Heavy Industries, Ltd
Iveco NV
Komatsu Ltd.
IHI Shibaura Machinery Corporation
Isuzu Motors Limited
Perkins Engines Co. Ltd.
Lombardini
Mahindra & Mahindra Ltd.
Kukje Machinery Co.
CNHUKLTD
Liebherr Machines Bulle SA
Daedong Industrial Co. Ltd.
Iseki Matsuyama Mfg. Co., Ltd.
AGCO Sisu Power Inc.
Hino Motors, Ltd.
AB Volvo Penta
Shandong Huayuan Laidong Engine Co.
Other
Total27
Number of Engine Families
MY 2009
49
46
46
42
26
27
28
25
22
23
22
20
18
14
12
9
10
8
9
9
7
6
7
6
120
611
MY 2010
51
45
45
41
34
32
28
25
28
25
22
20
17
14
13
12
10
12
10
9
7
5
6
130
641
MY 2011
50
16
40
40
16
29
28
25
22
15
22
18
13
13
11
12
10
3
8
9
5
5
8
6
96
520
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
About 10 percent of construction and agricultural engine manufacturers participated in ABT programs in
MY 2009-2011.
25 This figure does not include stationary-only engine families.
26 Manufacturers that certified only a few engine families in MY 2009 - 2011 are aggregated under "Other"
27 This figure does not include stationary-only engine families.
47
US-EPA [Industry Statistics
-------
F. NONROAD SPARK IGNITION ENGINES
SECTOR PROFILE:
• Nonroad spark ignition (Nonroad SI) engines are generally divided into three categories
for purposes of exhaust emission compliance:
• Small spark ignition engines (Small SI) are rated below 25 horsepower (19 kW) and
are generally used in household and commercial applications, including lawn and
garden equipment, utility vehicles, generators, and a variety of other construction,
farm, and industrial equipment
• Marine spark ignition (Marine SI) engines are used in marine vessels, including
outboard engines, personal watercraft, and sterndrive/inboard engines
• Large spark ignition (Large SI) engines are generally rated above 19 kW and used in
forklifts, compressors, generators, stationary equipment
• Equipment with NRSI engines installed is also subject to evaporative emissions
standards.
• Nonroad SI engines have been subject to emissions regulations since 1997
PRIMARY COMPLIANCE ACTIVITIES IN 2 009 - 2011:
• Certification
• Compliance programs
CERTIFICATION
As shown in Figure 6, for the 2009 - 2011 model years EPA certified aroundl,000 Small SI engine
families, around 100 engine emissions families each for Marine SI and Large SI, and between 150 and
425 Evaporative Component families. There are seven classes of Small SI engines. Figure 39 presents the
number of families certified in each Small SI class.28 Figures 40-43 present the number of engine families
certified by Small SI, Marine SI, Large SI and Evaporative Component manufacturers.
Figure 39 - MY 2009-2011 Small Spark Ignition Engine Families by Class
Small SI Class
Class I
Class II
Class I A
Class IB
Class III
Number of Engine Families
MY 2009
247
358
39
59
2
MY 2010
231
344
16
47
3
MY 2011
247
287
8
47
2
28 Classes are defined by whether or not the engine in applied in a hand held piece of equipment and by power rating. Classes I
through IB describe non hand held equipment whereas classes IV and V are in hand held equipment.
48
US-EPA [Industry Statistics
-------
Class IV
Class V
Total
307
148
1,160
268
111
1,020
275
119
985
Figure 40 - MY 2009-2011 Small Spark Ignition Engine Families by Manufacturer
Manufacturer
Briggs & Stratton Corporation
Andreas Stihl AG & Co KG
Kawasaki Heavy Industries, Ltd.
Husqvarna AB
Echo Incorporated/Kioritz Corporation
Fuji Heavy Industries Ltd.
Husqvarna Consumer Outdoor Products N.A. Inc.
Generac Power Systems Inc.
Honda Motor Co., Ltd.
Kohler Co.
Loncin Industrial Co., Ltd.
Jiangsu Jiangdong Group Co. Ltd.
Other29
Total
Number of Engine Families
MY 2009
69
62
50
44
37
32
32
31
29
23
-
-
751
1,160
MY 2010
65
58
47
38
52
32
32
-
29
28
31
28
580
1,020
MY 2011
57
59
37
42
56
29
30
17
33
28
29
27
541
985
Figure 41 - MY 2009-2011 Marine Spark Ignition Engine Families by Manufacturer
Manufacturer
Yamaha Motor Company Ltd.
Mercury Marine
Honda Motor Co., Ltd.
BRP US Inc.
Suzuki Motor Corporation
Tohatsu Corporation
Suzhou Parsun Power Machine Co., Ltd.
Hangzhou Hidea Power Machinery Co., Ltd
Kawasaki Heavy Industries, Ltd.
Weber Automotive GmbH
Volvo Penta of the Americas, Inc.
Zhejiang Shunfeng Power Machinery Manufacturer
Zhejiang Shengqi Motion Apparatus Co.
Flagship Marine Engine Company Inc
Ilmor Engineering, Inc
Number of Engine Families
MY 2009
38
28
12
11
11
9
5
4
3
2
-
-
1
-
-
MY 2010
24
31
11
14
12
8
5
4
3
-
2
2
1
-
-
MY 2011
23
30
10
13
11
8
5
5
3
-
5
-
1
1
1
29 For MY 2009 "Other" represents 168 manufacturers that collectively produced 751 engine families. For MY 2010 "Other"
represents 100 manufacturers that collectively produced 580 engine families. For MY 2011 "Other" represents 93 manufacturers
that collectively produced 541 engine families.
49
US-EPA [Industry Statistics
-------
Manufacturer
Indmar Products Company, Inc
KEM Equipment, Inc
Pleasurecraft Marine Engine Company
Total
Number of Engine Families
MY 2009
-
-
-
124
MY 2010
-
-
-
117
MY 2011
2
3
3
124
Figure 42 - MY 2009-2011 Large Spark Ignition Engine Families by Manufacturer
Manufacturer
KEM Equipment, Inc.
Generac Power Systems, Inc.
Bucks Engine Company
NGVI, Inc.
Woodward Governor Company
IMPCO Technologies
Zenith Power Products LLC
Nissan Motor Co., Ltd.
Power Solutions, Inc.
TeleflexGFI Control Systems
Engine Distributors, Inc
Cummins Inc.
Linde Material Handling N.A. Corp.
Wisconsin Motors, LLC
GE Jenbacher
John Deere Power Systems of Deere & Comp
Toyota Industrial Equipment
Westerbeke Corporation
PSI International
Deutz Corporation
GFI Control systems
API
Don Hardy Race Cars, Inc.
EControls, Inc.
Industrial Engines Ltd
Juniper Engines, Inc.
KaChing, LLC
SRC Automotive, Inc.
Kohler Company
Kubota Corporation
Vantage Vehicle International, Inc.
Total
Number of Engine Families
MY 2009
15
9
8
8
8
7
6
5
6
4
3
2
2
2
1
1
1
1
-
-
-
-
-
-
-
-
-
-
-
-
-
89
MY 2010
18
32
-
2
6
8
7
3
11
-
5
3
2
3
1
1
1
1
5
4
4
1
1
1
1
1
1
1
-
-
-
124
MY 2011
19
34
7
-
7
8
7
3
12
-
4
8
2
3
1
1
1
1
8
5
-
1
1
-
2
1
-
1
1
1
1
140
50
US-EPA [Industry Statistics
-------
Figure 43
MY 2009-2011 Nonroad Spark Ignition Evaporative Component Families by Manufacturer
Manufacturer
Honda Motor Co., Ltd.
Husqvarna Zenoah Co., Ltd.
MTD Southwest Inc.
Andreas Stihl AG & Co KG
Hitachi Koki USA, Ltd.
Kawasaki Heavy Industries, Ltd
Maruyama Mfg. Co., Inc.
Husqvarna AB, Sweden
ECHO Incorporated/Yamabiko Corporation
Husqvarna Consumer Outdoor Products N.A., Inc.
Sichuan Chuanhuan Technology Co. Inc
Other30
Total31
Number of Engine Families
MY 2009
22
16
15
10
10
7
7
5
-
-
-
69
161
MY 2010
7
16
12
18
17
8
11
5
6
5
5
85
195
MY 2011
4
8
5
36
17
6
11
1
8
10
5
313
424
PRODUCTION LINE TESTING (PLT)
Production line testing requires manufacturers to routinely test engines as they leave the assembly line
to demonstrate that production engines meet emission standards. In the Small SI and Marine SI sectors,
most engine manufacturers had at least one engine family subject to PLT.32 All engine families met the
PLT test requirements. In the Large SI sector, many engine families are not subject to PLT requirements
because the projected sales volume is less than 150 units. These engine families are only required to
submit production reports. Large SI manufacturers satisfied all requirements for families with high
enough volumes to require PLT testing and data submission in 2009 - 2011.
IN-USE COMPLIANCE TESTING
Marine SI and Large SI manufacturers are required to conduct in-use testing on up to 25 percent of
engine families at 50 percent or more of their useful life. The Marine SI program has been in place since
2007.
so For MY 2009 "Other" represents 38 manufacturers that collectively produced 69 evaporative families. For MY 2010 "Other"
represents 48 manufacturers that collectively produced 85 evaporative families. For MY 2011 "Other" represents 165
manufacturers that collectively produced 313 evaporative families.
31 The evaporative emissions rule for nonroad spark ignition manufacturers started to phase in for model year 2009. The number
of engine families affected by the rule should level off after the 2012 model year.
32 PLT requirements do not apply to small volume engine manufacturers.
51
US-EPA [Industry Statistics
-------
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
In MY 2009 about 15 percent of Small SI manufacturers participated in ABT programs. In MY 2010 and in
MY 2011about 21 percent of Small SI manufacturers participated. Prior to MY 2010 all types of Small SI
engines were averaged together. However, beginning in MY 2010, handheld and non-handheld engines
were averaged separately.
G. RECREATIONAL VEHICLES
SECTOR PROFILE:
• Emissions from recreational vehicles (RVs) were unregulated prior to MY 2006
• The regulations in 40 CFR part 1051 set the first emissions standards for RV categories,
including all terrain vehicles (ATVs); certain off-road utility vehicles (UTVs) (less than 30
kW, less than 1, 000 cc, and maximum speed more than 25 mph); off-highway
motorcycles; and snowmobiles. Each recreational vehicle category is subject to an
individual set of exhaust emission standards which phase in over several years. Regulated
pollutants are HC+NOx and CO
• All RVs became subject to the same fuel component based permeation emission
standards beginning in MY 2008. The regulated pollutant is HC
PRIMARY COMPLIANCE ACTIVITIES IN 2009 - 2011:
• Certification
• Defect Reporting
• Recall
• ABT
CERTIFICATION
There were 100 different recreational vehicle manufacturers that certified products in MY 2009 - 2011.
Figure 44 presents RV manufacturers that certified at least four engine families in one or more RV sectors
in MY 2009, 2010 and/or 20II.33 There were about 100 different recreational vehicle manufacturers that
33The number of engine families has no bearing on vehicle production volumes.
52
US-EPA [Industry Statistics
-------
certified products each model year 2009 - 2011. Figures 45 - 47 present data for manufacturers that
certified at least one MY 2009, MY 2010 and/or 2011 engine families in the ATV and UTV, off-highway
motorcycle, or snowmobile sectors
Figure 44 - MY 2009-2011 Recreational Vehicle Engine Families by Manufacturer
Manufacturer
Yamaha Motor Corporation
Arctic Cat inc
Polaris Industries Inc.
Bombardier Recreational Products, Inc
American Honda Motor Co., Inc.
Kawasaki Motors Corp., U.S.A.
American Suzuki Motor Corporation
Tomoto Industries, Inc.
Kymco USA
Taotao USA Inc.
Xingyue USA, INC
Loncin (USA) Inc.
Baja Inc.
JCL Powersports LLC.
Other
Total
Number of Engine Families
MY 2009
28
22
22
19
22
13
11
10
9
6
6
7
-
6
161
342
MY 2010
27
21
21
17
6
12
13
11
9
6
6
4
11
4
124
292
MY 2011
26
21
22
18
12
12
3
4
4
6
6
2
8
3
100
247
Figure 45 - MY 2009-2011 ATV and UTV Engine Families by Manufacturer
Manufacturer
Yamaha Motor Corporation
Arctic Cat
Polaris Industries Inc.
American Honda Motor Co., Inc.
Kawasaki Motors Corp., U.S.A.
Tomoto Industries, Inc.
American Suzuki Motor Corporation
Kymco USA
Bombardier Recreational Products, Inc
Taotao USA Inc.
Loncin (USA) Inc.
Kandi USA, Inc.
Xingyue USA, INC
High Rev Motorsports, LLC
Linhai USA, Inc.
Asian Ventures Inc.
Hammerhead Off-Road, Inc.
JCL Powersports LLC.
Team Joyner USA
Deere & Company
Easy Vehicle, Inc.
Eton America LLC
XY-Xinyang Motor, Inc.
Number of Engine Families
MY 2009
15
13
11
13
10
10
9
9
8
5
6
4
4
3
2
4
4
4
6
3
3
3
2
MY 2010
14
11
11
6
9
9
10
9
7
5
3
4
4
5
6
3
3
3
-
3
3
3
3
MY 2011
13
12
12
8
9
5
3
10
9
5
2
5
4
3
6
3
-
3
2
4
2
1
-
53
US-EPA [Industry Statistics
-------
Manufacturer
Baja Inc.
Other
Total
Number of Engine Families
MY 2009
-
91
242
MY 2010
5
58
197
MY 2011
-
45
166
Figure 46 - MY 2009-2011 Off-Highway Motorcycle Engine Families by Manufacturer
Manufacturer
Yamaha Motor Corporation
American Honda Motor Co., Inc.
Apollo Motorsports, Inc.
Kawasaki Motors Corp., U.S.A.
Pride Enterprise, LLC
Baja Inc.
Xmotos Worldwide, Inc.
American Suzuki Motor Corporation
KTM North America, Inc.
Other
Total
Number of Engine Families
MY 2009
7
9
4
3
1
-
3
2
2
31
62
MY 2010
7
-
4
3
5
6
2
3
3
25
58
MY 2011
7
4
3
3
-
8
-
-
3
18
46
Figure 47 - MY 2009-2011 Snowmobile Engine Families by Manufacturer
Manufacturer
Bombardier Recreational Products, Inc.
Polaris Industries Inc.
Arctic Cat Inc
Yamaha Motor Co., LTD.
HJR
Total
Number of Engine Families
MY 2009
11
11
9
6
1
38
MY 2010
10
10
10
6
1
37
MY 2011
9
10
9
6
1
35
As shown in Figure 48, in model years 2009-2011 very few ATV/UTV and off-highway motorcycle
manufacturers produced two-stroke engines. However, more than 50% of the snowmobile engine
families were two-stroke engines. This represents a technology shift When the current RV regulations
were written, a majority of ATVs sold in the United States and almost all snowmobiles used two-stroke
engines (see 67 FR 68262).
Figure 48 - MY 2009-2011 Recreational Vehicle Two-Stroke Engine Families
Category
ATV/UTV
Off-Highway Motorcycles
Snowmobiles
Percentage of Two Stroke Engine Families
MY 2009
0%
2%
63%
MY 2010
1%
10%
62%
MY 2011
1%
17%
53%
54
US-EPA [Industry Statistics
-------
In addition, in MY 2009-2011 over 50 percent of ATVs and UTV engine families either employed catalyst
or fuel injection technologies, or both, to meet the emission standards.
RV CERTIFICA TES VOIDED
In 2010 EPA withdrew emissions approval for the import and sale of approximately 200,000 MY 2006
and 2007 gasoline-powered off-road motorcycles and all terrain vehicles. The finding was the first case
of its kind. The action to void emissions certificates affects the companies that manufactured and
imported these vehicles. Consumers who own models covered by the voided certificates are not
responsible for the wrongdoing and can continue to use their vehicles.
In 2013 EPA withdrew its approval of the import and sale of over 70,000 gas-powered on- and off-road
motorcycles and all-terrain vehicles because the agency believes that it received either incomplete or
falsified certification information. EPA issued the vehicle certificates from 2006 to 2012 to two
companies which operate as Snyder Technology, Inc. and Snyder Computer Systems, Inc. (doing
business as Wildfire Motors Corporation). As a result of a lengthy investigation, the agency believes
that the applications for the certificates contained fallacious information and must be voided. These
actions affected between four and nine percent of the highway motorcycles and recreational vehicles
produced annually between 2006 and 2012. All vehicles imported into or manufactured in the United
States are required to have certificates of conformity.
DEFECT REPORTING
Recreational vehicle manufacturers are required to notify EPA when they learn of the existence of
emission-related defects in about 10 percent of the vehicles in an engine family.
Figures 49 and 50 present the 2009-2011 emission defect reports submitted by recreational vehicle
manufacturers. These reports can include multiple model years of a given vehicle and can span more than
one problem category. In calendar years 2009 - 2011, manufacturers submitted defect reports that
affected recreational vehicles in model years ranging from MY 2006-2010.
Figure 49 - 2009-2011 Recreational Vehicle Defect Reports by Manufacturer
Manufacturer
Arctic Cat
BRP
Honda
Polaris
Suzuki
Yamaha
Total
Reported in 2009
Number of
Defect
Reports
5
1
2
-
1
9
Number of
Affected
Vehicles
9,825
9,425
6,077
-
2,020
27,347
Reported in 2010
Number of
Defect
Reports
3
-
2
1
-
6
Number of
Affected
Vehicles
4,519
-
25,146
25,458
-
55,123
Reported in 2011
Number
of Defect
Reports
1
2
1
-
-
-
4
Number of
Affected
Vehicles
5,247
12,972
8,760
-
-
-
26,979
55
US-EPA [Industry Statistics
-------
Figure 50 - 2009-2011 Recreational Vehicle Defect Reports by Problem Category
Problem Category
Crankcase Vent System
PCV System
Fuel delivery component
OBD system
Internal engine component (piston, etc)
VECI label
Drivability problem
Miscellaneous
Computer related (other than OBD)
Exhaust system
Monitoring/measuring sensor/system
Intake/ exhaust manifold
Total
Reported in 2009
Number
of Defect
Reports
2
2
1
1
2
1
-
-
-
-
9
Number of
Affected
Vehicles
11,445
7,396
4,696
2,285
1,381
144
-
-
-
-
27,347
Reported in 2010
Number
of Defect
Reports
-
2
-
-
-
-
1
1
1
1
6
Number of
Affected
Vehicles
26,289
-
-
-
-
12,573
12,573
2,033
1,655
55,123
Reported in 2011
Number
of Defect
Reports
1
1
-
-
1
-
-
-
-
-
1
-
4
Number of
Affected
Vehicles
8,656
4,316
-
-
5,247
-
-
-
-
-
8,760
-
26,979
RECALL REPORTING
Figures 51 and 52 summarize the recreational vehicle recall actions in 2009 - 2011. The recalls in 2009
2011 affected vehicles in model years 2007-2010.
Figure 51 - 2009-2011 Recreational Vehicle Recall Reports by Manufacturer
Manufacturer
Arctic Cat
BRP
Polaris
Total
Recalls in 2009
Number
of
Recalls
5
1
1
7
Number of
Affected
Vehicles
9,932
4,530
1,381
15,843
Recalls in 2010
Number
of
Recalls
3
-
-
3
Number of
Affected
Vehicles
4,519
-
-
4,519
Recalls in 2011
Number
of
Recalls
1
2
-
3
Number of
Affected
Vehicles
5,247
12,404
-
17,651
Figure 52 - 2009-2011 Recreational Vehicle Recall Reports by Problem Category
Problem Category
Crankcase Vent System
PCV System
Internal engine component (piston, etc)
OBD system
Fuel delivery component
VECI Label
Recalls in 2009
Number
of
Recalls
2
1
2
Number of
Affected
Vehicles
7,503
4,530
2,285
Recalls in 2010
Number
of
Recalls
-
-
-
Number of
Affected
Vehicles
831
-
-
Recalls in 2011
Number
of
Recalls
1
1
1
-
-
-
Number of
Affected
Vehicles
8,729
3,675
5,247
-
-
-
56
US-EPA [Industry Statistics
-------
Problem Category
Drivability problem
Miscellaneous
Monitoring/measuring sensor/ system
Intake/exhaust manifold
Total
Recalls in 2009
Number
of
Recalls
1
1
-
-
7
Number of
Affected
Vehicles
1,381
144
-
-
15,843
Recalls in 2010
Number
of
Recalls
-
-
1
1
2
Number of
Affected
Vehicles
-
-
2,033
1,655
4,519
Recalls in 2011
Number
of
Recalls
-
-
-
-
3
Number of
Affected
Vehicles
-
-
-
-
17,651
AVERAGE BANKING AND TRADING (ABT) PROGRAMS
Only a few of the larger ATV, utility vehicle, and off-highway motorcycle manufacturers took advantage of
the ABT and emission averaging. On the other hand, almost all snowmobile manufacturers participated in
ABT.
Industry Statistics
This section presents additional information that EPA collects in the course of implementing compliance
programs.
ALTERNATIVE FUEL AND ALTERNATIVE FUEL CONVERSIONS34
Some vehicles and engines are designed to operate on fuels other than gasoline and diesel. Some are
manufactured by the OEM to operate on alternative fuels, while others are certified by the OEM to operate
on gasoline or diesel fuel and later converted by an aftermarket manufacturer to operate on an alternative
fuel. Generally, the CAA prohibits any aftermarket changes to a certified vehicle or engine configuration
that could affect emissions, but a regulatory exemption to the prohibition is available in the case of
alternative fuel conversions. Each sector has different criteria under which vehicles and engines can be
converted to operate on a new fuel. In some sectors fuel conversions are certified using OEM certification
provisions.
LIGHT-DUTY VEHICLE ALTERNATIVE FUEL DATA
Figures 53 - 55 present the production of MY 2009 - 2011 OEM light-duty vehicles by fuel type. Gasoline
vehicles comprise the dominant fuel type, followed by flexible fuel vehicles. After gasoline and ethanol,
diesel is the next most prevalent fuel, but still represents less than one percent of passenger car and light-
34 While alternative fuels are generally understood to mean non-petroleum alternatives to gasoline and diesel, this section of the
report also presents data for diesel-fueled vehicles and engines in the light-duty, motorcycle, and recreational vehicle sectors,
sectors that have historically been dominated by gasoline.
57
US-EPA [Industry Statistics
-------
duty truck production. Compressed natural gas (CNG) vehicles make up an even smaller fraction of MY
2009-2011 vehicle production.
Figure 53 - MY 2009 Light-Duty Vehicle Production Volume by Fuel Type
Diesel
50,880; 1%
CNG
1,590; 0%
I Gasoline
Ethanol
Diesel
I CNG
Figure 54 - MY 2010 Light-Duty Vehicle Production Volume by Fuel Type
Diesel CNG
76,272,1% 870,0%
58
US-EPA [Industry Statistics
-------
Figure 55 - MY 2011 Light-Duty Vehicle Production Volume by Fuel Type
Diesel, 91,774,1%
CNG, 990, 0% Hydrogen, 44, 0%
> Ethanol,
2,042,678,17%
Gasoline,
9,868,758, 82%
• Gasoline
• Ethanol
Diesel
• CNG
• Hydrogen
All MY 2009 - 2011 ethanol vehicles were flexible-fuel vehicles which are capable of operating on gasoline,
E85 (85 percent ethanol and 15 percent gasoline), or an intermediate blend.
Figure 56 summarizes the number of OEM light-duty vehicle diesel and alternative fuel test groups by
manufacturer.
Figure 56
MY 2009-2011 Light-Duty OEM Diesel and Alternative Fuel Test Groups by Manufacturer
Fuel
Battery Electric
CNG
Manufacturer
Azure Dynamics
BMW
Mercedes Benz
Nissan
Tesla
Think
Wheego
Honda
Number of Exhaust Test Groups
MY 2009
0
0
0
0
0
0
0
1
MY 2010
0
0
0
0
1
0
0
1
MY 2011
1
1
1
1
1
1
1
2
59
US-EPA [Industry Statistics
-------
Diesel
E85-Gasoline
Hydrogen Fuel Cell
BMW
Cummins
Ford
General Motors
Isuzu
Mahindra &
Mercedes Benz
Bentley
Chrysler
Ford
General Motors
Mercedes Benz
Nissan
Saab
Toyota
Honda
Toyota
2
2
0
0
0
0
3
0
4
6
13
1
1
0
1
1
1
2
2
0
0
0
0
4
0
3
13
10
1
1
0
1
1
1
2
2
2
2
1
1
5
1
5
14
10
1
1
1
1
1
1
Vehicles originally designed and certified to operate on gasoline or diesel fuel can be converted to operate
on an alternative fuel. Converters of new vehicles must obtain a certificate of conformity to avoid violating
the CAA prohibition against tampering.
A new regulation finalized in 2011 established alternative pathways to obtain a regulatory exemption from
tampering beyond certification for converters of older vehicles and engines. For the 2011 model year there
were 31 submissions through the Intermediate Age program and four submissions for the Outside Useful
Life program.
Figure 57 summarizes the number of certificates issued for light-duty vehicle alternative fuel conversions
by manufacturer in MY 2009 - 2011.35
Figure 57
MY 2009-2011 Light-Duty Alternative Fuel Conversion Certificates by Manufacturer
Fuel
CNG
Manufacturer
Altech-Eco
BAF Technologies
Baytech
Evotek
Go Natural CNG
Greenkraft
High Pressure Group
Landi Renzo USA
Nat Gas Car
Natural Drive Partners
Number of Certificates
MY 2009
6
6
1
-
-
-
-
-
-
2
MY 2010
3
3
2
5
-
-
-
-
-
4
MY 2011
19
5
3
10
2
1
1
3
2
5
35 Each light-duty vehicle certificate covers a unique combination of exhaust test group and evaporative emissions family.
Therefore the number of light-duty certificates and test groups is usually different. MY 2009-2011 conversion certificates maybe
issued for conversion of either current or earlier model year OEM vehicles.
60
US-EPA [Industry Statistics
-------
Fuel
CNG/E85-Gasoline
CNG/Gasoline
E85-Gasoline
LPG
LPG/E85-Gasoline
LPG/Gasoline
Plug-in Hybrid
Manufacturer
NGV Conversion
NGV Motori, USA
Altech-Eco
BAF Technologies
Evotek
Go Natural CNG
IMPCO Technologies
Parnell USA
The CNG Store- Auto Gas
Altech-Eco
Baytech
Evotek
FuelTek Conversion Corp.
Go Natural CNG
IMPCO Technologies
Nat Gas Car
The CNG Store- Auto Gas
Altech-Eco
Baytech
Flex Fuel U.S.
Roush Industries
Technocarb Equipment
Yellow Checker Star
American Alternative Fuel
Evotek
Icom North America
IMPCO Technologies
American Alternative Fuel
Icom North America
IMPCO Technologies
Parnell USA
Technocarb Equipment
A123 Systems
Number of Certificates
MY 2009
-
-
-
-
-
-
-
-
-
3
3
-
4
-
11
-
-
3
3
3
-
7
-
1
-
-
3
5
-
10
-
7
-
MY 2010
2
-
-
-
-
-
-
-
-
5
3
-
-
-
-
-
-
5
3
3
11
-
-
2
-
-
-
7
-
-
-
-
1
MY 2011
2
1
4
1
1
11
15
1
6
10
6
1
-
5
15
2
3
10
6
2
20
-
2
13
1
7
19
14
1
7
3
-
3
HIGHWAY MOTORCYCLE ALTERNATIVE FUEL DATA
The majority of highway motorcycles are certified to operate on gasoline. However, there are a few
highway motorcycle engine families certified to operate as battery-electrics, obtaining energy by charging a
battery with electricity from a 120V outlet See Figure 58 for a breakdown of electric motorcycle
manufacturers for MY 2009 - 2011.
61
US-EPA [Industry Statistics
-------
Figure 58
MY 2009-2011 Highway Motorcycle OEM Alternative Fuel Engine Families by Manufacturer
Fuel
Battery Electric36
Manufacturer
Brammo
Green Vehicles
Puma
Tom Notch Technology
Xtreme Green
Zero Motorcycles
ZT Power Station
Current Motors
Evolve Motorcycles
Oxygen World
Ridelectric LLC
Number of Engine Families
MY 2009
1
1
-
-
1
1
-
MY 2010
1
-
2
2
-
1
1
MY 2011
1
3
1
1
1
HEAVY-DUTY HIGHWAY ALTERNATIVE FUEL DATA
Figure 59 presents the OEM heavy-duty highway engines that were certified to operate on alternative fuels
in model years 2009- 2011.
Figure 59
MY 2009-2011 Heavy-Duty Highway Engine OEM Alternative Fuel Engine Families by Manufacturer
Fuel
CNG
CNG/Diesel
LPG
Manufacturer
Cummins Inc.
Doosan Infracore, Co
Westport Fuel Systems
Cummins Inc.
Number of Engine Families
MY 2009
4
2
1
1
MY 2010
3
2
1
-
MY 2011
3
2
1
-
HEAVY-DUTY HIGHWAY ALTERNATIVE FUEL CONVERSION DATA
Figure 60 presents the heavy-duty highway alternative fuel conversion certificates issued in model years
2009-2011.37
Figure 60
MY 2009-2011 Heavy-Duty Highway Engine Alternative Fuel Conversion Certificates by Manufacturer
Fuel
CNG
Manufacturer
BAF Technologies
Baytech
Corporation
Number of Certificates
MY 2009
1
3
MY 2010
2
3
MY 2011
2
4
36 EPA began issuing certificates for battery electric highway motorcycles in MY 2009.
37 MY 2009-2011 conversion certificates maybe issued for conversion of either current or earlier model year OEM highway
engines.
62
US-EPA [Industry Statistics
-------
CNG/Gasoline
LPG
LPG/Gasoline
Emission Solutions,
Inc.
Evotek, LLC
Greenkraft Inc
Baytech
Corporation
American
Alternative Fuel
Baytech
Corporation
Bi-Phase
Technologies, LLC
Clean Fuel USA Inc.
Roush
Icom North
America LLC
-
3
2
1
1
-
1
1
1
-
4
1
1
5
1
2
4
2
3
1
8
1
NONROAD COMPRESSION IGNITION ALTERNATIVE FUEL DATA
There were no MY 2009 - 2011 certificates issued for nonroad compression ignition engines that operate
on alternative fuels.
NONROAD SPARK IGNITION ALTERNATIVE FUEL AND FUEL CONVERSION DATA
There are numerous engine manufacturers that certify nonroad spark ignition engines to run on alternative
fuels, in both Small SI and Large SI categories.38 About 10 percent of Small SI engine families in MY 2009 -
2011 were certified to operate on alternative fuels. The majority of Large SI engine families are certified to
operate on alternative fuels. In MY 2009 of the 89 Large SI engine families, 77 were certified to operate on
one or more alternative fuels. In MY 2010, of the 124 Large SI engines families, 91 were certified to operate
on one or more alternative fuels. In MY 2011, of the 140 Large SI engines families, 123 were certified to
operate on one or more alternative fuels. Figures 61 and 62 summarize information about MY 2009 - 2011
Small SI and Large SI alternative fuel engine families.
Figure 61
MY 2009-2011 Small Spark Ignition Engine OEM Alternative Fuel Engine Families
Fuel
E85-Gasoline
Natural Gas/CNG
Natural Gas/CNG / Propane/LPG
Propane/LPG
Propane/LPG / Gasoline
Natural Gas/CNG / Propane/LPG / Gasoline
Number of Engine Families
MY 2009
2
21
28
63
6
MY 2010
1
17
22
46
5
MY 2011
-
15
16
42
9
1
38 No marine SI engines were certified to operate on alternative fuels in either MY 2009 or 2010. One marine SI engine family was
certified to operate on LPG in MY 2011.
63
US-EPA [Industry Statistics
-------
Figure 62
MY 2009-2011 Large Spark Ignition Engine OEM Alternative Fuel Engine Families
Fuel
Natural Gas/CNG
Natural Gas/CNG / Propane/LPG
Natural Gas/CNG / Propane/LPG / Gasoline
Propane/LPG
Propane/LPG / Gasoline
Number of Engine Families
MY 2009
8
5
4
20
40
MY 2010
10
17
7
34
23
MY 2011
42
23
7
34
27
RECREATIONAL VEHICLE ALTERNATIVE FUEL DATA
The majority of recreational vehicles are certified to operate on gasoline. However, there were two ATV
engine families certified to operate on diesel in MY 2009, two in MY 2010 and one in MY 2011. Figure 63
shows a breakdown of diesel recreational vehicle manufacturers.
Figure 63
MY 2009-2011 Recreational Vehicle OEM Diesel Engine Families by Manufacturer
Fuel
Diesel
Manufacturer
Tomcar USA Inc.
Deere & Company
Number of Engine Families
MY 2009
1
1
MY 2010
1
1
MY 2011
0
1
MANUFACTURER LOCATIONS
Consistent with past compliance reports, manufacturer locations here are attributed using two different
approaches. For light-duty vehicles and locomotives, we report data based on where a manufacturer's
headquarters are located, not necessarily where the vehicles are manufactured. For example, Toyota's
corporate headquarters are in Japan, so all of Toyota's MY 2009 - 2011 vehicles produced for sale in the
United States are presented with Japan listed as the country of origin, even though some Toyota vehicles
are built in the United States. For all other sectors, EPA generally reports manufacturer location based on
the actual location in which the vehicle or engine was manufactured.
LIGHT-DUTY VEHICLE MANUFACTURER LOCATIONS
Figure 64 presents the country of origin of MY 2009 - 2011 light-duty vehicles produced for sale in the
United States.39
39 These production data only include vehicles subject to Corporate Average Fuel Economy standards. Pickup trucks greater than
8,500 pounds Gross Vehicle Weight are not included.
64
US-EPA [Industry Statistics
-------
Figure 64
MY 2009-2011 Light-Duty Vehicle Production Volume by Manufacturer's Country of Origin
0)
S
j3
"o
6,000,000
5,000,000
4,000,000
3,000,000
3 2,000,000
T3
O
a.
1,000,000
12009
2010
2011
USA Japan Korea Germany UK Sweden Italy
Country of Origin
HIGHWAY MOTORCYCLE MANUFACTURER LOCATIONS
In MY 2009-2011, Chinese, Japanese, and Taiwanese manufacturers produced a large fraction of Class la
and Ib highway motorcycles sold in the United States while American, Japanese and European
manufacturers produced the largest share of U.S. Class III highway motorcycles.
HEAVY-DUTY HIGHWAY MANUFACTURER LOCATIONS
Figure 65 presents the number of highway engine families (both compression ignition and spark ignition
engine families) that were certified for sale in the United States by engine manufacturing plant location.
Figure 65
MY 2009-2011 Heavy-Duty Highway CI and SI Engines by Manufacturing Location
Country
USA
Japan
Germany
Brazil
Canada
Number of Engine Families
MY 2009
77
12
3
3
1
MY 2010
39
5
2
1
0
MY 2011
79
5
2
1
0
65
US-EPA [Industry Statistics
-------
Country
The Netherlands
Italy
Multiple countries40
Total
Number of Engine Families
MY 2009
1
0
3
100
MY 2010
0
0
5
52
MY 2011
0
2
3
92
NONROAD COMPRESSION IGNITION MANUFACTURER LOCATIONS
Figures 66 - 68 present the number of engine families intended for use in marine diesel (both EPA and IMO
certificates), locomotive, and construction/agricultural equipment applications that were certified for sale
in the United States by engine manufacturing plant location or country of origin.
Figure 66 - MY 2009-2011 Marine Diesel Engine Families by Manufacturing Location
Country
USA
Japan
Italy
Sweden
United Kingdom
Korea
The Netherlands
Germany
France
Mexico
Canada
Norway
Finland
Austria
Multiple Countries
Total
Number of Engine Families
MY 2009
86
20
17
12
11
10
8
6
5
4
0
2
1
1
16
199
MY 2010
86
20
17
20
13
3
8
10
10
0
0
0
1
1
17
206
MY 2011
107
27
19
16
18
5
10
15
6
1
4
0
0
1
30
259
Figure 67 - MY 2009-2011 Locomotive Engine Families by Country of Origin
Country
USA
Multiple countries
Number of Engine Families
MY 2009
70
2
MY 2010
43
4
MY 2011
43
1 "Multiple countries" means that engines within an engine family are manufactured in more than one country.
66
US-EPA [Industry Statistics
-------
Figure 68
MY 2009-2011 Construction and Agricultural Engine Families by Manufacturing Location
Country
Japan
Germany
China
Italy
England
USA
Korea
India
Mexico
Sweden
Switzerland
France
Czech Republic
Austria
Brazil
Belgium
Slovakia
Multiple countries
Total41
Number of Engine Families
MY 2009
193
83
60
46
47
43
31
23
8
8
7
8
2
1
1
0
-
50
611
MY 2010
195
83
65
49
47
47
36
25
7
2
11
7
2
1
1
0
4
59
641
MY 2011
179
75
43
50
32
21
27
22
8
9
3
2
2
-
-
-
4
43
520
NONROAD SPARK IGNITION MANUFACTURER LOCATIONS
Figures 69 - 71 present the number of Small SI, Marine SI and Large SI engine families that were certified
for sale in the United States by engine manufacturing plant location.
Figure 69 - MY 2009-2011 Small Spark Ignition Engine Families by Manufacturing Location
Country
China
USA
Japan
Germany
Sweden
Italy
Mexico
Thailand
Brazil
Taiwan
Czech Republic
Number of Engine Families
MY 2009
542
308
158
43
37
22
16
6
6
2
1
MY 2010
467
264
153
37
31
18
20
7
4
1
1
MY 2011
442
198
134
12
34
8
16
2
60
-
1
41 This figure does not include stationary-only engine families.
67
US-EPA [Industry Statistics
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Country
Multiple countries
Total
Number of Engine Families
MY 2009
19
1,160
MY 2010
17
1,020
MY 2011
78
985
Figure 70 - MY 2009-2011 Marine Spark Ignition Engine Families by Manufacturing Location
Country
Japan
USA
China
France
Thailand
Canada
Germany
Total
Number of Engine Families
MY 2009
64
37
10
5
4
2
2
124
MY 2010
52
44
12
-
5
4
-
117
MY 2011
52
52
13
-
5
2
-
124
Figure 71 - MY 2009-2011 Large Spark Ignition Engine Families by Manufacturing Location
Country
USA
Korea
Canada
Germany
Japan
Mexico
Austria
China
Multiple countries
Total
Number of Engine Families
MY 2009
59
17
4
2
1
1
1
-
4
89
MY 2010
95
10
6
6
2
1
1
1
2
124
MY 2011
113
7
9
5
2
1
1
-
2
140
68
US-EPA [Industry Statistics
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