1. February 28, 2006 ® Southwest Research Institute ® Engine Lubricants Research Department Overview of SwRI IR&D Program To Study Engine Oil Formulation Effects on Catalyst Poisoning in an Engine Dynamometer Test Presented to the GF-5 Emissions System Compatibility Improvement Team by Scott Ellis

2. February 28, 2006 ® Introduction IR&D Program: Development of an Engine Dynamometer Test to Evaluate Crankcase Phosphorus Formulation Effects on Catalytic Converters Program Duration: July 2005 through June 2006 Objective: Investigate feasibility of using an engine dynamometer test stand as evaluation platform for engine oil propensity to poison catalytic converters Emphasis: Utilize knowledge gained during and since OPEST and OPEST II with special focus on phosphorus volatility Approach: Run 4 tests using Afton 2002 Taxi Fleet oils 33 and 35 to demonstrate PCV-borne phosphorus effects, repeatability, and discrimination

3. February 28, 2006 ® Engine Selection Current MY 4-cyl engine desired for current applicability and lower test cost Hardware solicited from Detroit Big 3 – no commitments SwRI forced to use engine ‘on-hand’ in interest of time 2002 Chevrolet Malibu 3.1L V-6

4. February 28, 2006 ® Desired Test Cycle Features 150 °C oil temperature to maximize P-volatility in crankcase and ring-belt area Maximize blowby flow to transport ring-belt phosphorus into crankcase Maximize PCV flow to transport crankcase phosphorus into engine intake Catalyst inlet temperatures representative of field poisoning scenarios

5. February 28, 2006 ® Initially Proposed Test Cycle

6. February 28, 2006 ® Oil Temperature Control 150 °C can be maintained with GM 3.1L at 3500 rpm Potential phosphorus pathways

7. February 28, 2006 ® PCV Flow Rate Studies PCV/blowby both maximum at 3500 rpm, 45 % throttle angle Note: All flows corrected to 20 °C and 1 atm

8. February 28, 2006 ® PCV Flow Rate Studies Exhaust temperature maximum at 3500 rpm, 58 % throttle angle

9. February 28, 2006 ® PCV Flow Rate Studies O2S voltage indicates fueling not stoichiometric at 3500 rpm Note: plotted are 5 min. average of 10 sec. data

10. February 28, 2006 ® Desired Revisions to Test Cycle Utilize max. PCV condition (3500 rpm, 45 % throttle) for approx. 2/3 of test cycle Use full-rich condition for approx. 1/6 of test cycle Use stoichiometric condition for approx. 1/6 of test cycle Need to check for soot accumulation on catalyst face May need air injection at stoichiometric condition to oxidize soot

11. February 28, 2006 ® Revised Test Cycle * May need air injection if soot accumulation is evident

12. February 28, 2006 ® Phosphorus Retention Study Use same methodology as SAE paper 2003-01-1988

13. February 28, 2006 ® Phosphorus Retention Study Performed 24-hr repeat runs on revised test cycle with 10 ml oil samples every 2 hours

14. February 28, 2006 ® Research Catalysts Six units obtained, one baseline, four tests, one spare Approximately 1 liter volume Pd-only wash coating 900 c.p.i. Sliced 1” segment from face for core samples Reassembled in can with Interam packing Thermocouples installed approximately ¾” from face

15. February 28, 2006 ® Next Steps Run 10-hour degreen segment on baseline catalyst – Measure conversion efficiency in SGR (1” core sample from catalyst face) – Look for evidence of soot deposition on catalyst face Run 300-hr test on Oil 33 – Measure conversion efficiency on 1” core sample @ 150, 200, 250 and 300 hours – Determine test length required for significant degradation Run X-hour test on Oil 33 with PCV de-coupled Run X-hour test on Oil 33 for repeatability Run X-hour test on Oil 35 for discrimination