I thought I'd share some of the Roush Testing process with you.
Testing takes 2 days per test. When we arrive, they drain the fuel tank of pump gas. They then pump about 5 gallons of specially brewed test fuel into the tank. We wasted quite a bit of money, as we filled it up as we rolled into Detroit. They then push the car into the dyno booth and strap it down.
They run a full FTP-75 test to get the ECU happy with their test fuel. The engine has to then cool over-night. The actual test is conducted the next day.
Emissions are sampled with very expensive Horiba test equipment.
The test is broken into 4 parts; Cold Start, City, Hot Start, Highway. A Driver sits in the car and works the throttle pedal to keep the speed between the Max/Min parameters.
The Operator is in a booth monitoring the entire process on 3 different screens.
Once the test is complete, they shut it off, disconnect everything, then push it out of the dyno cell into another room. Total time is around 2 hours per test segment (including all 4 Cycles).