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This paper first presents a basic mean value engine plant model implemented in a hardware-in-the-loop (HIL) system. The plant model includes some basic engine parameters such as engine speed, manifold absolute pressure, etc., which are critical to both control algorithm integrity and default actions that result from improper signal performance (e.g., ECU shuts down due to corrupted signal(s)). The model is then improved to develop the HIL bench-based testing capabilities in the areas where a vehicle has traditionally been required. The on-board diagnostic monitor tests covered by SID $06 of SAE J1979 are selected as a case study. Specifically, for OBD exhaust gas sensor monitor testing purposes, the oxygen sensor model is developed to simulate normal or abnormal binary switching signals which might have asymmetric “lean to rich” and “rich to lean” transitions, or largely off maximum/minimum sensor voltages, etc.