diesel engines - jsae the commercial diesel engines launched in 2014 also featured reﬁnements to...

Copyright©2015SocietyofAutomotiveEngineersofJapan,Inc.Allrightsreserved

1 Introduction　　　　　　　　　　　　　　　

In2014,1.205milliondieselengines for four-wheeledvehicleswereproduced inJapan,up10.1% from2013.In termsof engine types, 428,000diesel engineswereproduced forpassengervehicles (up14.1% from2013),685,000 for trucks (up8.0%), and92,000 forbuses (up8.2%).In Japan, therewere few newly announced and

launchedengines in2014althoughseveralyearshavepassedsince the launchofvehiclescompliantwith thePostNewLongTermRegulations.However,theenginesthatwerelaunchedincludedanumberofso-called“cleandiesel”1.5-literenginesforpassengervehicles.Vehiclesinstalledwiththeseenginesareregardedasenvironmen-tallyfriendlyvehiclessimilartohybridvehicles.Severalof thecommercialdieselengines launched in2014alsofeaturedrefinementstoimprovefuelefficiency.InEurope,theEuro6emissionsstandardsforpassen-

gervehiclescame into force,prompting theannounce-mentand launchofanumberofnewengines. Dieselenginesareregardedasan importantmeansofhelpingtoreducegreenhousegasemissionsandaddressingtheissueofenergysecurityonaglobalscale.Fortheserea-sons,variousengineswereunveiledand launched inallregionsandvehicleclassesin2014withtheaimofreduc-ingCO2emissionsthroughimprovementstocombustionefficiencyandweightreduction.

2 Engine Trends in Japan　　　　　　　　　

2. 1. Summary2. 1. 1. Diesel engines for passenger vehiclesMazdaMotorCorporationunveiledanew1.5-literen-

ginefortheDemiothatwentonsalein2014.2. 1. 2. Diesel engines for commercial vehiclesWithaprimary focus on improving fuel efficiency,

IsuzuMotorsLimited launchedthe4JJ1engine for theElftruckandMitsubishiFuso

TruckandBusCorporationlaunchedthe6R10enginefor largebuses. Boththeseenginesarerefinementsofexistingengines.2. 2. New engine characteristics (Table 1)2. 2. 1. Mazda S5-DPTS engine (Fig. 2)Thisengine isa1.5-literversionof the2.2-literSH-

VPTSenginethatwentonsale in2013, featuring inno-vative technologiessuchasa lowercompressionratio.This enginealso incorporatesvarious technologies tofurtherboostfuelefficiency,suchasimprovedheatinsu-lationand lowermechanical losstorestrict increases incoolingloss.2. 2. 2. Isuzu 4JJ1 engine (Fig. 3)Thisengineachieveshigher fuelefficiencybyadopt-

inga lowercompressionratioandnewhigherpressureinjectors.2. 2. 3. Mitsubishi Fuso 6R10 engine (Fig. 4)Thisenginefeaturesanasymmetricturbochargerand

achievesefficientenginecoolingthroughanelectronical-lycontrolledvariableflowwaterpump,therebyreducingpumpdrivelossandimprovingfuelefficiency.

3 Engine Trends outside Japan　　　　　　

3. 1. Summary3. 1. 1. Diesel engines for passenger vehiclesEuro 6 emissions standards forpassengervehicles

came into force,prompting theannouncementandre-lease of newengines fromBMW,Volkswagen (VW),

Diesel Engines

Fig. 1 Diesel engine production in Japan in 2014

Trucks

Passenger cars

Buses

January February March April May June July August September October NovemberDecember

7

6

5

4

3

2

1

0Production volume (10,000 units)


andVolvo.Theseenginescomplywiththesestandardsthrough innovations such as high-pressure injection,2-stageturbochargers,andvariablegeometry(VG)turbo-charging. Theseenginesalsofeaturefuelefficiencyim-provementtechnologiestolowerfueleconomyandCO2.Othernoticeabletrendsincludemodulardesignmethodssuchassharingmaterialsandauxiliaryequipment lay-outswithgasolineengines installed in thesamemodelandotherdieselengines. However,nonewpassengervehicleengineswereannouncedinNorthAmerica.3. 1. 2. Diesel engines for commercial vehiclesFollowing thesame trendsaspassengervehicleen-

gines,newandrefinedcommercialvehicleengineswereannouncedand launchedbyMAN,Scania, andVolvoTrucks inEurope tocomplywithemissionsstandardsandimprovefuelefficiency.MostoftheseareequippedwithVGturbochargers,high-pressureinjectionsystems,and intake inter-cooling. Someof these engines alsoincludea low-pressureexhaustgasrecirculation (EGR)systemora2-stageEGRcooler.Incontrast,ScaniaalsounveiledasimplifiedenginesystemwithoutEGRoraVGturbochargerwiththeaimofimprovingfuelefficien-cyfocusingoncommercialvehiclecustomersinthelong-distance transportation field. InNorthAmerica,bothCumminsandFiatChryslerAutomobiles(FCA)launchednewengines.Thesefeaturedhigh-pressurefuelinjectionandVGturbochargers, aswell ascompactedgraphiteiron (CGI)cylinderblocksforhigh-efficiencycombustionandreducedweighttoimprovefuelefficiency.3. 2. New engine characteristics (Table 2)3. 2. 1. BMW B37/B47 enginesBMWareswitchingover tonewengines tocomply

withtheEuro6standards. Theseengines feature thesamebore/strokeratioandhavebeen installed incom-pactMiniandBMWbrandvehiclesin3-cylinder1.5-liter(B37)and4-cylinder2.0-liter(B47)formats.Theenginesweredeveloped followingamodulardesignapproachwithenhanced flexibility fordevelopmentandproduc-

Table 1 Specifications of new engines in 2014

Application Manufacturer Enginemodel

Cylinderarrangement

Bore×stroke(mm)

Displacement(cc)

Compressionratio

Maximumpower(kW/rpm)

Maximumtorque(Nm/rpm) Characteristics

Passengervehicles

Mazda S5-DPTS Inline4 76.0×82.6 1 498 14.8 77/4 000 250/1500─2 500

Lowcompression ratio, high-dispersionspray injectors, stepped egg-shapedpistons, high- and low-pressure EGRsystem,VGT, improvedheat insulation,lowermechanicalresistance

Commercialvehicles

Isuzu 4JJ1 Inline4 95.4×104.9 2 999 15.8 110/2 800 375/140─2 800 Lowcompressionratio,newhigh-pressureinjectors

MitsubishiFusoTruckandBus

6R10 Inline6 132.0×156.0 12 808 17.3 257─309/1 800 1 810/1 200 Asymmetric turbocharger,electronicallycontrolledvariablecapacitywaterpump

Fig. 2 Mazda S5-DPTS engine

Fig. 3 Isuzu 4JJI engine

Fig. 4 Mitsubishi Fuso 6R10 engine


tion. Underthisapproach, theenginessharethesameauxiliaryequipment layoutas thegasolineengines in-stalled in thesamemodels, aswellas thesamecrankcasematerials.TheB47hasaVGturbochargerwithalow-resistanceshaftbearingto improve intakepressure

transient response. Italso featuresnewsolenoid-typeinjectorsthatachieveaninjectionpressureof2,000bar.3. 2. 2. VW 2.0-liter TDI BiTurbo engine (Fig. 7)Thishigh-powerenginewasdeveloped followingthe

samemodulardesignapproachasVW＇s1.4 to2.0-liter

Table 2 Specifications of new engines in 2014

Application Manufacturer Enginemodel

Cylinderarrangement

Bore×stroke(mm)

Displacement(cc)

Compressionratio

Maximumpower(kW/rpm)

Maximumtorque(Nm/rpm) Characteristics

Passengervehicles

BMW B37 Inline3 84.0×90.0 1 496 16.5 85/4 000 270/1 750─2 000

Commonmodulardesign approach forcylinders, auxiliary equipment layout,andcrankcasematerial ofgasolineanddiesel engines,VG turbochargerwithlow-resistanceshaftbearings,2 ,000barsolenoid-typeinjectors

B47 Inline4 84.0×90.0 1 995 16.5 140/4 000 400/1 750─2 750

Volkswagen TDIBiTurbo

Inline4 81.0×95.5 1 968 15.5 176/4 000 500/1 750─2 500

Commonmodulardesignapproach for 1 .4 -to 2 .0 -literdiesel engines, 2 ,500barpiezoinjectors, low-swirl cylinderheads, electricwater pump, 2 -stage turbocharger (high-pressureside:VGT), low-andhigh-pressureEGR,aftertreatmentsystemdirectlyattachedtoengine(SCR-coatedparticulatefilter)

VolvoCars D5 Inline4 82.0×93.2 1 969 15.8 170/4 250 480/1 750─2 250

Commonizationbetweengasolineanddieselengines,high-pressurealuminumdie-castblock,high-strengthaluminumheads,2 ,500bar i-ARTinjectors,2 -stageturbocharger(high-pressureside:VGT)

Commercialvehicles

FCA L630 V6 83.0×91.4 2 987 16.5 179/4 000 570/1 800 CG I b l o c k , a l um i n um h e a d s ,electronicallycontrolledVGT,2 ,000barinjectionsystem,cooledEGR

Cummins ISV5.0 V8 94.0×90.0 4 997 149─205/1 600 705─759/3 200 Latest high-pressure fuel injection system, VGturbocharger,CGIblock,high-strengthaluminumheads

MAN D38 Inline6 138.0×170.0 15 256 18.0 382─471/1 800 2 500─3 000/930─1 350

Top-downcooling,2 -stageturbocharger,2 -stageintakecooling,domedintakeandexhaustvalves, fire ringsat the topofthecylinder,2 ,500barinjectionpressure,2 -stageEGRcooler,steelpistons

Scania DC16 V8 130×154 16 353 17.4 382─427/1 900 2 700─3 500/1 000─1 400

VGturbocharger,cooledEGR

DC13 Inline6 130×160 12 742 17.3 336/1 900 2 350 /1 000─1 300

NoEGR

VolvoTrucks D16K Inline6 144×165 16 123 16.0 405─552/1 350─1 900

2 800─3 550/900─1 450

2 -stage turbocharger, intake inter-cooling,cooledEGR

Fig. 5 BMW B37 engineFig. 6 BMW B47 engine


dieselengines,and installed in thePassat. TocomplywithEuro6whileachievingbothhighpowerand fuelefficiency, this engineuses 2,500barpiezo injectors,2-stage turbochargingwithaVGturbochargeron thehigh-pressureside,water-cooledcompressorhousing,aswellaslow-andhigh-pressureEGR.Theaftertreatmentsystem ispartly incorporated into thehousing imme-diatelybelowengine inconsiderationof lowerexhaustresistance.Otherinnovationsincludelowswirlcylinderheadsasameasure toboostpower, strongermovingparts toensuretoughness,durability,andreliability,aswellasalowercompressionratio.3. 2. 3. Volvo D5 engine (Fig. 8)Both thehigh-powerdieselandgasolineengines for

theXC90weredesignedthroughasharedmodularap-proach. Inaddition tomeasures toboostpower, suchasahigh-pressurealuminumdie-castcylinderblockandhigh-strengthaluminumcylinderheads, theD5enginealsomeetstherequirementsofEuro6through2,500barinjectors (developedusingtheIntelligentAccuracyRe-

finementTechnology(i-ART)concept),and2-stageturbo-chargingwithaVGturbochargeronthehigh-pressureside.3. 2. 4. FCA L630 engine (Fig. 9)TheL630 engine is installed in theRam1500 full-

sizepick-up truckandGrandCherokeeSUV. Itwasdesigned for compliancewith theTier 2Bin 5/LEVII standards. This enginewasmanufacturedbyVMMotoriundertheFCAgroupumbrellaandfeaturesanelectronicallycontrolledVGturbochargerandacommonrailsystemwithaninjectionpressureof2,000bar.ThemainengineunitusesaCGIblockandaluminumheads.3. 2. 5. Cummins ISV5.0 engine (Fig. 10)Thisnewenginewasdeveloped forpick-up trucks,

recreationalvehicles (RVs),andvehiclesmainlydrivenonthehighway.ItfeaturesaVGturbocharger,thelat-esthigh-pressurefuelinjectionsystem,aCGIblock,andhigh-strengthaluminumheads.Itwasdesignedforcom-pliancewiththeUS10emissionsstandards.3. 2. 6. MAN D38 engine (Fig. 11)This isthe largestdisplacementenginedevelopedby

MANfor installation inheavy-dutyvehicles. CompliantwithEuroVI,theD38enginealsofeaturesa2-stagetur-

Fig. 7 VW 2.0-liter TDI BiTurbo engine

Fig. 8 Volvo D5 engine

Fig. 9 FCA L630 engine

Fig. 10 Cummins ISV5.0 engine


bocharger,2-stage intakeaircoolingsystem,and2,500bar fuel injection system forhighlyefficient combus-tion. Otherdistinguishingcharacteristicsof thisengineincludeaso-called top-downcoolingsystemthat flowscoolantfromthehigh-temperatureheadstothecylinderblock,domed intakeandexhaustvalves, fire rings in-sertedatthetopofthecylinderboretopreventcarbondeposits,aswellassteelpistonsto improvetoughness,durabilityandreliability.3. 2. 7. Scania DC16 engine (Fig. 12)This isthe largestdisplacementenginedevelopedby

Scaniaforinstallationinheavy-dutyvehicles.ItfeaturesaVGturbochargerandcooledEGRforcompliancewithEuroVI.ItistheonlyV8engineinitsclass.3. 2. 8. Scania DC13 engine (Fig. 13)Scaniaunveiledand launchedtheEuroVI-compliant

DC13enginein2011.However,ithasbeenre-designedwithouteitherEGRoraVGturbochargerwithanem-phasison improved fuelefficiencyparticularly for long-distancefleetusers,whileretainingEuroVIcompliance.ThehigherNOxemissionscausedbyremovingtheEGR

systemarecounteredbyahigherconsumptionofAd-Blueintheureainjectionsystem.Toaccommodatethischange,theAdBluetankcapacitywasincreased.3. 2. 9. 3 Volvo Trucks D16K engine (Fig. 14)This isthe largestdisplacementenginedevelopedby

Volvoforinstallationinheavy-dutyvehicles.Itiscompli-antwithEuroVIandfeaturesa2-stageturbocharger,anintakeinter-coolingsystem,andcooledEGR.

4 Research and Development Trends　　

Inrecentyears,automakershavefocusedondevelop-ingtechnology forcompliancewithstringentemissionsstandardssuchasJapan＇sPostNewLongTermRegula-tions,andEuro6/VI. Inaddition toemissionscompli-ance, otherdeveloped technologiesaim to reduceme-chanicalengine lossesandoptimizecooling to improvecombustioncharacteristics for lowerCO2emissionsorhigherfuelefficiency.Recenttechnologicalapproachestocomplywithemis-

sionsstandards includedevelopingtechnologyto lowerengine-outemissions,aftertreatmentsystems,and inte-

Fig. 13 Scania DC13 engine

Fig. 14 Volvo D16K engine

Fig. 11 MAN D38 engine

Fig. 12 Scania DC16 engine


gratedcontroltechnologies.Keyfuturetrendsarelikelytoincludeagrowingemphasisonresearchanddevelop-ment intobasic technologies to reduceCO2emissionsand improve fuel efficiency, aswell as intooptimized“product”technologiesincorporatingthesebasictech-nologieswithemissionsstandardscompliance technolo-giesandhardware-andsoftware-basedtechnologies toimprovecontrolaccuracy. Manufacturersofexpensiveandcomplexdiesel enginesadopting thesenecessarynewtechnologies tocomplywithemissionsregulations(particularly commercialvehicle engines)willhave toselectwhichsystemstousebasedontheseoptimizationtechnologies toreducecostsandprovide improvedus-abilityforcustomers.Incontrast,mostmass-productionpassengervehicles

willcontinuetooffergasolineenginesandmultipledieselenginechoicesforthesamemodel.Therefore,fromthestandpointsofdevelopmentandproductionefficiency,passengervehicledieselengineswilladoptefficientpack-agingthatusecommonpartsandlayoutswithotheren-gines forthesamemodel,andthatalso incorporatetheaftertreatmentsystem.Theseenginepackageswillhavetosatisfytherestrictionsinherentinvehicleinstallation.Therefore, inadditiontothedevelopmentoftechnologyforcompliancewithemissionsstandardsand improving

combustioncharacteristics, researchanddevelopmentinto separatingandconsolidatingstructuresand func-tions inengineswithcomplexconfigurationswill con-tinuegrowinginimportancetoachieveenginepackagesthatsatisfytheserestrictions.

References(1) MonthlystatisticspublishedbytheJapanAuto-

mobileManufacturersAssociation(JAMA)(2) WebsiteofMazdaMotorCorporation(3) WebsiteofIsuzuMotorsLimited(4) WebsiteofMitsubishiFusoTruckandBusCor-

poration(5) 23rdAachenColloquiumAutomobileandEn-

gineTechnology,2014(6) WebsiteofBMW(7) WebsiteofVolkswagen(8) WebsiteofVolvoCarCorporation(9) WebsiteofFiatChryslerAutomobiles(10) WebsiteofCumminsInc.(11) WebsiteofMAN(12) WebsiteofScania(13) WebsiteofVolvoTrucks(14) WebsiteoftheEnvironmentProtectionAgency(15) WebsiteoftheCaliforniaAirResearchBoard

diesel engines - jsae the commercial diesel engines launched in 2014 also featured reﬁnements to...

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