Diesel Engines

Truck and Bus Corporation launched the 6R10 engine

1 Introduction
for large buses. Both these engines are refinements of
In 2014, 1.205 million diesel engines for four-wheeled existing engines.
vehicles were produced in Japan, up 10.1% from 2013.
In terms of engine types, 428,000 diesel engines were
produced for passenger vehicles (up 14.1% from 2013), This engine is a 1.5-liter version of the 2.2-liter SH-
685,000 for trucks (up 8.0%), and 92,000 for buses (up VPTS engine that went on sale in 2013, featuring inno-
8.2%). vative technologies such as a lower compression ratio.
In Japan, there were few newly announced and This engine also incorporates various technologies to
launched engines in 2014 although several years have further boost fuel efficiency, such as improved heat insu-
passed since the launch of vehicles compliant with the lation and lower mechanical loss to restrict increases in
Post New Long Term Regulations. However, the engines cooling loss.
that were launched included a number of so-called “clean
diesel” 1.5-liter engines for passenger vehicles. Vehicles This engine achieves higher fuel efficiency by adopt-
installed with these engines are regarded as environmen- ing a lower compression ratio and new higher pressure
tally friendly vehicles similar to hybrid vehicles. Several injectors.
of the commercial diesel engines launched in 2014 also
featured refinements to improve fuel efficiency. This engine features an asymmetric turbocharger and
In Europe, the Euro 6 emissions standards for passen- achieves efficient engine cooling through an electronical-
ger vehicles came into force, prompting the announce- ly controlled variable flow water pump, thereby reducing
ment and launch of a number of new engines. Diesel pump drive loss and improving fuel efficiency.
engines are regarded as an important means of helping
3 Engine Trends outside Japan
to reduce greenhouse gas emissions and addressing the
issue of energy security on a global scale. For these rea-
sons, various engines were unveiled and launched in all
regions and vehicle classes in 2014 with the aim of reduc- Euro 6 emissions standards for passenger vehicles
ing CO2 emissions through improvements to combustion came into force, prompting the announcement and re-
efficiency and weight reduction. lease of new engines from BMW, Volkswagen (VW),

2 Engine Trends in Japan

Mazda Motor Corporation unveiled a new 1.5-liter en-

gine for the Demio that went on sale in 2014.

With a primary focus on improving fuel efficiency,

Isuzu Motors Limited launched the 4JJ1 engine for the
Elf truck and Mitsubishi Fuso

Copyright© 2015 Society of Automotive Engineers of Japan, Inc. All rights reserved
 Table 1 Specifications of new engines in 2014
Engine Cylinder Bore Displacement Compression Maximum power Maximum torque
Application Manufacturer Characteristics
model arrangement stroke (mm) (cc) ratio (kW/rpm) (Nm/rpm)

Passenger Mazda S5-DPTS Inline 4 76.082.6 1 498 14.8 77/4 000 250/1500 Low compression ratio, high-dispersion
vehicles ─ 2 500 spray injectors, stepped egg-shaped
pistons, high- and low-pressure EGR
system, VGT, improved heat insulation,
lower mechanical resistance

Commercial Isuzu 4JJ1 Inline 4 95.4104.9 2 999 15.8 110/2 800 375/140 ─ 2 800 Low compression ratio, new high-pressure injectors
vehicles
Mitsubishi Fuso 6R10 Inline 6 132.01 56.0 12 808 17.3 257 ─ 309/1 800 1 810/1 200 Asymmetric turbocharger, electronically
Truck and Bus controlled variable capacity water pump

gines, new and refined commercial vehicle engines were

announced and launched by MAN, Scania, and Volvo
Trucks in Europe to comply with emissions standards
and improve fuel efficiency. Most of these are equipped
with VG turbochargers, high-pressure injection systems,
and intake inter-cooling. Some of these engines also
include a low-pressure exhaust gas recirculation (EGR)
system or a 2-stage EGR cooler. In contrast, Scania also
unveiled a simplified engine system without EGR or a
VG turbocharger with the aim of improving fuel efficien-
cy focusing on commercial vehicle customers in the long-
distance transportation field. In North America, both
Cummins and Fiat Chrysler Automobiles (FCA) launched
new engines. These featured high-pressure fuel injection
and Volvo. These engines comply with these standards and VG turbochargers, as well as compacted graphite
through innovations such as high-pressure injection, iron (CGI) cylinder blocks for high-efficiency combustion
2-stage turbochargers, and variable geometry (VG) turbo- and reduced weight to improve fuel efficiency.
charging. These engines also feature fuel efficiency im-
provement technologies to lower fuel economy and CO2.
Other noticeable trends include modular design methods BMW are switching over to new engines to comply
such as sharing materials and auxiliary equipment lay- with the Euro 6 standards. These engines feature the
outs with gasoline engines installed in the same model same bore/stroke ratio and have been installed in com-
and other diesel engines. However, no new passenger pact Mini and BMW brand vehicles in 3-cylinder 1.5-liter
vehicle engines were announced in North America. (B37) and 4-cylinder 2.0-liter (B47) formats. The engines
were developed following a modular design approach
Following the same trends as passenger vehicle en- with enhanced flexibility for development and produc-

Copyright© 2015 Society of Automotive Engineers of Japan, Inc. All rights reserved
 Table 2 Specifications of new engines in 2014
Engine Cylinder Bore Displacement Compression Maximum power Maximum torque
Application Manufacturer Characteristics
model arrangement stroke (mm) (cc) ratio (kW/rpm) (Nm/rpm)

Passenger BMW B37 Inline 3 84.090.0 1 496 16.5 85/4 000 270/1 750 Common modular design approach for
vehicles ─ 2 000 cylinders, auxiliary equipment layout,
and crankcase material of gasoline and
B47 Inline 4 84.090.0 1 995 16.5 140/4 000 400/1 750
diesel engines, VG turbocharger with
─ 2 750
low-resistance shaft bearings, 2 ,000 bar
solenoid-type injectors
Volkswagen TDI Inline 4 81.095.5 1 968 15.5 176/4 000 500/1 750 Common modular design approach for 1 .4 -
BiTurbo ─ 2 500 to 2 .0 -liter diesel engines, 2 ,500 bar piezo
injectors, low-swirl cylinder heads, electric
water pump, 2 -stage turbocharger (high-
pressure side: VGT), low- and high-pressure
EGR, aftertreatment system directly attached
to engine (SCR-coated particulate filter)
Volvo Cars D5 Inline 4 82.093.2 1 969 15.8 170/4 250 480/1 750 Commonization between gasoline and diesel engines,
─ 2 250 high-pressure aluminum die-cast block, high-strength
aluminum heads, 2 ,500 bar i-ART injectors, 2 -stage
turbocharger (high-pressure side: VGT)

Commercial FCA L630 V6 83.091.4 2 987 16.5 179/4 000 570/1 800 CGI block, aluminum heads,
vehicles electronically controlled VGT, 2 ,000
bar injection system, cooled EGR
Cummins ISV5.0 V8 94.090.0 4 997 149 ─ 205/1 600 705 ─ 759/3 200 Latest high-pressure fuel injection system, VG
turbocharger, CGI block, high-strength aluminum heads

MAN D38 Inline 6 138.01 70.0 15 256 18.0 382 ─ 471/1 800 2 500 ─ 3 000 Top-down cooling, 2 -stage turbocharger,
/930 ─ 1 350 2 -stage intake cooling, domed intake and
exhaust valves, fire rings at the top of
the cylinder, 2 ,500 bar injection pressure,
2 -stage EGR cooler, steel pistons

Scania DC16 V8 130154 16 353 17.4 382 ─ 427/1 900 2 700 ─ 3 500 VG turbocharger, cooled EGR
/1 000 ─ 1 400
DC13 Inline 6 130160 12 742 17.3 336/1 900 2 350 /1 000 No EGR
─ 1 300

Volvo Trucks D16K Inline 6 144165 16 123 16.0 405 ─ 552 2 800 ─ 3 550 2 -stage turbocharger, intake inter-
/1 350 ─ 1 900 /900 ─ 1 450 cooling, cooled EGR

tion. Under this approach, the engines share the same transient response. It also features new solenoid-type
auxiliary equipment layout as the gasoline engines in- injectors that achieve an injection pressure of 2,000 bar.
stalled in the same models, as well as the same crank
case materials. The B47 has a VG turbocharger with a This high-power engine was developed following the
low-resistance shaft bearing to improve intake pressure same modular design approach as VW＇s 1.4 to 2.0-liter

Copyright© 2015 Society of Automotive Engineers of Japan, Inc. All rights reserved
 finement Technology (i-ART) concept), and 2-stage turbo-
charging with a VG turbocharger on the high-pressure
side.
diesel engines, and installed in the Passat. To comply
with Euro 6 while achieving both high power and fuel The L630 engine is installed in the Ram 1500 full-
efficiency, this engine uses 2,500 bar piezo injectors, size pick-up truck and Grand Cherokee SUV. It was
2-stage turbocharging with a VG turbocharger on the designed for compliance with the Tier 2 Bin 5/LEV
high-pressure side, water-cooled compressor housing, as II standards. This engine was manufactured by VM
well as low- and high-pressure EGR. The aftertreatment Motori under the FCA group umbrella and features an
system is partly incorporated into the housing imme- electronically controlled VG turbocharger and a common
diately below engine in consideration of lower exhaust rail system with an injection pressure of 2,000 bar. The
resistance. Other innovations include low swirl cylinder main engine unit uses a CGI block and aluminum heads.
heads as a measure to boost power, stronger moving
parts to ensure toughness, durability, and reliability, as This new engine was developed for pick-up trucks,
well as a lower compression ratio. recreational vehicles (RVs), and vehicles mainly driven
on the highway. It features a VG turbocharger, the lat-
Both the high-power diesel and gasoline engines for est high-pressure fuel injection system, a CGI block, and
the XC90 were designed through a shared modular ap- high-strength aluminum heads. It was designed for com-
proach. In addition to measures to boost power, such pliance with the US10 emissions standards.
as a high-pressure aluminum die-cast cylinder block and
high-strength aluminum cylinder heads, the D5 engine This is the largest displacement engine developed by
also meets the requirements of Euro 6 through 2,500 bar MAN for installation in heavy-duty vehicles. Compliant
injectors (developed using the Intelligent Accuracy Re- with Euro VI, the D38 engine also features a 2-stage tur-

Copyright© 2015 Society of Automotive Engineers of Japan, Inc. All rights reserved
bocharger, 2-stage intake air cooling system, and 2,500 system are countered by a higher consumption of Ad-
bar fuel injection system for highly efficient combus- Blue in the urea injection system. To accommodate this
tion. Other distinguishing characteristics of this engine change, the AdBlue tank capacity was increased.
include a so-called top-down cooling system that flows
coolant from the high-temperature heads to the cylinder This is the largest displacement engine developed by
block, domed intake and exhaust valves, fire rings in- Volvo for installation in heavy-duty vehicles. It is compli-
serted at the top of the cylinder bore to prevent carbon ant with Euro VI and features a 2-stage turbocharger, an
deposits, as well as steel pistons to improve toughness, intake inter-cooling system, and cooled EGR.
durability and reliability.
4 Research and Development Trends

This is the largest displacement engine developed by In recent years, automakers have focused on develop-
Scania for installation in heavy-duty vehicles. It features ing technology for compliance with stringent emissions
a VG turbocharger and cooled EGR for compliance with standards such as Japan＇s Post New Long Term Regula-
Euro VI. It is the only V8 engine in its class. tions, and Euro 6/VI. In addition to emissions compli-
ance, other developed technologies aim to reduce me-
Scania unveiled and launched the Euro VI-compliant chanical engine losses and optimize cooling to improve
DC13 engine in 2011. However, it has been re-designed combustion characteristics for lower CO2 emissions or
without either EGR or a VG turbocharger with an em- higher fuel efficiency.
phasis on improved fuel efficiency particularly for long- Recent technological approaches to comply with emis-
distance fleet users, while retaining Euro VI compliance. sions standards include developing technology to lower
The higher NOx emissions caused by removing the EGR engine-out emissions, after treatment systems, and inte-

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grated control technologies. Key future trends are likely combustion characteristics, research and development
to include a growing emphasis on research and develop- into separating and consolidating structures and func-
ment into basic technologies to reduce CO 2 emissions tions in engines with complex configurations will con-
and improve fuel efficiency, as well as into optimized tinue growing in importance to achieve engine packages
“product” technologies incorporating these basic tech- that satisfy these restrictions.
nologies with emissions standards compliance technolo-
gies and hardware- and software-based technologies to References
improve control accuracy. Manufacturers of expensive (1) Monthly statistics published by the Japan Auto-
and complex diesel engines adopting these necessary mobile Manufacturers Association (JAMA)
new technologies to comply with emissions regulations (2) Website of Mazda Motor Corporation
(particularly commercial vehicle engines) will have to (3) Website of Isuzu Motors Limited
select which systems to use based on these optimization (4) Website of Mitsubishi Fuso Truck and Bus Cor-
technologies to reduce costs and provide improved us- poration
ability for customers. (5) 23rd Aachen Colloquium Automobile and En-
In contrast, most mass-production passenger vehicles gine Technology, 2014
will continue to offer gasoline engines and multiple diesel (6) Website of BMW
engine choices for the same model. Therefore, from the (7) Website of Volkswagen
standpoints of development and production efficiency, (8) Website of Volvo Car Corporation
passenger vehicle diesel engines will adopt efficient pack- (9) Website of Fiat Chrysler Automobiles
aging that use common parts and layouts with other en- (10) Website of Cummins Inc.
gines for the same model, and that also incorporate the (11) Website of MAN
aftertreatment system. These engine packages will have (12) Website of Scania
to satisfy the restrictions inherent in vehicle installation. (13) Website of Volvo Trucks
Therefore, in addition to the development of technology (14) Website of the Environment Protection Agency
for compliance with emissions standards and improving (15) Website of the California Air Research Board

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