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This paper involves increase in engine power by increasing bore size and stroke length along with other required engine level design modifications. Main focus is on addressing the cooling related issues by optimizing the cooling jacket design and water pump flow parameters. Engine cooling requirements need to be upgraded to address increase in thermal loads because of reduction in cooling area between cylinder block and cylinder liner due to increase in bore size keeping engine block size fixed. Methodology used is cooling jacket optimization and water pump design modifications. In internal combustion engines, cooling system involves a complex geometry of water jackets. For such complex systems, CFD simulations can be executed in a short period of time and are relatively inexpensive. CFD provides the ability to theoretically simulate any physical condition.

The increasing demand for higher specific power, fuel economy, Operating Costs as well as meeting global emission norms have become the driving factors of today’s product development in the automotive market. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. This becomes a challenge for every automotive engineer to balance the above parameters to make a highly competitive design. This work is a part of the Design and Development of 2.2 L, 4 Cylinder TCIC Diesel Engine for a whole new vehicle platform, concentrated on automotive passenger car operation. This paper explains the selection of a suitable cylinder head gasket technology for a lightweight engine that acts as a sealing interface between the cylinder block and cylinder head.