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Hino Motors developed J-series 4.7-liter inline-four cylinder and 7.7-liter inline-six cylinder engines for complying with the 2004 U.S. exhaust emissions regulations. Several technologies were incorporated in the development process to accomplish simultaneous reductions in both exhaust emissions and fuel consumption while the engine performance, reliability, and durability were maintained at the levels acceptable for truck application. Newly developed technologies include a cooled EGR system, a common-rail fuel injection system, a VNT system, and an engine control system for harmonized control of EGR valve and VNT. This paper reports the development approaches and results.

In the Japanese heavy duty truck market, demands of improved fuel economy and lighter vehicles to increase load capacity, and further improvements in emissions are constantly increasing. To satisfy these requirements, basically a smaller sized and higher boosted diesel engine is effective, because such an engine has a compact size and light weight, and shows improved fuel consumption due to a relatively lower frictional loss. On the basis of this concept Hino introduced the original EP100 in 1981 as the first Japanese turbocharged and air to air charge-cooled engine. Since then Hino has made many efforts to improve the engines and develop new technologies.

Hino Motors has developed the new K13C, a 12.9 liter six cylinder in-line, heavy duty diesel engine that provides superior fuel consumption, extra low noise and excellent driveability together with a lower exhaust emissions. The initial K13C engine, whose production began in 1986 and about 30,000 units have been produced, is recognized all over the world for its good reliability and fuel economy. The new K13C is using the basic design and manufacturing/assembly processes of the previous one but includes a common-rail type fuel injection system with enhanced electronic controls to meet future regulation and customer requirements. Major design changes consist of a new cylinder head, a new front gear train, a new air intake system, a new turbocharger, a new compression brake system and electronic control module. The optimization of the intake system includes a new intake port and an electronically controlled inertia charging system.