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The paper mainly deals with the heat transfer and thermal loading problems faced during the development of an high specific output IDI Diesel engine, suitable for a small van. Boundary conditions and heat transfer coefficients of the engine head were obtained from experimental measurements and a Finite Element Method model was developed to analyze temperature distribution in the head. The results of calculations and experimental tests led to an optimized solution for the cooling system based on air and oil passages in the hottest zone of the head.