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The amount of air sucked by an I.C. engine is one of the main factors in defining the combustion efficiency, power output and volumetric efficiency. This paper discusses various geometries of the air filter and pipes to reduce the pressure losses in the air intake system of a Common Rail Direct Injection (CRDI) engine using Computational Fluid Dynamics (CFD) methodology and how integration of various available softwares can be applied to design the air intake system of CRDI engine. Reduction in the pressure losses allows more air to enter inside the engine for the same amount of compressor work. It results in better volumetric efficiency. The entire process has been streamlined and major time and cost reduction achieved by using simulation for optimization. The simulated results have been validated by extensive trials for correlation and outdoor tests for durability. Same analysis technique is used as a template to modify the air intake system.