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To meet the latest trends in internal combustion engines pertaining efficiency, emissions and durability, downsizing of the engine has become the key focus area. This paper describes about a robust, reliable and an integrated approach used in design and development of state of art high power density/ high speed engine developed from the concept, which can be adopted for passenger car and LCV application. A three-cylinder, 1.5 liter displacement diesel engine, fully balanced is being designed with an objective to produce 115kW @ 4200 rpm, delivering a specific power output over 75 kW/liter, which is at par with a contemporary class of specification in it. In the first stage, a derated version of 75 kW (50 kW/liter) with Euro-IV and Euro-V specifications is targeted aiming at smaller car and light motor vehicle segment and a prime-mover for hybrid application.

The intensifying needs demanded by the legislation, shorter product development cycle and utmost attention given to durability aspects of product have surfaced out various complex technical areas in the field of engine out emissions, FIP hydraulics, computational fluid dynamics, thermal analysis and structural design of components. This paper is an endeavour to present the gesticulations used in one of the upgradation program for improving engine performance to meet desired emission and performance levels with the help of simulation tools and statistical database. The single cylinder air cooled D. I. engine under development is explored first for possible improvements in induction and exhaust systems, FIP performance and combustion package, valve train layout, cylinder head design, fin layout and pattern, features for improvement in oil consumption, modifications in engine block and crankcase etc.