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Reduction of NOx (Oxides of Nitrogen) and particulates from engine exhaust is one of the prime considerations in current research and development in automotive industry. The present paper describes the combustion optimization done on a four cylinder, 4 liter DI diesel engine to meet stringent Euro-III emission norms. The engine FIE (Fuel Injection Equipment) and injector geometry was optimized for performance and emission. Smoke measurements were considered as indicative of soot, to predict particulate emissions. This was done to simplify the overall process and save development time. It was concluded that by combining the flexibility of electronically controlled fuel injection begin, with improved nozzle technologies, with higher spray velocities and spray penetration, a considerable reduction in NOx and particulate emissions can be achieved. This can serve as a low cost solution, without any exhaust after-treatment systems.

The paper describes a first-of-its-kind attempt of authors to develop an intake manifold - combined with - rocker cover (IMCRC) in sheet molding compound (SMC) for 3 L and 4 L direct injection diesel engines with power ratings 75 kW and 92 kW respectively. The objective was to reduce overall engine weight, noise and cost. The intake manifold is designed to withstand absolute boost pressures of more than 2 bar, temperature in the range of 160 °C. and capable of carrying load of directly attached components such as an air intake pipe. It is worth to note that the designed SMC component always remains in the vicinity of the exhaust manifold by virtue of base engine layout constraint. The development if successful can expand the horizon of SMC in diesel engine application.