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In order to allow continued production of the AM General Optimizer 6500 during MY 2007 through 2010 this IDI engine (Indirect Injection - swirl chamber) requires sophisticated aftertreatment controls while maintaining its fuel economy and durability. The main purpose of the development program was to retain the relatively inexpensive and simple base engine with distributor pump and waste-gated turbocharger, while adding hardware and software components that allow achievement of the phase-in emission standards for 2007 through 2010. The aftertreatment system consists of Diesel Oxidation Catalyst (DOC), NOx Adsorber Catalyst (or DeNOx Trap - DNT) and Diesel Particle Filter (DPF). In addition to the base hardware, an intake air throttle valve and an in-exhaust fuel injector were installed. The presented work will document the development process for a 2004 certified 6.5 l IDI heavy-duty diesel engine to comply with the 2007 heavy-duty emission standards.

The purpose of the present paper is to develop an engine simulation tool in a commercial CFD code to study the spray and mixing process that can be used to access the performance of a Gasoline Direct Injection (GDI) engine. The ignition, combustion and pollutant formation are strongly dependent on the quality of the fuel-air mixture. The fuel is injected directly into the combustion chamber by high-pressure fuel injector. The fuel atomization and evaporation process takes place due to the interaction of the small fuel particles generated by the injector and the in-cylinder air motion. Experimental study on the spray and mixing process is difficult and expensive, which has been recognized as a major obstacle towards the optimization of the combustion chamber geometry, engine components and the injection strategies.