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Modern diesel passenger car technology continues to develop rapidly in response to demanding emissions, performance, refinement, cost and fuel efficiency requirements. This has included the implementation of high pressure common rail fuel systems employing high precision injectors with complex injection strategies, higher hydraulic efficiency injector nozzles and in some cases <100µm nozzle hole diameters. With the trend towards lower diameter diesel injector nozzle holes and reduced cleaning through cavitation with higher hydraulic efficiency nozzles, it is increasingly important to focus on understanding the mechanism of diesel injector nozzle deposit formation and growth. In this study such deposits were analysed by cross-sectioning the diesel injector along the length of the nozzle hole enabling in-depth analysis of deposit morphology and composition change from the inlet to the outlet, using state-of-the-art electron microscopy techniques.

The accurate confirmation of fuel economy benefits arising from the use of a gasoline additive package is a difficult exercise. In order to fully understand, and accurately quantify, the interaction between the treated fuel and the engine it is necessary to carry out a fleet test which allows the benefit to be measured precisely yet under realistic conditions. A series of road tests, based on a ‘paired fleet’ design, has been carried out over the last two decades. Careful analysis of the results of these tests has led to the design of a new fleet testing protocol based around ‘quads’ rather than pairs of vehicles. This new test protocol also incorporates advances in vehicle selection and preparation procedures and has resulted in a test that is both more robust and flexible, and that achieves even better resolution than before.

Improved fuel economy is increasingly a key measure of performance in the automotive industry driven by market demands and tighter emissions regulations. Within this environment, one way to improve fuel economy is via fuel additives that deliver friction- reducing components to the piston-cylinder wall interface. Whilst the use of friction modifiers (FMs) in fuel or lubricant additives to achieve fuel economy improvements is not new, demonstrating the efficacy of these FMs in vehicles is challenging and requires statistical design together with carefully controlled test conditions. This paper describes a bespoke, efficient, high-precision vehicle testing procedure designed to evaluate the fuel economy credentials of fuel-borne FMs. By their nature, FMs persist on engine surfaces and so their effects are not immediately reversible upon changing to a non FM-containing fuel (“carryover” effect), therefore requiring careful design of the test programme.

Precise, repeatable and representative testing is a key tool for developing and demonstrating automotive fuel and lubricant products. This paper reports on the first findings of a project that aims to determine the requirements for highly repeatable test methods to measure very small differences in fuel economy and powertrain performance. This will be underpinned by identifying and quantifying the variations inherent to this specific test vehicle, both on-road and on Chassis Dynamometer (CD), that create a barrier to improved testing methods. In this initial work, a comparison was made between on-road driving, the New European Drive Cycle (NEDC) and World harmonized Light-duty Test Cycle (WLTC) cycles to understand the behavior of various vehicle systems along with the discrepancies that can arise owing to the particular conditions of the standard test cycles.

A series of viscous and surface friction modifier additives has been studied in a modified SI engine with separable valve train lubrication. From the results, it has been possible to classify the hydrodynamic or boundary lubrication nature of the observed effects for a series of lubricant additives. It is shown that the frictional benefit of a given additive depends not only on the engine operating condition but also on the engine components on which it is acting. For some additives a fuel economy benefit can switch to a disbenefit as operating regime changes and a different aspect of the additive properties becomes important. Such observations are rationalised in the context of conventional lubrication theory.

Downsized turbocharged gasoline direct injection (TGDI) engines with high specific power and torque can enable reduced fuel consumption in passenger vehicles while maintaining or even improving on the performance of larger naturally aspirated engines. However, high specific torque levels, especially at low speeds, can lead to abnormal combustion phenomena such as knock or Low-Speed Pre-Ignition (LSPI). LSPI, in particular, can limit further downsizing due to resulting and potentially damaging mega-knock events. Herein, we characterize the impacts of lubricant and fuel composition on LSPI frequency in a TGDI engine while specifically exploring the correlation between fuel composition, particulate emissions, and LSPI events. Our research shows that: (1) oil composition has a strong impact on LSPI frequency and that LSPI frequency can be reduced through a carefully focused approach to lubricant formulation.

Carbonaceous deposits can accumulate on various surfaces of the internal combustion engine and affect its performance. The porous nature of these deposits means that they act like a “sponge”, adsorbing fuel components and changing both the composition and the amount of fuel in the combustion chamber. Here we use a previously developed and validated model of engine deposits to predict adsorption of normal heptane, isooctane, toluene and their mixtures in deposits of different origin within a port fuel injected spark ignition engine (Combustion Chamber Deposits, or CCDs, and Intake Valve Deposits, or IVDs) and under different conditions. We explore the influence of molecular structure of adsorbing species, composition of the bulk mixture and temperature on the uptake and selectivity behaviour of the deposits. While deposits generally show high capacity toward all three components, we observe that selectivity behaviour is a more subtle and complex property.

Exhaust Gas Recirculation (EGR) is employed in diesel engines to reduce engine-out NOx emissions. Despite the concerted design efforts of manufacturers, high-pressure Exhaust Gas Recirculation (HP-EGR) systems can be susceptible to fouling as the particulate matter, hydrocarbons and other entrained species deposit from the exhaust gas flow as it cools on its passage through the EGR system. Such deposits can lead to a number of problems including deterioration of emissions, fuel efficiency, performance and drivability, as well as breakdowns. The development of an engine test method to enable the study of the impact of fuel on deposits in the HP-EGR system was reported in 2020. In the test, a 4-cylinder light-duty diesel engine of 1.6L displacement runs at conditions conducive to EGR deposit formation over 24 hours and the impact of fuels on deposit formation is determined through weighing of the EGR system components before and after the test.

Gasoline direct injection (GDI) engines have been developed rapidly in recent years, driven by stringent legislative requirements on vehicle fuel efficiency and emissions. However, one challenge facing GDI is the formation of particulate emissions, particularly with the presence of injector tip deposits. The Chinese market features some gasoline fuels that contain no detergent additives and are prone to deposit formation, which can affect engine performance and emissions. The use of detergent additives to mitigate the formation of injector deposits in a GDI engine was investigated in this study by testing a 1.5L turbocharged GDI engine available in the Chinese market. The engine was operated both on base gasoline and on gasoline dosed with detergent additives to evaluate the effect on injector deposit formation and engine performance and emissions.

Port fuel injected (PFI) technology remains the most common fuel delivery type present in the marketplace for gasoline spark ignition engines and a legacy vehicle fleet featuring PFI technology will remain in the market for decades to come. This is especially the case in parts of Asia where PFI technology is still prominent, although direct injection (DI) technology adoption is starting to catch up. PFI engines can, when operated with lower quality fuels and lubricants, build up performance impairing deposits on a range of critical engine parts including in the fuel injectors, combustion chamber and on inlet valves. Inlet valve deposits (IVDs) in more severe cases have been associated with drivability issues such as engine stumble and engine hesitation on sudden acceleration. Deposit control additives in gasoline formulations are a well-established route to managing and even reversing fuel system fouling.

Engine technology in passenger vehicles continues to evolve to meet consumer needs, improve fuel efficiency and reduce emissions. Likewise, engine oil classifications and performance requirements have evolved to meet the demands of the latest engine technology. This paper explores the degradation of engine oil quality in service by monitoring the condition of the used oil samples obtained from real-world, non-fleet consumer applications. In a previous study (SAE 2003-01-1957), used oil analysis results were reported for API/ILSAC GF-2 engine oil samples to determine oil degradation trends during service life. These samples were collected from a variety of vehicles, representing different driving conditions and oil brands. Each sample was analyzed to monitor additive depletion, accumulation of contaminants, and change in the physical and chemical properties of the oils. This study is a continuation of the previous work and includes API/ILSAC GF-4 engine oil samples.

The majority of passenger car and light-duty trucks, especially in North America, operate using port-fuel injection (PFI) engines. In PFI engines, the fuel is injected onto the intake valves and then pulled into the combustion chamber during the intake stroke. Components of the fuel are unstable in this environment and form deposits on the upstream face of the intake valve. These deposits have been found to affect a vehicle’s drivability, emissions and engine performance. Therefore, it is critical for the gasoline to be blended with additives containing detergents capable of removing the harmful intake valve deposits (IVDs). Established standards are available to measure the propensity of IVD formation, for example the ASTM D6201 engine test and ASTM D5500 vehicle test.

It is anticipated that worldwide energy demand will approximately double by 2050, whilst at the same time, CO2 emissions need to be halved. Therefore, there is increasing pressure to improve the efficiency of all machines, with great focus on improving the fuel efficiency of passenger cars. The use of downsized, boosted, gasoline engines, can lead to exceptional fuel economy, and on a well-to-wheels basis, can give similar CO2 emissions to electric vehicles (depending, of course, on how the electricity is generated). In this paper, the development of a low weight concept car is reported. The car is equipped with a three-cylinder 0.66 litre gasoline engine, and has achieved over 100 miles per imperial gallon, in real world driving conditions.

Six 2001 International Class 6 trucks participated in a project to determine the impact of gas-to-liquid (GTL) fuel and catalyzed diesel particle filters (DPFs) on emissions and operations from December 2003 through August 2004. The vehicles operated in Southern California and were nominally identical. Three vehicles operated “as-is” on California Air Resources Board (CARB) specification diesel fuel and no emission control devices. Three vehicles were retrofit with Johnson Matthey CCRT® (Catalyzed Continuously Regenerating Technology) filters and fueled with Shell GTL Fuel. Two rounds of emissions tests were conducted on a chassis dynamometer over the City Suburban Heavy Vehicle Route (CSHVR) and the New York City Bus (NYCB) cycle. The CARB-fueled vehicles served as the baseline, while the GTL-fueled vehicles were tested with and without the CCRT filters. Results from the first round of testing have been reported previously (see 2004-01-2959).

Deposits forming in the injector nozzle holes of modern diesel cars can reduce and disrupt the fuel injected into the combustion chamber, causing reduced or less efficient combustion, resulting in power loss and increased fuel consumption. A study of the factors affecting injector nozzle tip temperature, a parameter critical to nozzle deposit formation, has been conducted in a Peugeot DW10 passenger car bench engine, as used in the industry standard CEC F-098 injector nozzle deposit test, [1]. The findings of the bench engine study were applied in the development of a Chassis Dynamometer (CD) based vehicle test method using Euro 5 compliant vehicles. The developed test method was refined to tune the conditions as far as practicable towards a realistic driving pattern whilst maintaining sufficient deposit forming tendency to enable test duration to be limited to a reasonable period.

Due to the recent drive to reduce CO₂ emissions, the turbocharged direct injection spark ignition (turbo DISI) gasoline engine has become increasingly popular. In addition, future turbo DISI engines could incorporate a form of charge dilution (e.g., lean operation or external EGR) to further increase fuel efficiency. Thus, the conditions experienced by the fuel before and during combustion are and will continue to be different from those experienced in naturally aspirated SI engines. This work investigates the effects of fuel properties on a modern and prototype turbo DISI engine, with particular focus on the octane appetite: How relevant are RON and MON in predicting a fuel's anti-knock performance in these modern/future engines? It is found that fuels with high RON and low MON values perform the best, suggesting the current MON requirements in fuel specifications could actually be detrimental.

The influence of gasoline quality on exhaust emissions has been evaluated using four modern European gasoline cars with advanced features designed to improve fuel economy and CO2 emissions, including stoichiometric direct injection, lean direct injection and MPI with variable valve actuation. Fuel effects studied included sulphur content, evaluated over a range from 4 to 148 mg/kg, and other gasoline properties, including aromatics content, olefins content, volatility and final boiling point (FBP). All four cars achieved very low emissions levels, with some clear differences between the vehicle technologies. Even at these low emissions levels, all four cars showed very little short-term sensitivity to gasoline sulphur content. The measured effects of the other gasoline properties were small and often conflicting, with differing directional responses for different vehicles and emissions.

Laminar burning velocity is a fundamental combustion property of any fuel/air mixture. Formulating gasoline fuel blends having faster burning velocities can be an effective strategy for enhancing engine and vehicle performance. Formulation of faster burning fuels by changing the fuel composition has been explored in this work leading to a clear correlation between engine performance and fuel burning velocity. In principle a gasoline vehicle should be calibrated to give optimal ignition timing (also known as MBT - minimum spark advance for best torque) while at the same time avoiding any possible engine knock. However, modern downsized/boosted engines frequently tend to be limited by knock and the spark timing is retarded in respect of the optimum. In such scenarios, faster burning fuels can lead to a more optimum combustion phasing resulting in a more efficient energy transfer and hence a faster acceleration and better performance.

The octane appetite of an engine is frequently characterised by the so-called K value. It is usually assumed that K is dependent only on the thermodynamic conditions in the engine when knock occurs. In this work we test this hypothesis: further analysis was conducted on experimental results from SAE 2019-01-0035 in which a matrix of fuels was tested in a single cylinder engine. The fuels consisted of a relatively small number of components, thereby simplifying the analysis of the chemical kinetic proprieties. Through dividing the original fuel matrix into subsets, it was possible to explore the variation of K value with fuel properties. It was found that K value tends to increase slightly with RON. The explanation for this finding is that higher RON leads to advanced ignition timing (i.e. closer to MBT conditions) and advanced ignition timing results in faster combustion because of the higher pressures and temperatures reached in the thermodynamic trajectory.

Worldwide, Fuel Economy (FE) legislation increasingly influences vehicle and engine design, and drives friction reduction. The link between lubricant formulation and mechanical friction is complex and depends on engine component design and test cycle. This Motored Friction Tear Down (MFTD) study characterizes the friction within a 3.6L V6 engine under operating conditions and lubricant choices relevant to the legislated FE cycles. The high-fidelity MFTD results presented indicate that the engine is a low-friction engine tolerant of low viscosity oils. Experiments spanned four groups of engine hardware (reciprocating, crankshaft, valvetrain, oil pump), five lubricants (four candidates referenced against an SAE 0W-20) and five temperature regimes. The candidate lubricants explored the impact of base oil viscosity, viscosity modifier (VM) and friction modifier (FM) content.