Fuel System Investigation and Performance Development of a Prototype V6 Gasoline Direct Injection Engine

Cosworth Technology has converted a prototype V6 Manifold Port Injected (MPI) gasoline engine to homogeneous charge Gasoline Direct Injection (GDI), whilst increasing rated power by over 16% despite higher inlet and exhaust pressure loss targets. This paper describes the development methods used to deliver the project in very short time scales, and includes details on the how five different GDI injectors were tested on a GDI slave engine, followed by results from further part and full load engine testing of the best injector configuration. In parallel with the GDI developments, 1-D cycle simulation in GT-Power was used in conjunction with engine dynamometer testing to develop hardware to meet performance targets, and details of the results of predicted and actual performance are included. Overviews of tools and techniques utilized to speed up this GDI application, such as GT-Power, CFD, DOE and hydraulic system simulation and rig testing are also presented.