Lightweight Crankcase for a New Turbo-Charged Direct Injection Diesel Engine

The comparison of a light weight crankcase to the production cast iron crankcase of the new Mercedes Benz 2.9-liter direct injection (DI) five-cylinder turbo diesel engine with intercooler is described. The light weight crankcase is cast from the aluminum alloy A 356 while other engine components like oil pan, timing case cover and brackets are manufactured from a magnesium alloy.

This paper describes the engine design with the simultaneous calculation, the mechanical development and the acoustic measurements.

In this study an engine weight reduction of about 30 kg with comparable noise emission compared to the production engine with cast iron crankcase is realized.