TABLE G.3 Estimates of Incremental Costs to Implement Developments Whose Estimated Fuel Consumption Reduction Gains Are Summarized in Table 5.2

Item

Midsize Car (e.g., Malibu) 1.6-L L4

Midsize SUV (e.g., Explorer) 2.8-L V6

Full-size Pickup (e.g., Ram 1500) 3.5-L V6

 

Downsize engines 2-L L4 to 1.6 L, 3.5-L V6 to 2.8 L, 4.4-L V6 to 3.5 L

50

75

75

Higher load capacity rod bearings and head gasket for higher cylinder pressures (~$12.50/cylinder)

Two-stage turbocharger system

375

545

0a

Additional air flow control valves, piping, cost of additional turbo, water-to-air intercooler with control valve, separate pump

Dual-pressure oil pump

5

6

6

Switchable pressure relief valve for high or low oil pressure

Nonrecirculating LP fuel pump

10

12

12

Variable output LP pump controlled by HP pump output

Low-pressure EGR

95

95

Additional piping (~$20) and valves (e.g., integrated back pressure and LP EGR rate ~$75), much more difficult to package for V6 engine with underfloor DPF, cost for L-4 already included in Table 5.4

Direct-acting HP (maximum injection pressures > 2,000 bar) piezo injectors

80

120

120

$20/injector, benefits derived from combination of higher rail pressure and more injector controllability

Total

520

853

308

 

NOTE: These developments are CI-diesel downsizing from base level to advanced level, thermodynamic improvements, friction reduction, and engine accessory improvements. Total for full-size body-on-frame pickup ($308 at bottom of Column 4) used in Table G.1. FC, fuel consumption.

aTwo-stage turbo system already comprehended in Table G.1.



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