TABLE 5.5 Committee’s Estimates of Incremental Cost of CI Diesel Engine over a Baseline SI Gasoline Engine for Cost Estimations to Replace SI MPFI DOHC Four-Valve 4.0- to 4.2-L Six-Cylinder Engine in a Midsize Body-on-Frame SUV (e.g., Explorer, Durango) with a 3.5-L V6 DOHC CI Engine

50-State-Saleable ULEV II 3.5-L V6 DOHC CI Diesel Engine Baseline: SI Gasoline DOHC 4V 4.0-4.2-L Six Cylinder

Estimated Cost vs. Baseline ($)

Common rail 1,800 bar piezo-actuated fuel system with six injectors (@$75), high-pressure pump ($270), fuel rail, regulator and fuel storage upgrades plus high-energy driver upgrades to the engine control module. Credit for MPFI content deleted ($48).

911

Variable-geometry turbocharger (VGT) ($350) with electronic controls, water-air charge air cooler, circulation pump, thermostat/valve and plumbing ($135)

485

Upgrades to electrical system: starter motor, alternator, battery, and the 1.5-kW supplemental electrical cabin heater standard in Europe ($99)

167

Cam, crank, connecting rod, bearing, and piston upgrades, oil lines ($62) plus NVH countermeasures to engine ($47) and vehicle ($85)

194

HP/LP EGR system to suppress NOx at light and heavy loads; includes hot side and cold side electronic rotary diesel EGR valves plus EGR cooler and all plumbing

226

Emissions control system including the following functionality: DOC, CDPF, selective catalytic reduction (SCR), urea dosing system ($363). Stoichiometric MPFI emissions and evaporative systems credit ($343). See Table 5.6 for a detailed breakdown of the emissions control system components leading to the total shown here.

964

On-board diagnostics (OBD) and sensing including four temperature sensors (@$13), wide-range air-fuel ratio sensor ($30), NOx sensor ($85), two pressure-sensing glow plugs (@17), four glow plugs (@$3), and Delta-P sensor for DPF ($25). Credit for four switching O2 sensors (@$9)

227

Total variable cost with credits for SI parts removed. Excludes any necessary transmission, chassis, or driveline upgrades.

3,174

NOTE: The credit for downsizing from V8 to V6 included in Martec Group, Inc. (2008) was not used here because the baseline 2007 SI engine was a V6, not the V8 assumed in Martec Group, Inc. (2008). Aftertreatment system cost estimates reflect April 2009 prices for platinum group metals.

TABLE 5.6 Cost Estimates for Exhaust Emissions Aftertreatment Technologies Capable of Enabling Tier 2, Bin 5 Compliance

Item

Midsize Car (e.g., Malibu)

Catalytic Device Sizing Based on 2 L (Nov. 2007 PGM prices)

Midsize Car (e.g., Malibu)

Catalytic Device Sizing Based on 2 L (Apr. 2009 PGM prices)

Midsize SUV (e.g., Explorer),

Catalytic Device Sizing Based on 3.5 L (Nov. 2007 PGM prices)

Midsize SUV (e.g., Explorer),

Catalytic Device Sizing Based on 3.5 L (Apr. 2009 PGM prices)

DOC 1

 

 

 

 

Monolith and can

$52

$52

$52

$52

PGM loading

$174

$139

$210

$200

DOC 2

 

 

 

 

Monolith and can

Not used

$0

$52

$52

PGM loading

Not used

$0

$73

$70

EGR catalyst

 

 

 

 

Monolith and can

$7

$7

Not used

Not used

PGM loading

$22

$13

Not used

Not used

Coated DPF

 

 

 

 

Advanced cordierite brick and can

$124

$124

$270

$270

PGM loading

$160

$131

$29

$26

NSC system

 

 

 

 

Catalyst brick and can

$114

$114

Not used

Not used

PGM loading

$533

$314

Not used

Not used

SCR-urea system

 

 

 

 

SCR brick and can

$39

$39

$274

$274

Urea dosing system

Passive SCR

Passive SCR

$363

$363

Stoichiometric gasoline emissions and evaporative system credit

−$245

−$245

−$343

−$343

Emissions System Total

$980

$688

$980

$964

NOTE: The significant impact of platinum group metals (PGM) commodity prices is illustrated by the difference between the costs in columns 2 and 4 (based on November 2007 prices) and the costs in columns 3 and 5 (based on April 2009 prices).



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