Engine - VE / Cost Reduction Ideas

SNO. Component
1 lub Oil Pump

VE / Cost reduction Idea

Simplification Integral casting of body(one piece instead of two pieces) Sintered Gears instead of forged gears Relief valve integral part of cover Delete the idler gear by changing the gear train drive to LOP Alternately, change ball bearing to bimetal bush Change to single breather design instead of two breathers Optimise breather tube dia to maintain crankcase pressure within acceptable limits Increase passage cavities between tappet holes in crankcase

2 3

Lub oil Pump- Idler gear Breather

4 5 6 7 8 9 10 11 12 13 14 15 16

Intake manifold water return line Valve cover Front cover oil Sump Side Cover Fly wheels Cylinder liner Sheet metal tab washers Crank case Fuel filter Crankshaft Connecting rod

Plastic instead of sheet metal Plastic instead of Aluminium Plastic instead of sheet metal Plastic instead of cast iron Delete two nos. baffle plates inside the oil sump Delete side cover & close opening in crank case Alternately, make side cover of plastic instead of sheet metal Review moment of inertia & reduce weight for desired moment of inertia Raise 'O' rings pad, reduce length & wall thickness. Delete sheet metal tab washers Reduce crankcase height below crankcentre & incrtease oil sump height (Major change) Single fuel filter with integral water separator instead of dual fuel filter with separate water separator Microalloyed material Microalloyed material

Engine - VE / Cost Reduction Ideas

SNO. Component
1 lub Oil Pump

VE / Cost reduction Idea

Simplification Integral casting of body(one piece instead of two pieces) Sintered Gears instead of forged gears Relief valve integral part of cover Delete the idler gear by changing the gear train drive to LOP Alternately, change ball bearing to bimetal bush Change to single breather design instead of two breathers Optimise breather tube dia to maintain crankcase pressure within acceptable limits Increase passage cavities between tappet holes in crankcase

2 3

Lub oil Pump- Idler gear Breather

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

oil Sump Side Cover Fly wheels Crankshaft Connecting rod Sheet metal tab washers Radiator Fan Valve cover water return line Intake manifold Front cover Cylinder liner Crank case Fuel filter

Delete two nos. baffle plates inside the oil sump Delete side cover & close opening in crank case Alternately, make side cover of plastic instead of sheet metal Review moment of inertia & reduce weight for desired moment of inertia Microalloyed material Microalloyed material Delete sheet metal tab washers Aluminium instead of Copper Plastic instead of sheet metal Plastic instead of sheet metal Plastic instead of Aluminium Plastic instead of sheet metal Plastic instead of cast iron Raise 'O' rings pad, reduce length & wall thickness. Reduce crankcase height below crankcentre & incrtease oil sump height (Major change) Single fuel filter with integral water separator instead of dual fuel filter with separate water separator

Engine - VE / Cost Reduction Ideas

SNO. Component
1 lub Oil Pump

VE / Cost reduction Idea

Simplification Integral casting of body(one piece instead of two pieces) Sintered Gears instead of forged gears Relief valve integral part of cover Delete the idler gear by changing the gear train drive to LOP Alternately, change ball bearing to bimetal bush Change to single breather design instead of two breathers Optimise breather tube dia to maintain crankcase pressure within acceptable limits Increase passage cavities between tappet holes in crankcase

2 3

Lub oil Pump- Idler gear Breather

4 5 6 7 8 9 10 11 12 13 14 15

oil Sump Side Cover Fly wheels Crankshaft Connecting rod Sheet metal tab washers Valve cover water return line Intake manifold Front cover Cylinder liner Crank case

Delete two nos. baffle plates inside the oil sump Delete side cover & close opening in crank case Alternately, make side cover of plastic instead of sheet metal Review moment of inertia & reduce weight for desired moment of inertia Microalloyed material Microalloyed material Delete sheet metal tab washers Plastic instead of sheet metal Plastic instead of Aluminium Plastic instead of sheet metal Plastic instead of cast iron Raise 'O' rings pad, reduce length & wall thickness. Reduce crankcase height below crankcentre & incrtease oil sump height (Major change)