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A new V-6 stoichiometric gasoline direct injection engine was developed for high performance FR (Front Engine Rear Drive) vehicles. High power performance, low fuel consumption and low exhaust emissions were achieved by employing a stoichiometric direct injection system that uses Toyota's unique slit nozzle injector that generates a fan-shaped fuel spray and variable intake and exhaust valve timing systems. Focusing on the power performance, maximum power of 183kW (61kW/L) is achieved at 6200rpm and maximum torque is 312Nm at 3600rpm. This power performance is among the top production 3.0 L gasoline engines in the world. This paper outlines the features of this engine and some special technologies contributing to the achievement of the above-mentioned high performance. Optimizing the intake-port design was done to improve power performance.

A new 2.0 ℓ DOHC 4-valve direct injection (DI) gasoline engine has been developed which features new technologies such as swirl intake ports to produce an optimum swirl in the cylinder by variable controlled swirl control valve, pistons with a concave combustion chamber, and high pressure fuel injection system to provide a fine fuel-air mixture cloud in the combustion chamber. These all help to control fuel-air mixture preparation and flame propagation under ultra lean, stratified combustion at partial loads. NOx emission is reduced by using an electrically controlled EGR system and an NOx storage-reduction catalyst. At higher loads, a homogeneous mixture is obtained with direct injection during the intake stroke. A seamless output torque transition between stratified charge and homogeneous charge condition is achieved by an electronic throttle control system.

A new 3-way catalyst with NOx conversion performance for lean-burn engines has been developed. The catalyst oxidizes NOx and stores the resulting nitrate, which is then reduced by HC and CO during engine operation around the stoichiometric air/fuel ratio. Both the composition of the storage component and the particle sizes of the noble metal were optimized. In addition, a special air fuel mixture control has been developed to make the best of the NOx storage-reduction function. The present catalyst showed 90% conversion efficiency and improved fuel economy by 4% in the Japanese 10-15 mode test cycle. The efficiency remained at 60% or more after durability test.