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For the 1999 model year, DaimlerChrysler Corporation has introduced a totally new V-8 engine for use in the Grand Cherokee sport utility vehicle and in other later model year applications. The engine is produced at a totally new facility, The Mack Avenue Engine Plant (MAEP), located in Detroit, Michigan. This paper provides details of the product and product engineering process as well as highlights of the manufacturing facility. Coverage includes program objectives, program management processes, design features, predictive engineering, development challenges, and system functional performance. Both component and system level technical data are included.

Rapid change is a way of life in Chrysler. Facing increasing competition, we realize that the traditional practices are no longer sufficient. Accordingly, a new process using simultaneous engineering (SE) teams in conjunction with reliability tools has been used to design and develop a new family of Chrysler engines. These SE teams include representatives from engine engineering, vehicle platform engineering, electrical engineering, manufacturing, reliability & service engineering, finance and suppliers. The SE teams maximize the use of up-front engineering tools, such as Finite Element Analysis (FEA), Digital Model Assembly (DMA), Variation Simulation Analysis (VSA) and Rapid Prototyping with StereoLithography (SLA), Laminated Object Manufacturing (LOM), etc. The new process combines these up-front engineering activities and the appropriate reliability testing as an integral part of the reliability growth process. It enhances the design decisions made with reliability.