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The requirements for diesel and gasoline engines are continuously increasing with respect to emissions, fuel consumption and durability. Besides the engine development process the quality of the production engine itself has to be ensured. This paper discusses alternative philosophies and approaches in terms of the quality management process. Based on a detailed analysis of the required equipment advanced solutions are presented. Modular containerized test cells are described being equipped exactly to the current testing task ready to use in low infrastructure. The testing capacity of the facility can be adjusted to the actual production volume by simply removing or adding modular test cells. Thus, at every facility the testing tasks can be executed successfully and the investment can be kept low.

In the early design stage a 16-cylinder V-engine is optimized with respect to its vibrational and acoustic behavior. The objectives of the development are: (1) to minimize vibrations of the crankcase with special focus on the structure-borne noise transmission via the engine mounts, and (2) in this context, to identify the appropriate locations for the engine mounts. The NVH behavior of the engine structure is simulated using the Finite Element Method (FEM). The dynamic FE-model of the engine is excited via synthesized cylinder pressure force spectra. The corresponding vibrations of the sound emitting surface are calculated, thereby revealing structural weaknesses. By calculation of the crankcase modal vibrations, the noise relevant modes are identified. Based on these results the influence of structural modifications on the NVH behavior is predicted.