Here's a press release describing a project DC gave its staff back in 2002 to improve the Durango 4.7's MPG
It's Called MAGIC, But It's Pure Engineering from Chrysler Group
* Small Changes to Engine, Vehicle Add Up to 25 Percent Better Fuel Efficiency
AUBURN HILLS, Mich., June 13, 2002 -------- Chrysler Group
researchers are using a series of small steps in engineering to produce a
giant leap in fuel efficiency that could benefit consumers in the not-too-
With a series of engineering changes to Chrysler's standard gasoline-
powered, 4.7-liter V-8 engine, researchers have produced an engine with 14
percent better fuel efficiency. The cost of those changes: less than $200 per
engine. The project has been nicknamed the MAGIC engine, which stands for
Multiple Approaches to Great Internal Combustion. The improvement in fuel
efficiency was achieved with no sacrifice in emissions, power, cost, weight,
engine life or other engine characteristics such as noise, vibration or
"We call it the MAGIC engine, but it's really pure engineering," said
Thomas Moore, DaimlerChrysler Vice President and head of the Liberty &
Technical Affairs advanced technology research group in Rochester Hills,
Michigan. "Our goal was to demonstrate that all these little changes actually
work in the real world and add up to major improvements in efficiency. Today
we can say that it all works."
Eight different design and engineering changes were made to the standard
engine. "Most of these changes are not new, and individually, they produce
miniscule gains in fuel efficiency," Moore said. "The idea of the MAGIC
engine is to package them all together so the overall gain is significant."
As a next step, Chrysler engineers packaged the MAGIC engine into a Dodge
Durango SUV with several additional design changes to enhance fuel efficiency.
That vehicle, project Apollo, achieves an overall improvement in fuel
efficiency of 25 percent.
Total additional costs for project Apollo are only about $700 per vehicle.
Areas of improvement are:
* Increased compression ratio (4 percent) -- resulting in greater
efficiency and lower emissions -- through:
+ Intake port air-gap thermal barrier.
Chrysler Group has applied for a patent for this innovative feature.
+ On-demand piston oil-squirters
+ Precision cooling system
* Charge motion control (5 percent). Use of swirl control valves to
enhance flame propagation during warm-up and partial load
This also enables increased EGR (Exhaust Gas Recirculation)
* Friction loss reduction (4 percent). Design changes to lower friction
at no extra cost:
+ Crankshaft offset
+ Reduced oil-ring tension
+ Shortened coolant jacket
* Parasitic loss reduction (1 percent). New design oil pump with reduced
internal leakage and reduced friction
Chrysler Group engineers used the same incremental approach to fuel
efficiency improvements in the Dodge Durango SUV fuel efficiency demonstration
The Apollo project includes the following enhancements:
* A 12V alternator/restarter to allow transparent shutdown and restarting
of a warm engine in stop/start traffic conditions (4 percent)
* Improved cooling technologies, including electronic thermostat,
electric water pump, transmission temperature management and multi-mode
temperature strategy (5 percent)
* Improved undercarriage aerodynamics (belly pans and air dams) and
grille shutters resulting in reduced drag (1.2 percent)
* Electro-hydraulic power steering (1 percent)
"Engineers have been improving the internal combustion engine for 130
years, so big improvements are hard to come by," Moore said. "We made the big
improvement one small step at a time."