Optimizing Diesel engine design for tactical ground platforms through comparative analysis of Direct Injection and common rail systems

The ongoing evolution of military ground vehicles entails the integration of increasingly complex electronic systems, alongside growing diversification in platform types and operational capabilities. As these vehicles become more reliant on digital subsystems and automated diagnostics, powertrain reliability and maintainability emerge as critical design parameters. This paper examines the comparative advantages and limitations of Direct Injection (DI) Diesel engines versus Common Rail Diesel Injection (CRDI) systems in the context of military vehicle applications. While CRDI engines offer superior performance, efficiency, and emissions control, their dependence on high-pressure components and electronic control units significantly reduces robustness and maintainability under harsh field conditions. In contrast, DI engines — despite their lower performance ceiling — demonstrate higher real-world reliability and simplified logistics, particularly in low-support environments. Through analysis of Mean Time Between Failures (MTBF), failure modes, and logistical implications, this study highlights key trade-offs that must inform propulsion system choices in next-generation tactical platforms.