Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles (2015)

Chapter: Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies

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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Appendix S

NHTSA’s Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies

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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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TABLE S.1 NHTSA’s Estimated Fuel Consumption Reduction Effectiveness of Technologies

Percent Incremental Fuel Consumption Reductions: NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Spark Ignition Engine Technologies Abbreviation Avg Avg Avg Relative To
Source: NHTSA RIA          
Low Friction Lubricants - Level 1 LUB1   0.7   0.8   0.7 Baseline
Engine Friction Reduction - Level 1 EFR1   2.6   2.7   2.4 Baseline
Low Friction Lubricants and Engine Friction Reduction - Level 2 LUB2_EFR2   1.3   1.4   1.2 Previous Tech
VVT- Intake Cam Phasing ICP   2.6   2.7   2.5 Baseline for DOHC
VVT- Dual Cam Phasing DCP   2.5   2.7   2.4 Previous Tech
Discrete Variable Valve Lift DVVL   3.6   3.9   3.4 Previous Tech
Continuously Variable Valve Lift CVVL   1.0   1.0   0.9 Previous Tech
Cylinder Deactivation (V6-DOHC, V8-OHV) DEACD NA   0.7   5.5 Previous Tech
Variable Valve Actuation (CCP + DVVL) VVA NA NA   3.2 Baseline for OHV
Stoichiometric Gasoline Direct Injection SGDI   1.5   1.5   1.5 Previous Tech
Turbocharging and Downsizing Level 1 - 18 bar BMEP 33%DS TRBDS1   8.3   7.8   7.3 Previous Tech
Turbocharging and Downsizing Level 2 - 24 bar BMEP 50%DS TRBDS2   3.5   3.7   3.4 Previous Tech
Cooled EGR Level 1 - 24 bar BMEP, 50% DS CEGR1   3.5   3.5   3.6 Previous Tech
Cooled EGR Level 2 - 27 bar BMEP, 56% DS CEGR2   1.4   1.4   1.2 Previous Tech
Diesel Engine Technologies
Source: EPA/NHTSA TSD          
Advanced Diesel (Ref: Decision Trees) ADSL 29.4 30.5 29.0 Baseline
Transmission Technologies
Source: NHTSA RIA          
Improved Auto. Trans. Controls/Externals (ASL-1 & Early TC Lockup) IATC   3.0   3.1   2.9 Previous Tech
6-speed Transmission with Improved Internals (Rel to 4 sp AT) NUATO   2.0   2.0   2.1 Previous Tech
6-speed DCT (Rel to 4 sp AT) (Dry, Wet is 1% Lower) DCT   4.1   3.8   3.8 Previous Tech
8-speed Transmission (Auto or DCT) 8SPD   4.6   4.6   5.3 Previous Tech
High Efficiency Gearbox (Auto or DCT) HETRANS   2.7   2.6   3.7 Previous Tech
Shift Optimizer (ASL-2) SHFTOPT   4.1   4.3   3.9 Previous Tech
Secondary Axle Disconnect SAX   1.4   1.3   1.6 Baseline
Electrified Accessories Technologies
Source: NHTSA RIA          
Electric Power Steering EPS   1.3   1.1   0.8 Baseline
Improved Accessories - Level 1 (70% Eff Alt, Elec. Water Pump and Fan) IACC1   1.2   1.0   1.6 Baseline
Improved Accessories - Level 2 (Mild regen alt strategy, Intelligent cooling) IACC2   2.4   2.6   2.2 Previous Tech
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Percent Incremental Fuel Consumption Reductions: NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Hybrid Technologies Abbreviation Avg Avg Avg Relative To
Source: EPA/NHTSA TSD, except as noted          
Stop-Start (12V Micro-Hybrid) (RIA) MHEV   2.1   2.2   2.1 Previous Tech
Integrated Starter Generator (RIA) ISG   6.5   6.5   3.0 Previous Tech
Strong Hybrid - P2 - Level 2 (Parallel 2 Clutch System) SHEV2-P2 33.6 34.5 30.1 All SI Technogies
Strong Hybrid - PS - Level 2 (Power Split System) SHEV2-PS 33.0 32.0 33.0 Baseline for DOHC
Plug-in Hybrid - 40 mile range (w/charger & labor) PHEV40 65.1 69.5 68.5 Baseline
Electric Vehicle - 75 miles (w/charger & labor) EV75 87.2 87.0 NA Baseline
Electric Vehicle - 100 mile (w/charger & labor) EV100 87.2 87.0   Baseline
Electric Vehicle - 150 mile (w/charger & labor) EV150 87.2 87.0   Baseline
Vehicle Technologies
Source: NHTSA RIA          
Mass Reduction Relative to Previous Mass Reductiona          
Mass Reduction - Level 1 (0 - 1.5%) (Subcompact to Large LT) MR1   0.5   0.5   0.5 Baseline
Mass Reduction - Level 2 (1.5% - 7.5%) (Subcompact to Large LT) MR2   2.1   2.1   2.1 Previous MR
Mass Reduction - Level 3 (7.5% - 10%) (Subcompact to Large LT) MR3   0.9   0.9   0.9 Previous MR
Mass Reduction - Level 4 (10% - 15%) (Subcompact to Large LT) MR4   2.6   2.6   2.6 Previous MR
Mass Reduction - Level 5 (15% - 20%) (Subcompact to Large LT) MR5   2.6   2.6   2.6 Previous MR
Mass Reduction Relative to Baselinea          
0 - 5% Mass Reduction MR5   1.75   1.75   1.75 Baseline
0 - 10% Mass Reduciton MR10   3.50   3.50   3.50 Baseline
0 - 15% Mass Reduction MR15   7.65   7.65   7.65 Baseline
0 - 20% Mass Reduction MR20 10.20 10.20 10.20 Baseline
Low Rolling Resistance Tires - Level 1 (10% reduction in rolling resistance) ROLL1   1.9   1.9   1.9 Baseline
Low Rolling Resistance Tires - Level 2 (20% reduction in rolling resistance) ROLL2   2.0   2.0   2.0 Previous Tech
Low Drag Brakes LDB   0.8   0.8   0.8 Baseline
Aerodynamic Drag Reduction - Level 1 AERO1   2.3   2.3   2.3 Baseline
Aerodynamic Drag Reduction - Level 2 AERO2   2.5   2.5   2.5 Previous Tech

a 3.5% FC reduction for every 10% mass reduction - Under 10%; 5.1% FC reduction for every 10% mass reduction - Over 10%; without engine downsizing.

NOTE: Midsize car: 3500 lbs, large car: 4500 lbs, large light truck: 5500 lbs.

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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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TABLE S.2a NHTSA’s Estimated 2017 Costs of Technologies (2010 dollars)

2017 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Spark Ignition Engine Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Low Friction Lubricants - Level 1 LUB1        3        4        3        4        3        4 Baseline
Engine Friction Reduction - Level 1 EFR1      48      59      71      89      95    118 Baseline
Low Friction Lubricants and Engine Friction Reduction - Level 2 LUB2_EFR2      51      63      75      92      99    122 Previous Tech
VVT- Intake Cam Phasing ICP      37      46      74      93      37      46 Baseline
VVT- Dual Cam Phasing DCP      31      49      72    112   NA Previous Tech
Discrete Variable Valve Lift DVVL    116    163    168    236    240    338 Previous Tech
Continuously Variable Valve Lift CVVL      58      81    151    212    108    151 Previous Tech
Cylinder Deactivation (V6-DOHC, V8-OHV) DEACD   NA    139    196    157    220 Previous Tech
Variable Valve Actuation (CCP + DVVL) VVA   NA   NA    296    416 Baseline for OHV
Stoichiometric Gasoline Direct Injection SGDI    192    277    290    417    348    501 Previous Tech
Turbocharging and Downsizing Level 1 - 18 bar BMEP 33%DS TRBDS1    288    482   -129    248    942 1,339 Previous Tech
V6 to I4 and V8 to V6         -455*   -120*   841* 1,212*  
Turbocharging and Downsizing Level 2 - 24 bar BMEP 50%DS TRBDS2    182    262    182    262    308    442 Previous Tech
I4 to I3       -92*     26*          
Cooled EGR Level 1 - 24 bar BMEP, 50% DS CEGR1    212    305    212    305    212    305 Previous Tech
Cooled EGR Level 2 - 27 bar BMEP, 56% DS CEGR2    364    525    364    525    614    885 Previous Tech
V6 to I4             -524*   -300*  
Diesel Engine Technologies
Defined by EPA and NHTSA                
Advanced Diesel ADSL 2,059 2,965 2,522 3,631 2,886 4,145 Baseline
Transmission Technologies
Defined by EPA and NHTSA                
Improved Auto. Trans. Controls/Externals (ASL-1 & Early TC Lockup) IATC      50      63      50      63      50      63 Previous Tech
6-speed Transmission with Improved Internals (Rel to 4 sp AT) NUATO     -13       -9     -13       -9     -13       -9 Previous Tech
6-speed DCT (Rel to 4 sp AT) (Dry, Wet is 1% Lower) DCT   -146   -114   -146   -114   -146   -114 Previous Tech
8-speed Transmission (Auto or DCT) 8SPD      56      80      56      80      56      80 Previous Tech
High Efficiency Gearbox (Auto or DCT) HETRANS    202    251    202    251    202    251 Previous Tech
Shift Optimizer (ASL-2) SHFTOPT        1        2        1        2        1        2 Previous Tech
Secondary Axle Disconnect SAX      78      98      78      98      78      98 Baseline
Electrified Accessories Technologies
Defined by EPA and NHTSA                
Electric Power Steering EPA      87    109      87    109      87    109 Baseline
Improved Accessories - Level 1 (70% Eff Alt, Elec. Water Pump and Fan) IACC1      71      89      71      89      71      89 Baseline
Improved Accessories - Level 2 (Mild regen alt strategy, Intelligent cooling) IACC2      43      54      43      54      43      54 Previous Tech
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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2017 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Hybrid Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Stop-Start (12V Micro-Hybrid) SS      287      401      325      454      356      498 Previous Tech
Integrated Starter Generator MHEV   1,087   1,634   1,087   1,634   1,087   1,634 Baseline
Strong Hybrid - P2 - Level 2 (Parallel 2 Clutch System) SHEV2-P2   2,463   3,976   2,908   4,696   2,947   4,753 All SI Technogies
Strong Hybrid - PS - Level 2 (Power Split System) (Ref: Ricardo, 2011) SHEV2-PS   3,139   4,990   3,396   5,398   5,023   8,146 Baseline for DOHC
Plug-in Hybrid - 40 mile range (w/charger & labor) PHEV40 13,193 19,089 17,854 26,052   NA Baseline
Electric Vehicle - 75 miles (w/charger & labor) EV75 14,812 21,136 19,275 27,849   NA Baseline
Electric Vehicle - 100 mile (w/charger & labor) EV100 16,831 24,024 21,123 30,492   NA Baseline
Electric Vehicle - 150 mile (w/charger & labor) EV150 22,257 31,784 26,193 37,744   NA Baseline
Vehicle Technologies
Defined by EPA and NHTSA                
Mass Reduction Relative to Previous Mass Reduction                
Mass Reduction - Level 1 (0 - 1.5%) (Subcompact to Large LT) MR1          3          4          4          5          5          6 Baseline
Mass Reduction - Level 2 (1.5% - 7.5%) (Subcompact to Large LT) MR2        82      102      105      131      129      160 Previous Tech
Mass Reduction - Level 3 (7.5% - 10%) (Subcompact to Large LT) MR3        67        82        86      106      105      130 Previous Tech
Mass Reduction - Level 4 (10% - 15%) (Subcompact to Large LT) MR4      189      263      243      338      297      413 Previous Tech
Mass Reduction - Level 5 (15% - 20%) (Subcompact to Large LT) MR5      264      367      340      472      415      577 Previous Tech
Alternative Format for Comparison to NRC Estimates                
0 - 2.5% Mass Reduction MR2.5          4          5          5          6          6          7  
2.5 - 5% Mass Reduction          34        42        44        54        53        66 Previous MR
0 - 5% Mass Reduction MR5        38        47        49        60        59        74 Baseline
5 - 10% Mass Reduction        113      140      146      181      178      221 Previous MR
0 - 10% Mass Reduction MR10      151      187      194      241      237      294 Baseline
10 - 15% Mass Reduction        189      262      243      337      297      412 Previous MR
0 - 15% Mass Reduction MR15      340      450      437      578      534      707 Baseline
15 - 20% Mass Reduction        264      367      340      472      415      577 Previous MR
0 - 20% Mass Reduction MR20      604      817      777 1050      949   1,284 Baseline
Mass Reduction Relative to Baseline - Cost per lb.                
0 - 1% Mass Reduction MR1           0.04           0.05           0.04           0.05           0.04           0.05 Baseline
0 - 5% Mass Reduction MR5           0.22           0.27           0.22           0.27           0.22           0.27 Baseline
0 - 10% Mass Reduction MR10           0.43           0.54           0.43           0.54           0.43           0.54 Baseline
0 - 15% Mass Reduction MR15           0.65           0.86           0.65           0.86           0.65           0.86 Baseline
0 - 20% Mass Reduction MR20           0.86           1.17           0.86           1.17           0.86           1.17 Baseline
Low Rolling Resistance Tires - Level 1 (10% reduction in rolling resistance) ROLL1          5          7          5          7          5          7 Baseline
Low Rolling Resistance Tires - Level 2 (20% reduction in rolling resistance) ROLL2        58        66        58        66        58        66 Previous Tech
Low Drag Brakes LDB        59        74        59        74        59        74 Baseline
Aerodynamic Drag Reduction - Level 1 AERO1        39        49        39        49        39        49 Baseline
Aerodynamic Drag Reduction - Level 2 AERO2      117      164      117      164      117      164 Previous Tech

NOTE: Midsize car: 3500 lbs, large car: 4500 lbs, large light truck: 5500 lbs.

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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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TABLE S.2b NHTSA’s Estimated 2020 Costs of Technologies (2010 dollars)

2020 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Spark Ignition Engine Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Low Friction Lubricants – Level 1 LUB1        3        4        3        4        3        4 Baseline
Engine Friction Reduction – Level 1 EFR1      48      57      71      85      95    113 Baseline
Low Friction Lubricants and Engine Friction Reduction – Level 2 LUB2_EFR2      51      65      75      96      99    127 Previous Tech
VVT– Intake Cam Phasing ICP      35      42      70      84      70      84 Baseline
VVT– Dual Cam Phasing DCP      29      42      67      97      67      97 Previous Tech
Discrete Variable Valve Lift DVVL    109    144    158    209    226    298 Previous Tech
Continuously Variable Valve Lift CVVL      55      72    142    187    101    134 Previous Tech
Cylinder Deactivation (V6–DOHC, V8–OHV) DEACD   NA    131    173    147    195 Previous Tech
Variable Valve Actuation (CCP + DVVL) VVA   NA   NA    280    368 Baseline for OHV
Stoichiometric Gasoline Direct Injection SGDI    181    244    273    367    328    442 Previous Tech
Turbocharging and Downsizing Level 1 – 18 bar BMEP 33%DS TRBDS1    271    415  –122    159    877 1,172 Previous Tech
V6 to I4 and V8 to V6         –432*   –173*    779* 1,065*  
Turbocharging and Downsizing Level 2 – 24 bar BMEP 50%DS TRBDS2    172    292    172    251    289    491 Previous Tech
I4 to I3       –89*     19*          
Cooled EGR Level 1 – 24 bar BMEP, 50% DS CEGR1    199    292    199    292    199    292 Previous Tech
Cooled EGR Level 2 – 27 bar BMEP, 56% DS CEGR2    343    502    343    503    579    847 Previous Tech
V6 to I4             –522*   –305*  
Diesel Engine Technologies
Defined by EPA and NHTSA                
Advanced Diesel Technologies ADSL 1,938 2,612 2,374 3,200 2,716 3,661 Baseline
Transmission Technologies
Defined by EPA and NHTSA                
Improved Auto. Trans. Controls/Externals (ASL–1 & Early TC Lockup) IATC      46      57      46      57      46      57 Previous Tech
6–speed Transmission with Improved Internals (Rel to 4 sp AT) NUATO    –12      –9    –12      –9    –12      –9 Previous Tech
6–speed DCT (Rel to 4 sp AT) (Dry, Wet is 1% Lower) DCT  –137    –89  –137    –89  –137    –89 Previous Tech
8–speed Transmission (Auto or DCT) 8SPD      53      71      53      71      53      71 Previous Tech
High Efficiency Gearbox (Auto or DCT) HETRANS    184    233    184    233    184    233 Previous Tech
Shift Optimizer (ASL–2) SHFTOPT        1        2        1        2        1        2 Previous Tech
Secondary Axle Disconnect SAX      73      89      73      89      73      89 Baseline
Page 415 Cite Bookmark
Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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2020 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Electrified Accessories Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Electric Power Steering EPA        82      100        82      100        82      100 Baseline
Improved Accessories – Level 1 (70% Eff Alt, Elec. Water Pump and Fan) IACC1        69        81        69        81        69        81 Baseline
Improved Accessories – Level 2 (Mild regen alt strategy, Intelligent cooling) IACC2        40        50        40        50        40        50 Previous Tech
Hybrid Technologies                
Defined by EPA and NHTSA                
Stop–Start (12V Micro–Hybrid) SS      261      346      296      392      325      430 Previous Tech
Integrated Starter Generator MHEV   1,008   1,491   1,008   1,491   1,008   1,491 Baseline
Strong Hybrid – P2 – Level 2 (Parallel 2 Clutch System) SHEV2–P2   2,295   3,394   2,410   4,008   2,744   4,068 All SI Technogies
Strong Hybrid – PS – Level 2 (Power Split System) SHEV2–PS   2,954   4,084   3,196   4,418   4,824   6,668 Baseline for DOHC
Plug–in Hybrid – 40 mile range (w/charger & labor) PHEV40   9,763 14,608 13,172 19,881 NA NA Baseline
Electric Vehicle – 75 miles (w/charger & labor) EV75 10,189 16,175 13,310 21,446 NA NA Baseline
Electric Vehicle – 100 mile (w/charger & labor) EV100 11,482 18,283 14,492 23,374 NA NA Baseline
Electric Vehicle – 150 mile (w/charger & labor) EV150 14,954 23,946 17,737 28,666 NA NA Baseline
Vehicle Technologies                
Defined by EPA and NHTSA                
Mass Reduction Relative to Previous Mass Reduction                
Mass Reduction – Level 1 (0 – 1.5%) (Subcompact to Large LT) MR1          3          3          3          4          4          5 Baseline
Mass Reduction – Level 2 (1.5% – 7.5%) (Subcompact to Large LT) MR2        76        90        97      116      119      141 Previous Tech
Mass Reduction – Level 3 (7.5% – 10%) (Subcompact to Large LT) MR3        60        72        78        92        95      113 Previous Tech
Mass Reduction – Level 4 (10% – 15%) (Subcompact to Large LT) MR4      173      241      223      310      272      378 Previous Tech
Mass Reduction – Level 5 (15% – 20%) (Subcompact to Large LT) MR5      242      336      311      432      380      528 Previous Tech
Alternative Format for Comparison to NRC Estimates                
0 – 1% Mass Reduction MR1          3          4          4          5          5          6 Baseline
1 – 5% Mass Reduction          31        37        40        47        49        58 Previous MR
0 – 5% Mass Reduction MR5        34        41        44        53        54        64 Baseline
5 – 10% Mass Reduction        103      123      133      158      162      193 Previous MR
0 – 10% Mass Reduction MR10      137      164      177      210      216      257 Baseline
10 – 15% Mass Reduction        172      239      221      307      270      375 Previous MR
Page 416 Cite Bookmark
Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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2020 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
  Abbreviation DMC TC DMC TC DMC TC Relative To
0 – 15% Mass Reduction MR15    309    402    398    517    486    632 Baseline
15 – 20% Mass Reduction      241    334    309    430    378    525 Previous MR
0 – 20% Mass Reduction MR20    550    737    707    947    864 1,158 Baseline
Mass Reduction Relative to Baseline – Cost per lb.                
0 – 1% Mass Reduction MR1        0.04        0.05        0.04        0.05        0.04        0.05  
0 – 5% Mass Reduction MR5        0.20        0.23        0.20        0.23        0.20        0.23 Baseline
0 – 10% Mass Reduction MR10        0.39        0.47        0.39        0.47        0.39        0.47 Baseline
0 – 15% Mass Reduction MR15        0.59        0.77        0.59        0.77        0.59        0.77 Baseline
0 – 20% Mass Reduction MR20        0.79        1.05        0.79        1.05        0.79        1.05 Baseline
Low Rolling Resistance Tires – Level 1 (10% reduction in rolling resistance) ROLL1        5        6        5        6        5        6 Baseline
Low Rolling Resistance Tires – Level 2 (20% reduction in rolling resistance) ROLL2      46      54      46      54      46      54 Previous Tech
Low Drag Brakes LDB      59      71      59      71      59      71 Baseline
Aerodynamic Drag Reduction – Level 1 AERO1      37      45      37      45      37      45 Baseline
Aerodynamic Drag Reduction – Level 2 AERO2    110    157    110    157    110    157 Previous Tech

NOTE: Midsize car: 3500 lbs, large car: 4500 lbs, large light truck: 5500 lbs.

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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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TABLE S.2c NHTSA’s Estimated 2025 Costs of Technologies (2010 dollars)

2025 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Spark Ignition Engine Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Low Friction Lubricants - Level 1 LUB1        3        4        3        4        3        4 Baseline
Engine Friction Reduction - Level 1 EFR1      48      57      71      85      95    113 Baseline
Low Friction Lubricants and Engine Friction Reduction - Level 2 LUB2_EFR2      51      60      75      89      99    117 Previous Tech
VVT- Intake Cam Phasing ICP      31      39      63      78      63      78 Baseline
VVT- Dual Cam Phasing DCP      27      39      61      90      61      90 Previous Tech
Discrete Variable Valve Lift DVVL      99    133    143    193    204    276 Previous Tech
Continuously Variable Valve Lift CVVL      49      67    128    174      92    124 Previous Tech
Cylinder Deactivation (V6-DOHC, V8-OHV) DEACD   NA    118    160    133    180 Previous Tech
Variable Valve Actuation (CCP + DVVL) VVA   NA   NA    248    336 Baseline for OHV
Stoichiometric Gasoline Direct Injection SGDI    164    226    246    340    296    409 Previous Tech
Turbocharging and Downsizing Level 1 - 18 bar BMEP 33%DS TRBDS1    245    388   –110    168    788 1,080 Previous Tech
V6 to I4 and V8 to V6        –396*  –142*   700*   983*  
Turbocharging and Downsizing Level 2 - 24 bar BMEP 50%DS TRBDS2    155    214    155    214    261    361 Previous Tech
I4 to I3      –82*        5*          
Cooled EGR Level 1 - 24 bar BMEP, 50% DS CEGR1    180    249    180    249    180    249 Previous Tech
Cooled EGR Level 2 - 27 bar BMEP, 56% DS CEGR2    310    429    310    428    523    722 Previous Tech
V6 to I4            –453*  -289*  
Diesel Engine Technologies
Defined by EPA and NHTSA                
Advanced Diesel ADSL 1,752 2,420 2,146 2,954 2,455 3,392 Baseline
Transmission Technologies
Defined by EPA and NHTSA                
Improved Auto. Trans. Controls/Externals (ASL-1 & Early TC Lockup) IATC      42      52      42      52      42      52 Previous Tech
6-speed Transmission with Improved Internals (Rel to 4 sp AT) NUATO    –11      –8    –11      –8    –11      -8 Previous Tech
6-speed DCT (Rel to 4 sp AT) (Dry, Wet is 1% Lower) DCT  –124    –77  –124    –77  –124    -77 Previous Tech
8-speed Transmission (Auto or DCT) 8SPD      47      66      47      66      47      66 Previous Tech
High Efficiency Gearbox (Auto or DCT) HETRANS    163    202    163    202    163    202 Previous Tech
Shift Optimizer (ASL-2) SHFTOPT        0        0        0        0        0        0 Previous Tech
Secondary Axle Disconnect SAX      66      82      66      82      66      82 Baseline
Page 418 Cite Bookmark
Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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2025 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
Electrified Accessories Technologies Abbreviation DMC TC DMC TC DMC TC Relative To
Defined by EPA and NHTSA                
Electric Power Steering EPA       74       92       74       92       74       92 Baseline
Improved Accessories - Level 1 (70% Eff Alt, Elec. Water Pump and Fan) IACC1       64       75       64       75       64       75 Baseline
Improved Accessories - Level 2 (Mild regen alt strategy, Intelligent cooling) IACC2       37       45       37       45       37       45 Previous Tech
Hybrid Technologies
Defined by EPA and NHTSA                
Stop-Start (12V Micro-Hybrid) SS     225     308     255     349     279     383 Previous Tech
Integrated Starter Generator MHEV     888 1,249     888 1,249     888 1,249 Baseline
Strong Hybrid - P2 - Level 2 (Parallel 2 Clutch System) SHEV2-P2   2041 2,957 2,410 3,492 2,438 3,531 All SI Technogies
Strong Hybrid - PS - Level 2 (Power Split System) SHEV2-PS   2671 3,791 2,889 4,101 4,360 6,190 Baseline for DOHC
Plug-in Hybrid - 40 mile range (w/charger & labor) PHEV40   8325 11,826 11,189 16,066   NA Baseline
Electric Vehicle - 75 miles (w/charger & labor) EV75   8451 12,226 11,025 16,159   NA Baseline
Electric Vehicle - 100 mile (w/charger & labor) EV100   9486 13,774 11,971 17,575   NA Baseline
Electric Vehicle - 150 mile (w/charger & labor) EV150 12264 17,931 14,567 21,460   NA Baseline
Vehicle Technologies
Defined by EPA and NHTSA                
Mass Reduction Relative to Previous Mass Reduction                
Mass Reduction - Level 1 (0 - 1.5%) (Subcompact to Large LT) MR1         3         3         3         4         4         5 Baseline
Mass Reduction - Level 2 (1.5% - 7.5%) (Subcompact to Large LT) MR2       67       80       86     103     106     126 Previous Tech
Mass Reduction - Level 3 (7.5% - 10%) (Subcompact to Large LT) MR3       53       64       69       82       84     100 Previous Tech
Mass Reduction - Level 4 (10% - 15%) (Subcompact to Large LT) MR4     152     196     196     253     239     309 Previous Tech
Mass Reduction - Level 5 (15% - 20%) (Subcompact to Large LT) MR5     214     275     275     354     336     433 Previous Tech
Alternative Format for Comparison to NRC Estimates                
0 - 1% Mass Reduction MR1         3         4         4         5         5         6  
1 - 5% Mass Reduction         28       33       35       42       43       51 Previous MR
0 - 5% Mass Reduction MR5       31       36       39       47       48       57 Baseline
5 - 10% Mass Reduction         92     109     118     140     144     172 Previous MR
0 - 10% Mass Reduction MR10     122     146     157     187     192     229 Baseline
10 - 15% Mass Reduction       153     197     197     254     240     310 Previous MR
Page 419 Cite Bookmark
Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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2025 Incremental Costs (2010$): NHTSA Estimates (TSD, RIA, Decision Trees)
  Midsize Car I4 DOHC Large Car V6 DOHC Large Light Truck V8 OHV  
  Abbreviation DMC TC DMC TC DMC TC Relative To
0 - 15% Mass Reduction MR15 275 343 354 441 433 539 Baseline
15 - 20% Mass Reduction   214 276 275 355 336 434 Previous MR
0 - 20% Mass Reduction MR20 489 619 629 796 769 973 Baseline
Mass Reduction Relative to Baseline - Cost per lb.                
0 - 1% Mass Reduction MR1     0.03     0.04     0.03     0.04     0.03     0.04 Baseline
0 - 5% Mass Reduction MR5     0.17     0.21     0.17     0.21     0.17     0.21 Baseline
0 - 10% Mass Reduction MR10     0.35     0.42     0.35     0.42     0.35     0.42 Baseline
0 - 15% Mass Reduction MR15     0.52     0.65     0.52     0.65     0.52     0.65 Baseline
0 - 20% Mass Reduction MR20     0.70     0.88     0.70     0.88     0.70     0.88 Baseline
Low Rolling Resistance Tires - Level 1 (10% reduction in rolling resistance) ROLL1     5     6     5     6     5     6 Baseline
Low Rolling Resistance Tires - Level 2 (20% reduction in rolling resistance) ROLL2   31   38   31   38   31   38 Previous Tech
Low Drag Brakes LDB   59   71   59   71   59   71 Baseline
Aerodynamic Drag Reduction - Level 1 AERO1   33   41   33   41   33   41 Baseline
Aerodynamic Drag Reduction - Level 2 AERO2 100 135 100 135 100 135 Previous Tech

NOTE: Midsize car: 3500 lbs, large car: 4500 lbs, large light truck: 5500 lbs.

Page 409 Cite Bookmark
Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Suggested Citation: "Appendix S: NHTSA's Estimated Fuel Consumption Reduction Effectiveness of Technologies and Estimated Costs of Technologies." National Research Council. 2015. Cost, Effectiveness, and Deployment of Fuel Economy Technologies for Light-Duty Vehicles. Washington, DC: The National Academies Press. doi: 10.17226/21744.
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Next Chapter: Appendix T: Derivation of Turbocharged, Downsized Engine Direct Manufacturing Costs
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