Fuel spray is the pivotal process of direct injection engine combustion. The accuracy of spray simulation determines the reliability of combustion calculation. However, the traditional techniques of spray simulation in KIVA and commercial CFD codes are very susceptible to grid resolution. As a consequence, predicted engine performance and emission can depend on the computational mesh. The two main causes of this problem are the droplet collision algorithm and coupling between gas and liquid phases. In order to improve the accuracy of spray simulation, the original KIVA code is modified using the cross mesh droplet collision (CMC) algorithm and gas phase velocity interpolation algorithm. In the constant volume apparatus and D.I. diesel engine, the improvements of the modified KIVA code in spray simulation accuracy are checked from spray structure, predicted average drop size and spray tip penetration, respectively. The results show a dramatic decrease in grid dependency. With these changes, the distorted phenomenon of spray structure is vanished. The uncertainty in predicted average drop size is reduced from 30 to 5 μm in constant volume apparatus calculation, and the uncertainty is further reduced to 2 μm in an engine simulation. The predicted spray tip penetrations in engine simulation also have better consistency in medium and fine meshes. droplet collision algorithm, coupling between gas and liquid phases, accuracy of spray simulation, spray structure, average drop size, spray tip penetrationIn diesel engine and direct injection gasoline engine, the fuel spray, atomization, evaporation and mixing with air are significant to the combustion and emission of engine. Therefore, the simulation of direct injection engine requires accurate treatment of the spray. Currently, KIVA is the most widely used CFD code in engine simulation. Though KIVA is constructed via good engineering practice and is a laudable achievement, the code is severely grid-dependent. The simulation errors caused by grid dependency are possibly more serious than the errors caused by physical uncertainty, on the order of one-hundred percent [1] . Even worse, these errors can be completely unpredictable, increasing or decreasing predicted drop size depending on the mesh resolution [2] .These simulation errors have two very serious consequences [3] . First, the simulation error impedes the correct evaluation of physical models. When a model predicts incorrect spray behavior, it is difficult to identify whether this is the fault of mesh or physical model. If a model gives the correct result, it is also difficult to make clear whether it will continue to function when one changes the mesh or time step. It is quite possible that researchers make bad decisions based on the results contaminated by simulation error. The second issue is that multi-dimensional computational fluid dynamics (CFD) is becoming more central to the engine design process; the importance of reliability also increases. In order to use CFD in the design process of direct injection eng...