This paper presents performance evaluation of an Integrated Starter-Alternator (ISA) prototype with an Interior Permanent Magnet (IPM) synchronous machine under sensor-less operation. To attain a high starting torque at zero speed and in subsequent extremely low speed range, a hybrid signal injection method is proposed. At higher speed, an improved stator flux observer is used for the stator flux estimation. This observer is able to produce accurately-estimated stator flux linkage for high performance Direct Torque and Flux Control (DTFC) implementation. The sensor-less DTFC IPM synchronous machine drive takes full advantage of the capacity of the power converter and fulfills the control specifications for the ISA. The trajectory control algorithm responds rapidly and in a well behaved manner over a wide range of operating conditions. The experimental results verify the feasibility and advantages of the system.