!NEW! Light, Lighter – New Opel Astra

• Consistent lightweight design: Five-door model up to 200 kilograms lighter
• Engineered from white sheet of paper: Every component trimmed to highest efficiency
• Compact: All-aluminum engines and interior concept save more weight
• Intelligent architecture: More space in slimmer shell

Consistent lightweight design: New Opel Astra is up to 200 kilograms lighter than its predecessor

Lighter, more frugal and compact while offering more generous interior space – everything about the new Opel Astra follows the maxim of highest efficiency. All components and design features are aligned to this touchstone, resulting in intelligent packaging à la Astra. The next generation of the compact bestseller that makes its premiere at the IAA in Frankfurt (September 17 – 27) is based on an all-new lightweight architecture, its body is noticeably slimmer and it is driven by powerful, weight- and CO2-optimized all-aluminum engines. All told, the new Astra is up to 200 kilograms lighter than its predecessor.

Consistent lightweight design: The new vehicle architecture

The visionary Monza Concept presented at the 2013 IAA was the role model for Opel’s eleventh compact class generation. Every component of the study reflects the efficiency maxim. The new Opel Astra already consistently realizes this vision: depending on the model and trim level, it is up to 200 – but in any case at least 120 – kilograms lighter than its predecessor. The new, thoroughly slimmed down vehicle architecture plays a decisive role in this weight loss: the bodyshell (body-in-white) and structure alone are over 20 percent lighter, down from 357 to 280 kilograms. Another 50 kilograms were saved in the design of chassis components: high-strength and ultra-high-strength lightweight steels, more compact subframes as well as modification to the front and rear suspensions all contributed to this end result. In addition, engineers decided against full underbody paneling to further optimize the aerodynamics of chassis and drivetrain elements, resulting in a double advantage: lower weight and reduced production costs that enable more attractive price structures for customers.

Bodyshell weight alone was reduced by 20% from 357 to 280 kilograms

Further size- and mass-optimization measures include shorter front and rear overhangs, as well as the up to 25 percent lighter exhaust system which saves around 4.5 kilograms on this part alone. The smaller wheels and tires weigh up to 11.5 kilograms less. The same is true for the brakes: as the system has less mass to decelerate, a more compact design weighing 10 kilograms less was possible – while delivering even better braking performance.

Lose the weight: Engines make their contribution

Another plus on the efficiency side is the new-generation engines. They distinguish themselves with their compact and ultra-efficient design: for instance the new 1.4 ECOTEC Direct Injection Turbo engine making its premiere in the Astra weighs much less than current comparable units. Its aluminum engine block alone is ten kilograms lighter than the cast-iron block of its predecessor. Thanks to their compact design, the newest-generation, ultra-modern transmissions save just as much weight.

All-aluminum: New 1.4 ECOTEC Direct Injection Turbo with central direct fuel injection will be available in the new Opel Astra in two outputs, 92 kW/125 hp and 110 kW/150 hp.

Reduced weight also leads to noticeably higher agility. The new Astra is more fun to drive than ever before – while saving fuel and CO2 emissions. The newcomer with the 1.0 Turbo and Easytronic 3.0 combination is one of the most economical and cleanest gasoline models in its segment. The 77 kW/105 hp three-cylinder unit reduces consumption in the combined cycle to 4.2 liters per 100 kilometers and CO2 emissions to an exemplary 96 g/km.

Lose the weight: Light all-aluminum engines like the highly efficient 1.0 Turbo make their important contribution to it.

The interior was also put through a fitness program. Take, for instance, the seats: after five years of detailed work, the development team presented compact class seats that are more functional and comfortable, while featuring more of a space- and weight-saving design than ever before. State-of-the-art packaging calculation methods enable this, as do lighter polyurethane foams and ultra-high-strength steels that are built in under the robust seat upholstery. So the new Opel Astra seats in front and rear are a total of around ten kilograms lighter than in the previous model.

Intelligent packaging: Lighter, more compact yet more spacious

Intelligent packaging: New Opel Astra is lighter, more compact yet more spacious than its predecessor.

The new Astra generation not only looks more sophisticated and athletic, it is also more compact. With a total length of 4.37 meters, the five-door hatchback is almost five centimeters shorter than its predecessor, its height of 1.48 meters is 2.5 centimeters smaller and its width has been reduced by 0.5 centimeters to 1.81 meters. These dimensions also have a positive effect on the vehicle’s weight. At the same time, interior space is more generous. Together with the newly designed, lighter and more compact seats, rear-seat passengers now benefit from 35 millimeters more legroom than before. This puts the five-door model in first place ahead of all the competition. Distance between the first and second rows has been increased by 1.5 centimeters, greatly enhancing traveling comfort and sense of space. The same is true for upper-body freedom of movement for passengers in both front and rear seats. Especially in terms of headroom, the new Opel Astra sets standards in its class: the driver has 2.2 centimeters more headroom than in the predecessor. So the new Opel Astra successfully squares the circle: it is lighter and more compact while offering more space and comfort than before.

!NEW! Four decades of top design: Opel Monza GSE meets Opel Monza Concept

• Style icons in comparison: Dream coupé of the seventies meets the IAA study 2013
• Designers from back then and now in dialogue: George Gallion and Friedhelm Engler
• Fascinating double interview: The Opel design language of yesterday and today

Four decades of top design: The Monza GSE meets the Monza Concept. Opel is continuing the tradition of beautiful Gran Turismo models coming out of Rüsselsheim.

A beautiful autumnal day at the river Main: Riding on a yellow truck, the Opel Monza Concept rolls up in front of the Adam Opel Building. The namesake of the brand-new concept vehicle, Opel Monza GSE, is already set. George Gallion, who designed the original 1977 Monza, and Friedhelm Engler, Director of Advanced Design of the Opel Monza Concept, follow spellbound, as the two cars are placed side by side – a moment worthy of goose bumps. Dozens of employees gather immediately, pulling out their smartphones as they walk around the racers. Even the two designers cannot be persuaded to pose for the photographers as planned. While the Opel Monza Concept is still assuming its position, Gallion opens the tailgate of the GSE. “That was a tricky thing,” he says, stroking the delicate trimming of the rear window. “It ensures the extremely slender structure is rigid enough, and we wanted this structure at all costs,” he explains. “When designing the Opel Monza Concept,” says Engler, “we were inspired by the tailgate’s glass.” And the car is now finally good to go. With a stroke of his finger over the rear fender, Engler opens the huge gull-wing door. Silently. Gallion takes his seat. Using a touchpad, Engler raises the LED projection. The curved cockpit, stretching from door to door, springs to life. Virtual buttons and control dials appear on the cockpit surface. “Everything can be shown here. A CD cover, the navigational map, a Facebook app, whatever you want, when you want it,” explains Engler.

Two designers and their works. Friedhelm Engler (on left) with his Opel Monza Concept with George Gallion in front of his Opel Monza GSE.

Ten questions for Opel designers George Gallion and Friedhelm Engler:

Mr. Gallion, you made history with the Opel Monza A2 in 1983. It was the first car with a digital display. What do you think of this new kind of instrument panel ?

GALLION: Some newspapers called our display a ‘mouse screen’ back then. I liked that. This is like, how should I call it, “Mickey Mouse meets Star Wars.” I am even slightly envious when I see what’s possible today. How beautiful this car has become.

ENGLER: Hey, George, you’ve got goose bumps. This interface between human and machine is crazy, right? The infotainment and instrument panel was originally intended to be a lot smaller, more reduced. Then we realized that it works really well. We can place the multifunctional, customizable dash panel across the entire width of the dashboard. It’s state of the art.

Opel Monza GSE: A luxury of the late seventies and early eighties. A coupé for daily driving with a six cylinder in-line engine that runs with silky smoothness.

Two generations: George Gallion (on left) and Friedhelm Engler under the large wing door of the Opel Monza Concept.

Mr. Gallion and Mr. Engler, your paths coincided at Opel in 1992. Did you ever run into each other ?

GALLION: But of course. I actually interviewed Friedhelm for the job.

ENGLER: I still remember it well. After the interview, George showed me around the studio and let me look under all the car covers. That was actually against the rules. But that’s typical of the fascination with Opel / Vauxhall. It’s approachable, both then and now.

How has the work of designers changed ?

ENGLER: The early stages always involve the vision, the idea and then pencils, and quality paper. That hasn’t changed. Right, George?

GALLION: Yes. It’s the old cliché – the designer sits in a café and sketches with pencil and paper in front of them. That’s true. Even in meetings, while designers are listening, well, most of the time, they are drawing while they’re at it.

ENGLER: What has changed, of course, are the tools – computer development and 3D programs, shaping machines and simulations.

48 years ago, Opel was the world’s first car manufacturer to present a concept car at the IAA, the Experimental Opel GT. This year it’s the Opel Monza Concept. How important are concept cars for the evolution of design ?

GALLION: The show cars are there in order to showcase new design ideas. They don’t necessarily have to result in a product. Rather, they aim to illustrate a trend. At that time, Opel had the first design department that was only allowed to research without regard to a particular product line.

48 years of Opel concept cars: The Experimental GT was in 1965 the first concept car made by a European manufacturer. Just like the Monza Concept, the GT celebrated its premiere at the IAA in Frankfurt.

ENGLER: The Monza Concept is the vision of the Opel brand, and for us, too, for designers, employees, and colleagues. It is incredibly motivating to see a vision take shape. Indeed, we have just seen what happened in front of the Adam Opel Building. Before the car is even in position, colleagues gather in droves to see the car and take photos.

How was the idea of the Opel Monza Concept born?

ENGLER: It began with a vision of the brand. We wanted to visualize efficiency that could also be realized from the point of view of engineering. The idea was for it not to convey heaviness but also not fragility. That is how the original sketch of the lady and the dog was born. (Engler pulls out a poster showing the car next to a lady and a greyhound.) This greyhound is just skin and bone, is incredibly agile, and at the same time looks elegant. That is perfect. Also, this woman, she’s got a 70s, 80s look on the one hand, but is also modern and cool. That was it, that was a full story. Together we developed the idea for another two years. A show car is not the work of just one person. It is a team effort, involving 70 or 80 people.

Dream car: The Monza Concept will sustainably influence the design of upcoming Opel models.

Getting back to the greyhound, over and again we read that animals are the inspiration for car designs. Do designers visit the zoo regularly in their free time ?

ENGLER: I don’t think that our people hang out at the zoo. Although, George, there is that story about the manta ray …

GALLION: That was in 1969. In response to the Ford Capri, we designed a prototype for a coupé in the space of four weeks. Predator names were ‘in’ at the time. We wanted to name it manta and use the shape of the fish as the emblem. But nobody could tell us what this fish looked like at all. Nobody but Jacques Cousteau, the marine biologist. So I went to see him in Paris to get photos of the manta ray. And well, the fish wasn’t all that beautiful in the end. So then we gave it a more elegant look in the design.

ENGLER: Examples from the animal world are appreciated simply because they mean something to everyone. When I talk about a cheetah or a greyhound in conversation, everyone has an image in their mind straight away.

Elegant design paired with ultra-modern efficiency on four wheels: The visionary Monza Concept shows what Opel drivers can expect in future. Its formal tension and lightness remind of a beautiful greyhound.

Opel Monza: that means, a sports coupé with a lot of space inside. What parallels can be drawn between the Opel Monza A and the Opel Monza Concept ?

ENGLER: Opel Monza Concept stands on its own. However, there are certain intentional references to the Opel Monza A, for example, the implied air ducts of the C pillar. The duct along the roofline reflects functionality which is what Opel stands for. This makes it a high-value four seater that makes no compromises. That’s why we call it a sports break and not a sports coupé. The generous sculpted glass – another reference – brings lightness and also gives it a more slender appearance. Otherwise, Opel Monza A is just a namesake, a reference. While we had it with us in the studio, we didn’t do a retro design, and we didn’t cook or rehash any old ideas. George and his team never looked back either.

How much of the Opel Monza Concept’s design will be incorporated into new Opel models ?

ENGLER: Like all Opels, the Monza Concept vehicle is the embodiment of our basic messages – sculpted design and German engineering skill. But it develops the topic, the design philosophy further, pushes it to the next level – by placing the emphasis on extremely strong proportions. Simple lines are therefore sufficient in other areas. Just like a beautifully grown Christmas tree. That’s sculpted design. And it’s evident in the Astra GTC: The lateral, fully pulled sheet metal completes the stage performance.

Is it often the case that you have to sacrifice a brilliant design idea for functional or technical specifications ?

ENGLER: No, not if you develop the idea from the beginning together with colleagues from the engineering and marketing departments.

GALLION: I’ve never tried to do anything that wasn’t technically feasible. But if the engineers said to me, “no, we cannot tilt this component another degree,” then I’d say, “Ok, then just try half a degree more.”

By the way, what cars do you have in your private garage ? 
Mr. Gallion, you arrived today in Opel Meriva …

GALLION: Yes, that’s my fourth already! The door design of the Opel Meriva B is very practical, particularly when I have my five-year-old grandchild with me. And the blue Opel Aero GT, at Opel Classic, that’s mine also.

ENGLER: I’m pursuing a special project at the moment. My son and I are turning an Opel GT into a rally vehicle, which we want to use for racing. When it’s finished, I’ll come over to your place and we can do some laps.

GALLION: It’s a deal! 

In brief: The designers and their concept cars

Friedhelm Engler

Born in 1963, the Director of Advanced Design at GM Europe studied design at the University of Pforzheim for three years, before moving to Tokyo to work as a product designer. At Opel, he began as a transport designer, was later head designer on the Meriva A and the Astra H, then Director of Design for Global Compact Car Architecture. Until 2010, he managed the design department of the PATAC development center in Shanghai. As Director, he was responsible for show cars and studies, including RAK e, RAD e, and the Monza Concept.

George Gallion

Born in the U.S. in 1937, he joined GM in Detroit after having studied industrial design in Atlanta, Georgia. In 1969, he moved to Opel and became Deputy Design Director. Many Opel / Vauxhalls carry his signature, from the Manta A to Monza to his latest projects, the Signum and Movano. He retired in 2002 and lives with his wife in the Taunus mountain range in Germany.

Opel Monza A1/A2

First Sketch: The design for the Opel Monza A. The large coupé celebrates in 1977 its world premiere at the IAA in Frankfurt.

Opel Monza A1 was presented at the Frankfurt Motor Show (IAA) in 1977. The three-door coupé of the new top model, Senator, was ideal for everyday use with its four seats. The Monza was powered by six-cylinder engines with 2.5- to 3.0-liter cubic capacity. The Monza A2 replaced it at the end of 1982. In 1983, the top GSE line featured digital display instruments for the first time. Production of the coupé ended in 1986, but today it is fast becoming a cult classic.

Opel Monza Concept

  The visionary Monza Concept shows what Opel drivers can expect in future.

It combines the silhouette of a sports break with the line of a coupé, and gull-wing doors with functionality. Highly modern instruments and infotainment displays using LED projection technology are indicative of O / V’s plan for sweeping integration. As for the drive system, the modular design ensures the highest degree of flexibility. A 1.0 turbo engine is connected to the electric drive system of the design study, with more combinations possible.

!NEW! Opel presents new 1.0 SIDI Turbo engine at Aachen Colloquium

• New 85 kW/115 hp, 1.0 liter turbo raises benchmark for three-cylinder refinement
• First in new family of small, direct injection gasoline engines to debut in Opel ADAM
• More torque and better fuel economy than 1.6 naturally-aspirated engine
• Cutting-edge design includes exhaust manifold integrated within cylinder head

New Opel ECOTEC 1.0 SIDI Turbo with 85 kW/115 hp

Opel revealed details of its new three-cylinder gasoline engine at the Aachen Colloquium in Germany. Clean, smooth and quiet: Opel’s all-new 1.0 liter SIDI Turbo will raise the bar for three-cylinder engine refinement when it makes its debut in the Opel ADAM next year. It is not only economical and more friendly to the climate, it is also silky smooth to drive, with noise and vibration characteristics superior to many four-cylinder engines.

New Opel ECOTEC 1.0 SIDI Turbo developing 166 Nm torque 

This pocket powerhouse belies its diminutive size by developing 85 kW/115 hp, together with strong torque of 166 Nm all the way from 1,800 to 4,700 rpm. It therefore enables better acceleration at low rpm than larger engines with similar horsepower, together with much lower fuel consumption and CO2 emissions. For example, compared to Opel’s current 1.6 liter naturally-aspirated engine, the new 1.0 SIDI Turbo (Spark Ignition Direct Injection) offers the same maximum power output, while delivering 30 percent more torque and 20 percent better fuel economy.

State-of-the-art technologies include high-pressure direct fuel injection, an ultra-compact turbocharging system, continuously variable valve timing and a lightweight aluminum construction with a cylinder head-integrated exhaust manifold. Numerous ‘sound engineering’ measures which contribute to the engine’s benchmark refinement include an acoustically-developed cylinder block; a sump-mounted balancer shaft; structural isolation of the fuel injection system and crankshaft; drive chains with inverted teeth and engine covers designed for acoustic attenuation.

New Opel ADAM 1.0 SIDI Turbo

The 1.0 SIDI Turbo is the first in a new, modular family of three and four-cylinder gasoline engines in the sub-1.6-liter class which are engineered to meet customer demand for strong, downsized engine performance. It makes its debut in the Opel ADAM next year, together with an all-new, six-speed manual gearbox. All vehicle applications of the 1.0 SIDI Turbo are designed to operate with Start/Stop functionality and are expected to deliver combined cycle CO2 emissions significantly lower than 100 g/km.

“In developing this small engine, we not only set out to minimize fuel consumption and CO2 emissions, but also wanted to demonstrate that three cylinders can be just as refined as four or more,” says Dr. Matthias Alt, Opel’s Chief Engineer, Small Gasoline Engines.

“We tackled at source the various balance, noise and vibration issues typical of conventional three-cylinder engines, and we’re confident customers will be pleasantly surprised by the results. This is a very lively and refined three-cylinder engine, which doesn’t compromise on driving fun. Put simply, it’s big on refinement and performance but small on fuel consumption.”

German engineering for class-leading refinement

Starting with a clean sheet of paper, Opel and GM global engineering teams leveraged their combined expertise to eliminate the harsh, ‘off-beat’ running characteristics, which have traditionally been a downside to the economical driving appeal of three-cylinder engines. As a result, the 1.0 SIDI Turbo boasts a four cylinder-like ‘soundtrack’, which clearly positions it as the new benchmark for refinement among three-cylinder engines.

Throughout the development process, the prevention and mitigation of vibration and harshness was achieved through extensive modeling work, as well as component hardware and whole-engine validation on the test bench. The scope of the work also included the development of engine management functions and the in-vehicle integration of the entire powertrain.

The engine’s all-aluminum architecture was acoustically designed to reduce both airborne and structure-borne operating noise, as well as to save weight. Its inherent refinement is so good, the need to mask the transfer of engine noise with in-car sound insulation, or complex engine and sub-frame mountings, is significantly reduced. The persistent reduction of unwelcome engine sounds also gives engineers greater freedom in fine-tuning the sound of induction and exhaust systems to meet the requirements of specific vehicle applications.

As a result of this intense focus on refinement, the 1.0 SIDI Turbo not only runs more smoothly than similar three-cylinder engines, but also more quietly than many four-cylinder units. For example, during development in laboratory bench testing at full throttle, it emitted lower sounds levels across all engine speeds than gasoline turbos up to 1.6 liters in displacement.

Other specific features that contribute to the engine’s impressive refinement include:

• A small balance-shaft mounted longitudinally in the oil sump. Driven by a chain with inverted teeth for quiet running, this counter-rotating shaft revolves at crankshaft speed and is mass-optimized to off-set the inherent vibrations from a three cylinder operation.
  
• The high-pressure fuel rail and injectors are isolated from the cylinder head. This ensures there is no metal-to-metal contact and prevents the transmission of pulsing energy through the engine structure. The fuel pump and fuel line are also acoustically optimized.
  
• Camshaft drive-chain optimized for low sound levels through an inverted-tooth design. The entire chain architecture, including its tensioning, wrap and guides, is designed for reduced overall noise radiation and the elimination of any perceived abnormal sounds.
• The integration of a stamped steel plate in the oil pan at the bottom of the aluminum sump also reduces noise radiation.
• Further noise attenuation measures are: acoustically-optimized covers for the top and front of the engine, the design of the intake manifold and camshaft housings, crankshaft isolation with iron main bearing inserts, and the use of a low-hiss compressor in the turbocharger.

Lightweight all-aluminum architecture

The core engine-architecture is focused on saving weight and consists of an aluminum, high pressure, die-cast cylinder block, cylinder head and crankshaft bedplate. The combined block/bedplate weight is just 15.5 kg, while the complete engine offers a ten percent weight saving compared to Opel’s current 1.6 naturally-aspirated engine of similar power.

The ‘long-stroke’ cylinder layout supports superior torque characteristics, with the piston stroke of 77.4 mm exceeding its diameter of 74.0 mm. For high power, a compression ratio of 10.5:1 is combined with turbocharging and high-pressure direct fuel injection.

The cylinder head features a water-cooled exhaust manifold integrated within the aluminum casting. This single-piece concept provides a number of benefits: it contributes to fast engine warm-up, and enhances durability by eliminating the need for gasket sealing around the exhaust ports, as well as offering under-hood packaging advantages.

For structural stiffness, the block has cast-in-place iron cylinder liners, with aluminum cast over the top surfaces to optimize cylinder head gasket sealing. The bedplate bulkheads also contain cast-in, nodular iron inserts for localized structural stiffness. Additional structural strength is contributed by the die-cast aluminum sump.

A six-counterweight, forged steel crankshaft transfers the high specific output of the 1.0 SIDI Turbo to the driveline with a minimum of vibration. The upper front main bearings are polymer coated for enhanced durability, particularly under Start/Stop conditions.

The steel con-rods are forged from Powder Metal (PM), which provides equivalent or improved strength compared to a standard forging, while ensuring reduced mass variation. An oil-retaining groove, in combination with an optimized taper angle at the small end, reduces bushing wear. Under-skirt oil jets cool the aluminium pistons and provide additional bore lubrication, which also reduces engine sound during cold starts.

Dual overhead camshafts, operating four valves per cylinder with low-friction, hydraulic roller finger followers, are hollow in section to save weight, and driven by a timing chain with life-long automatic hydraulic tensioning. Aluminum cam phasers enable variable timing for the opening and closing of the inlet and exhaust valves, giving best possible fuel consumption, performance and low emissions under all engine load conditions.

Direct fuel injection delivers more power and greater fuel economy

The 1.0 SIDI Turbo packs a punch, generating 30 percent more torque than Opel’s current 1.6 liter, naturally-aspirated engine, as well as the same 85 kW/115 hp maximum power output. Peak torque of 166 Nm is available across a wide plateau from 1,800 rpm to 4,700 rpm, while maximum power is delivered at just 5,200 rpm. This is an engine that is small in size but big in performance.

The 1.0 SIDI Turbo is also extremely frugal, delivering a 20 percent improvement in fuel economy compared to the 1.6-liter engine. In the Opel ADAM, it will give CO2 emissions of well under 100 g/km, as well as combined cycle fuel consumption approaching 4.0 l/100 km.

Key to both power and frugality is a high-pressure, direct fuel injection system, which helps extract as much energy from the fuel as possible. The six-hole, SIDI injectors, operating at a maximum pressure of 200 bar, are ideally positioned over the center of the combustion chamber and deliver a fine, homogenous spray without wasteful wetting of the inlet valves or port walls. The fuel flow rate at the injectors supports the metering of small, multiple injections.

There is no metal-to-metal contact between the cylinder head and the fuel rail or the injectors. This careful isolation eliminates a major, structure-borne path for operating noise from the injection system. The fuel rail is decoupled by a rubber/steel damper and the injectors are isolated in the combustion chamber by carbon-filled Teflon seals. Acoustics are further enhanced by software algorithms suppressing noises generated from a high pressure fuel pump needle and a foam outer shell.

The longer firing intervals of a three-cylinder enable the use of wider cam profiles than possible with a four-cylinder engine, which extends the duration of the valve opening times to give better cylinder scavenging (gas exchange) for more complete combustion.

To further improve fuel economy and engine operating efficiency, oil is circulated by a two-stage, variable displacement oil pump. This supplies high or low pressure as required by running conditions and includes on-off control of the under-skirt piston cooling jets. A switchable water pump, which is disengaged when the engine is cold in order to give a faster warm-up, also contributes to low fuel consumption.

The Front End Accessory Drive (FEAD) – a five-rib belt connecting the water pump, the alternator and the air conditioning compressor – features a mechanical isolator to remove the effect of crankshaft oscillations. In addition to refinement benefits, this also allows a reduction in tensioning force to reduce friction levels and improve efficiency.

Ultra-compact, fast boost turbocharging system

While high-pressure, direct injection fills the engine’s combustion chambers with a fine mist of fuel, an ultra-compact turbocharging system packs its cylinders with air. Leveraging the design advantages of the cylinder head-integrated exhaust manifold, the 1.0 SIDI’s turbocharger is more closely coupled to the engine than on any other power unit – giving the driver a fast and strong throttle response.

The integration of the water-cooled exhaust manifold within the cylinder head, and the design of the tiny, low-inertia turbocharger, which is also water-cooled, is an exercise in jewel-like, precision engineering.

The sizing of the turbocharger is key to achieving a fine balance between the need for strong low-end torque, fast throttle response, reduced fuel consumption and high maximum power. A single stage, single scroll turbocharger generating maximum boost pressure of 1.5 bar with an intercooler and pressure-operated wastegate was selected as the best configuration. The diameter of the turbine wheel is just 35 mm, while the low-hiss compressor measures only 40 mm across. This combination delivers an excellent transient throttle response, generating 90 percent of maximum torque within 1.5 seconds from just 1,500 rpm. That entails a six-fold increase in cylinder pressure, with the turbo shaft spinning at up to 250,000 rpm.

Water-cooling of the exhaust reduces temperatures for improved emissions control, while also reducing heat build-up around the turbine. This allows the use of an Inconel turbine wheel and a medium grade austenitic steel turbine housing. The gasket to the cylinder head is integrated in one of the heat shields, and V-band clamps and a weight-optimized design all contribute to the turbocharger's lightweight construction.

The turbo feeds the engine through high tumble intake ports, which facilitate early combustion phasing, a short burn duration and good combustion stability. Running turbocharged engines at high loads usually requires retardation of the spark timing to avoid ‘knocking’ or harmful pre-ignition of the intake charge. A high tumble port minimizes the need for this measure.

Meeting current and future needs

The launch of the 1.0 SIDI Turbo is the latest step in the substantial renewal of Opel’s powertrain portfolio, which will see 13 new engines introduced between 2012 and 2016, plus a host of new transmissions.

The program has already begun with the launch of the first 1.6-liter turbo engines from new medium displacement gasoline and diesel families. Now the 1.0 SIDI Turbo arrives as the first example of a new, modular small displacement gasoline engine family, comprising three and four-cylinder engines of less than 1.6 liters displacement. All variants of these new engine families are built at Opel’s state-of-the-art plant in Szentgotthard, Hungary, where gasoline and diesel engines are produced on a shared assembly line.

While the 1.0 SIDI Turbo makes its debut next year in the small ADAM, it can also be used globally in a range of GM applications including larger vehicles, in combination with manual or automatic transmissions.

Like all new-generation Opel power plants, the 1.0 SIDI Turbo is successfully focused on meeting a growing customer demand for ‘downsized’ engines which are able to deliver reduced fuel consumption and CO2 emissions, as well as the power and refinement typical of larger displacement engines.

!NEW! Seven IAA World Premieres: From Opel Insignia OPC to Opel Monza Concept

Opel at 65th Frankfurt International Motor Show

New Opel Insignia OPC Sports Tourer

Self confidence: New Opel sports star Insignia OPC on the IAA stage

Premium enjoyment: New Opel Insignia family with adventure loving Country Tourer

Future mobility: Opel Monza Concept shows tomorrow’s automobile design and connectivity

Individuality: Connected and up-to-date with Opel ADAM Black Link and ADAM White Link

Top class: New engines combine more refinement and power with lower consumption 

New Opel Insignia Country Tourer 4X4

Opel heads into the future with seven world premieres at the 65th International Motor Show (IAA) in Frankfurt from September 12 – 22. The Rüsselsheim automaker reveals the new Opel Insignia OPC, with a fresh look, re-worked chassis and innovative infotainment, at its Stand D 09 in Hall 8, covering more than 3,200 m2. The 239 kW/325 hp 2.8 liter V6 Turbo engine with maximum torque of 435 Nm catapults Opel’s top athlete from zero to 100 km/h in 6.0 seconds. Just as spectacular as the OPC version of the brand’s flagship are world premieres for the Opel Insignia Country Tourer, the adventure loving member of the new Insignia family, as well as the hatchback, notchback and Sports Tourer models – all with a new design, trendsetting infotainment and best-in-class engines.

New Opel Insignia notchback

New Opel Insignia Sports Tourer

Opel also shows the public what mobility of the future will look like with the premiere of its Monza Concept – Opel’s vision of connected and efficient mobility. At the same time, Opel showcases what modern day driving has to offer with innovative models and infotainment solutions such as the Opel ADAM Black Link and Opel ADAM White Link and new engine generations. A new, 200 hp 1.6 SIDI Turbo for the Opel Cascada convertible and the new family of small gasoline engines, coupled with a new six-speed transmission, also make their debuts in Frankfurt.

New Opel Monza Concept 

“We have strong products that will lead Opel back onto the road to success, as well as innovative concepts which show the future direction of the automobile. “We are now better positioned than ever before with our broad portfolio of attractive models and trendsetting technologies. Come see for yourself at the IAA,” says Opel CEO Dr. Karl-Thomas Neumann, inviting all visitors to stop by the Opel stand and see the brand’s products up close.

 New Opel ADAM Black Link and Opel ADAM White Link

New Opel Insignia OPC: World premiere for the ultimate Opel powerhouse

With 239 kW/325 hp and 435 Nm maximum torque, Opel Insignia OPC is the ultimate top-of-the-line performer among Opel models. It makes its debut at the IAA with new and refreshed looks. The re-styled front and rear, with signature OPC design elements such as distinctive saber-tooth detailing at the front and the tailpipe trim integrated in the rear, underline its power and evoke visions of high-speed laps around the Nürburgring.

New Opel Insignia OPC Sports Tourer - LED tail lights

The eye-catching bodywork encapsulates state-of-the-art technology. The OPC chassis is enhanced, with special focus on the re-worked rear axle – as in the other members of the new Insignia family – where engineers have modified around 60 percent of the componentry. In addition, noise and vibration behavior is improved through numerous fine-tuning measures. New ESP software enables even more precise dynamics tuning, especially in reaction to understeer tendencies. Modified damper software for the FlexRide chassis with its adjustable shock absorbers ensures optimum roadholding. This OPC-specific programming improves driving dynamics, allowing a quicker and more precise response to different maneuvers and road conditions. Opel Insignia OPC sprints from zero to 100 km/h in 6.0 seconds (Sports Tourer: 6.3 seconds) and reaches a top speed of 250 km/h (electronically limited). In unrestricted specification, the OPC with manual transmission goes on to a maximum speed of 270 km/h (Sports Tourer: 265 km/h). The high performance, Brembo braking system ensures rapid deceleration with maximum stability, even during high-intensity use.

The cabin welcomes OPC drivers with pure motorsport ambience. Recaro performance seats, also optionally available in leather with a memory function, the OPC gearshift knob and a completely new main instrument panel and center console exude premium flair. Beyond basic information, drivers can see specific details like oil pressure and temperature, battery voltage, throttle position, brake power and the g-force resulting from lateral acceleration on the optional, 8-inch instrument readout display. 

The new performance steering wheel (optionally heated) features shift levers when it is combined with automatic transmission. This enables the OPC driver to execute extremely quick manual shifts, even when in automatic mode. If the shift levers are then idle for at least 12 seconds, the vehicle continues to drive normally in automatic mode. In this way the new Insignia OPC comfortably combines the advantages of a manual and automatic operation.

New Opel Insignia line-up: The infotainment revolution

The new Opel Insignia makes its world premiere at the IAA with following variants: four-door, five-door and Sports Tourer as well as Country Tourer and OPC versions. Opel’s top model range impresses with even more attractive interior and exterior styling, taking the brand’s award-winning design philosophy ‘sculptural artistry meets German precision’ to the next level. A special highlight is the introduction of a completely new infotainment generation that is now available for all Insignia models. It integrates many smartphone functions into the car and can be operated intuitively and simply via a touchpad, touchscreen or steering wheel controls, as well as voice commands.

New Opel Insignia 2.0 CDTI engine

Under the hood, new powerful and ultra-efficient direct injection engines, like the two turbo gasoline units and the new 99 g CO2 turbo diesel, expand the wide portfolio. This exceptionally low emissions level puts the 88 kW/120 hp and 103 kW/140 hp 2.0-liter turbo diesel engine variants in the German A+ efficiency class. In four and five-door models with a six-speed manual gearbox and Start/Stop, both output variants consume just 3.7 liters of fuel per 100 km over the combined cycle, emitting only 99 g/km CO2 (according to Regulation [EC] No 715/2007), while the Sports Tourer achieves 3.9 l/100 km and 104 g/km CO2. As a result, the Opel Insignia 2.0 CDTI is the most fuel efficient diesel car in its class. Engineers have also made the new Insignia’s body even more aerodynamic. With exceptionally low Cd values of 0.25 and 0.28 respectively, the Insignia hatchback is the world’s most streamlined five-door car, while the Sports Tourer is the most aerodynamic series production station wagon on the market.

New Opel Insignia Country Tourer: Adventure-loving Insignia family member

New Opel Insignia Country Tourer 4X4 

World premiere number three is the Opel Insignia Country Tourer. While its Sports Tourer sibling is an elegant family and business station wagon, the new Insignia Country Tourer expresses an innate desire for adventure. This athletic all-rounder, with its higher ground clearance, provides freedom beyond the constraints of city limits and asphalt roads. Defining features include elements hinting at protective under-body guards front and rear, combined with prominent wheel-arch and lower body cladding, all complemented by dual exhaust tailpipes. State-of-the-art all-wheel drive ensures grip and sure-footed handling in all driving conditions. It is teamed with powerful turbo engines, such as a 184 kW/250 hp, 2.0-liter SIDI direct injection gasoline unit or a high-performance 2.0 BiTurbo CDTI – both generating impressive maximum torque of 400 Nm.

Opel Monza Concept: Visionary study shows automobility of the future

Lithe, athletic looks outside, unique projection technology inside and a modular design that enables sustainable propulsion systems par excellence: the Opel Monza Concept is stylish, ultra-modern efficiency on four wheels. This visionary concept car also makes its world premiere at the IAA and shows what people can expect from Opel in the future.

Efficiency and connectivity is the main focus of development for the next generation of Opel models. The Monza Concept therefore offers a fascinating preview of what is in store. To visually express Opel’s quest for increased efficiency, the Monza study presents an evolution of Opel’s current design philosophy of ‘sculptural artistry meets German precision’, featuring body contours which convey a sense of lithe athleticism rather than pure muscle power. In terms of connectivity, it offers trailblazing possibilities that are a quantum leap forward in the development of infotainment systems. All information is displayed via innovative projection technology within an instrument panel that stretches door-to-door – a world ‘first’ in the automotive sector. Just as ground-breaking is the Monza Concept’s modular design, which allows the highest-possible flexibility in the selection of propulsions systems. The Monza Concepts makes the future of automobiles tangible today.

Individuality champion Opel ADAM: Even more choice, even better connectivity

New Opel ADAM Black Link

The stylish Opel ADAM is not only the individualization champion, it is also the best connected small car on the market. This is again demonstrated by the new Opel ADAM Black Link and ADAM White Link special models, which come with the IntelliLink infotainment system and Siri Eyes Free voice control fitted as standard. Both new models make their debut at the International Motor Show (IAA). Produced in a limited edition of 2,000 units, the Opel ADAM Black Link and White Link variants reflect typical smartphone looks in black or white, with accents in brushed aluminum. They thus embody a perfect blend of ultra-modern infotainment and connectivity technology with clear, technically-inspired design.

New Opel ADAM White Link

In addition, the chic Opel ADAM will strengthen its position as individualization champion over the coming months with more interior and exterior options. New colors for the body and roof, new wheel designs and new décor elements also now add to customization possibilities. In the interior, the ADAM shines with new colors and graphics for the instrument panel, center console and doors, as well as new seat upholstery and additional roofliner designs. All this greatly increases personalization possibilities, enabling ADAM buyers to put together the car of their dreams.

1.0 liter SIDI Turbo with 85 kW/115 hp: New three-cylinder standards

New Opel ECOTEC 1.0 SIDI Turbo

With three all-new engine families and the introduction of 13 new power units through 2016, Opel is also in the fast lane in terms of enhancing its engine portfolio. A newly-designed 85 kW/115 hp three-cylinder SIDI (Spark Ignition Direct Injection) engine now makes its world premiere at the IAA. This 1.0-liter turbo gasoline engine is not only environmentally friendly, it also sets a new benchmark for three-cylinder refinement, with noise and vibration characteristics that are superior to many four cylinder units. This pocket powerhouse also delivers high low-end torque of 166 Nm all the way from 1,800 to 4,700 rpm. It makes its debut with a newly-developed six-speed manual gearbox in the Opel ADAM next year.

Opel Cascada 1.6 SIDI Turbo with 147 kW/200 hp: Pure convertible feeling

One displacement class higher, a high-performance version of Opel’s new 1.6 SIDI turbo engine – delivering 147 kW/200 hp, 300 Newton meters of torque with overboost and enabling a top speed of 235 km/h – makes its world premiere in the Opel Cascada. It is one of an entirely new generation of mid-size, four-cylinder Opel engines using gasoline direct injection. This second, new variant marks the power peak of Opel’s 1.6-liter class engine, and it is the outright torque champion in its competitive field. It joins the 1.6 SIDI turbo with 125 kW/170 hp, which was introduced at the Cascada’s market launch in the spring. 

!NEW! All Aluminum 3 Cylinder Turbo Engine Sets Refinement Benchmark

• New 85 kW/115 hp, 1.0 liter Turbo raises bar for Three-Cylinder refinement
• First in all-new family of small-displacement direct injection gasoline engines to debut in Opel ADAM
• Higher torque, better fuel efficiency than 1.6 liter engine
• Cylinder head-integrated exhaust manifold
• Teamed with all-new six-speed gearbox, 30 percent lighter than predecessor

New Opel ECOTEC 1.0 12V SIDI Turbo gasoline engine

Clean, smooth and quiet: Opel’s all-new three-cylinder will be celebrating its world premiere at the Frankfurt International Motor Show in September. The 1.0 liter turbo gasoline engine is not only climate-friendly, it also represents a new benchmark for refinement in three-cylinder engines, with noise and vibration characteristics superior to many four cylinder units.

Precision engineering is used in the integration of the exhaust manifold inside the aluminum cylinder head, which is bolted directly to the low-inertia, water-cooled turbocharger. This compact installation contributes to the delivery of a fast boost charge for strong, low-end power. Maximum torque of 166 Nm from just 1,800 rpm is almost 30 percent higher than the 1.6 liter engine generates at the same rpm.

Developing 85 kW/115 hp, this pocket powerhouse also delivers high low-end torque of 166 Nm all the way from 1,800 to 4,700 rpm, belying its diminutive size. The 1.0 SIDI Turbo (Spark Ignition Direct Injection) generates more torque throughout its operating range than equally powerful, higher displacement engines, while fuel efficiency is improved by 20 percent compared to Opel’s current 1.6-liter naturally aspirated power unit.

Opel ADAM 1.0 12V SIDI Turbo

To be launched in the Opel ADAM small car next year with an all-new six-speed gearbox, the 12 Valve, 1.0 Turbo is the first in a new, modular family of three and four-cylinder gasoline engines in the up to 1.6 liters class. State-of-the-art technologies such as direct injection, continuously variable valve timing, and a lightweight aluminium cylinder-block, are key efficiency enablers. Opel expects the new engine family to deliver impressive fuel economy and CO₂ emissions significantly lower than 100 g/km.

The 1.0 SIDI Turbo is mated to an all-new, six-speed manual gearbox specially designed for medium torque applications. The new gearbox will be used in a broad range of small and sub-compact Opel vehicles with engines rated at up to 220 Nm torque. With a dry weight of only 37 kilograms, it is about 30 percent lighter than its current counterpart.

“In developing this small engine, we not only set out to minimize fuel consumption and CO₂ emissions, we also wanted to demonstrate that three cylinders can be just as refined as four or more,” says Dr. Matthias Alt, Opel’s Chief Engineer, Small Gasoline Engines. “We tackled at source the balance, noise and vibration issues typical of conventional three-cylinder engines, and we’re confident customers will be pleasantly surprised by the results. This is a very lively and refined three-cylinder engine which doesn’t compromise on driving fun.”

German engineering for class-leading acoustics

Opel engineers started with a clean sheet of paper, which enabled the incorporation of a series of measures to eliminate the typical, ‘off-beat’ running characteristics which have traditionally accompanied the economical driving appeal of three-cylinder engines.

The cylinder block made of high pressure die-cast aluminum is designed to reduce radiated and structure-borne engine noise, as well as reduce weight. The high-pressure fuel rail and injectors are also structurally isolated from the cylinder head to minimize the transmission of pulsing, while the fuel pump and fuel line are acoustically treated.

Another major contributor to refinement is the installation of a balance shaft in the oil sump. Driven by a chain with inverted teeth for quiet running, the counter-rotating shaft spins at crankshaft speed and is carefully mass-optimized to offset the inherent vibrations from a three cylinder operation.

Other noise attenuation measures include: acoustically-optimized covers for the top and front of the engine, the intake manifold and camshaft housings; crankshaft isolation with iron main bearing inserts; inverted teeth for camshaft drive chain; a low-hiss turbo compressor; and a lower oil pan in steel.

As a result of these engineering features, the new 1.0 SIDI Turbo is not only more refined than other three-cylinder engines, but also quieter than many four-cylinder units. For example, in bench testing at full throttle, it emits lower noise levels across all engine speeds than similarly powerful gasoline turbos with 1.6 liters displacement.  Its inherent refinement is so good, that the need for additional in-car sound insulation, or complex engine mountings and sub-frames, is significantly reduced.

Strong power and torque

The 1.0 SIDI Turbo also packs a punch, generating more torque than Opel’s current 1.6 liter, naturally-aspirated engine, as well as the same 85 kW/115 hp maximum power output.

Jewel-like precision engineering is used in the integration of the exhaust manifold inside the aluminum cylinder head, which is bolted directly to the low-inertia, water-cooled turbocharger. This compact installation contributes to the delivery of a fast boost charge for strong, low-end power. Maximum torque of 166 Nm from just 1,800 rpm is almost 30 percent higher than the 1.6 liter engine generates at the same rpm.

The six-hole fuel injectors are centrally located above each piston to provide efficient combustion, and dual cam-phasing enables variable valve timing for optimum engine breathing. A twin displacement oil pump and a switchable water pump, which is disengaged when the engine coolant is cold in order to accelerate warm-up, also contribute to low fuel consumption.

All-new, weight-saving six-speed gearbox

The 1.0 SIDI Turbo is mated to an all-new, six-speed manual gearbox specially designed for medium torque applications. With a dry weight of only 37 kilograms, it is about 30 percent lighter than its current counterpart. It is also extremely compact, measuring just 375 mm along its axis.

Featuring superior shift quality, with a short lever travel and low shifting effort, the new transmission incorporates many of the refinements recently introduced on Opel’s next-generation gearboxes. These include gears with wide, asymmetrically-cut dog teeth, and triple-cone synchronizers for first/second gear, with double cones for third/fourth. Reverse gear is also synchronized.

The new gearbox will be used in a broad range of small and sub-compact Opel vehicles with engines rated at up to 220 Nm torque. For optimum powertrain efficiency in each application, the matrix of gearing choices comprises 12 sets of gear ratios and seven final drives.

Next step in Opel’s powertrain renewal program

The launch of the 1.0 SIDI Turbo and its new six-speed gearbox is the latest step in the   renewal of Opel’s powertrain portfolio, which will see three new engine families and 13 new engines introduced between 2012 and 2016, plus a host of new transmissions.

The program began with the launch of the first engines in new mid-size gasoline and diesel families. These 1.6-liter turbo units are now joined by the 1.0 turbo, as the first example of a new, small displacement engine family.  All will be built at GM’s new Szentgotthard plant in Hungary, where gasoline and diesel engines are produced on a shared assembly line.

New generation Opel power plants are focused on meeting a growing customer demand for ‘downsized’ engines which are able to deliver reduced fuel consumption and CO₂ emissions, in combination with the power and refinement typical of larger displacement engines.