!NEW! Opel Begins Extensive Powertrain Renewal

Three new engine families, 13 new engines by 2016

Engine portfolio 80 percent new by 2016

New 1.6-liter gasoline and diesel turbo engines deliver class-leading performance

Downsizing for more power, reduced fuel consumption and lower CO₂

Extensive ‘sound engineering’ measures give class-leading refinement

Revised manual gearboxes offer superior shift quality 

CDTI Engine Development in Torino                 

Opel is launching three new engine families and 13 new engines between 2012 and 2016, renewing 80 percent of its engine portfolio. In the same period the company will also launch a host of new transmissions. Opel is beginning the renewal of its powertrain portfolio now, by introducing all-new 1.6 liter gasoline and diesel engines, together with next generation five and six-speed gearboxes. They will be joined by the end of this year by a new small displacement gasoline engine family. All are developed to deliver class leading performance and refinement.

Focused on meeting a growing customer demand for ‘downsized’ engines offering strong power with reduced fuel consumption and CO₂ emissions, the new gasoline and diesel powertrains are being progressively introduced across the Opel product range.

Best-in-class power densities and levels of refinement define both 1.6 liter engine families, while the further improved gearboxes provide a smooth gear shifting quality which matches the benchmarks amongst Opel’s competitors. An all-new six speed gearbox and a new automated manual transmission follow in the near future.

Class leading: All-new  gasoline engine

Featuring Spark Ignition Direct Injection (SIDI), this all-new, four cylinder gasoline engine comes in two configurations. 

New Opel ECOTEC 1.6 SIDI 125 kW (Eco Turbo) engine in Opel Cascada

The Eco Turbo version, delivering 125 kW/170 hp and 280 Nm peak torque, is focused on optimized fuel economy, high low-end torque and outstanding elasticity. 

The Performance Turbo, packing 147 kW/200 hp and 300 Nm peak torque, boasts an exceptional specific power output of 125 hp per liter which is best in class amongst Opel’s competition.

Compared to Opel’s previous 1.6 liter turbo engine, CO₂ emissions and fuel consumption have been cut by 13 percent, while peak power and torque are increased by up to 30 percent. The Eco Turbo’s superb elasticity is demonstrated by a 20 percent improvement in fifth gear acceleration from 80 to 120 km/h, while the 200 hp Performance Turbo adds an even sportier edge to the new engine’s character.

Technical highlights include:

• Class leading refinement: only engine in its class to feature balance shafts for smooth running. Innovative thin wall cylinder block with mass saving, two piece crankcase and diecast aluminum bedplate. Host of ‘sound engineering’ measures for low noise and vibration, including fine tuning for specific vehicle applications.
• Optimum fuel efficiency with minimal emissions: spark plug/fuel injector units centrally located at top of combustion chamber.
• Fast throttle response: dynamic turbocharger boost strategy giving rapid response comparable to twin-scroll design, plus improved packaging. Compressor with low and high-pressure resonators to suppress airborne hiss and pulsation noise.

Class leading: All-new 1.6 CDTI diesel engine

Opel’s all-new, 1.6 liter turbo diesel delivers class leading performance across all key engine parameters. It is launched in the Zafira Tourer and will be rolled out to replace the current 1.7 liter and lower powered 2.0 liter diesel engines in a wide range of Opel models, with even more powerful versions to come.

New Opel 1.6 CDTI ECOTEC Euro 6 engine in Opel Zafira Tourer MPV

Packing 100 kW/136 hp and strong torque of 320 Nm, Opel’s first all aluminum diesel engine boasts an exceptional power density of 85 hp per liter which is unrivalled in its class. Its low fuel consumption and CO₂ emissions are already demonstrated by the Zafira Tourer’s best-in-class figures.

In common with its gasoline counterpart, the 1.6 CDTI benefits from a series of ‘sound engineering’ measures in its design and fine tuning to minimize noise, vibration and harshness. It has recorded the lowest sound ratings in testing with the Zafira Tourer against other vehicles using 1.6 liter Turbo Diesel engines.

With Opel’s BlueInjection Selective Catalytic Reduction (SCR) system or Lean Nox Trap (LNT) technology enabling compliance with Euro 6 emissions standards, the 1.6 CDTI is as clean as a gasoline engine in operation.

Technical highlights include:

• Aluminum cylinder block and bedplate, saving more than 20 kilograms in weight.
• Optimized performance with closed-loop combustion control and multiple fuel injections, up to 10 per cycle, for efficient, clean and quiet running.
• Rapid throttle response with variable geometry, water cooled turbocharger operating at high peak boost pressure of 1.7 bar.
• Lowest internal engine friction rating, switchable water pump and variable displacement oil pump all contribute to fuel economy and reduced CO₂ emissions.   

Enhanced manual and automatic transmissions portfolio
With numerous revisions to internals and the shifter mechanism, Opel’s next generation five and six-speed gearboxes have been benchmarked against competitor offerings for superior shift quality. They are now being rolled out for ADAM, Corsa, Meriva, Mokka, Astra, Antara, Zafira and Insignia models with engines exceeding 130 Nm of torque.

New medium torque 6-speed manual transmission (MT6)

For small and sub-compact vehicles, with engines rated up to 235 Nm maximum torque, Opel has designed an all-new six-speed gearbox. It is significantly lighter than similar gearboxes and incorporates many of the modifications from the next generation units.

 Manual Transmission Automated (MTA)

For the ADAM and Corsa, a new automated manual transmission offering sequential style gear shifting and start/stop functionality, as well as five-speed automatic operation, is under development.

In the longer term, improvements to Opel’s current generation six-speed automatic transmission will be followed by the debut of an all-new, eight-speed transmission. The wider gear spread will enable an average improvement in fuel economy of more than three percent.

Opel presents new midsize gasoline engines at Aachen Colloquium

• All-new family of downsized turbocharged engines
• CO₂ emissions and fuel consumption reduced by 13 percent
• 33 percent higher power and torque
• Class leading refinement

Opel revealed details of its new midsize gasoline engine family at the Aachen Colloquium in Germany. The all-new 1.6 liter, four cylinder, SIDI (Spark Ignition Direct Injection) ECOTEC Turbo engines, which begin Opel’s renewal of its powertrain portfolio, bring significant benefits to the customer in terms of fuel consumption, performance and refinement, while affecting the environment as little as possible. CO₂ emissions and fuel consumption have been cut by 13 percent compared to the predecessor engine, while peak torque and peak power have been increased by up to 33 percent.

The new engine family comprises a 1.6 liter Eco Turbo with 125 KW/170 hp and 280 Nm peak torque, as well as a Performance Turbo variant offering 147 kW/200 hp and 300 Nm peak torque. The 170 hp engine has been developed with fuel economy, high low end torque and elasticity in mind, while the performance of the 200 hp unit makes it the benchmark in its class. The roll out of the new engine family – which has been developed in Ruesselsheim, Germany – will begin in early 2013.

Opel ECOTEC 1.6 SIDI Turbo EURO 6 Engine

“The new midsize gasoline engine family is the first milestone in the fundamental renewal of our powertrain portfolio. Not only do these downsized engines deliver smooth acceleration and strong pulling power, they are also highly refined and environmentally compatible,” says Global Assistant Chief Engineer MGE, Marcel Frensch.

At the heart of the new SIDI ECOTEC Turbo family is an all-new cylinder block able to withstand peak cylinder pressure of 130 bar. Cast iron was selected as the preferred material for the cylinder block in combination with an aluminum bedplate.

Class leading refinement and performance

Opel has designed the new midsize gasoline engine family to be a leader not only in emissions and fuel consumption, but also in terms of refinement and performance.

Key development objectives for refinement were low overall radiated noise and vibration levels, and no unusual sounds. Achieving these goals enabled vehicle integration that can tune primary engine orders in the induction and exhaust systems to meet specific vehicle objectives. The excellent acoustic and vibration performance of the engine is crowned by the cam cover, which is decoupled from the cylinder head via specific fasteners and a sealing system designed for high temperatures, due to the nearby turbocharger.

As a result of these “sound engineering” measures, the customer perceives quiet and smooth idling, no unusual noises throughout the operating range, and a pleasant sound quality even at high speeds and loads.

Balance shafts are industry first for 1.6 liter four cylinder engines

Opel’s SIDI ECOTEC is the only engine in its class to offer balance shafts. The two balance shafts are inserted in tunnels from the rear end of the cylinder block and are driven by an inverted tooth chain. The exhaust side shaft features cast iron gears to reverse rotational direction of the exhaust shaft. The optional system offsets the vibrations inherent in the design of four cylinder engines and thus helps to maximize comfort and reduce noise to a minimum.

Turbocharging for high low end torque

The design and sizing of the turbocharging system plays a key role in enabling downsized engines to deliver excellent performance and drivability, while meeting CO₂ targets.

Smaller displacement engines with high specific torque and boost levels require fast transient response, especially at low engine speeds, in order to be a valid replacement for larger displacement engines. Thanks to its specially designed turbines, the midsize gas engine’s turbocharger provides response that is usually generated by twin scroll turbines on larger engines.

The engine retains the proven concept of a turbine integrated exhaust manifold. This design was chosen instead of a twin scroll concept because of its packaging and manufacturing advantages. Although the turbocharger has identical interfaces, each variant of the new SIDI ECOTEC engine features a dedicated turbo aerodynamic.

The compressors are designed to deliver high low end torque without generating noticeable aerodynamic sounds. Combined with low and high pressure resonators, airborne noises effects like hiss, pulsation and blade pass noise are almost completely suppressed. With additional aspects like air handling, duct design and control strategies for let off noise, the new engine benefits from an aggressive boost strategy without the typically associated turbo related acoustic degradation.

Compared to the predecessor engine the new SIDI ECOTEC turbo delivers a remarkable improvement in elasticity, for example, reducing the time for 80 km/h to 120 km/h fifth gear acceleration by about 20 percent.

Direct Injection for High fuel Efficiency and Performance

In addition to refinement and performance, high fuel economy and low emissions were the main development objectives of the new 1.6 liter engines. Opel’s engineers therefore selected a central direct-injection fuel system, for optimum fuel efficiency and minimal emissions.

The central location of spark plug and injector over the combustion chamber, and their orientation parallel to the crankshaft, forms a compact package with the capability to support homogeneous and stratified engine operation.

The valve train is operated by low friction hydraulic roller finger followers and driven by a timing chain with a maintenance free hydraulic tensioner. Acoustics are further improved by the inverted teeth of the cam drive chain. For mass reduction the midsize gasoline engine features a two piece crankcase design, supported at the lower end by a die cast aluminum bedplate.

The cylinder block is manufactured using an innovative thin wall casting method. This allows the integration of different functional features directly into the raw block and offers potential to reduce production time.

The engine uses a broached press fit between the cylinder block and the bedplate instead of dowels, in order to optimize the main bearing shape as well as its positional accuracy. The structural design considers the engine’s use in a variety of vehicle applications, allowing minimum integration effort and consistent part interchangeability.

The structural benefit derived from the combination of a forged steel crankshaft, optimized main bearing journal diameters, and iron main bearing cap inserts results in minimized noise and vibration at mid and high rpm.

Two different pistons have been designed for the Eco and Performance Turbo engines. Each has a dedicated top land including a small bowl. A cast iron ring carrier adapted to the high cylinder pressures is common to each piston. The PVD coated first piston ring is an additional friction reduction measure.

“Flex Plant” in Hungary is home to the engine renewal

Production of the new 1.6 liter SIDI ECOTEC Turbo engine alongside the other new engine families will be at the Szentgotthárd plant in Hungary and will begin in late 2012. The factory uses the “Flex Plant” concept which enables gasoline and diesel engines to be built on a shared assembly line.

Opel celebrates Four Moscow World Premieres

• Highlight of Moscow Auto Salon: The new Astra J sedan
• Additional  debuts for updated five door and Sports Tourer
• Opel launches powertrain renewal with New Generation SIDI gasoline engine
• Strengthened commitment to Russia as high growth market
  
  

  

  
  
  Opel is for the first time celebrating an automotive world premiere in Russia. At the Moscow International Auto Salon (August 29 - September 9), the unveiling of the all-new four door Astra J sedan is the undisputed highlight of Opel’s show.
  

  Never before has the Opel stand, which is located in Hall 14 and covers an area of 1,750 square meters, been so vast. This is also the place where visitors can see a further two world premieres. For the first time, the Astra five door and the Astra Sports Tourer are being unveiled with their updated and fresh design cues. Added to that is the world debut of the new mid size gasoline engine generation.
  
  
  

  More than a million visitors are expected at the Auto Salon. They will have the chance to see a further two premieres for the Russian market: the Astra OPC with its 206 kW/280 hp engine and the Mokka with which Opel is entering the SUV-B segment as the first German manufacturer. 
  
  
  Astra J sedan as key component of growth strategy
  The sedan is an important addition to the Astra J line-up which is now even more diverse and offers new powertrains and driver assistance systems combined with fresh, sporty design. With its elegant appearance, typical Astra qualities and a large array of technological highlights – some are unique, some are unusual for the segment - Opel´s new compact four-door notchback (length/width/height: 4,658/1,814/1,476 mm) targets customers with high expectations. It has a wheelbase of 2,685 mm and provides generous interior space. The separate trunk offers 460 liters of volume - 90 liters more than the five door model. By folding the 60:40 split rear bench flat the luggage volume can be increased up to a maximum of 1,010 liters.
  
  
  Start of powertrain renewal with High Torque 1.6 liter Turbocharged gasoline engine
  Opel has announced that it is fundamentally renewing its engine range and the first phase of this plan is starting now. Three completely new engine families are in the pipeline. The gasoline turbocharged four cylinder with a displacement of 1598 cc, central direct injection and Start/Stop technology is now the first such engine to be unveiled when it makes its debut in Moscow.
  
  

  

  The new SIDI (Spark Ignition Direct Injection) ECOTEC engine provides an extraordinarily high maximum torque of up to 300 Nm. The production start is scheduled for the end of the year; Russia is expected to be one its biggest markets.
  

  
  

  Russia is third biggest Astra market, high demand for compact sedans

  Russia is of great importance to Opel. After Germany, it is currently the second biggest automotive market in Europe. Last year around 70,000 Opel cars were sold there. This year, from January to July, the Opel brand grew by 29 percent – more than twice as fast as the market. According to predictions Russia is expected to become Europe´s main market with up to 3.4 million total vehicle sales in 2014. Its high growth potential is down to the low average of vehicles per capita. For example, Russia has half as many vehicles per 1,000 inhabitants as Germany. More than half of all cars on Russian roads are more than ten years old. In this high growth market, four door sedans and SUVs are in high demand. Across all segments, more than 60 percent of all sedans sold in Europe are sold in Russia. Last year, in the compact segment 51 percent of customers there opted for a notchback version. As Russia is the third biggest market for the Astra in Europe after Germany and the UK, the Moscow Auto Salon was a natural choice for Opel as the venue to celebrate the world premiere of the all-new sedan as well as the five door and Sports Tourer variants of the new Astra model line-up.

  
  

  The Astra is by far the most successful Opel model in Russia. In the first half of 2012 alone, it managed to increase its compact segment share from 4.4 to six percent.
  
  
  
  

New Generation 1.6 Turbo engines family from Opel

New Generation 1.6 Turbo begins powertrain renewal at Opel

• 1.6 liter Spark Ignition Direct Injection Turbo engine with Start/Stop system
• 13 percent less CO₂ and fuel consumption than predecessor
• High-torque concept maximizes refinement
• Three all new engine families within 12 months

Opel is fundamentally renewing its engine range. Three completely new gasoline and diesel families are replacing the core of the current portfolio. The aim is to take an industry lead, not just with fuel consumption and emissions but with specific torque and noise reduction.

The first new engine to be introduced is a turbocharged 1598 cc, four cylinder gasoline unit with direct injection and Start/Stop. The new SIDI (Spark Ignition Direct Injection) ECOTEC engine will be available in various power outputs and across several car lines. Production at the Szentgotthardt plant in Hungary will begin in late 2012.

Smooth acceleration, strong pulling power, low noise levels and low fuel consumption were the main focus. The emphasis was on torque with the engineers achieving up to 187.5 Nm per liter of displacement – a benchmark for gasoline engines produced in high volume. Maximum torque is up to 300 Nm and is already available at 1,700 rpm. Peak power of up to 200 hp is reached at 4,700 rpm. Compared to the predecessor 1.6 liter turbocharged gasoline engine, fuel consumption and CO₂ have been cut by 13 percent.

The first Opel engine with Spark Ignition Direct Injection technology, the 114kW/155 hp “2.2 ECOTEC Direct” made its debut in Opel’s Signum and Vectra in 2003, succeeded by the Zafira. In 2007, the GT offered the first turbocharged gasoline engine with Direct Injection from Opel, a 2.0 liter unit with 194kW/264 hp. One year later this engine was introduced in the Insignia and was available in the Opel flagship in two variants: 162 kW/220 hp and 184kW/250 hp. The new Astra J OPC will be powered by the latest version of this engine offering an output of 206kW/280 hp.