Smooth Operator: Opel Astra with Efficient Stepless Transmission

• Almost infinite: variety of gear ratios optimises efficiency at all engine speeds
• High comfort: Astra’s stepless transmission delivers imperceptible gear shifts
• Perfect match: optimum balance of refinement and responsiveness
• Up to 21 per cent lower CO2: most efficient Opel Astra of all time

With the launch of the new Astra, Opel took the car industry by surprise by introducing a state-of-the-art stepless transmission on the Astra hatchback and estate. The typical smooth power delivery and high efficiency of the stepless transmission is a perfect match for the new generation of the award-winning Opel Astra (European Car Of The Year 2016). In combination with the 107 kW (145 hp) 1.4-litre, Direct Injection Turbo petrol engine (NEDC fuel consumption1: 6.3 l/100km urban, 4.3-4.2 l/100km extra-urban, 5.1-5.0 l/100km and 116-114 g/km CO2 combined), the stepless transmission (aka Continuously Variable Transmission or CVT) brings a refined, frugal and lively power unit to the brand’s powertrain portfolio. With a completely new generation of engines and transmissions, the Opel Astra sets standards for low emissions, putting it at the top of the compact class. This new Astra is the most efficient ever with up to 21 per cent lower CO2 emissions than the predecessor. Five of the seven powertrain combinations on offer even undercut the magical 100 gram mark for CO2 emissions per kilometre driven (NEDC 1).

Smart operating principle: Two pulleys and chain belt instead of gears and clutches

Peter Naumann, Global Program Manager and acting Chief Engineer Automatic Transmissions in Rüsselsheim, explains how stepless transmissions work: “Operating principle is smart and simple. In contrast to a traditional torque converter automatic transmission that has planetary gears, clutches and fixed gear ratios, a stepless transmission has two pulleys connected by a chain belt under tension. Between the outsides of the pulleys, there is a conical shaft, which the chain belt sits on. By continuously adapting the space between the pulleys, you get a variable gear ratio, because the change of the contact surface alters the diameter. This is comparable to transmitting torque from small to big gears and vice versa. Finally, one planetary gear set on the input shaft is still required in order to select forward or reverse driving.”

Due to the almost infinite availability of gear ratios, powertrains with a stepless transmission operate at the most efficient point across all engine speed bandwidths. Peter Naumann: “For each operation point, the transmission enables the powertrain to find the optimum balance of fuel efficiency, attenuation of noise and vibrations, and accelerator pedal responsiveness.”

“Cars with low weight and powertrains producing maximum torque of 230-300 Nm are most suitable for stepless transmissions”, says Naumann. “With 236 Nm of torque and a kerb weight of 1,350kg, the new Astra 1.4 is therefore ideal.”

Great idea: Stepless transmissions in automotive development

Idea of a stepless or shiftless transmission is not new. American engineer Milton Reeves invented a variable speed transmission for saw milling way back in 1879, which he then applied to his first automobile in 1896.

Numerous variations on the stepless-theme followed in the 1920s, on motorcycles as well as automobiles. George Constantinesco, an engineer and inventor from Romania, created one of the most interesting in 1926. The “Constantinesco Car” featured a 5hp engine with an integrated torque converter. According to advertisements, it was the car with “No clutch, no gears, only one control – the accelerator”!

It took until 1958 for the stepless concept to become more widely known. At the Amsterdam Motor Show, DAF presented the 600 small family car with its innovative Variomatic transmission. Designed by Dutchman Hub van Doorne, the Variomatic made the little DAF sedan famous, among other things, for driving backwards as fast as forwards! Thereafter, stepless transmissions appeared on all sorts of machines, from tractors and snowmobiles to motorbikes and all-terrain vehicles, as well as automobiles.

Opel offered its first example in the Vectra C, which made its debut in 2002. However, the career of the “CVTronic” was short-lived, with production at the Szentgotthard factory in Hungary ending in 2005.

Suitable for a variety of vehicles: From small cars and SUVs to vans and hybrids

Today, “stepless” is making a comeback, aided by the increasingly strict global targets for fuel consumption and CO2 emissions. Because stepless transmissions adjust gear ratios continuously, the engine can always run at its most efficient speed, which saves fuel, especially in city driving.

As a result, they are available on a variety of automobiles, such as small cars and limousines, SUVs, minivans and hybrids. However, modern stepless transmissions are notable for more than just their high efficiency. They are also popular with drivers and passengers who appreciate the imperceptible shifting of gears.

Stepless transmissions are already common in Asian markets, where their smooth and quiet performance makes them very popular. New Opel Astra with 1.4 engine and stepless transmission is perfect for customers looking for a compact hatchback or estate car with an automatic transmission that offers not only lower noise and vibrations but also moderate fuel consumption and good responsiveness.

[1] Fuel consumption and CO2-emission data given have been determined according to WLTP test procedure methodology, and the relevant values are translated back into NEDC to allow the comparability with other vehicles, according to regulations R (EC) No. 715/2007, R (EU) No. 2017/1153 and R (EU) No. 2017/1151.

Efficiency champion: New Opel Astra

• New generation engines: for minimum consumption and low emissions
• New emissions standard: all powertrains already meet future Euro 6d
• New benchmark: top aerodynamics for lowest drag coefficients
• New top transmission: efficient nine-speed automatic for five-door and Sports Tourer
• New sport chassis: direct steering, revised shock absorbers, Watts link
• New top technologies: optimised front camera and digital instruments
• New comfort: heated windshield, further improved infotainment, wireless charging
• Proven strengths: Intellilux LED matrix light and AGR ergonomic seats

New Opel Astra

New Opel Astra Sports Tourer

Thanks to excellent aerodynamics as well as highly efficient new engines and transmissions, the new Opel Astra sets standards for efficiency and low emissions. Compared with the previous model, CO2 has been cut by up to 19 percent, putting the Astra at the top of the compact class. Current Astra generation already ushered in a new era at its premiere and was elected European Car Of The Year 2016. With its lightweight design (200 kg lighter than the predecessor) and top technologies from higher classes, the Astra set benchmarks. Opel continues to pursue this strategy with ultra-modern new generations of highly efficient and lightweight petrol and diesel engines. The 1.2-1.5-litre three-cylinder power units produce 77 kW (105 hp) to 107 kW (145hp), making both the Astra five-door and Sports Tourer real fuel-saving and CO2 champions (NEDC fuel consumption: urban 6.1-4.5 l/100 km, extra-urban 4.0-3.1 l/100 km, combined 4.8-3.6 l/100 km, 115-96 g/km CO2; WLTP combined: 5.9-4.4, 139-117 g/km CO2; preliminary figures). A counter-rotating balance shaft in the block of the three-cylinder engines offsets vibrations. Base power units already have a six-speed manual gearbox as standard. A smooth-shifting nine-speed automatic is optional.

Meticulous development in the wind tunnel also made a significant contribution to the reductions in fuel consumption and CO2 emissions. As a result, the new Astra is one of the most aerodynamic compact cars on the market.

At 0.25 Cd, New Opel Astra Sports Tourer belongs to the estate cars with the lowest drag coefficient in the world

At 0.25 Cd, New Opel Astra Sports Tourer belongs to the estate cars with the lowest drag coefficient in the world, while the five-door leads the hatchback class at 0.26 Cd.

New Opel Astra: five-door leads the hatchback class at 0.26 Cd

Aero-benchmarks have been achieved through numerous measures, including an engine compartment cover, deflector-shaped rear axle control arms and a full-face shutter. The upper and lower portions of the new Astra’s radiator grille automatically open and close independently of one another, further improving the frontal airflow. The underbody optimisation improves the drag coefficient by reducing turbulence.

Astra’s dynamic chassis has been further developed. New shock absorbers increase comfort. The optional sports chassis features stiffer dampers, a more direct steering and a Watts link at the rear axle.

“We focussed on reducing fuel consumption and emissions during the development of the new Astra”, said Christian Müller, Managing Director Engineering. “Thanks to the excellent aerodynamics as well as new-generation engines and transmissions, we reduced CO2 emissions by up to 19 percent. That is a huge step to the benefit of our customers, who can also profit from lower running costs. This all puts the new Astra at the top of its class.”

Thanks to state-of-the-art emissions reduction technologies such as Gasoline Particulate Filter (GPF) and diesel Selective Catalytic Reduction (SCR), all the Astra’s new powertrains already meet Euro 6d. The strict emissions standard first comes into force for all new registrations in 2021. The all-aluminium diesel and petrol engines are equipped as standard with fuel-saving stop/start technology.

But the new Opel Astra, which can already be ordered in a few weeks, not only boasts exemplary aerodynamics and engine technology. It also comes with many other top technologies, from the new front and rear view camera to the digital speedometer and the next generation of infotainment. The E-Call emergency call system is also on board. A wireless charger in the centre console for smartphones is optionally available.

New Opel Astra: grille in 3D-look

New Opel Astra front impresses with a grille in 3D-look. And while the interior transforms into a concert hall with the optional high-end Bose sound system, Opel Astra turns heads with the optional High Gloss Black Pack.

Efficiency champions: Up to 19 percent lower CO2 emissions

Low consumption and CO2 figures are also enabled by the modern six-speed manual gearboxes, the seven-speed Continuously Variable Transmission (CVT) and new nine-speed automatic.

New turbocharged petrol and diesel engines, which are as economical as they are lively, are primarily responsible for the exemplary efficiency. Low consumption and CO2 figures are also enabled by the modern six-speed manual gearboxes, the seven-speed Continuously Variable Transmission (CVT) and – for the first time at Opel – a new nine-speed automatic.

New Opel Astra: 9-Speed-AT HydraMatic

Compact, three-cylinder, turbo petrol units are available with 1.2 and 1.4 litre displacements. With power outputs extending from 81 kW (110 hp) to 107 kW (145 hp) and maximum torque from 195 to 236 Newton metres, they achieve an excellent balance between performance and efficiency (NEDC fuel consumption: urban 6.1-5.4 l/100 km, extra-urban 4.0-3.8 l/100 km, combined 4.8-4.4 l/100 km, 110-101 g/km CO2; WLTP2 combined: 5.9-5.2, 136-120 g/km CO2; preliminary figures). Astra 1.2 is combined with a smooth-shifting six-speed manual gearbox while the Astra 1.4 is available exclusively with a new seven-speed continuously variable transmission (CVT). With the CVT, Astra drivers can enjoy the convenience of automatic gear changing or select gears themselves via the shift lever.

Integration of the water-cooled exhaust manifold in the cylinder head contributes to quick engine warm-up, which lowers emissions after a cold start.

New Opel Astra: Three Cylinder 1.2 Direct Injection Turbo

Compared to the previous model, the fuel consumption and CO2 figures of the 77 kW (105 hp) and 90 kW (122 hp) Astra diesels have been reduced by up to 17 percent and around 10 percent respectively.

Instead of the precise, six-speed manual gearbox, the most powerful diesel is optionally available with the seamless shifting of a new nine-speed automatic transmission, which is making its debut at Opel in the Astra.

The diesel engines feature an electrically-activated turbocharger with variable geometry turbine vanes (VGT) and, similar to their petrol counterparts, a balance shaft in the block for additional refinement. Likewise, the exhaust manifold is also integrated in the cylinder head.

Optimum exhaust after-treatment of the Astra 1.5 diesel is delivered by the emissions reduction system consisting of a passive oxidation catalyst, AdBlue injector, SCR catalyst and Diesel Particulate Filter (DPF).

Fully digital: New front and rear view camera, digital speedometer

New Opel Astra: Digital speedometer

Opel Astra already offers a portfolio of state-of-the-art technologies and assistance systems that is unrivalled in this vehicle class – first and foremost the intelligent, glare-free IntelliLux LED Matrix light. The extensive offer also includes systems such as adaptive cruise control, following distance indication, forward collision alert with automatic emergency braking, traffic sign recognition and lane keep assist, to name but a few. Also available are AGR-certified (Aktion Gesunder Rücken e.V.) ergonomic seats with ventilation and massage function. New Opel Astra is also highly digitalised with a new optional high-tech front camera as well as rear view camera.

New Opel Astra: AGR-certified Ergonomic seats with ventilation and massage function.

New front camera is smaller, but more powerful than before thanks to a faster processor. It now not only recognises vehicles, but also pedestrians – an important safety bonus. Furthermore, thanks to the high-resolution camera, traffic sign recognition can now process even more traffic signs and show them as symbols on the display. Digital rear view camera available in conjunction with the new Multimedia Navi Pro infotainment system is also more powerful. View of the traffic behind the vehicle on the monitor is more distinct and precise; the contrasts are more visible in the dark.

Opel Astra customers enjoy top connectivity with the Apple CarPlay and Android Auto compatible systems Multimedia Radio, Multimedia Navi and Multimedia Navi Pro. They belong to the newest infotainment generation – smarter, faster and more intuitive. Top-of-the-line Multimedia Navi Pro – as in the Opel Insignia flagship – has an eight-inch colour touchscreen and can also be operated by voice control. Connected Navigation services with real-time traffic information and online map updates make the journey more relaxed. The navigation display itself appears with redesigned symbols in a fresher, more modern look. The same applies to the instrument cluster: drivers in the new Opel Astra are the first to have a digital speedometer.

Optionally available is the E-Call emergency call function. If needed, help is just seconds away by pressing the red button. If the seatbelt tensioners or airbags are deployed, the system automatically makes an emergency call.

Driving pleasure: Wireless charging and Bose sound system

Comfort is a top priority in the new Astra. A practical feature when travelling: compatible smartphones can now also be charged inductively via wireless charging. All you have to do is insert your smartphone into the opening provided in the centre console – a flat battery is a thing of the past.

The new Astra transforms into a concert hall with the optional Bose high-end sound system. A total of seven loudspeakers including a RichBass subwoofer under the boot ensure optimum listening pleasure. The driver and passengers are surrounded by a rich sound – regardless of where they are in the vehicle. In addition, up to eight different sound profiles can be stored via the digital amplifier – depending on the taste and preference of the music lover.

Last but not least, the new Astra introduces another comfort feature that makes driving in the cold season more pleasant and safer: the heated windscreen. Fine, almost invisible wires in the windscreen ensure that Astra drivers quickly have a clear view of the road on frosty days and that the windscreen no longer fogs up.

New Opel Astra Sports Tourer