Rüsselsheim Engineering Center Develops Next Four-Cylinder Petrol Engine Generation for Groupe PSA

• Innovative four-cylinder petrol engine family for highest efficiency and low emissions
• Market-introduction as of 2022 in China, Europe and North America
• Optimised for use with electric motors in hybrid systems
• Global responsibility for new engine family adds to earlier announced competencies in Rüsselsheim

The Rüsselsheim Engineering Center will take on the global responsibility for the development of the next-generation of high-efficiency petrol engines for all Groupe PSA brands (Peugeot, Citroën, DS Automobiles, Opel and Vauxhall). The next generation of four-cylinder engines will be optimised for operation in combination with electric motors and will be used in the drive train of hybrid systems. Market-introduction will begin in 2022.

The new generation of engines is designated for use in all Groupe PSA brands in China, Europe and North America, meeting the future emission standards of these markets. The power units feature state-of-the-art technologies such as direct-injection, turbocharging and variable valve control. The engines are thus highly efficient and will deliver low fuel consumption and low CO₂ values.

“Rüsselsheim already had global responsibility for engine development when we were still part of GM. With the development of the new generation of four-cylinder petrol engines, we can exploit one of our key competencies. The economic direct-injection, in combination with hybrid technology, will consolidate the strong position of Groupe PSA in lowering CO₂ emissions,” said Opel’s Managing Director Engineering, Christian Müller.

The Rüsselsheim Engineering Center has decades of experience in the construction of efficient petrol engines. The engineers are now developing the new engine generation on the basis of the current Groupe PSA four-cylinder PureTech units. These all-aluminium engine, which have a displacement of 1.6 litres, already convince with a high level of efficiency and direct throttle response – virtues that the successor generation will build upon.

The upcoming four-cylinder units form the second petrol engine family of Groupe PSA from 2022 alongside the well-known three-cylinder PureTech turbo engine that only recently won the “Engine of the Year” award for the fourth time in a row. In addition to the responsibility for the new engine family, the engineering team in Rüsselsheim also leads the development of light commercial vehicles (LCVs) for the entire group. This includes the development of LCV platforms and modules from advanced development to production maturity. Furthermore, Groupe PSA has currently established 15 Centers of Competence in Rüsselsheim – from hydrogen & fuel cell to seat development.

Groupe PSA’s Turbo PureTech petrol engine named International Engine of the Year for the 4th year in a row

Today, the Turbo PureTech 3-cylinder petrol engine (110 hp and 130 hp) was named International Engine of the Year in the 1-litre to 1.4-litre category, for the 4^th year in a row, by the panel of the 20^th International Engine of the Year Awards in Stuttgart.

Groupe PSA has filed 210 patents for its family of 3-cylinder petrol engines. The new‑generation PureTech engine offers improved performance, fuel consumption and efficiency, with specific benefits including:

• a 4% improvement in fuel consumption on average compared with the previous generation;
• improved engine response time thanks to an optimised turbocharger (20% faster increase in torque from 1500 rpm);
• a 75% reduction in particulate emissions through the use of a gasoline particulate filter (GPF), meeting the Real Driving Emissions (RDE) conformity factor of 1.5 set by EU regulations for 2020, three years in advance;
• a more compact structure, to adapt to the new Common Modular Platform (CMP) dedicated to small city cars, core sedans and compact SUVs.

Launched in 2017 on the new Peugeot 308, the new generation is now being deployed on Groupe PSA’s vehicles across some hundred applications in more than 70 countries. The engines comply with Euro 6d-TEMP and China 6b standards.

The PureTech 3-cylinder engine is currently manufactured in France (Française de Mécanique plants in Douvrin, Pas-de-Calais and Trémery, Moselle) and China (Xiang Yang plant). In addition to production capacity being doubled in the French plants in 2018, the plants in Tychy, Poland, and Szentgotthárd, Hungary, will also start producing the PureTech engine in 2019 and 2020, respectively.

On this occasion, Alain Raposo, Senior Vice President, Powertrain and Chassis Engineering at Groupe PSA, said: “We’re proud to receive this prestigious award for the fourth year in a row, as proof of the skills of our development teams. Most of our vehicles are now equipped with this engine, which has been highly successful among our customers. This award is a global recognition of the competitiveness and efficiency of our petrol range, and in particular our PureTech 3-cylinder engine.”

Groupe PSA optimizes its manufacturing base in Europe

• Improving performance of powertrain plants to fulfil orders for future Opel/Vauxhall models based on PSA platforms
• Preparing manufacturing facilities for the ICE energy mix transition as well as the electrification push
• Localising automatic gearbox production to meet shifting customer demand

In order to step up its development and boost its competitiveness in Europe, the Group has decided to:

• Increase the agility of its manufacturing base by producing components as close as possible to car plants,
• Adapt its output to customer expectations, taking into account technological and energy shifts.

These changes are also an opportunity to adjust production capacity for Group engines as the manufacture of Opel/Vauxhall models is gradually ramped up on Groupe PSA platforms and fitted with Groupe PSA powertrains and technologies.

In light of the above, the Group has decided to make three adjustments:

• Increase production of the 3-cylinder Turbo PureTech petrol engine – awarded “Engine of the Year” in its category for three years in a row – as close as possible to car plants. In addition to doubling production capacity in France, compared to 2016, already in progress in Douvrin and Trémery plants, the Group will be producing PureTech engines in Tychy (Poland) and Szentgotthárd (Hungary) from 2019 onwards.
• Increase production of gearboxes from 2019 with the manufacture under license of automatic gearbox in Valenciennes (France), set to reach full potential by 2020, thanks to a strategic partnership signed with AISIN AW. Until now, this component has been manufactured in Japan and China. The Group will also invest to produce additional volumes of manual ML gearboxes in Metz-Borny (France) and MB6 gearboxes in Aspern (Austria), in particular to equip its high-end and light commercial vehicles and serve growing needs driven by production of Opel/Vauxhall cars.
• Prepare the Trémery plant (France) to produce electrical motors from 2019 onwards, before acceleration from 2021 onwards, thanks to the joint venture signed with Nidec. They will support the electrification push, as 100% of the Group’s vehicle range will include e an electrified offering by 2025.

These decisions have been made based on a performance assessment of manufacturing sites and in accordance with the New Momentum for Growth commitments signed in July 2016 by five out of six trade union organisations. The new production allocations also take into account what has been presented to employee representatives as part of the Opel/Vauxhall PACE! plan.

Yann Vincent, Executive Vice- President, Manufacturing and Supply Chain, said: “What will make the difference will be our agility to prepare our manufacturing base to produce components that meet customer needs and respond to the energy shift, creating the conditions for a sustainable future through enhanced performance. Groupe PSA’s 15 component production plants in Europe, located in France, Germany, Austria, Hungary and Poland, are eager to propose the best quality and performance to our customers.”