!NEW! Precise and Comfortable: New Opel Corsa E, the Small Car with High Standards

• Newly designed chassis provides more comfort, pleasure and safety 
• New steering with precise feel for the road, City Mode for maneuvers
• From test track to road: Fifth generation Corsa passes toughest tests

Chassis engineers in charge of developing the fifth generation Opel Corsa have set to themselves the objective of delighting future customers with a driving experience comparable to the one provided by larger, more expensive cars in terms of comfort and precision. They have lowered the center of gravity of the new Corsa by 5 millimeters and completely redesigned its chassis and steering systems. 

“The chassis of the new generation Corsa does not inherit a single component from the previous model. We turned every conceivable setscrew to achieve a better drive experience with new levels of comfort, precision and pleasure. At the same time, we concentrated on finding the optimal balance between enjoyable dynamics and predictable, safest road-handling,” said Michael Ableson, Vice-President Vehicle Engineering Europe. 

New Opel Corsa chassis raises the bar for comfort, fun and safety

In addition to its 5 millimeter lower center of gravity, the Corsa receives a new, stiffer, redesigned chassis. The front MacPherson suspension has a new geometry with new front knuckles which improve the vehicle’s roll behavior, steering response and understeer behavior. A new, reinforced sub-frame increases torsional rigidity, while dual strut mounts provide improved responsiveness on uneven surfaces. Furthermore, the new spring rates and damper characteristics in the front reduce the pitching moment during sharp braking maneuvers. This results in the Corsa remaining controllable in case of emergency braking, even for inexperienced drivers. The rear axle torsion bar has been redesigned too, and an enhanced stabilizer has been added to reduce tilting for a better cornering compliance and stability.

Corsa customers can choose between two chassis set-ups, the standard ‘Comfort’ and the more active and direct ‘Sport’. The Comfort chassis is featured with 14 to 16 inch wheels. The Sport chassis has stiffer springs and shock absorbers as well as a specific steering geometry and calibration for a more direct response. It is optional with 16-inch wheels and comes standard on Corsa models equipped with 17-inch wheels.  

New steering system with numerous innovations

In order to improve directional stability, the Opel engineers changed the mounting points of the rack-and-pinion steering shaft and optimized its geometry. A newly constructed mounting for the steering column saves space which is filled with additional padding material and increases driver safety in case of a collision. Furthermore, the steering column possesses special impact absorbers.

The development of a completely new electrical architecture for the fifth generation Corsa enables a more sophisticated level of interaction between its various systems. An optimized software for the electrical and speed-dependent power steering adds additional possibilities. For instance, all new Corsa are equipped with a new standard ‘City’ steering mode that allows reducing steering effort at low speeds for easing maneuvers. The City mode is activated at the press of a button located on the center console.

Furthermore, the active cornering component of the Corsa’s steering aids the driver in crosswinds and on convex roads. Amongst others, the software is fed with the data from the ninth generation Electronic Stability Program (ESPPlus). This system contains no less than eleven different functions, including, for example, the new Hill Start Assist (HSA).

Elsewhere, the fifth generation of the Opel bestseller can be fitted with an Advanced Parking Assistant (€580 including VAT). This system recognizes parallel and perpendicular parking spaces and takes over the steering, meaning that the driver only has to control the pedals.

Well-rounded: Brakes and wheels

The base new Corsa comes with 14-inch steel rims and 185/70 tires. In combination with a turbocharged engine (1.0 Turbo, 1.4 Turbo and 1.3 CDTI), the new Corsa is always fitted with 15-inch or bigger wheels. However, the Opel bestseller can optionally be ordered with 17-inch rims and 215-wide tires. The standard Tire Pressure Monitoring System (TMPS) display warns the driver in the event of excessive pressure loss in one of the tires.

The braking system consists of ventilated front and solid rear discs which can easily cope with high stress. The pedal feel is distinguished by the exactly defined pressure point and excellent controllability. The braking systems is assisted by electronic aids that permanently receive information for the ABS/ESP sensors. For example, the systems recognizes if the braking maneuver is being performed while cornering and distributes the braking force to all four wheels depending on the load. 

A car’s life in high speed: Fifth generation Opel Corsa at the test center 

The engineers in Opel’s Test Center in Dudenhofen have tested the new generation Corsa extensively over thousands of kilometers before allowing it to be presented to the customers. The Opel Development Team pushed the new Corsa to its limits during the tests: the development prototypes had to master 40,000 kilometers on the torture track, the high speed circuit and in hilly terrain, equivalent to 160,000 kilometer on “normal” demanding roads. Within only 24 weeks, these development prototypes are put through burdens that a production car would normally only encounter during its entire life cycle.

The new Corsa was asked to prove its resilience time and time again on the torture track. The track delivers exactly what its name promises: more than 900 meters of potholes, humps, the “washboard“, a cobbled section and a pavé track. It’s a really tough test for the chassis, which will most probably never go through such torture in real life – but the Corsa mastered it comfortably. To put the steering, transmission and brakes to the test, the new Corsa also successfully completed the hill track many thousand times. 

On Dudenhofen’s 40-degree banking circuit without lateral forces engineers can test the stability at high speed. Another circuit that is used during the testing procedure has rising and falling gradients, ranging from eight to 30 percent, with different road surfaces and a serpentine section including hairpin turns – similar to conditions found in alpine mountains. 

The endurance test, which all new Opel models are put through, was decisive for the new generation Corsa. The longest track at the test center offers many different road surfaces including asphalt and cobblestones, bumps and numerous curves. Here engineers test if the performance and quality they fine-tuned and approved in the development vehicles have been successfully transferred to the production vehicles. This final quality control ensures that any minute disturbances or doubts are erased, thus guaranteeing that the new Corsa reaches the customers perfectly aligned with the stringent performance and quality targets set at the beginning of its development.

!NEW! Opel Cuts Consumption with Ultra-modern Radiator Shutter

• Drag reduced by up to ten percent, fuel consumption by up to five percent
• Active full-face shutter enables highly efficient driving in real-life conditions
• Portfolio of affordable emission cutting technologies instead of single-solution focus

Active full-face shutter closes when the engine needs little cooling, thus improving aero performance and reducing C02 emissions

Opel is continuously improving the efficiency of its conventionally powered vehicles and thus reducing its fleet CO2 emissions. The next step of this strategy is the development of an innovative active full-face shutter. Michael Ableson, Speaker of the Management Board Adam Opel AG and Vice President Vehicle Engineering, presented the shutter at this year’s Aachen Colloquium, the largest automotive and engine technology congress in Europe.

Mike Ableson, Speaker of the Management Board Adam Opel AG and Vice President Vehicle Engineering, presented the ultra-modern radio shutter at this year’s Aachen Colloquium

“We are serious about reducing CO2 emissions. Electric cars are part of that effort, but instead of focusing on a single solution, we aim to meet our responsibility for protecting the climate and satisfy our customers with a portfolio of more affordable technologies,” said Ableson.

One of the technologies under development at Opel is an evolution of the so-called active aeroshutter in the cooling air opening. Active shutters improve fuel efficiency by automatically closing the frontal opening when cooling air is least needed. When closed, the shutter system enhances aero performance by redirecting airflow around the front of the vehicle and down the sides, rather than through the less aero efficient engine compartment. The shutter is open or closed depending on engine coolant temperature and speed. For example, the shutter opens when the car is traveling up a hill or in hot city driving. The shutter closes at highway speeds when less engine cooling is required.

While most cars today still have frontal cooling openings that are permanently open, Opel introduced an active partial aero shutter back in 2010 that cut the CO2 emissions of the Astra ecoFLEX to only 99 g/km (New European Driving Cycle combined). In the meantime, the company has rolled out this technology to additional carlines such as the Insignia and the Zafira Tourer.

Opel is now developing a new full-face active shutter, which further improves fuel efficiency by closing the top of the grille as well as the bottom.

By combining thermal, electrical and aerodynamic considerations, intelligent control strategies for opening and closing the upper and lower portions of the grille – even independently from each other – can enable highly efficient driving under a variety of real-life conditions. For example, the primary benefit of improving the aerodynamics of the car can cut total drag by up to ten percent, which consequently results in a reduction in fuel consumption of around two percent in the NEDC, or up to five percent when driving at 130 km/h.

The full-face aero shutter also delivers thermal advantages by delaying cooling down after switching off the engine, or by accelerating the engine warm-up after a cold start, which especially in winter provides significant benefits in fuel consumption and cabin heating comfort.

“The full-face active shutter perfectly suits our exciting, approachable, German brand character”, says Martin Holzhofer, director of Opel’s CO2 engineering center. “It is the first in a series of new highly efficient, affordable technologies with which we aim to cut further the emissions and fuel consumption of our future automobiles.”

Despite the apparent simplicity and logic of the solution, the full-face active shutter represents a significant challenge for designers and engineers: they need to consider numerous factors, including not only styling, packaging, and pedestrian protection, but also insurance ratings, engine and transmission types, their corresponding thermal management and, of course, cooling requirements.

Opel plans to introduce its first active full-face shutter in the near term, on an all-new model. The rollout of additional climate-friendly technologies will follow in its slipstream.

!NEW! Opel Builds Center for Engines of the Future

• Automaker investing 210 million euros in Rüsselsheim
• State-of-the-art facilities to develop and test clean engines
• 43 modern performance test benches available by 2017
• Hesse’s Minister for Economic Affairs Tarek Al-Wazir at groundbreaking ceremony

Opel starts major construction project at its Rüsselsheim headquarters: The company continues its investment offensive, allocating 210 million euros to the construction of a complex of buildings – the tallest seven stories high – on the south-west sector of the International Technical Development Center (ITDC) premises. On a total building surface area of around 36,000 square meters, from 2017 engineers and technicians will develop the powertrains of the future. The new center will also house 43 newest-generation performance test benches.

The groundbreaking ceremony for the major project took place on Monday. Manning the shovels were CEO Dr. Karl-Thomas Neumann, Head of Opel Works Council Dr. Wolfgang Schäfer-Klug, Vice President of the GM Powertrain Division Steven Kiefer, Opel Board Member for Engineering Michael Ableson, and two high-ranking political guests: Hesse’s Minister for Economic Affairs Tarek Al-Wazir and Rüsselsheim’s mayor Patrick Burghardt.

“With this investment we very clearly show: Opel is back. Opel is on the attack,” said Karl-Thomas Neumann. “Our model offensive is in full swing – and engines are a very important part of this offensive.”  

The construction project is part of the investment announced last year that earmarks 230 million euros for new testing and engineering facilities at the ITDC and at the Test Center Rodgau-Dudenhofen. The lion’s share of that, 210 million euros, is being invested in the Rüsselsheim site. The complex will cover an area of around 13,000 square meters south of the railroad tracks and west of Portal 45 in Rüsselsheim, parallel to the Rugbyring. This is the largest building investment in Rüsselsheim since the opening of the new production plant in 2002.

The site is embedded in the engineering network of the GM Powertrain Organization. Due to internationally synchronized test methods and software, findings can be optimally analyzed and implemented. Steven Kiefer, Head of GM Powertrain, said, “For us, Rüsselsheim is the center for the development of small and mid-size gasoline engines. We rely on internationally-networked German engineering and with the construction of this new site, we create optimum working conditions for our experts.” Kiefer continued, “Important new engine generations will be created in Rüsselsheim, including their applications for all markets where GM is present. The new facilities meet globally uniform technical standards and increase the flexibility, development speed and efficiency of the entire group.”

A new building as symbol for the engine offensive

The construction project in Rüsselsheim is a visible sign of the Opel engine offensive. To 2018, Opel will introduce 27 new models and 17 new, economical engines to the market. With the refreshed product portfolio, market share in Europe is to be substantially increased to 8 percent by 2022. Board Member for Engineering Michael Ableson, said, “We are looking at the whole diverse variety of future propulsion technologies that are more economical and environmentally friendly. The combustion engine maintains an important role, as it still has a lot of potential. As one of the pioneers of clean propulsion, it is Opel’s goal to not only undercut the future stringent CO2 barriers, but to also ensure driving fun and best performance at the same time.”

Head of Works Council Schäfer-Klug said: “As employee representatives, from the very beginning we advocated investment in, preservation and expansion of engineering jobs. So I am delighted that we are laying this foundation stone today. It is more proof of growth and job security at Opel.”

Hesse’s Minister of Economic Affairs Tarek Al-Wazir praised Opel‘s commitment to the region: “I am sure that fuel consumption and CO2 emissions of engines will always be important to customers. Therefore the new development center for efficient engines is a smart, climate-friendly investment. I am pleased that Opel invests a three-figure million amount in these future technologies here in the Rhine-Main area”.

And Rüsselheim’s mayor Patrick Burghardt also sees the engine building complex as a sign of a new start for the city: “A new site of this size has not been built here in a long time. Rüsselsheim and Opel – this is not only a long, rich tradition, it is also a clear prospect for the future.” 

!NEW! Opel extends engagement for Formula Student

• Four teams supported by Opel get an Ampera as team car for the racing season
• Team Fast Forest from Hochschule Deggendorf joins the Opel family

Engagement for the Formula Student international racing competition: The Opel board members Mike Ableson, Vice President Engineering, and Johan Willems, Vice President Communications, handed over four Opel Ampera to the teams supported by Opel

Opel extends its engagement for the Formula Student international racing competition. The Opel board members Mike Ableson, Vice President Engineering, and Johan Willems, Vice President Communications, handed over four Opel Ampera to the teams supported by Opel. Each car proudly carries the individual logo of the team and the university. Opel also announced that it welcomes Fast Forest team from Deggendorf University as new member of the Opel Formula Student family.

Mike Ableson explained the importance of the Opel engagement: “Support for Formula Student teams is an investment in our own future. The students experience similar engineering and manufacturing challenges like in real automotive business. It challenges the team members to go the extra step in their education by considering production and manufacture as well as the economic aspects of the automotive industry. It’s a complete engineering development lifecycle that has to be covered over just one racing season!”

The idea of the Formula Student competition is that the teams take on the assumption that they are a manufacturer developing a prototype to be evaluated for production. The racecar must show very good driving characteristics such as acceleration, braking and handling. It should be offered at a very reasonable cost and be reliable and durable. The German SAE association (Verein Deutscher Ingenieure, VDI) is patron of the Formula Student competition in Germany.

Ableson also talked about the kind of support Opel is offering to the teams: ”Opel supports each team according to the particular philosophy of the team. The support varies from manufacturing of parts and components, use of the test tracks at the Opel Test Center Rodgau-Dudenhofen and comprehensive engineering advice, to public and media events, with the teams as brilliant and congenial brand ambassadors.”

The Opel teams demonstrated real team spirit when the Fast Forest team from Deggendorf was hit by the catastrophic flood last year. Together with Opel they helped to enable the Deggendorf team participate in the central event in Hockenheim. Inspired by that Fast Forest achieved one of their best performances ever.

As a team-car the Opel Ampera not only fits best with the Formula Student e-racing intention, but also provides practical advantages for the teams regarding daily operations: most of the time the car will be driven in battery mode. In addition the range extender technology also allows longer distance drives to the Formula Student events in Europe like Silverstone and Hockenheim and further events in Austria, Hungary, Czech Republic and Italy. Support for Formula Student teams is a worldwide initiative of General Motors. It’s a long lasting tradition that US-Teams supported by General Motors like MRacing from the Michigan University (Ann Arbor) participating in the central German racing event in Hockenheim are hosted by the Opel teams. The Hockenheim event will take place from July 29 to August 3.

The teams supported by Opel are:

TU DART Racing (Darmstadt Technical University)              dart-racing.de
Scuderia Mensa (University Rhein-Main)                               scuderia-mensa.de
HAWKS Racing (Hamburg University)                                  hawksracing.de
Fast Forest (Deggendorf University)                                      fast-forest.de

!NEW! Opel and UR:BAN: Making urban driving safer and more efficient

• Cognitive assistance systems increase safety
• Networking of vehicles and infrastructure in urban traffic
• Urban-appropriate human-machine interaction

Smart intersection: Car-to-X information about the phasing of traffic lights and the traffic situation, sent to the car via Wi-Fi from the traffic management infrastructure and other vehicles, can help to generate recommendations for driving at intersections. Communicated to the driver via an intuitive human-machine-interface, this information can enable the driver to approach and cross the intersection comfortably, safely and energy-efficiently, preferably without stopping.

Driving a car in towns or cities means a coexistence of various road users and means of transport. It also means coping with a complex traffic situation and a high density of activities.

Expert teams at Opel developing innovative assistance systems to increase efficiency and safety in urban transport are participating in the UR:BAN research project (user oriented assistance systems and network management). The goal of the partly German government funded project is to provide drivers of passenger cars and commercial vehicles with forward-looking support, tailored and customized to driving in urban traffic. Thirty-one partners from the automotive industry, electronics and software companies, together with research institutes and local authorities, are developing intelligent assistance and cooperative traffic management systems.

The results and findings obtained so far were delivered today in the UR:BAN mid-term presentation at the Deutsche Zentrum für Luft - und Raumfahrt e.V. (DLR – German Center for Air and Space Travel) in Braunschweig, Germany.

The on-going, until 2016, UR:BAN research project, is divided into three pillars: "Cognitive Assistance", "Networked Traffic System", and "Human Factors in Traffic". "Opel is a partner in all three project pillars", explains Michael F. Ableson, Member of the Management Board and GM Europe Vice President, Engineering. "The focus is always on the human being. Teams of engineers, physicists and traffic psychologists are exploring assistance in difficult situations, the intelligent networking of vehicles and infrastructure, driver behavior, and the appropriate human-machine interaction for urban driving."

Cognitive Assistance - Collision avoidance by evading and braking

Especially in urban traffic, difficult situations can occur where the driver may not react in time. This is where the sub-project "collision avoidance by steering and braking" comes in. The Opel team is developing an advanced driver assistance system that takes advantage of the extra road space created by steering intervention to implement an additional situation-specific evasion. This system should help avoid collisions with vehicles and pedestrians in inner-city traffic.

At the mid-term presentation, Opel will show a demonstration vehicle equipped with advanced camera and radar, complemented by modified braking and steering systems, which allow an intervention in the control over the vehicle. Consideration of the driver’s reaction represents an important criterion for the optimization of the intervention strategy. In addition, Opel will integrate the latest findings of human-machine interaction and driver intention detection in the demonstration vehicle.

Networked Traffic System - Smart intersection

Information sent to the vehicle via Wi-Fi from the traffic management infrastructure and other vehicles can help to generate recommendations for driving at intersections, which an intuitive Human-Machine-Interaction  (HMI) can communicate to the driver. This could enable the driver to approach the intersection comfortably, safely and energy efficiently and preferably cross without stopping. This optimization and the further development of car-to-X technology specifically for driving in an urban environment is presented within the framework of UR:BAN.

HMI display in Opel Insignia - Optimized speed for approach he intersection comfortably, safely and energy efficiently and preferably cross without stopping.

In this part of the project, Opel is building on many years of experience in the field of car-to-X communication, as shown in projects such as the successfully completed SIM-TD field test. A networked traffic system and cooperative driving will enable the future step from the mere exchange of information to the joint action of all relevant actors.

Human Factors in Traffic – The appropriate HMI for urban driving

Within UR:BAN, an Opel team is working on improving technical systems. However, the information gained by the new technical systems can only improve driving and safety when drivers also know how to deal with the newly won information and how to react correctly. The focus of the sub-project “Human-Machine Interaction” (HMI) therefore is the way humans experience the behavior of driver assistance systems. In the foreground is interdisciplinary teamwork, with psychologists, engineers and physicists collaborating on the development and implementation of new technology elements to communicate with the driver.

Important questions addressed here include what information content do drivers need in order to follow a driving strategy; or what forms of representation motivate drivers to use a system; and how to avoid driver distraction. The experts test the influence of the assistance systems in various simulators and in real traffic, under controlled conditions.

The evaluation of the objective and subjective data provides the basis for the evaluation of system design and layout. Assistance systems that optimally support the user in his driving behavior are then integrated, in close cooperation with the other sub-projects.

Human Factors in Traffic - Behavior prediction and intention recognition

Understanding driver behavior can help to optimize the warning strategy of the man-machine interface of assistance systems. Opel’s target in the sub-project "behavior prediction and intention recognition" is therefore to develop an algorithm to detect driver intention using standard vehicle sensors. This allows a prediction of driver behavior in difficult driving situations.

The algorithm should identify, at an early stage, future avoidance maneuvers or emergency braking situations. Extensive testing and test data records show that, before maneuvers begin, specific behavior patterns and characteristics in the transverse and longitudinal guidance of the vehicle show up with all drivers. More than 50 volunteers completed a specific drive route under controlled conditions, where they encountered unexpected situations and the resultant maneuvers.

Based on the tests, the Opel team expects to predict whether the driver can mitigate an emergency situation through steering or braking. This information can help to adapt appropriate warning and intervention strategies beneficial for the sub-project "collision avoidance by evading and braking". If the system detects that the driver alone can mitigate a difficult situation, it can delay or suppress a driver warning.

!NEW! Pioneering climate friendliness: 25 years of catalytic converters at Opel

• Opel first European manufacturer to install catalysts on entire range as standard
• Commitment to environmental leadership, emissions lowered by over 90% in 25 years
• Never so clean: Converters today complemented by more efficient powertrains

Catalytic converter technology 

When Louis R. Hughes took over at the helm of Opel in April 1989 – 25 years ago this month – he was faced with a myriad of tasks, but his attention immediately turned to catalytic converters. His first decision also became a first for any volume European manufacturer: the entire Opel gasoline range would be fitted with catalytic converters as standard.

The measuring procedure: On the exhaust test rig, the engineers at the Technical Development Center investigate exhaust emissions from various engine concepts. The closed-loop catalytic converter reduces pollutants to about one- tenth of the previous amount. 

By mid-1989, 19 of every 20 gasoline-powered Opels sold had a converter installed as standard, proving that Hughes’ decision, spurred by environmental concerns and tax incentives, and not a little business acumen, was timely.

Catalytic converter for everyone: From 1989 on, the Opel bestsellers Corsa and Kadett also featured a catalytic converter as standard

Today, emissions have been reduced drastically – to less than 10 percent of pre-catalytic converter levels – and Opel is committed to lowering them even further: “We are at the forefront of developing environmentally friendly technology to reduce the carbon footprint of our automobiles. This is not only being done through constantly improving our catalytic converter technology, but also by developing clean and efficient engines,” says Michael F. Ableson, Vice President GME Engineering. “Between 2013 and the end of 2016, Opel will bring in three fully new engine families and 13 new variants including numerous frugal derivatives with even lower emissions. Additionally, the company is proactively rolling out products that go over and above compliance with legal requirements.”

The rationale behind the decision

Andreas Dindorf, Engineering Group Manager, Product Regulations, explains why the decision was taken to install catalytic converters as standard in 1989: “Cars equipped with converters were environmentally friendly and customers benefited from tax breaks. Additionally, since we are part of General Motors, we leveraged the know-how and technologies used for the U.S. – which required converters – and therefore were better prepared to take the plunge.”

As early as 1984, Opel was working on the project and was the first volume manufacturer in Europe to introduce a European-made catalytic converter on a 1.8 liter Opel Ascona made for the German Police and handed over on December 7 that same year.

First volume manufacturer in Europe with a European-made catalytic converter: The first car featuring this, a 1.8-liter Opel Ascona made for the German Police, was delivered on December 7, 1984.

This was more than a PR stunt. By the end of 1984, Opel had committed 1,000 employees to work on catalytic converters and invested a staggering DM1 billion, more than €500 million. Previously, modified U.S. converters were imported into Europe. GM, Opel’s parent company, was the biggest manufacturer of converters at the time.

A step ahead – from Euro 0 to Euro 6

“We have made evolutionary steps in the way converters are designed to ensure maximum environmental protection,” said Staff Engineer, Engine Management Systems (EMS) Components, Roland Maucher. “Diagnostics have also improved considerably and today sensors are placed on either side of the converter to ensure the system is functioning properly. Another significant change was to integrate the converter with the exhaust manifold, making it far more efficient. Opel is committed to environmental leadership.”

Green fleet: From 1989 on, Opel introduced the catalytic converter in all gas-driven models as standard

Environmental awareness started gaining traction in the 1980s, leading car manufacturers, such as Opel, to take a decision that has since prevented billions of tons of pollutant gases from entering the atmosphere. Converters were made obligatory in the EU in 1992. The reduction in emissions from the initial Euro 0 level to Euro 6 is staggering.

Strong and clean sports coupé: The Opel Calibra built from late 1989 was also equipped with a catalytic converter as standard

“Emissions regulations started being introduced in the 1970s, but the biggest impact was felt in 1992 when Euro 1 became effective. At that time, having a catalytic converter was not obligatory and depended on various factors,” he says.

Diesel offensive: The particulate converters are coming

Diesel offensive with particulate converters: In 2005 Opel introduced particulate filters for diesel-powered cars across the range, cutting particulate emissions to almost zero. This was done four years earlier than the 2009 Euro 5 requirements.

Euro 4 became mandatory in 2005, the same year Opel introduced particulate filters for diesel-powered cars across the range, cutting particulate emissions to almost zero. This was done four years earlier than the 2009 Euro 5 requirements. Opel has begun production of two new systems – the Lean Nox Trap (LNT) and the AdBlue Selective Catalyst Reduction (SCR) system, both of which reduce nitrogen oxides (NOx) from exhaust gases. The results have been staggering: Effectively, the emissions of one diesel-powered car in 1992 is equivalent to 140 diesel cars in 2014.

“This year, Euro 6 standards become effective on new models and provide for further incremental reductions. With Euro 6, emission limits for diesel and petrol cars will be similarly tough. The focus of regulations is clearly shifting towards more stringent testing and tighter diagnostics requirements. We are now entering a new phase,” Dindorf says. “It’s no longer the case of whether cars are clean or dirty – they are all relatively speaking clean, and being made cleaner.”

The future will bring even further tightening through a new testing protocol. “We now expect a new test cycle, the World Light-duty Test Procedure, to be introduced. Additionally, we will eventually see the start of additional testing requirements on Real Driving Emissions (RDE), whereby mobile equipment will be used on cars on the road to check emission standards” Dindorf explains.

More efficient powertrains

“It is not only a matter of dealing with exhaust gases after they leave the engine “ says Dr Maucher, “but also reducing the amount of gases produced by the engine in the first place. Improved efficiency reduces so-called ‘engine-out’ emissions, so our engineers are putting a great deal of effort into making the combustion better and more effective.”

Between 2013 and 2016, Opel is renewing 80 percent of its engine portfolio, with three new engine families and 13 derivatives. This includes new families of powerful yet frugal 1.6 liter gasoline and diesel engines with lower CO2 emissions. Additionally, a new standard-setting 1.0 liter three-cylinder gasoline engine will be introduced this summer.

The new generation four-cylinder 1.6 ECOTEC Direct Injection Turbo gasoline engine is focused on optimized fuel economy, high low-end torque and outstanding elasticity. Compared to Opel’s previous 1.6 liter turbo engine, CO2 emissions and fuel consumption are 13 percent lower, while peak power and torque are up to 30 percent higher. The new Cascada mid-size convertible was the first Opel model available with this new engine, which now also powers the Astra, Astra GTC, and Zafira Tourer.

Opel ECOTEC 1.6 Direct Injection Turbo - New gasoline engine

Opel’s all-new 1.6 CDTI Turbo diesel engine delivers class-leading performance across all key engine parameters. It was launched in the Zafira Tourer and is now already available in the Meriva and Astra. Both Opel’s BlueInjection Selective Catalytic Reduction (SCR) system in the Zafira Tourer and Lean Nox Trap (LNT) technology in the Meriva and Astra are Euro 6 compliant, making the 1.6 CDTI as clean as a gasoline.

All-new Opel ECOTEC 1.6 CDTI - Euro 6 Turbo diesel engine

The new ADAM ROCKS and the ADAM will be the first Opel models to feature the new generation 1.0 ECOTEC Direct Injection Turbo three-cylinder gasoline engine. This “pocket-powerhouse” already complies with Euro 6 emission standards and raises the bar for three-cylinder engine refinement.

Opel ECOTEC 1.0 Direct Injection Turbo - Three-cylinder gasoline engine

!NEW! Opel ADAM Saves Raw Materials and Energy

• Eco angel: 170 Opel ADAM components are recyclates
• Climate savers: Recycled materials account for 30 percent lower CO₂ emissions
• Trendsetter: Since 1990 – committed to recycling; today – an industry leader

Eco angel: 170 Opel ADAM components are recyclates.

85 percent of every new vehicle must be recyclable, according to the EU End of Vehicle Life Directive. And this guideline will become even more stringent: from 2015, 95 percent of all new vehicles’ overall weight must be recyclable. Opel is ideally equipped to meet this strict directive, as the Rüsselsheim automaker has been working with recyclate components since 1990. Initially four approved recyclate types were used in the Opel Calibra – today 200 are used across the model portfolio. This enables Opel to use a total of 45,000 tons of recyclates in new vehicles every year.

1990- Recycled materials on Opel Calibra

In the stylish Opel ADAM, a potentially record-breaking 170 components made of recycled materials are used. This is in perfect harmony with the urban lifestyle car that saves resources thanks to its small size, low fuel consumption and high number of recyclate components. This also means that the eco angel’s environmental footprint is already reduced during its production, which takes place in Opel’s Eisenach plant. And that is another special ADAM characteristic – it is the only small car from a German manufacturer that is also built in Germany. The pressures and temperatures required for processing pellets made from recycled materials are lower than when using new materials. The energy this saves leads to 30 percent lower CO2 emissions.

Easy assembly: Recyclates may even be superior to new plastic products, as they are less prone to warp and expand or contract.

The raw materials for the headlight housings, bumper mounts and water deflector between the engine compartment and splash wall are all made from recycled plastics. Plastic bottle tops are the basis for such unmixed, pure pellets. High-tech components are then created from these black pellets, for example in a plastic injection molding process. Recyclates may even be superior to new plastic products, as they are less prone to warp and expand or contract. In the Opel ADAM, even the inlet manifold is a recyclate. It is extremely durable, holding up under temperatures ranging from -40° up to +200° C during exhaust gas recirculation.  Further benefits of recycled materials include their vibration behavior (low risk of breakage), their UV resistance and the fitting accuracy of the components created from them.

Trendsetter: Uwe Ruster, Opel Lead Engineer Recycled/Sustainable Materials, presents a water deflector made from recycled plastics.

"Today Opel is an industry leader in the development and use of recyclates that are produced by suppliers who meticulously follow our guidelines. We use recycled plastic where it makes technical sense. In this way we save raw materials and energy, and reduce our environmental footprint without the slightest technical disadvantage," says Michael Ableson, Vice President Engineering, explaining Opel's sustainability concept

!NEW! Opel Insignia OPC: World Premiere for the Ultimate Opel Powerhouse

• Bold appearance: New design combined with characteristic OPC elements
• Ultra-modern technology: Modified chassis for even more driving fun
• Detailed readouts: Instrument display with specific engine information

  New Opel Insignia OPC Sports Tourer

With 239 kW/325 hp and 435 Nm maximum torque, the Insignia OPC is the ultimate top-of-the-line performer among Opel models. The all-wheel drive model makes its debut with a new, refreshed look and modified chassis at the International Motor Show (IAA) in Frankfurt (September 12 – 22).

Opel ECOTEC 2.8 V6 Turbo engine with 239 kW/325 hp and 435 Nm max. torque

“The Insignia OPC dazzles with new radiance,” says Michael Ableson, Vice President GME Engineering. “With great attention to detail, our engineers have given it some decisive fine-tuning. This is evident in its design and in its even better driving performance. This puts the OPC squarely in the first league of mid-size series production sports cars.”

Attention to detail – inside and out
The new Insignia OPC impresses at first glance. 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.

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 Opel 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.

With six-speed manual transmission and all-wheel drive, the 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.

New Opel Insignia OPC - Brembo brakes

In addition, the Insignia OPC benefits from its electronically controlled 4x4 system. The all-wheel drive system incorporates a high-quality clutch, operating on Haldex principles, and an electronic limited-slip differential to ensure superb traction. It constantly adapts to prevailing road conditions and varies torque distribution seamlessly from zero to 100 percent between the front and rear axles, as well as between the rear wheels. In combination with the electronically controlled FlexRide premium chassis, the all-wheel drive system sets standards in terms of reaction time and vehicle control.

New Opel Insignia OPC - FlexRide (active chassis) OPC mode button 

Motorsports feeling flows into interior
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 is hiring 350 Engineers

ITDC will be enhanced and get additional responsibilities in the global network

Mike Ableson, Vice President Engineering and Member of the Board at press conference 

Opel is hiring 350 engineers in order to support the brand’s ongoing product offensive. 300 of them will be hired to work at the International Technical Development Center in Rüsselsheim, the Torino Engineering Center is looking for 50 new engineers. New hires at ITDC Rüsselsheim will be in vehicle engineering as well as in powertrain engineering. Therewith Opel strengthens the role of the International Technical Development Center (ITDC) in Rüsselsheim with currently more than 6,000 employees.

At today's press conference Mike Ableson, Vice President Engineering and Member of the Board, announced that Opel is hiring 350 additional engineers. 300 of them will be hired to work at the Internationel Technical Developement Center in Rüsselsheim, the Torino Engineering Center is looking for 50 new engineers

The main areas of hiring are simulation, validation, construction, cost engineering and accessories engineering. For powertrain Opel is mainly looking for experts in the areas of engine and transmission engineering and calibration. The hiring process has already started and will be finalized by the end of the year.

"This is not only an evident proof that Opel/Vauxhall is taking the realization of its product offensive seriously. It is also another sign from General Motors that our parent company values German engineering and so the German ITDC is taking on more work in order to support Opel and Europe," said Michael Ableson, Vice President Engineering and Member of the Board. "By doing that we are securing the long-term importance of the ITDC as an integral part of GM's global engineering network."

Mike Ableson, Vice President Engineering and Member of the Board in Opel HQ 

In addition, GM will make more use of synergies between the brands, particularly between Buick and Opel will increase. This will result in further economies of scale that benefit both brands.

The recruitment goes along with the 230 million euro investment that GM announced in April 2013. This investment will be used for building new testing facilities into its European Product Development Center at the Opel headquarters in Rüsselsheim and at the proving ground in Dudenhofen. New dynamometers for engines and transmissions will replace older equipment to allow for development of the following generation of powertrains for 2020 and beyond. This will be a key enabler for Opel/Vauxhall in the development of next generation engines and compliance with European and global emissions regulations.

The powertrain development work that will be done in Rüsselsheim will translate into engines and transmissions not only for Europe but also for the rest of the world. Dr. Thomas Johnen, Vice President Powertrain Engineering, said: "Two next generation gasoline engine lines, which will be key building blocks to reach the next step of environmentally friendly mobility solutions, will be developed in Rüsselsheim for applications in Europe and worldwide."

Opel and GM are investing heavily into future Opel/Vauxhall products. Four billion euros have been earmarked for future product between 2013 and 2016. Through 2016, Opel is introducing 23 new models and 13 new powertrains.

!NEW! Tests of Opel and TÜV Rheinland confirm refrigerant safety

• Safety of R1234yf in air conditioners confirmed under realistic conditions
• Opel Mokka SUV meets EU directive for climate-friendly refrigerant
• GWP lower by 99 percent compared with predecessor

Sure thing: The new climate-friendly refrigerant R1234yf can be safely used in air conditioning systems of automobiles. The photo was taken at a realistic crash test, Opel has carried out jointly with TÜV Rheinland. The violent collision with subsequent loss of water vapor and caused much damage to the climate system that led to the escape of refrigerant near the hot exhaust manifold. Nevertheless, it did not cause inflammation of the refrigerant. Test object was awarded five Euro NCAP stars Opel Mokka

The new climate-friendly refrigerant R1234yf can be safely used in air conditioning systems of automobiles. This now live crash tests have confirmed that Opel has performed together with renowned technical service corporation TÜV Rheinland. Test object was the award-winning and awarded five Euro NCAP stars SUV Opel Mokka.

Conditioners all Mokka produced since January 2013, to fill with the new, strict requirements of the EU Directive 2006/40/EC with a climate-friendly refrigerant. The rule states that all new type-approved vehicles must be equipped with a refrigerant, the global warming potential (GWP = Global Warming Potential) is below 150. While the conventional refrigerant R134a has a GWP of 1430, has the new R1234yf only a GWP of 4, and thus has a lower 99 percent greenhouse effect. R134a builds up in the Earth's atmosphere also be delayed by 30 years - R1234yf already after eleven days.

The Opel and TÜV Rheinland conducted under realistic conditions Crash tests have confirmed the safety of the new refrigerant in Opel cars. This conclusion is supported by studies of other organizations, including SAE International, the U.S. EPA (Environmental Protection Agency) as well as European, North American and Asian car manufacturers.

Opel and TÜV Rheinland have the Opel Mokka 1.4 Turbo subjected to a dynamic crash test under extreme conditions at 50 km / h against a moving deformable barrier. These test parameters correspond to an accident on the highway, where a fully loaded vehicle, previously moved with speed ascends, the traffic jam on a stationary vehicle.

The violent collision caused the crash test at Opel Mokka damage the climate system, leading to a leak and thus the escape of refrigerant near the hot exhaust manifold. Nevertheless, it did not cause inflammation of the refrigerant.

"The safety of our vehicles and our customers is a top priority for Opel. And environmental performance in our company has a long tradition. The Mokka strengthens with the new refrigerant our leading role in linking mobility, environmental protection and safety. We are proud to introduce an equally safe, effective and environmentally friendly climate system, "said Michael F. Ableson, Opel Chief Development Officer and GM Europe Vice President, Engineering.

The automobile industry dominated the safe use of potentially flammable liquids such as gasoline, antifreeze, grease, brake fluid and windshield washer. Compared to gasoline requires 5000 times more energy to ignite the new refrigerant. "In the near future there is no way to R1234yf. Possible alternatives as refrigerant CO2-based are still in development and so years away from the market", said Ableson.

Since its launch in June 2012, the new Opel Mokka learns much praise from press and public alike. Accordingly, there are currently more than 90,000 orders for the new mocha, with which Opel became the first German car manufacturer, the fast growing subcompact SUV enters (SUV B-segment).