35 Years Ago: Opel Ascona 1.8i First German Car with Catalytic Converter Engineered for Europe

• Forerunner: after the Ascona the whole Opel model range got catalytic converters
• Complicated operation: Opel Ascona significantly modified for three-way catalytic converter
• Eye for detail: even fuel tank filler neck redesigned for unleaded petrol
• Major commitment: Opel invested DM 1.0 billion in catalytic converter development

Opel Ascona 1.8i GT

Thirty-five years ago, the era of the catalytic converter began at Opel. In 1985, the Opel Ascona 1.8i was the first German car with a catalytic converter developed especially for the European market, instead of merely modified for export from the USA.

Opel Ascona 1.8i  for Rhineland-Palatinate Police

Rhineland-Palatinate Police force took delivery of the first Opel Ascona 1.8i with three-way catalytic converter actually produced, on December 7, 1984. During the course of the following year, Opel introduced catalytic converters across the model range – from Corsa, Kadett and Ascona, to Rekord, Monza and Senator. German manufacturer was the first European brand to offer three-way catalytic converters standard.

Catalytic converters are not all the same

Opel’s engineers were well aware that European traffic conditions necessitated the appropriate technology and quality. They therefore developed a catalytic converter especially for European driving conditions – just as they would when it came to bodywork, suspension, engines and brakes. For Opel, it was about more than just installing a catalytic converter in the exhaust system; reducing emissions via catalytic converter represented a complicated operation on the “internal organs” of the automobile.

Compared with a conventional car, the design of a vehicle with catalytic converter required numerous alterations. For example, the converter radiates a lot of heat when it has reached its operating temperature (600 degrees Celsius). Heat-sensitive components and the passenger compartment therefore needed protection from reflective shields.

In order for the catalytic converter to operate at optimum efficiency, it required an electronic mixture preparation system and a multitude of controls, which in turn made further modifications necessary. Even the filler neck of the fuel tank needed a redesign to prevent drivers from mistakenly filling the tank with leaded instead of unleaded petrol.

One billion Deutsche Mark for the environmentally friendly automobile

Opel committed more than one billion Deutsche Mark (DM) as well as hundreds of engineers to the development of catalytic converters and the environmentally friendly automobile. Company invested DM 100 million alone in new test rigs and test equipment for durability and high-speed testing.

New facilities also included a 13-storey-high “soak tower”. In this insulated building, more than 130 cars could be prepared simultaneously for emissions testing. The standards required that, before the emissions test, each car had to be stored for at least 12 hours at a temperature of 20 to 25 degrees Celsius.

As well as offering cars with a three-way catalytic converter installed at the factory, Opel offered customers a kit for retrofit. However, the carmaker was not content to innovate only in technology. Opel also took new paths in Public Relations. Company offered people the opportunity to inform themselves actively about catalytic converters and retrofitting. For a few hours every day, motorists and interested parties could call a telephone “hotline” and get answers to their questions first-hand from the company’s experts.

Opel Ascona 1.8i GT

Today, 35 years after introducing the three-way catalytic converter on the Ascona 1.8i, Opel continues to take its responsibility for the environment seriously. Following the Opel Grandland X as plug-in hybrid and the battery powered Opel Corsa-e, the brand recently unveiled all-new Mokka-e, the Vivaro-e and the Zafira-e Life, all with pure electric drive and therefore locally emission-free.

30 Years Ago: Opel First to Offer 3-Way Catalytic Converter as Standard

• From Opel Corsa to Opel Senator: Three-way catalytic converter on every model
• Pro-environmental investment: DM 1.0 billion for new test facilities and equipment
• Opel Ascona 1.8i: First German car with catalytic converter especially for Europe
• Today: All Opel passenger cars meet strict EURO 6d-TEMP emissions standard

Thirty years ago, on April 21, 1989, Opel announced it would become the first German car manufacturer to offer the three-way catalytic converter as standard equipment on all its passenger cars – from Corsa and Kadett, to Vectra, Omega and Senator. Or as Opel’s Managing Director at the time, Louis R. Hughes, told the journalists at the press conference in Bonn: “Opel is the first carmaker to offer the best environmental technology as standard across the model range, from compact car to limousine.”

3-Way Catalytic Converter

But true to the entrepreneurial motto, “do the unexpected”, Opel went even further: in order to make it easier for customers to buy a car with the climate-friendly technology, the company also lowered prices for many models.

Opel continues to take its responsibility for the environment seriously today. All current Opel passenger cars already meet the strict Euro 6d-TEMP emissions standard; and on the eve of the breakthrough for electric mobility, the carmaker is now putting the finishing touches to two of its next big steps towards sustainable mobility: Opel Grandland X as plug-in hybrid electric vehicle and the battery-powered version of the next-generation Corsa. Opel will open the order banks for both cars later this year. Every European Opel passenger car model will have an electrified version by 2024.

From Corsa to Senator: Three-way catalytic converter on every model

March 1988: with 20,451 units, Opel has established itself as the leader in new registrations of cars with three-way catalytic converters in Germany. By the end of the year the number had increased to 208,000. The amount of Opel cars equipped with catalytic converters rose again in early 1989 following the introduction of the Vectra, which Opel offered with the three-way catalytic converter as standard right from the start of sales.

The automotive engineering community at the time was convinced that there was no alternative to the three-way catalytic converter if exhaust emissions were to be reduced as much as possible. While the three-way converter removed around 90 per cent of the emissions, it was only about 50 per cent with a conventional two-way converter or 60 percent with a lean-burn engine. The three-way converter performed even better when it came to nitrogen oxides, with a reduction of 90 percent.

Opel’s smallest car with three-way catalytic converter in 1989 was the Corsa, fitted as standard with a 44 kW (60hp) 1.3-litre fuel-injection engine. Then came the 1.3-litre Kadett in the compact class, while the midsize Vectra featured not only a 55 kW (75 hp) 1.6-litre base engine, but also an 85 kW (115 hp) 2.0-litre power unit.

In the upper midsize class, the Omega was equipped as standard with the 85 kW (115 hp) 2.0 engine. The top-of-the-line model with three-way catalytic converter was the Senator. The Opel flagship was available with two 3.0-litre, in-line six-cylinder engines that produced 115 kW (156 hp) and 130 kW (177 hp) respectively.

Offering the three-way catalytic converter as standard across the range was the provisional climax of an environmental offensive that Opel had started five years before.

Exemplary behaviour: Opel shows responsibility for environmental protection

In the early 1980s, a discussion about acid rain and dying forests took hold in Germany. Emissions of nitrogen oxides were identified as a contributory factor. Road traffic, as well as industry, was seen as a cause.

Opel immediately recognised its responsibility for the protection of the environment and committed more than one billion Deutsche Mark (DM), as well as hundreds of engineers, to the development of catalytic converters.

Opel invested DM 100 million alone in new test rigs and test equipment for durability and high-speed testing. The new facilities included a 13-storey-high “soak tower”. In this insulated building, more than 130 cars could be prepared simultaneously for emissions testing. The legal standards required that, before the emissions test, each car had to be stored for at least 12 hours at a temperature of 20 to 25 degrees Celsius.

Initially, most catalytic converters in Europe were just modifications of the U.S. version. But with the introduction of the Opel Ascona 1.8i in early 1985, Opel was the first German manufacturer to bring a model onto the market with a catalytic converter that was specially developed for European conditions. The first example actually produced was delivered to the Rhineland-Palatinate police force.

Environmental offensive: Catalytic converter at no extra cost

Environmental offensive continued the following autumn, when Opel presented the first European small car with three-way catalytic converter, the Corsa 1.3i. In 1986, the carmaker offered the new Opel Omega at no additional cost for the catalytic converter. Launches of the Opel Senator (1987) and the Opel Vectra (1988) followed the same strategy. Additionally, all Opel cars with three-way catalytic converter were equipped with active carbon filters for capturing hydrocarbons that escaped from the fuel tank.

!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 four-valve engines look back on 100 year tradition

First four-valve engine: In 1913, Opel developed a new generation of racing cars for the Grand Prix de France, a forerunner of today’s formula one races.

1913 Grand Prix car: First Opel with four-valve engine

Opel Kadett GSi 16V: First Opel volume model with four-valves per cylinder

Opel Calibra Turbo 4x4: First Opel with gasoline turbo engine

Opel ECOTEC DTI 16V: First direct injection turbo diesel with four-valve technology

Opel 1.0 ECOTEC Turbo

Opel 1.6 ECOTEC Turbo

Opel 1.6 CDTI ECOTEC

The all-new turbocharged 1.6 liter gasoline and diesel engines which began the current renewal of Opel’s powertrain portfolio, and the compact 1.0 three-cylinder turbo that made its world premiere at the 2013 Frankfurt International Motor Show, are the latest in a long line of Opel engines with four valves per cylinder that stretches back 100 years.

In 1913, Opel developed a new generation of racing cars for the Grand Prix de France, a forerunner of today’s formula one races.

1913 Grand Prix car - First Opel with four-valve engine

Opel produced three of these cars, each one built down to a rigorous weight limit of only 1000 kg. The real highlight, however, was under the hood, where an innovative new four-cylinder power unit provided the motive force.

First four-valve engine: In 1913, Opel developed a new generation of racing cars for the Grand Prix de France, a forerunner of today’s formula one races.

In addition to an aluminum crankcase and a single camshaft in the cylinder head, the 4.5 liter, 110 hp engine also featured two intake valves and two exhaust valves per cylinder – Opel’s first internal combustion engine with four valves per cylinder.

From “Green Monster” to Ascona 400

Opel Green Monster 

Opel further developed the concept the following year, resulting in the most gigantic automobile the company has ever made – the 12.3 liter “Opel Rennwagen”, also known as “Das grüne Monster”, the “Green Monster”.

Opel Green Monster - 12.3 liter 4-valve engine developed a huge 260 hp

The revised 12.3 liter 4-valve engine developed a huge 260 hp, capable of propelling the 2000 kg “Monster” to a maximum speed of 228 km/h!

Opel works racing driver, Carl Joerns, scored most of his victories in this magnificent car, especially in beach races on the Danish island of Fanø.

Four valves per cylinder went out of fashion throughout the automotive industry in the 1920s. They did not reappear until the late 1950s, in motor racing, and it was via rallying that Opel introduced the technology to its road cars in 1979.

In order to compete in group 4, the top class of rallying at the time, with the Ascona 400, Opel had to produce a “road-going” model. While the rally-thoroughbred featured a newly developed, 177 kW (240 hp), 4-valve power unit, the homologation-special was equipped with a 140-hp version of the 2.4-liter engine.

1979 Opel Ascona 400 -  Rally version

Despite this detuning, the “street-legal” Ascona 400 was still good enough for a maximum speed of 200 km/h and zero to 100 km/h-acceleration in 7.6 seconds.

1979 Opel Ascona 400 -  Road version

In the 1980s, four-valve engines became increasingly attractive, not only because of their inherent horsepower-advantage, but also because of their lower fuel consumption and reduced exhaust emissions.

1988 Opel Kadett GSi - 2.0 16V engine produced 110 kW (150 hp)

When Opel introduced the legendary Kadett GSi 16V in 1988, the brand’s first volume-model with four valves per cylinder, it immediately became an industry-icon.

1988 Opel Kadett GSi 2.0 16V 

Opel 2.0 16V DOHC – The engine to beat

The technological highlight of the new high performance engine designed by Dr. Fritz Indra was its aluminum cylinder head developed in cooperation with Cosworth, the famous English racing engine builder.

Opel 2.0 16V DOHC Engine

The sporty engine 2.0 16V produced 110 kW (150 hp) and maximum torque of 196 Nm at 4800 rpm. Ninety-percent of this torque was already available in a wide rev-band between 3100 and 6000 rpm.

With its specific fuel consumption of 232 g/kWh, equivalent to an efficiency rating of 37 percent, the engine was a long-standing benchmark for specific fuel consumption in four-cylinder power units.

The Opel 2.0 16V became the engine to beat in many other disciplines, too – in Formula 3 motor racing, for example, which produced so many future F1-stars like Michael Schumacher, Jarno Trulli, Nick Heidfeld and Alexander Wurz. During the classic era from the late 1990s through the mid-2000s, Opel F3 engines established themselves as the most successful in the world.

Opel Formula 3 

Despite factory-supported competition from Alfa Romeo, Fiat, Mercedes-Benz, Toyota and VW, Opel scored 164 F3 victories in Germany alone, plus another 30 national championship titles around the world.

Opel Formula 3 

Opel rapidly spread four-valves per cylinder to the rest of its powertrain portfolio.

The company applied four-valve technology to the smooth-running, inline six-cylinder engine in its top-of-the-line models, Omega and Senator, in 1989.

Four valves per cylinder + “Dual Ram” = Omega 3000 24V

Think big: Opel applied four-valve technology to the smooth-running, inline six-cylinder engine in its top-of-the-line models, Omega and Senator, in 1989.

1989 Opel Omega 3.0 24V  

Thanks to the so-called “Dual Ram” induction system the engine was famous for its impressive power delivery at low revs. With 90 percent of the 270 Nm maximum torque available between 3000 and 5800 rpm, the Omega 3000 24V, for example, could accelerate from zero to 100 km/h in 7.6 seconds.

1989 Opel Omega 3000 24V  

By the way, the 3000 24V also provided the basis for the strongest Omega ever, the Lotus Omega, which was powered by a 3.6 liter, twin-turbocharged version of the engine developing 277 kW (377 hp). At the time, the Lotus Omega ranked just behind an extremely powerful Alpina limo as the fastest production-sedan in the world.

Lotus Omega 3.6 24V BiTurbo: The six-cylinder provided the basis for the strongest Omega ever, the Lotus Omega, which was powered by a 3.6 liter, twin-turbocharged version of the engine developing 277 kW (377 hp).

The 2.0 16V from the Kadett GSi provided the basis for the first Opel turbocharged gasoline engine, which made its world premiere at the 1991 Frankfurt motor show in the Calibra Turbo 4x4.

1991 Opel Calibra Turbo 4x4

The 150 kW (204 hp) 2.0 16V turbo was notable not only for its high torque of 280 Nm at only 2400 rpm, but also the turbocharger and the exhaust manifold, which were integrated in a single component. The extremely low thermal losses of this integrated system significantly increased the efficiency of the turbocharger.

With all wheel drive: The 2.0 16V from the Kadett GSi provided the basis for the first Opel turbocharged gasoline engine, which made its world premiere at the 1991 Frankfurt motor show in the Calibra Turbo 4x4.

Despite the 42-percent higher torque and 36-percent higher power-output of the 2.0 16V Turbo compared with the naturally aspirated version, the average fuel consumption of both engines in the Calibra was almost the same – 8.9 versus 8.7 l/100 km.

This tradition of high performance and high efficiency begun by the 2.0 16V in 1988 continues today with the new 1.6 ECOTEC Direct Injection Turbo gasoline engines.

Opel 1.6 ECOTEC Direct Injection Turbo: New powerful and highly efficient gasoline engine with 170 and 200 hp

Opel’s reputation for innovative four-valve engines reached another peak in 1996 when the company became the first automobile manufacturer to combine the advantages of four-valve technology with diesel direct-injection and turbocharging.

Direct - Injection Turbo diesels with patented valve train

Opel ECOTEC DTI 16V: Opel’s reputation for innovative four-valve engines reached another peak in 1996 when the company became the first automobile manufacturer to combine the advantages of four-valve technology with diesel direct-injection and turbocharging.

The ECOTEC DTI 16V diesels delivered high low-end torque, as well as low fuel consumption and emissions. The performance spectrum of the 2.0 and 2.2 liter engines stretched from 60 kW (82 hp) and 74 kW (100 hp) up to 92 kW (125 hp). They featured a patented valve-train operated by a single overhead camshaft.

The introduction of the all-new, four-cylinder, 1.6 liter CDTI turbo family earlier this year demonstrates how Opel continues to play a leading role in diesel engine development.

New Opel 1.6 CDTI ECOTEC - Euro 6 diesel engine

Featuring closed-loop combustion control and an aluminum block, the new 1.6 CDTI is the first diesel from Opel to comply with future Euro 6 emissions requirements, delivering climate friendliness, low fuel consumption, class-leading refinement, and high power/torque density.

Drivers can look forward to more such benefits in the immediate future, as Opel continues its current product-offensive and long-standing tradition of technological innovation. By 2016, the Rüsselsheim manufacturer will have renewed 80 percent of its powertrain portfolio.