Sophisticated Diesel Power for 2010 Volvo Range

SYDNEY – November 9, 2009: Two new turbodiesels - an all-new twin-turbo D5 and an ultra-efficient four-cylinder 2.0D - head Volvo’s diesel range for 2010.

The new engines bring the best of Volvo’s advanced diesel technology to bear, resulting in high power outputs, maximised fuel economy and minimised exhaust emissions.

Other than its designation and its inline, five-cylinder configuration, the all-new twin-turbo D5 diesel engine has no relationship with the previous D5.

Available in Volvo XC60, XC70 and S80, the new D5 engine brings remarkable performance combined with average fuel consumption figures as low as 6.2l/100km.

The twin-turbo D5 engine drives through Volvo’s six-speed adaptive Geartronic transmission to a Haldex All Wheel Drive system that is standard in XC60, XC70 and S80 models.

The new 2.0D engine replaces the previous-generation D5 formerly available in Volvo C30, S40 and V50 models and combines smooth, torque-rich power with fuel consumption as low as 5.9l/100km. It also introduces the refined and highly efficient dual-clutch, six-speed Powershift gearbox jointly developed by Volvo and its transmission partner Getrag.

With ultra-efficient all-round performance, the 2.0D Powershift drivetrain brings lower fuel consumption and cleaner exhaust emissions than the previous D5 turbodiesel engine.

The new turbodiesel powerplants showcase Volvo’s commitment to providing leading-edge engine technology that plays a significant role in reducing fuel consumption and emissions while maintaining high levels of performance and driving pleasure.

All-new D5 diesel upgrades power, economy while reducing emissions
With 151kW of power and a muscular 420Nm of torque, the all-new twin-turbo 2.4-litre D5 engine improves on all aspects of the already impressive outgoing D5 powerplant.

It improves zero to 100km/h acceleration times in XC60, XC70 and S80 models by up to a full second, while reducing fuel consumption by as much as 1.2 litres per 100km.

For example, the D5 XC70 accelerates to 100km/h in 8.9 seconds, while consuming a combined average of 7.5l/100km of diesel. CO2 emissions are 199g/km.

The new all wheel drive Volvo S80 D5 reaches 100km/h even faster in 8.5 seconds, while consuming 7.4l/100km of diesel and recording a CO2 figure of 199g/km.

A remarkably high specific power output of 63 kW per litre rates the new S80 D5 among the top passenger vehicle diesel engines. This is backed by the serious 420Nm of torque, which comes in as low as 1500rpm and continues through to 3250rpm for strong, steady power delivery across a broad operating range.

On top of all this, the new D5 is certified to Euro 5 emission standards. In the Volvo S80, it emits 199g/km of CO2.

Volvo developed the new D5 engine entirely in-house over a period of less than three years, starting with a clean sheet of paper.

The long-stroke, twin overhead camshaft, four valves per cylinder D5 engine has a compression ratio of 16.5:1 and uses aluminium for both the cylinder head and engine block.

Central to its outstanding statistics is the twin turbocharger system. The sequentially arranged turbos provide extremely high boost pressures up to 1.8 bar across a wider rpm range than a single turbocharger, dramatically improving accelerator response at all speeds. The smaller turbo spools up rapidly to deliver boost at low engine speeds, while the larger unit ups the volume of the inlet charge at higher revs.

The twin turbo arrangement also helps increase the efficiency of the exhaust gas recirculation system, reducing the temperature of recirculated gasses and helping lower nitrogen oxide emissions.

The new D5 engine also employs piezoelectric direct fuel injection and a high-pressure fuel pump producing a massive 1800 bar to control the combustion process with extreme accuracy.

With a response time twice as fast as regular injectors, the piezoelectric system helps reduce fuel consumption and exhaust emissions while lowering engine noise and increasing power.

The system is able to produce as many as seven separate injections during each injection cycle and can provide short pre-delivery injections at engine speeds of more than 3000rpm. This helps reduce noise levels.

The D5 also uses post-injection, in which tiny amounts of fuel are injected into the combustion chamber after the main charge to help remove particulates in the exhaust gasses.

Ceramic glow plugs provide rapid warm-up even in cold climates by reaching a temperature of 1000 degrees in just two seconds. The maximum operating temperature of 1300 degrees is about 30 per cent higher than a conventional glow plug.

The ceramic glow plugs are also able to improve combustion efficiency further by increasing temperature in the cylinders at very low rpm.

An interesting supplementary benefit is the quality of the sound: The high technology featured in the new D5 contributes to an engine note similar to that of a refined six-cylinder petrol powerplant.

The D5 engine was developed on a modular basis with standardised fittings for the turbochargers and other ancillaries, allowing for easier installation in other Volvo models and providing for future development. Transverse cooling allows uniform cooling of the cylinder head and engine block, contributing to long-term reliability and longevity.

A lot of development work also went into the mounting system, which is supplemented by a third stabilising rod and has been tailored to match the high torque of the engine.

And the new D5 engine does away with a dipstick: The driver simply refers to the information display on the instrument panel, where the system not only advises when it is time to top up with oil, but also how much is needed.

New Powershift transmission in C30, S40 and V50 ups efficiency, lowers fuel consumption by 8 per cent
The ultra-efficient 2.0-litre four-cylinder turbodiesel adopted in the Volvo C30, S40 and V50 replaces the previous-generation D5 engine.

It brings improved fuel economy and lower exhaust emissions, along with a remarkably efficient dual-clutch Powershift automated manual transmission.

The combination of the 2.0-litre turbodiesel engine and the Powershift transmission results in reduction of fuel consumption by as much as eight per cent, as well as lower exhaust emissions yet contributes to high levels of refinement and driving enjoyment.

The twin overhead camshaft, four valves per cylinder 2.0D turbodiesel engine uses second generation 1600 bar high pressure common rail fuel injection and runs an 18.5:1 compression ratio. A digital two-speed CAN bus electrical network looks after the electronics, while the accelerator is controlled by a drive-by-wire system.

The long-stroke engine’s bore/stroke measurements are 85mm by 88mm. It uses an aluminium alloy cylinder head with a strong cast iron block designed to minimise weight and maximise rigidity, while moving parts are designed to minimise losses due to friction.

A variable nozzle turbocharger enables faster engine response than a normal turbocharger, improving efficiency and raising power and torque across the rpm range.

The engine produces 100kW at 4000rpm and develops 320Nm of torque at 2000rpm.

Working in perfect harmony with this highly efficient engine is the six-speed Powershift gearbox.

According to Magnus Jonsson, Senior Vice President, Research and Development, Volvo Cars, “Powershift contributes to a fuel consumption saving of about eight percent compared with a conventional automatic transmission."

The gearbox was developed as a cooperative venture with Volvo’s transmission partner Getrag. It basically operates as two parallel manual transmissions, with twin wet clutches working independently on different gear sets.

One clutch controls first, third, fifth and reverse gears, while the other controls second, fourth and sixth gears, operating alternately with one disengaging as the other engages. Each clutch functions like a slip clutch. A piston pushes a multi-plate clutch assembly together, locking the plates through frictional forces.

Changing from ratio to ratio is, in effect, nothing more than the engagement of a clutch as the gears themselves are preselected.

The result is an almost imperceptible shift from one ratio to another – up or down - and a smooth, uninterrupted power delivery.

The Powershift transmission is able to accommodate torque levels as high as 450Nm and is a perfect partner for the 2.0-litre turbodiesel.

"It's not just any old automatic transmission: lower fuel consumption combined with increased comfort and higher performance sounds like an impossible equation. But with Powershift we have shown that this is perfectly possible," says Magnus Jonsson.

In the Volvo C30, the 2.0D Powershift returns a combined fuel consumption figure of 5.9/100km, along with CO2 emissions of 156g/km. The 2.0D Powershift S40 and V50 have a combined fuel consumption of 6.0l/100km and 159g/km CO2 emissions.

The efficient new gearbox helps performance too: the 2.0D Powershift Volvo C30, S40 and V50 accelerate from zero to 100km/h in 9.5 seconds, 9.6 seconds and 9.7 seconds respectively.