Alt and his 200-man team have developed a whole new engine fort he Corsa: a three-cylinder turbo turbocharged direct injection aggregate.

Unveiled:
D turns into E


http://www.youtube.com/watch?v=fG9B7Bxaalo

 

When the gossip factory is working overtime again, then the situation heats up most notably in internet forums. Any evidence required? Let’s take all the speculation and discussions about the development of the fifth-generation Corsa, especially users of the Opel-Blog can attest that. Now, the secret about the “Project 4500”, as they call it internally, has been finally revealed. At least partially. As the Corsa D looks like that will not be shown yet. But it can be experienced how it feels to drive the car – in test called “Dalidation Drive”. Opel Post has accompanied one of them.

New_Corsa_E_Validation_087

Matthias Alt, senior engineer for small gas engines at Opel, (left) und Thomas Wanke, chief development engineer.

 

Curves, inclines, acceleration: The prototype is tested on the street
An Opel convoy rolls through the scenic hills and meadows in the borderland between the Palatinate and Alsace. Countless curves. Inclines. But also excellent opportunities to do more than just caressing the accelerator gently with the foot. An Astra GTC is the pace maker, a Cascada brings up the rear, between them the main actors in the pixelated camouflage outfit – prototype copies of the new Corsa. Not only the exterior design is masked. Also the dashboard remains in disguise, thick black cloth mats cover the displays and functions. Journalists taking part in the trip get to know by Thomas Wanke, chief development engineer: “With this series our bestseller has matured, he is quieter, more comfortable and of high quality in terms of features.”

 

How can   harmonization of engine, chassis and gearbox get improved?
Certainly, the ride in the countryside is not a pure pleasure trip. After Opel CEO Karl-Thomas Neumann and Management Board Member Michael. F. Abelson (Engineering) have accepted the prototype, now, the practice test is a further step towards start of serial production. Opel engineers check whether something can be improved in the harmonization of the engine, chassis and transmission. “We get the answers when we strain the vehicle under a variety of road conditions,” explains Werner Joeris who supervises the project together with Wanke as chief development engineer. “Only in this way fine-tuning will succeed.” Okay, so let us look at the technical highlights.

 

The new engine: 1.0 three-cylinder turbocharged direct injection

Motor_engl

 

 

The Corsa D – as indeed from autumn the ADAM – deploys a completely new engine: the three-cylinder turbo turbocharged direct injection aggregate. It was developed by Matthias Alt, senior engineer for small gas engines at Opel, with a team of more than 200 employees. From the cylinder head and spherical wave to the flywheel, it was necessary to take into account a total of 40 components and assemblies. “The goal was to build a small engine that is fuel efficient, but that comes along like a big a big one in terms of noise and smoothness,” says Alt. The field test has confirmed: mission accomplished. During the Validation Drive the 115-hp Corsa variant rotates at 170 Newton meters light-footed, no annoying vibrations, one hears pithy snarling, here and there the turbo is buzzing. And the absence of the fourth cylinder? Made forgotten totally. “Today, we test most phases of the engine development in the simulation, and later on test stands,” says Alt. However, according to Alt, the rides clarify the final details. Are there maybe any unusual noises in a certain position? Would another part, perhaps a lighter bearing, fit more optimal? It was “a delight”, says Alt. “Projects like the current begin with a blank sheet of paper, before finally getting to see the end result live and in person after many years of hard work.”

 

Also new in the big brother of ADAM: chassis and six-speed gearbox
Along with the smooth running of the new engine, the thoroughly revised chassis is very convincing. Wanke’s and Joeris’ team of development engineers has improved the steering and stability feeling quite noticeable. For that, the car body was placed a little lower, the technicians also optimized the stiffness of the subframe and the damping characteristics. “Moreover, we have installed a new steering gear and changed the front suspension geometry”, says Wanke. The Validation Drive mainly shows: The handling guarantees driving pleasure, and the very precise steering gives a lot of feedback from the road. First time on board is also the newly-designed six-speed gearbox, which weighs 37 kilograms – and 30 percent less than the predecessor. Designed for torques of up to 220 Newton meters, it scores with smoothness.

 

 

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Corsa

He is 32 years old, a real success type and is now breaking through again: The Corsa – since 1982 it was sold 12.3 million times and is now approaching confidently a new chapter in its life with a completely refurbished version.

The meanwhile 5th range will be presented at the Paris Motor Show and will replace the current generation letter “D”. The Corsa E’s manufacturing locations are Eisenach and Saragossa. The first models will be carried out to Opel-traders at the end of the year.