Volvo Car Corporation has launched all-new four-cylinder 2-litre GTDi (Gasoline Turbocharged Direct Injection) engine in the Volvo S80, V70 and XC60.

New Volvo-developed turbocharging technology, direct injection and twin variable camshafts give a unique combination of low fuel consumption, low emissions and high performance across a wide rev range – all in a particularly compact format.

The new petrol engine, the 2.0 GTDi, produces no less than 203 hp despite its compact size and cylinder capacity. It pumps out 300 Nm of torque already from 1750 rpm thus securing a refined driving experience.

The turbocharger system has been developed in cooperation between Volvo Cars, Borg-Warner Turbo System and steel component manufacturer Benteler Automotive. The turbocharger (K03) is the market’s smallest in relation to the engine’s maximum output. The turbo not only gives excellent performance properties, it also improves exhaust aftertreatment by enabling quick heating of the catalyst.

The turbine housing is integrated into the manifold, an efficient solution with which Volvo already had previous good experience. The difference is that the new manifold and turbine housing are made of sheet steel instead of a casting. The sheet is lighter and more compact and, above all, this system generates less heat owing to its extra insulating layer. This allows high gas flow temperature and thus more efficient combustion.

A manifold made of sheet steel is admittedly nothing new but so far it has only been used in combination with cast turbine housing. The new, fully integrated turbo package made entirely of sheet steel is a world innovation and has been patented by Volvo.

This innovative technology has made it possible to shape the exhaust ducts optimally to allow an optimal gas flow and generate the maximum pulse effect for the highest possible turbine efficiency. The pulse dynamics can thus be utilised to the limits in order to generate a high power output level across a wider range of engine revs. This translates into close to immediate response and good acceleration at both low and high speeds.

The new engine features direct injection. The injectors have seven holes for precisely controlled injection into each cylinder. The injectors are side-mounted.

Direct injection gives a high fill rate in the combustion chamber, efficient combustion and low emissions. Thanks to this high fill rate, the turbo also starts spinning earlier, delivering alert response from low revs. This in turn results in swift acceleration and good driveability even from low speeds.

Direct injection also contributes to quick and stable combustion at high loads, and thus smooth engine operation even when the accelerator is floored.

Volvo’s new GTDi engine utilises variable timing for both camshafts. Both the inlet and the exhaust valves’ opening times can be varied to optimise the overlap and ensure the correct fill rate in the combustion chamber irrespective of engine revs. This gives the combustion process maximum efficiency throughout the rev range and helps generate rapid acceleration at all speeds.

Both VVTs are of the conventional vane-type. The rotation of the inner and outer rotor is regulated by hydraulic pressure from the engine oil. By opening and closing the oil control valves, the oil pressure and flow through the VVTs are changed until the desired angular deviation between the inner and outer rotor is achieved. The oil control valves are controlled by software in the Engine Management System using feedback from the cam position sensors.

The engine will be offered in combination with Volvo’s automatic six-speed Powershift transmission or a six-speed manual gearbox.

This new six-speed double-clutch automatic transmission combines the efficiency and driving dynamics of a manual transmission with the ease of a quality automatic transmission. The clutch activations are co-ordinated so that no torque interruption occurs during gear changing. This provides both the ease and permanent motion of a conventional automatic transmission and the performance of a manual transmission.

Volvo’s new 2.0 GTDi engine is being initially launched on markets that offer tax incentives for engines below two litres in displacement: South-East Asia, the Netherlands, China and Japan.

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