THE STRENGTHS OF THE NEW ENGINE
 

The entire world acknowledges the fact that the Italian motoring school has always had the ability to produce gritty and temperamental engines, true "jewels" that are the result of the experience and passion of the engineers matched with their technical competencies acquired over years. The new 200 HP 1.8 Di TurboJet (Euro 5) is no exception.

The new engine is produced by FPT – Fiat Powertrain Technologies - and has a maximum power of 200 HP (147 kw) at 5,000 rpm and a maximum drive torque of 320 Nm (32.6 Kgm) at 1,400 rpm. Thanks to its combination with a 6 gear automatic/sequential transmission, the 200 HP 1.8 Di TurboJet provides an exciting and unmatchable drive: it can reach a maximum speed of 230 km/h and accelerate from 0 to 100 km/h in 7.4 seconds. In spite of these amazing performances, fuel consumption and emissions are surprisingly low: respectively 7.8 l/100km in the combined cycle and 185 g/km of CO2.

Thus, these innovative engines prove Lancia Automobiles' commitment to protecting the environment by containing emissions as well as reducing fuel consumption. All this is achieved by enhancing brilliance, flexibility and the pleasure of driving which have always made this model stand out. In order to achieve these extraordinary results, the 200 HP 1.8 Di TurboJet introduces petrol direct injection, turbocharging and an exhaust and intake double continuous phase transformer. The merging of these different technological solutions offers important advantages to clients such as the direct injection which means low fuel consumption for high engine performance. Furthermore, the turbocharger associated with the double phase transformer enables quick acceleration thanks to a particularly favourable drive torque curve.

Here are the details of all the innovations of the new 200 HP 1.8 Di TurboJet which was designed and developed by engineers of FPT - Fiat Powertrain Technologies, the sector of Fiat Group that provides innovation, design, plan and production activities for engines and gearboxes of all uses: from cars to industrial vehicles, from boats to agricultural machines. With about 20,000 employees, 16 plants and 11 research centres located in 9 different countries, this Sector represents a most significant presence in the field of engines at world level. In FPT, about 3,000 highly specialized engineers work on innovation technologies development and automation. The over 40 patents registered every year show quality and reliability of this group, making FPT – Fiat Powertrain Technologies - a great centre of technological excellence and constant innovation.

The Scavenging Technology

The amazing performances of this engine are a result of the application of the Scavenging technology which maximizes the drive torque at very low rpm by guaranteeing an incredible engine response speed to any driver request. Scavenging can be obtained by controlling and optimising at every instant engine parameters such as dosage, position of the two phase transformers, ignition advance and injection timing. Basically, it is possible to define the angle and overlapping time of the valves with extreme precision in order to generate direct air flow from the intake to the exhaust manifolds and start the turbocharger in very short times. This means the engine can make better use of the supercharging when compared to standard turbocharged petrol engines. The system is managed by an innovative engine management control unit integrating an extremely modern software which manages all parameters. The result is remarkable: the maximum drive torque at 1,400 rpm increases by 70% compared to traditional turbo engines and response times are halved, getting close to those of aspirated engines.

Direct injection

The direct injection reduces the temperatures in the combustion chambers through the evaporation of fuel and lowers the knock sensitivity. This enables the engine to achieve great performances even for a moderately high compression ratio (equal to 9.5) and ensures limited fuel consumption at a "partial" speed.

The direct injection system is essential in reducing emissions thanks to an advanced strategy of double injection. Furthermore, thanks to the direct control of fuel, it is possible to avoid some of the petrol getting directly to the exhaust manifold during the scavenging with negative effects on the catalytic converter's functionality.
 

Lastly, this injection system of second generation is provided with a new high pressure pump (capable of managing petrol pressure of 150 bar) and innovative injectors with 7 holes that guarantee ideal evaporation for all operating conditions.

Double phase transformer

The two continuous phase transformers on the intake and exhaust camshafts enable phase optimisation at any speed and engine load by reducing fuel consumption and emissions as much as possible. Moreover, by combining the two transformers with the turbocharger, it is possible to manage the Scavenging strategy by defining the correct overlapping during the transitory phases. In this way it is possible to respond to a sudden driver request by maximising the engine's response speed at low rpm.

Turbo

This engine is provided with a new generation turbocharger connected to an innovative “Pulse Converter”-type exhaust manifold which optimises the use of exhaust pressure waves to increment the driving torque at low speeds. Both manifold and turbine are made of microcast steel so that they can reach very high working temperatures (up to a maximum of 1020 °C). This is very important for reducing consumption while operating at medium/high speed - i.e. on a motorway.

Thermal Fluid Dynamics

The intake ducts were designed and optimised by using mono and three-dimensional calculation technologies through which it was possible to obtain a correct and high turbulence level. Even the combustion chamber was optimised by using wide squish areas and by minimising area/volume ratios with clear benefits in terms of combustion efficiency. Lastly, the exhaust ducts were designed to work in tune with the exhaust manifold and maximise its pulse converter effect.

“Friction”

The entire engine was made with the aim of minimising friction losses. The pistons are provided with piston rings with a reduced tangent load and are made of advanced materials to minimise wear and tear. Furthermore, the engine cylinder head was designed with two roller rocker arms placed on the valve control which reduce losses by friction of 65% at 2000 rpm compared to direct command. This is a typical solution adopted for Brand Premium engines. The mechanic optimisation with very long rods combined with a moderately short travel has resulted in a drop of vibrations which are typical of four cylinder engines operating at very high speeds. As it wasn't necessary to utilize balancing countershafts, the weight was further optimised and consequently, the fuel consumption was reduced.

Performances

The Scavenging strategy combined with the innovative control system has allowed this engine to reach new benchmarks in terms of performance. The specific drive torque (185 Nm/l) is extremely high, one of the highest among the engines available nowadays. Furthermore, we can confidently say that the maximum drive torque value (320 Nm) achieved at 1400 rpm represents a point of absolute excellence. This value ensures excellent performances in terms of acceleration and allows a greater car response without having to change gear frequently. Lastly, the high specific power of 115 HP/l can be reached at a relatively low speed of 5,000 rpm and remains constant up to 5,500 rpm. In brief, the 200 HP 1.8 Di Turbo Jet E5 drive torque is comparable to the one of an aspirated V6 engine which is almost twice its displacement. However, thanks to the downsizing philosophy, it was possible to reduce the weight with great efficiency benefits.

Emissions

One of the main priorities of FTP – Fiat Powertrain Technologies - engineers was to guarantee a low level of emissions together with excellent performances, in line with the Lancia Automobiles' philosophy which places the protection of the environment at the core of its products' design and improvement. Just like the Lancia Delta diesel engines (the 190 HP 1.9 Twin Turbo MultiJet, 120 HP 1.6 MultiJet and 165 HP 2.0 MultiJet), the brand new 1.8 Di Turbo Jet 200HP E5 was Euro 5 approved even before the standard enforcement date.