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Volvo S80 Receives New D5 Twin-Turbo Diesel Engine

Posted in Car Tech, Cars, Diesel, Environment, Press Release, Volvo by Suzanne Denbow | January 7th, 2009 | 1 Response |

Fighting to remain relevant in the shifting market, Volvo recently announced the launch of an aggressive new technology program aimed at boosting the fuel-efficiency of the entire Volvo line-up. Although the more long-term goals call for the introduction of several new hybrid models, smaller, more immediate changes call for giving a few of Volvo’s old favorites some much-needed upgrades. First on the list to receive a green makeover is the Volvo S80, for which Volvo announced today they have developed an entirely new, 2.4L I5 Diesel powertrain. Thanks equally to its aluminum construction and sequential twin-turbo technology, the Volvo S80’s new D5 diesel engine successfully reduces fuel consumption to a record 6.2 litres/100 km (38mpg, combined), and CO2 emissions to a mere 164 grams per kilometer. Although Volvo’s 5-bangers are usually noted for their durability as opposed to their performance output, the S80 D5 doesn’t skimp on performance. Receiving a significant boost from the inline-5 of previous generations, the S80 D5 produces 185-hp and 295 lb-ft of torque from 1750 revs.

Taking great pains to note that Volvo’s newest technological achievement was developed entirely in-house (read: “Up yours, Ford”), Derek Crabb, Vice President of Engineering at Volvo Powertrain explained, “The previous generation of engines we…developed [had] reached the end of its potential. Therefore we decided to take a fresh start and to apply advanced technology in our house. The result is better than we dared to dream.” Continued Crabb, “Moreover, this engine is entirely in-house developed by Volvo. “


New D5 engine for Volvo S80

High performance and low fuel consumption record

Volvo introduces a completely new 2.4-liter diesel engine for the Volvo S80. In fact, only the label and the D5 five-cylinder configuration similar to the previous D5 diesel engine for the rest, he is completely different. The new D5 Volvo meets the EURO5 emission and is considerably cleaner and more economical than its predecessor.

Thanks to high-tech solutions such as sequential twin-turbo technology, glow plugs and ceramic piezoelectric fuel injectors are the engineers of Volvo managed to reduce the fuel consumption to a record low for a car in this class: 6.2 litres/100 km. The CO2 emissions is 164 grams per kilometer. Due to its low fuel consumption combined with the power of 205 hp and torque of no less than 420 Nm, the Volvo S80 with the D5 engine, the best in its class.

“Our mission was to develop a modern diesel engine – with the benefits that go with them – which also meets the emission EURO5,” says Derek Crabb, Vice President, Engineering at Volvo Powertrain. “The previous generation of engines we have ever developed and has now reached the end of its potential. Therefore we decided to take a fresh start and to apply advanced technology in our house. The result is better than we dared to dream. Moreover, this engine is entirely in-house developed by Volvo. ”

Performance and driving comfort in the top of its class

Volvo’s new D5 engine has a capacity of 2.4-liter and provides its performance at the lightest touch of the throttle. It provides excellent driving and is flexible in character under all circumstances. Especially in combination with an automatic transmission, the D5 engine useful. The tension in a wide toerengebied combined with fast switching gear provides a remarkably smooth ride, the fuel consumption in practice is still very modest.

The performance and driving improvement through the use of two turbochargers of different sizes. They enter into force after the other, so that they provide additional capacity in a broader toerengebied. This results in an alert gasrespons at all speeds and a very smooth power delivery. Therefore, there is always enough power available for overtaking, especially between 80 and 120 km / hr. The smooth transition of power issue of the individual’s turbo provides a highly refined driving experience.
Advanced injection technology, using piezoelectric fuel injectors, accurate distribution of geatomiseerde fuel combustion. It has an efficient combustion and low emissions as a result. At the same time, this technique for a pleasant engine sound, reminiscent of that of a petrol zescilinder. The new engine has excellent values in terms of noise and sound perception, or better known as NVH Noise, Vibration and Harsh Ness.

Lower fuel consumption
“Then once the project was underway, we aim to reduce fuel consumption to 6.4 liters per 100 kilometers in the Volvo S80, which is a relatively big car, looks back Derek Crabb. “But as the development progressed, we found that that number could dive. Eventually, we now 6.2 liters per 100 kilometers. The fuel for a Volvo S80 with automatic transmission, we have more than eight percent reduced from 7.3 to 6.7 liters per 100 kilometers. This is a significant improvement. ” The low fuel consumption is a result of advanced technology, including the two operating sequential turbochargers that help reduce fuel consumption on a wide toerengebied and high torque.

The twin-turbo technology also enables a higher level of exhaust gas recirculation (Exaust Gas Recirculation, EGR) to apply on a broader toerengebied than before. This is the best advantage of the dual turbo for performance at low fuel consumption.
The injection with piezo-electric injectors and highly efficient fuel pump helps fuel the engine to reduce fuel by using extremely precise intervals and under extremely high pressure spraying, resulting in a highly effective combustion.

Low emissions and clean air
“The technology that contributes to reduced fuel consumption will also provide a reduced burden on the environment,” says Derek Crabb. “Reducing harmful emissions and soot particles was one of the basic requirements in developing the new engine.”
In addition to the twin turbo chargers, the piezo-electric fuel injectors and improved Exaust Gas Recirculation (EGR), the new D5 engine also equipped with ceramic glow plugs, a high-tech solution for an excellent cold start the engine makes, because they are very quick hot. Within two seconds, they reach a temperature of one thousand degrees Celsius. As the engine started easily and quickly, and the emission of pollutants reduced.
Under certain circumstances, for example, while driving at low speeds, the ceramic glow plugs also help the temperature in the cylinders in order to improve the combustion process.

The advanced injection technique makes it possible for additional fuel in small quantities to normal after injecting fuel injection. This process aims to excess soot particles in the exhaust gas to remove.

To achieve a low emissions of soot particles to be, a free and efficient engine can ‘breathe’. The new D5 engine Volvo is at this point very successful thanks to the best regular air to the cylinders.

‘Thanks to the perfect household air and the low carbon emissions, we have the harmful emissions from the engine significantly reduced. We are proud of the new Volvo S80 D5 and not ashamed of us for the double exhaust, “says Derek Crabb.

From start to delivery in three years
Five new diesel engine is the first of the new division of Volvo engaged in the development of diesel engines.

“The whole development of the engine, from the time we got the contract to the assembly in the car, has less than three years. This is a benefit of size, “says Derek Crabb. “And we continue to engine life ‘follow’. That makes it easier for us to further improve and develop other Volvo models. ”
Volvo’s objective was to create an engine performance and comfort that meet the high demands of customers in the segment of the Volvo S80. Moreover, he had to meet the stringent environmental requirements of the future.

The engine is built on a modular system, both in the design and production. There are standardized mounting points for the turbine and other components, making it easier for the engine in other Volvo’s site. In addition, it provides additional opportunities for further development to meet future requirements.
“The modular approach also ensures that the engine can be easily built in the factory,” says Derek Crabb. ‘To the right conditions and optimal working conditions, and the highest production quality to ensure we exchange experiences and ideas with the highly experienced staff in our factory. ”

Technology in brief
The D5 engine is made entirely of aluminum. This reduces the weight and provides a good warm.

Optimized cooling of the cylinder as the engine provides optimum control of temperature, thus contributing to the reliability and longevity of the engine.

The two turbochargers are different in size and together deliver an extreme high loading pressure of 1.8 bar on a large toerengebied. The smaller turbo works at low speeds and reacting more alert than the large, for a quick response to pressing the accelerator. At higher speeds, the larger turbo on it for extra traction when accelerating at high speeds. In addition to the improved performance and reduce fuel consumption, the twin-turbo technology for a more efficient operation of the EGR system.

The volume of the EGR cooler to him and be equipped with effective cooling fins, it is possible to warmteafdrijving much as 25 percent increase. As a result, the recycled gases much cooler, and the emission of nitrous oxide (NO2) reduced to a level that the emission EURO5 easily reach. NOx contributes to the formation of ozone at ground level and is one of the reasons for overloading and acidification of soils and groundwater. Nitrogen oxides also affects the respiratory system.

The piezo-electric fuel injectors are used in combination with a highly efficient fuel pump to an injection pressure of 1800 bar as much as possible.

This type of injector has a spray which the response is half that of a conventional injector. This allows the number of injected fuel very precisely tailored to the needs at that time. A more effective combustion, lower fuel consumption and reduced emissions of harmful emissions are the result.

Its speed can be a piezoelectric fuel injector to inject seven times per cycle. In combination with the high pressure of the fuel is injected, the small quantities of fuel injector issue before the actual time of injection, even if the engine over 3,000 rpm running. This also explains why the engine is so quiet.
The piezo-electric injector can also extremely small quantities of fuel issued after the actual time of injection. The regeneration process of the particle could take place even at low speeds.

The D5 diesel engine is equipped with common-rail technology with a stainless steel fuel rail. This is specially designed to function under high pressure. The injection pressure can reach up to 1800 bar.

The fuel pump performs high-pressure pump and has two elements instead of three as in the previous generation D5 engines. The pump runs it easier, with less load on various components of the pump. And a pump that is more flexible, it has limited fuel.

Ceramic glow plugs are high-tech components with an excellent cold start the engine as possible. They are extremely fast temperature and reach a temperature of 1,000 degrees Celsius within two seconds after the cold start. The maximum temperature in which they operate is 1300 degrees Celsius, about 30 percent higher than that of conventional ignition coils. With ceramic glow plugs, the engine started immediately, without pre-annealing, even at temperatures of -30 degrees Celsius.

Instead of using a dipstick, the driver via the Information alerted to the need to fill motor oil. The system even indicates how much oil is needed.

Finally, the engine support further developed and adapted to the high torque of the engine. The engine is supplemented with support third torsion rod to stabilize the engine during heavy acceleration.

Specifics of the new D5 engine (EURO5 emission) for the Volvo S80

Number of cylinders

2400 cm3

Bore x stroke
81 x 93.15 mm

Number of valves

Double, parent

16.5: 1

700 t.p.m.

Maximum Speed
5000 t.p.m.

Maximum power (hp (kW) / t.p.m.)
205 (151) / 4,000

Maximum torque (Nm / t.p.m.)

Electronically controlled common-rail injection

Injection Press
1800 bar

180 kPa


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