F1 EURO VI Step D diesel engines at IAA 2018

27th September 2018
Alex Lynn

At IAA 2018 in Hannover, FPT Industrial introduced its Euro VI Step D Standard. This new regulation will be applied to all new heavy duty commercial vehicles and buses registered from 1st September 2019. At IAA FPT Industrial exhibited a Diesel-Hybrid Powertrain featuring the F1A Euro VI Step D engine and is RDE (Real Driving Emissions) ready.

For the first time this 2.3l engine is presented in a configuration for heavy duty applications, as well as the other F1 family's engine, the three litre F1C. It is compliant with Euro VI Step D Standard, with increased performance reaching up to 210hp and up to 470Nm of torque.

The Diesel-Hybrid Powertrain on display is composed of an F1A Euro VI Step D engine, now suitable for heavy duty homologation, with a power range between 136 and 156hp. The engine, shown with this specific homologation configuration for the first time, was presented in a parallel-hybrid configuration, which enhances the already low emissions.

The other powertrain elements are the FPT Industrial 2835.6 manual transmission, the transfer box and the NDA rear axles. To be compliant with the Euro VI Step D Standard FPT Industrial's F1 Series adopts an external cooled EGR with SCR, as the best solution on Light Commercial Vehicles (LCV) applications to minimise vehicle dimensions constraints.

The F1A engine, has a displacement of 2.3l and combines the lowest emission rate in its category (RDE ready) with the qualities of a regular Diesel engine. It features durability and real driving low NOx emissions due to higher displacement than other manufacturers. It was completely re-engineered in 2016 and the developments focused on the reduction of friction, the optimisation of the cooling system and the adoption of a variable displacement oil pump, which led to a reduction of both fuel consumption and TCO.

Furthermore, with regards its LCV application, the F1A equips the IVECO Daily Blue Power, winner of the International Van of the Year 2018. To further improve fuel consumption and performance a new electronic Variable Geometry Turbocharger has been introduced.

FPT Industrial's F1 Series builds upon more than 35 years’ experience in commercial vehicles. In the LCV sector, in particular, FPT Industrial is currently the European market leader with some 300,000 units produced per year. F1 Series engines deliver optimum efficiency and performance, together with long service intervals.

The F1 series meets all worldwide emission certifications (from Euro 3/III to Euro 6d/VI D, JP09, EPA17) and it is reportedly the first LCV engine ready for the 2020 RDE regulation. With the introduction of the Euro VI Step D Standard, the F1C three litre engine will also feature increased performance and Heavy Duty homologation, reaching high performance, with up to 210hp and up to 470Nm of torque.

The F1 engines are available for both transversal and longitudinal installation, in diesel, CNG/LNG and hybrid versions.

Engines from the NEF and Cursor families (displacement range from 4.5 to 12.9l) will also be ready for the Euro VI Step D Standard. FPT Industrial is focusing its research and development activities in order to remain the innovation leader in the industrial powertrain field and a reference provider of the most cost efficient powertrain solutions for Euro VI step D. The Brand aims to comply with the new emission limits ensuring minimal impact on vehicle architecture and the lowest possible increase in cost, an objective that, for its medium and high displacement range, will be achieved through HI-eSCR technology.

The technology, based on more than 25 years’ experience and more than one million engines produced, allows FPT’s engines to meet Euro VI Step D standards without resorting to EGR (Exhaust Gas Recirculation), guaranteeing very high NOx conversion efficiency (over 95% versus 80-85% from competitors adopting EGR).

Based on FPT Industrial's engine range, Euro VI step D maintains the same base engine hardware of Euro VI Step C, allowing customers to retain their class leading features, such as minimised Total Cost of Ownership. Key to the optimisation of combustion efficiency is high mean effective cylinder pressure and high injector nozzle pressures. To achieve these aims, important changes to the crankcase and cylinder head design have already been made in Euro VI step C, resulting in an increase in structural rigidity and in swept volume.

The engines are fitted with the latest generation of multiple events Common Rail fuel injection equipment with peak nozzle pressures of up to 2,200 bar. An Electronic Control Unit manages both engine parameters and accurately controls the after-treatment system. The control unit has been designed to optimise packaging and to fully integrate all engine, SCR and DPF (Diesel Particulate Filter) functions.

For Cursor Series engines using the Variable Geometry Turbocharger, electronic control is used to optimise load response at low engine speeds and to increase the effectiveness of the engine brake. In addition, all engines make use of the flap type engine brake valve in order to support the after-treatment thermal management and to guarantee engine brake performance.

For the very best in environmental performance, engines are equipped with closed circuit engine breathing systems. By means of the optimised combustion regime, engine-out particulate emissions are very low, meaning that forced/parked regeneration of the DPF is not required, an important aspect in terms of fuel consumption and periodic servicing.

Furthermore, since the engine only breathes clean filtered air, rather than recirculated exhaust gases, engine wear is minimised and oil change intervals remain extended, with service intervals of up to 150,000 km without an increased oil sump. This also brings advantages in terms of operating costs and reduced down time for scheduled maintenance.

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