InterviewInterview WilliamWilliam ClayClay FordFord JnrJnr RaceRace transmissionstransmissions ImprovingImproving onon thethe veryvery bestbest VolvoVolvo D5D5 LeanLean BoostBoost TheThe world’sworld’s firstfirst all-aluminiumall-aluminium DirectDirect InjectionInjection five-cylinderfive-cylinder dieseldiesel engineengine waswas NewNew routeroute toto engineengine downsizingdownsizing developeddeveloped inin recordrecord timetime –– withwith thethe Spring 2002 helphelp ofof Ricardo Ricardo know-howknow-how Our automotive systems make driving more of a pleasure. Today’s driver expects their journey to be a much more enjoyable And we continuously improve performance by using our and productive experience. understanding of vehicle dynamics and chassis systems to create ride and handling that improves the enjoyment of any journey. To deliver this, Visteon is continuously developing the in-car environment. Our interiors, climate control, communication and Our philosophy of designing systems with the driver in mind entertainment systems are flexible enough to meet drivers’ has prompted 18 of the world’s top 20 vehicle manufacturers to individual desires and, of course, their comfort and safety needs. work with us. From an environmental perspective, our engine management To find out more about how Visteon make vehicles more of systems cut emissions without cutting back on performance. a pleasure for today’s driver, visit www.visteon.com contents 14 Spring 2002 4 8 6 NEWS FEATURES QUESTIONS & ANSWERS Industry update 4 Volvo’s new diesel 8 William Clay Ford Jnr 6 Supercharged MINI Cooper S is launched With premium diesel sales poised for take- The removal of Ford CEO Jac Nasser last supported by Ricardo engineering, Visteon off, Volvo needed its own diesel engine. November stunned the industry. But the Ford develops a one-piece facia, Eaton unwraps Tony Lewin describes how, with help from Motor Company is fighting back under the a hydraulic energy-storage system, US Ricardo, it’s one of the most advanced of all guiding hand of Henry Ford’s great- government axes PNGV in favour of grandson, William Clay Ford Jnr. His Freedom CAR project, rear steer-by-wire That final two per cent 12 Revitalisation Plan will reduce capacity, arrives from Delphi. And Ricardo chief Audi dominates long-distance sportscar create redundancies, slash costs and make executive Rodney Westhead has a welcome racing. Ricardo supplies the transmissions. for a healthy and profitable Ford. He message So how can the best gearbox be made even explains to Anthony Lewis and Chris better? William Kimberley finds out Wright how it will work News from Ricardo 20 Ricardo publishes its new Diesel Report, Keeping the peace 14 Maxime Boniteau 18 plans a diesel seminar for May, and reveals The British Army frequently finds itself in a Renault is taking a very different approach growth and profits in its interim results. peace-keeping role. The Ricardo conversion to high-image luxury car design from the Ford’s Group A rally kit for the Focus 2.0 of a Land Rover into a Rapid Deployment conservatism favoured by the established features Ricardo calibration, and Dallara Vehicle makes the task a little easier leaders. As the radical Vel Satis is launched, chooses Ricardo transmissions for its new the company’s director of product planning single-seaters. Plus an insight into Ricardo Lean Boost Direct Injection 16 for upper range models explains the bold engineering support for Maserati’s new Direct injection brings fuel efficiency to strategy to Tony Lewin Spyder gasoline engines. Pressure boosting with a lean mixture brings even more, and could be the key to downsizing Editor: John Simister Ricardo enquiries Design editor: Paul Bale at Visual Image UK: +44 (0) 1273 455611 USA: +1 (734) 397 6666 Germany: +49 (0) 711 806082-20 Conceived and produced for Ricardo Czech Republic: +42 0296331150 by TwoTone Media Ltd Business development: [email protected] Anthony Smith [email protected] Head office: Ricardo plc, Bridge Works, Shoreham-by-Sea, Tony Lewin [email protected] West Sussex BN43 5FG, United Kingdom Spring 2002 Ricardo Quarterly Review 3 G in brief Cooper S raises MINI game US Army goes hybrid package, with the water pump Heavy duty hybrid trucks will ingeniously moved to the rear of be widespread in the US Army by the middle of the decade, the supercharger. improving both environmental External changes include a performance and “energy large hood scoop to feed the security”. Fuel currently intercooler, and the suspension accounts for 70 per cent of the has been stiffened to handle the bulk tonnage transported by extra performance. The other army vehicles during combat, major change is a six-speed but the army plans a 75 per gearbox with three shafts and cent cut in its fleet fuel con- two final-drive pinions, a configu- sumption by 2010. ration chosen for its compact- ness which suits the MINI’s Massachusetts slow to follow California restricted width. Following Texas and New The Cooper S marks the York, with Vermont also likely launch of the MINI brand in the to do likewise, Massachusetts US, where sales began in mid has decided not to adopt strict March. Japan was next, at the Californian emissions stan- The highly successful MINI the past two years – as reported the end of March, while dards yet. The main concern is range now has a Cooper S flag- in RQ Autumn 2001. European buyers must wait until the target of 10 per cent ZEVs ship, reviving the model name of With 163bhp, achieved with June (UK) and summer 2002 in new car sales, which is the ultimate original-style Mini the help of an Eaton supercharg- (other EU countries). It will be thought unachievable by the launched in 1963. The new car er, the Cooper S has a 48bhp worth the wait, as first press original 2003 adoption date. has a supercharged version of power advantage over the regu- reports suggest that the Cooper The new proposal is 2007. the 1.6-litre engine already seen lar Cooper. “Of course, the S S may be the most entertaining Netherlands proposes in the MINI One and MINI name refers to the shape of the hot hatchback since the mid- distance charging Cooper: the unit is built in Brazil intake path from the airflow 1980s Peugeot 205 GTI. “It even The Dutch government is plan- by Tritec Motors Ltda, a joint meter through the supercharger sounds like an original Cooper ning to charge all vehicles venture between the BMW and then the intercooler,” says S,” said one journalist, “because according to how far they are Group and DaimlerChrysler. It MINI powertrain leader it has a deep exhaust note and driven from 2004, using satel- represents the next stage in a Johannes Guggenmos, not the supercharger whine mimics lite technology. The idea is to programme with which Ricardo entirely seriously. He points out the old car’s transfer-gear noise.” make the scheme revenue- has been intimately involved for that the installation is a very tight JOHN SIMISTER neutral, so those driving over 18,000km a year pay more than now, others pay less thanks to reduced fuel, car and purchase taxes. Delphi launches rear US carmakers exhorted to use aluminium steer-by-wire The Aluminum Association GM’s Sierra Denali luxury pick-up has championed the lightweight become the first truck to be fitted with metal’s use at January’s four-wheel steering, although several Detroit Auto Show, giving cars have been so equipped during awards to Nissan for the the last decade. And, for the rear Altima and Chevrolet for the wheels, it is a steer-by-wire system. Trailblazer SUV. Both vehicles Delphi’s QuadraSteer uses signals use much aluminium, helping to reverse the trend towards from steering wheel angle and front ever-greater weight. wheel position sensors, computes them with road fronts which, says Delphi, greatly enhances stabili- speed information and decides which way the rear ty, especially when towing. Sulphur-free diesel in wheels should turn. This is possibly the first time rear-wheel steering Europe from 2009? In low-speed manoeuvres the rear wheels has been applied to a solid rear axle. Actuation is EU environment ministers turn up to 12 degrees in the opposite direc- by electric motor and a rack-and-pinion. have set 2009 as the target tion to the fronts. At medium speeds they Delphi is among the components manufacturers date for sulphur-free diesel. stay straight (the default position in case developing steer-by-wire for the front wheels, but This would enable vehicle of a system failure), and at as yet it is not legislated for by the European manufacturers to develop high speeds they Commission. Legislation is expected to be in place cleaner engine technology, turn a little in the by 2004, with low-volume production by 2005. currently inhibited by high lev- els of sulphur. same direction as Driving enthusiasts need not worry: Dr Ulrich the Eichhorn, Volkswagen’s executive director for AW Knowledge (AWK) research, environment and transportation, says [email protected] that with the right feedback sensors such a system can give excellent steering feel to the vehicle. AWK 4 INDUSTRY NEWS Ricardo Quarterly Review Spring 2002 Eaton previews hydraulic energy storage HYDRAULIC Launch Assist Detroit, the device could pro- (HLA) is the name of a new duce fuel economy improve- device, developed by Eaton, ments “as high as 25 or 30 per which can store and release cent”, significantly higher than kinetic energy in the form of claims made for electrical inte- hydraulic fluid pressure. grated starter/alternator devices. Revealed at the Detroit Auto The concept, patented by the Show in January, the device US Environmental Protection works by recovering some of the Agency, has been developed energy normally lost during brak- jointly by Eaton and Ford.