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Chevy Corvette

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CARS ARE BACK! Tech Preview of the 2005 Domestics BY PAUL WEISSLER Chrysler 300 After a multiyear infatuation with SUVs, the domestic automakers have ‘rediscovered’ the automobile. Our annual report covers several all-new models that have resulted from this new marketing direction.

ord is calling 2005 the Year of the Car, and is introduc- ing brand-new cars and carlike “” vehicles. But Fit’s not alone, as and the Chrysler Group also are focusing on the passenger car for 2005. At Ford, the new Mustang gets the most head-turning looks, of course, but the new Ford 500 and Mercury Montego sedans, and the Freestyle “almost SUV,” are a higher volume group. At Chrysler, the in-your-face 300 and Dodge Magnum wagon are getting plenty of attention. And GM has several significant new Dodge Magnum cars—the compact Chevrolet Cobalt (which replaces the Cava- lier), Pontiac G6 (replacing the Grand Am), Buick LaCrosse (replacing the Regal and Century), STS (replacing the Seville) and the Corvette, which is irreplaceable. Let’s delve further into it and see what the three domestic camps are offering for 2005. Ford The Ford 500 and its sister Mercury Montego clearly are cars, but what’s the Freestyle? The North American jury placed it in the truck/SUV category (it has suspension modifications to increase ride height and a wagon-type body with three-row seating), but it’s technically very close to the 500. So we’ll save the truck report for the real trucks and less carlike SUVs, and cover the Freestyle and similar vehicles here. The 500/Montego/Freestyle is built on a Volvo S80 platform with a Ford Duratec V6 and a ZF-designed CVT (con- tinuously variable ). But if the buyer has a thing against CVTs, there’s a six-speed automatic made by Aisin (which is also used by Toyota) that’s a no-cost alternative on Ford 500 front-drive versions of the 500/Montego.

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The engine is the 3.0L Duratec V6. ratio for decent acceleration—the bigger? It couldn’t. The engine was en- It develops just 203 hp and 207 ft.-lbs. 500/Montego does 0 to 60 in just about larged from 2.5L and 3.0 is as big as it of , which may seem like margin- eight seconds, which matches the new could go. There’s a new V6, starting at al power. However, combined with the Chrysler 300 with a 3.5L V6. Why 3.5L and presumably going to over 4.0, CVT—which provides a tall overall gear didn’t Ford just make the 3.0 Duratec that will be out soon and eventually will go into these cars. Other Ford V6s, such as the 4.0L single OHC in the Ranger and Mustang, are cast-iron, two-valve units that produce no more power and are just not suitable and too heavy for the transverse mounting. Even the Duratec wasn’t an easy in- stallation in the new powertrain com- partment. Ford had to relocate the wa- ter pump to the rear, and direct-drive it—which means no pulley and belt— off the back of the . The Ford/ZF CVT uses a chain, and is a design somewhat similar to that used by Audi. This contrasts with the steel-link belt used by most other mak- ers, including Nissan and Honda, and that was used by GM until this year. The Duratec 3.0 V6 is the one and only engine for the Ford 500/Mercury Mon- The AWD system is the Haldex design tego and Ford Freestyle. However, even this engine posed packaging issues. In- also used in the Volvo XC90, except for stalling the water pump on the rear of the engine and driving it directly off the minor calibration differences. An elec- camshaft solved the fitting-it-in problem. To facilitate flush & fill services, an tronically controlled hydraulic pumping air bleed is installed on the top of the coolant hose attached to the pump. system applies a multidisc clutch to re- 1 spond to slippage in as little as ⁄7 of a Developed in wheel turn. Europe and The new Mustang chassis is really made by ZF, the new—no more reworking of the 27- Ford CVT uses a chain drive year-old Fox platform. Its chassis is rather than somewhat akin to the one for the Lin- the steel-link coln LS/Thunderbird platform, but un- belt of other like the independent-suspension rear- CVTs. It per- drive LS/Thunderbird, Mustang contin- mits a large ues with a solid rear . The base en- ratio spread— gine is the 4.0L single OHC V6, a two- 6—which en- valve overhead-cam 60° engine that de- ables Ford to velops 210 hp and 240 ft.-lbs. of torque, have tall gear- heavily reworked to make the move ing for accel- eration, and from the F-150 to a car. It’s a quantum good 0-to-60 improvement over the 3.9L 90° pushrod numbers with V6 previously used, which developed a relatively 190 hp and 220 ft.-lbs. of torque. Two- lower-perfor- thirds of Mustangs are V6-equipped. mance engine However, the muscle comes from a for the vehicle three-valve version of the 4.6L SOHC size class. V8, which produces 300 hp—same as the 5.4 V8. The three-valve head de- sign, adapted from the 5.4L V8 in the F-150, also has , charge motion valves in the man- 9 ifold and uses the ultra-thin ( ⁄16-in. hex) spark plugs.

Photos: Paul Weissler Paul Photos: If Ford can produce 300 hp with the

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CARS ARE BACK! Photo courtesy Ford Motor Co. Motor Ford courtesy Photo The three-valve head (two ), with a single overhead camshaft, is an engineering feature in the new 4.6L Mustang V8 that was adapted from the Ford F-150 truck engine. Like the truck’s 5.4 V8, the Mustang’s 4.6 V8 develops 300 hp. IfIf thethe chartchart same systems in the 4.6 V8, you may used for lateral stability, and the longer wonder why it didn’t get more horse- leg at the rear, where a softer (hydraulic) power with the larger displacement 5.4 bushing both absorbs road vibration and atat rightright isis V8. The reason is that the 5.4 V8 pro- controls chassis fore & aft movements. duces the 300 hp at 5000 rpm and 365 The three-link rear suspension fea- ft.-lbs. of torque at 3750 rpm. The high- tures a massive center-mounted torque missing,missing, strung 4.6 V8 develops its 300 horses at control link attached to the top of the 5750 rpm, and 320 ft.-lbs. of torque at banjo, a design prominent in racing cir- 4500 rpm. cles. There’s a trailing arm at each side please circle The Mustang has an advanced design and a stiff rod (called a Panhard rod) please circle MacPherson strut front suspension that from one end of the axle to the chassis uses a reverse L-shaped lower control at the other end, to maintain lateral lo- arm. The lightweight steel design cation of the axle. #40#40 onon thethe weighs about the same as cast alu- Five-speed manuals are standard— minum. The reverse L-shape isolates specific ones for the two —but the control bushings. It puts the shorter the engines share a five-speed automatic. ProductProduct leg at the front, where a firm bushing is Gone is the 2.0L, 110-horse base InformationInformation CardCard onon pagepage 65.65. Photo: Paul Weissler Paul Photo: The charge motion valves in the intake manifold on Ford’s 4.6 V8 create an air swirl at lower engine speeds, promoting better fuel mixing in the cylinders. The valves are on a shaft with a computer-controlled linkage.

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four-cylinder in the Focus, a pickup from the retired Escort. It’s been re- placed by another 2.0L Four that devel- ops 136 hp. It’s a shorter- version of the 151-hp, 2.3L Four that’s the op- tional engine, and in 2004 was the PZEV (Partial Zero Emission Vehicle) engine used in California. For 2005, the 2.0 Four is Ford’s PZEV entry. Chrysler The new Chrysler 300 has been out since the spring, so its in-your-face grille should be a familiar sight by now. Same with the Dodge Magnum, a built on the same new rear-drive platform. All-wheel-drive is optional on both vehicles. You’ve probably heard about the 340- Photo: Paul Weissler Paul Photo: hp, 5.7L Hemi pushrod engine, but The reverse-L lower control arm on the new Mustang is a lightweight steel most 300s and Magnums will go out the design (comparable to aluminum). The rear pivot is in a hydraulic bushing. door with one of two OHC V6s. There’s the base engine, a 190-hp, 2.7L V6 from the discontinued L/H front-drive cars (Dodge Intrepid, Chrysler Con- corde, etc.). Then there’s the 250-hp, 3.5L V6, the engine used in the discon- tinued front-drive 300M. For the new models, the V6s are mated to a version of the 42LE four-speed transmission that was modified to provide an output for a propshaft to the rear wheels. The optional AWD system has a single- speed planetary-gearset center differen- tial with a fixed torque split of 38% front, 62% rear. The V6 engines are basically the Panhard Rod same as in other Chrysler applications, but with new plastic intake manifolds. The 2.7 V6 has a two-stage manifold Co. Motor Ford courtesy Photo (one electric motor-operated valve), the The rear suspension of the new Mustang has a center torque control link on top of the banjo, trailing arms, a sway bar and a Panhard rod to locate the solid rear axle. 3.5 V6 a three-stage unit (two motors). Eight press-in-place gaskets—one for bank) with special two-section hydraulic ic” powertrain computers that if re- each port—ensure good sealing for the lifters that contain spring-loaded pin placed are supplied blank. They must plastic intake manifold. valves. The springs keep the pins in po- be programmed before use, and that The 5.7 Hemi V8 is the first U.S. en- sition to maintain the operating height means a Pass-Thru device (meeting gine to actually go on the market with of the lifters. But these pins are open to SAE J2534) that connects to your shop the multidisplacement system (cylinder ports that align with oil passages from PC. The software is available on the cutouts) since the Cadillac V8-6-4 of four computer-controlled solenoid Chrysler www.techauthority.com web- nearly a quarter of a century ago. Elec- valves. When the solenoid valves open, site under “FLASH.” There are two tronics and the electromechanical de- oil pressure pushes the spring-loaded powertrain computers—one for the two vices they control have come a long way pins in, and one lifter section collapses V6s and one for the Hemi V8 (not the in that time, and the Hemi switches within the other. With the lifter col- same computer as used in other Hemi from 8 to 4 cylinders and back with lapsed, the valve doesn’t open. A similar applications). great smoothness, providing a measur- system is being introduced by GM in The engine compartment has to ac- able improvement in fuel economy. the 5.3L V8 in its SUVs and pickups. commodate the big V8, so you won’t There are four cylinders (two on each All three engines come with “gener- find the battery under the hood. It’s in

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the trunk on the 300, in a rear storage equipped with yaw-sensing electronic wells into the floorpan, however, raises area on the Magnum wagon. stability control. the issue of “oil canning” (drumming) The suspension for both vehicles is a The underbody has seven plastic aero noises. To maintain silence, Chrysler Mercedes design. The front has a tall covers, which reduce drag and (in front) has made extensive use of so-called knuckle with a high-mount A-type up- direct airflow for brake cooling. The Quiet Steel, a steel sandwich containing per arm, a shock absorber with a top- muffler is a semisaddlebags shape, to a fiber isolation pad, plus mastic patches half coil spring and two parallel lower provide a cooling airflow path up to the and foam blocks or injected foam into arms that connect to the bottom of the rear axle banjo. A replacement muffler body cavities. “Stow & go” was consid- knuckle with separate ball joints. The would have to be the same shape to ered such an important feature for the AWD front suspension design is similar, provide adequate cooling. minivan market that Chrysler dropped but the members are reshaped to pro- The Chrysler minivans’ “stow & the AWD option; it just couldn’t pack- vide clearance for the axle shafts. The go” system allows both second- and age AWD with the deep floor wells rear suspension is a five-link design with third-row seats to fold into the floor, needed for the seats to fold down. If a coil springs mounted to an isolated cra- producing a flat floor from the rear of customer really wants AWD, Chrysler dle. Most 300 and Magnum models are the front seats to the liftgate. Building will be happy to sell him a Pacifica. The Chrysler Pacifica has had sales troubles, so for 2005 there’s an entry- level model at a lower price. How can you identify it? Well, it won’t be equipped with AWD and it won’t have the 3.5L OHC V6, which wasn’t exactly a stormin’ stocker in this not-so-light ve- hicle. Instead, you’ll find the 3.8L pushrod V6 used in the minivans. It de- velops just 210 hp (vs. 250), but only 10 ft.-lbs. less torque (240 vs. 250), so there’s probably not much difference. Also, the pushrod is a lower-cost engine. General Motors From the GM camp, the Cadillac Although the Hemi V8 is the glamour engine, most Chrysler 300s and Dodge Seville is gone, but the STS (which had Magnum wagons will have a V6, and this 3.5L V6 (which had been used in the been the top model in the line) is a front-drive 300M) is it. The rear of the engine tucks under the top rear of the engine compartment, reminiscent of cab-forward models. nameplate of its own for 2005. The STS is the latest model on the GM Sigma rear-drive/AWD platform, joining the CTS and SRX. It’s also the biggest, at 196 in. long. That leaves the DeVille as Cadillac’s only remaining front-drive car. The STS gets a base six-cylinder en- gine, the 3.6L GM “world” engine, which develops 255 hp and, like the 4.6L Northstar V8, features variable in- take and exhaust valve timing. This en- gine will be going into other premium GM vehicles, including the Buick Ren- dezvous and a new model, the LaCrosse. However, the 320-horse Northstar V8 is the optional engine, and it’s available in an AWD package—three open differentials with 40/60 front-rear torque split and four-wheel traction Photos: Paul Weissler Paul Photos: Four cylinders in the 5.7L Hemi V8 have special two-section lifters, each with a control. Cadillac also is introducing a spring-loaded pin (circled, shown removed from a lifter). When oil pressure is ap- dual-strategy version of its Magne-Ride plied to the pins, the lifters collapse (one section into the other), and the engine suspension (a computer-controlled elec- runs on four cylinders. This occurs during cruising operation, when loads are low. tromagnet at the shock absorber orifice

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and shock fluid mixture with iron pow- der). The driver can choose between performance and touring control with the press of a dashboard button. Incidentally, before you quote the price of an oil change on an STS, here’s something you should know: Although the 3.6 V6 has a 5-qt. capacity, the Northstar takes 10 qts. And don’t let the driver leave the car without handing over the electronic ID fob that replaces the remote. With the ID fob in his pocket, he can push a button to start the car, drive it, etc., but you can’t if he’s taken it to work. If by some chance you’ve already seen a keyless start 2004 Cadillac XLR or some European with a similar system, you know the routine. You’ll also find that system on The saddlebag shape of the muffler on Chrysler 300s/Dodge Magnum wagons the new Corvette. provides a path for underbody airflow to cool the rear axle banjo. Would you believe that the small block V8 is celebrating its 50th birthday a version of GM’s Magne-Ride (with Don’t say we didn’t warn you. Of in the new Corvette? Okay, the current touring and sport-selectable settings) course, most Bonnevilles aren’t GXPs, engine really dates back only about sev- and the competition version. The tires and they’re equipped with the Series II en years, and it’s been substantially re- are Goodyear run-flats, on 18-in. wheels 3800 V6. worked since ’97, with noteworthy in front, 19-in. in the rear. GM made a large investment in changes for 2005. The base engine is up You’re probably just now seeing the changing over Buick’s aging Regal and from 350 to 400 hp, close to the 405 of 2004 Chevy Malibu in significant Century to the new LaCrosse. It’s a far the high-performance LS6 version in numbers. Now there’s a Pontiac version, more stylish car with a premium look, the 2003-04 Z06 model. GM adapted the G6, which is technically the same but is still front-drive. Much of the in- some of the LS6 engineering, including (3.5L V6, etc.) but much sharper look- vestment went to make the car very qui- the cylinder heads, but the big change ing. It replaces the Grand Am. et—even the glass has a layer of sound- was the increase in displacement from What would be your reaction if you deadening laminate. Another chunk was 5.7 to 6.0L (cylinders bored out from lifted the hood of a Pontiac Bon- spent to rework the suspension and 3.90 to 4.0 in.), a larger diameter throttle neville and saw the Cadillac Northstar steering, so the car has a more contem- body and new fuel injectors, which actu- 4.6 V8? No, the owner didn’t do a swap. porary road feel and handling. Power- ally are smaller than the previous ones. GM is installing what had been a Cadil- plants are the familiar 3800 V6, but Se- The 0-to-62 mph time is 4.2 seconds, lac exclusive powerplant in a premum ries III, and a 240-hp version of the 3.6L and if that’s not fast enough, there’s an Bonneville model, the 2005 GXP. “world” V6 is available as an option. optional Z51 package that lowers it to 4.1 seconds—with different ratios in the . The car itself is built on the same platform as the previous Corvette gen- eration, but with an all-new body that’s 5 in. shorter and 1 in. narrower overall. Most noticeable are the first exposed on a Corvette since 1962— xenon HID (high-intensity discharge). And the also is the first one with a power softtop (optional) since ’62. The basic configuration of the inde- pendent suspension still is short-long arm in front, transverse leaf spring in Photos: Paul Weissler Paul Photos: the rear, but every single part was re- The throttle body for the 2005 Corvette (right) is noticeably larger than the designed—no carryovers. There are 2004 version. Engine breathing was enhanced to increase standard horse- three suspension calibrations: standard, power from 350 to 400 for the V8, which was enlarged from 5.7 to 6.0L.

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The provides a major power boost, from 140 hp for the normally aspirated 2.2 Ecotec in the Saturn ION to 205 for the 2.0L version in a performance model This supercharged Chevy engine is water-to-air inter- called the Red Line. The supercharged engine also is used cooled. This cutaway shows the , which is in a version of the new Chevrolet Cobalt called the SS. neatly positioned directly under the supercharger.

But let’s back up to the 3800 V6. Relay, are powered by the 3.5L V6 also has dropped the one used with the Did we say Series III? Yup! Not only is used in the Chevy Malibu. All continue VUE four-cylinder. Although it was a the 3800 V6 still around (it goes back to offer the Versatrak AWD system conventional steel belt design CVT, it over 40 years), but there’s Generation (gerotor oil pump, multidisc clutch cou- was delayed by production problems in III for 2005. It meets the ultra-tight pling). The AWD models also get a fully a new Hungarian plant, and GM appar- SULEV (Super Low Emission Vehicle) independent rear suspension, which also ently never completely overcame them. standards, with help from a close-cou- goes into the front-drive Terraza, which So a GM four-speed automatic takes its pled larger catalytic converter, three- is an upscale model. The Uplander, place. The V6 automatic is a five-speed. point air injection and faster acting oxy- Montana SV6 and Relay without the The Cavalier and Sunfire were hope- gen sensors. It doesn’t cost much to Versatrak get the less costly twist axle. lessly out of date, and after a quarter build, gets good fuel economy and of- GM wants Saturn to shed the dowdy century of tweaking, they’re gone. This fers decent performance, too. image, so now there are performance year Chevy gets a new econocar, the The new version—installed in the models labeled Red Line. It’s straight- Cobalt, which is technically almost Buick LaCrosse and Pontiac Grand forward for the VUE—just order the identical to the Saturn ION—also built Prix—produces 200 hp, a minute drop Red Line package. The suspension was on GM’s Delta platform, but without from the previous 205. But the super- lowered an inch and recalibrated, and ION’s plastic body panels. The Cobalt charged version, available in the Grand the car was given a sportier-feel electric also gets the 2.2 Ecotec, and there’s an Prix, is rated at 260. GM added engine- power steering. And with it comes the SS model that’s got the same 2.0L su- to- braces and a structural oil Honda V6, which produces 250 hp, a percharged engine and five-speed man- pan, plus improved oil seals and gaskets healthy boost over the sister Chevy ual as the Red Line. to both II and III. Series II still is in Equinox’ 185-hp GM pushrod 3.4L V6. There’s a “new” 210-hp, 2.8L V6 that production until its line is converted. The Red Line ION is an appealing replaces the -designed 220-horse, You’ll find the 3800 Series II in the car for about 20 grand. A 2.0L version 3.2 V6 base engine in the Cadillac CTS. 2005 Chevy Impala and Monte Carlo, of the Ecotec 2.2L Four is super- Where’d it come from? Answer: It’s just Pontiac Bonneville and Buick LeSabre charged and air-to-water intercooled, the 3.6L “world” V6 with a smaller and Park Avenue. boosting horsepower from 140 to 205. and stroke, and 45 fewer horses. If you What’s a crossover sport van? It’s a The heavy-duty front axle has equal- want the bigger engine, it’s a CTS option minivan with SUV cues and new names length shafts to minimize torque steer, at a higher price. Externally, the 2.8 and at GM: Chevy Venture becomes Uplan- and four-wheel-discs with ABS and a 3.6 look identical to the naked eye. der, Pontiac Montana becomes Mon- race-tuned lowered suspension with 17- tana SV6 and Olds Silhouette is gone, in. wheels and Continental perfor- Visit www.motor.com to download but meet the Buick Terraza. Those mance tires. a free copy of this article. three, plus a Saturn version called While Ford has adopted a CVT, GM

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