The biggest strategic engine initiative in the history of Mercedes-Benz will enter its decisive phase in 2017. Following the launch of the new four-cylinder diesel engine in spring 2016, next year will see the addition of no fewer than four more members to the all-new family of engines: six-cylinder in-line engines in both diesel and petrol versions, a new four-cylinder petrol engine and a new biturbo V8. At the same time, there will be world premieres for ground-breaking technologies, such as the Integrated Starter-Alternator (ISG), the 48 V electrical system and the electric auxiliary compressor (eZV). These new technologies are tuned to the vehicles on state-of-the-art test rigs at the equally new Powertrain Integration Centre (AIZ) in Sindelfingen.

"More powerful, more economical and cleaner - the new modular family of engines from Mercedes-Benz offers the right powertrain for every vehicle," says Prof. Dr Thomas Weber, 62, Member of the Daimler Board of Management with responsibility for Group Research at Daimler AG and Mercedes-Benz Cars Development. "The systematic optimisation of our high-tech engines plays a crucial role in the road map towards sustainable mobility. They also need to be designed with a view to all current and future requirements. A key success factor in this regard is the extensive electrification of the powertrain."

Systematic electrification: new six-cylinder in-line petrol engine M 256

The new six-cylinder in-line petrol engine M 256 represents an outstanding example of electrification, including a 48 V electrical system. New, intelligent turbocharging, e.g. with an electric auxiliary compressor (eZV), as well as an Integrated Starter-Alternator (ISG) provide the guarantee of excellent drivability with no turbo lag. The ISG is responsible for hybrid functions, such as boost or energy recovery, while allowing fuel savings that were previously reserved for high-voltage hybrid technology. The bottom line is that the new six-cylinder in-line engine offers the same performance as an eight-cylinder machine while being much more fuel-efficient. The new petrol engine (internal code: M 256) launches next year in the new S-Class.

Systematic electrification dispenses with the need for a belt drive for ancillary components at the front of the engine, which reduces its overall length. The narrow construction, together with the physical separation of intake/exhaust, creates space for near-engine exhaust aftertreatment. The 48 V electrical system serves not only high power consumers, such as the water pump and air-conditioning compressor, but also the Integrated Starter-Alternator (ISG), which also supplies energy to the battery by means of highly efficient energy recovery.

An additional bonus is the unsurpassed refinement of the six-cylinder in-line engine. Output and torque are similar to the current eight-cylinder engine, i.e. over 300 kW (408 hp) and more than 500 Nm. In comparison with the previous V6, the CO2 emissions from the engine have been reduced by around 15 percent.

At 500 cc, the new machine has the same displacement per cylinder as the premium diesel engine family unveiled last year as well as the family of four-cylinder petrol engines.

Most powerful passenger-car diesel engine in the history of Mercedes-Benz: six-cylinder OM 656

The new top-of-the-line engine in the premium diesel family is likewise a six-cylinder in-line machine. The characteristics of the OM 656 include the stepped-bowl combustion process, two-stage exhaust turbocharging and, for the first time, the use of CAMTRONIC variable valve timing. Its design features a combination of aluminium engine block and steel pistons as well as further-improved NANOSLIDE® coating of the cylinder walls. Although there is a significant increase in output compared with the previous OM 642 (over 230 kW/313 hp instead of 190 kW/258 hp), the new engine consumes more than seven percent less fuel.

Like the already unveiled four-cylinder OM654, the new six-cylinder diesel engine OM 656 is likewise designed to comply with future emissions legislation (RDE – Real Driving Emissions). All the components of relevance for efficient emissions reduction are installed directly on the engine. The integrated technology approach of new stepped-bowl combustion process, dynamic multi-way exhaust gas recirculation and near-engine exhaust aftertreatment, combined for the first time with variable valve timing, opens the way for further reductions in consumption together with extremely low emissions. Thanks to the near-engine insulated configuration, exhaust aftertreatment has a low heat loss and extremely favourable operating conditions. This is reinforced by the CAMTRONIC switchable exhaust camshaft, which supports the consumption-neutral heating of the exhaust system.

Number of cylinders to suit the requirements: new V8 biturbo petrol engine M 176

Dynamic power delivery combined with high efficiency: the new biturbo (internal code: M 176) is one of the most economical V8 petrol engines in the world. Its special features include cylinder shutoff at part load as well as the positioning of the turbochargers in the V between the cylinder banks. From its 3982 cc displacement, the new V8 biturbo produces over 350 kW (476 hp) with a maximum torque of around 700 Nm from 2000 rpm. The new engine will consume over 10 percent less fuel than its predecessor, which is rated at 335 kW (455 hp). The new V8 will launch with this technology next year in the new S-Class.

For lower fuel consumption, when operated at part load the new M 176 shuts off four cylinders simultaneously by means of CAMTRONIC valve timing. This reduces the pumping losses while improving the overall efficiency of the remaining four cylinders by shifting the operating point towards higher loads.

Sporty specific output: new four-cylinder petrol engine M 264

A two-litre four-cylinder engine with a specific output of around 100 kW: the new Toptype petrol engine from Mercedes-Benz (internal code: M 264) advances into output regions previously reserved for high-displacement six-cylinder machines. At the same time, it consumes significantly less fuel than a comparable six-cylinder engine. The engine's special features include twin-scroll turbochargers, belt-driven 48 V starter-alternator (BSA) and electric 48 V water pump.

The BSA is also responsible for fuel-saving hybrid functions:

- Easy start: virtually imperceptible starting and acceleration of the engine
- Boost in the engine-speed range up to 2500 rpm
- Energy recovery up to 12.5 kW
- Shifting of the load point: allows operation in a more favourable area of the engine map
- Coasting with engine off.

In the interests of high power output and a spontaneous engine response, Mercedes-Benz has opted for twin-scroll turbocharging. Unlike conventional systems, a twin-scroll turbocharger merges the exhaust gas ducts of cylinder pairs in the flow-optimised manifold. This turbocharging concept with systematic cylinder flow separation produces high torque in the low-rpm range together with high specific output. Further efficiency measures include intake CAMTRONIC and a friction loss reduction package.

Even cleaner: particulate filter for petrol engines as standard

Mercedes-Benz is the first manufacturer to opt for the large-scale use of particulate filters for petrol engines to further improve their environmental compatibility. After more than two years of positive experience in the field with the S 500, in 2017 further S-Class variants will be equipped with the new M 256 and M 176 petrol engines with this technology. The filter will then be gradually introduced in other new vehicle models, facelifted models and new engine generations, such as the M 264.

The particulate filter for petrol engines reduces the emissions of fine soot particles. How it works: the exhaust-gas stream is supplied to a particulate filter system. The filter has a honeycomb structure with alternately sealed inlet and outlet channels. This forces the exhaust gas to flow through a porous filter wall, which traps the soot. The filter can be continuously regenerated under corresponding driving conditions.

New Powertrain Integration Centre (AIZ): state-of-the-art test rigs

With its new Powertrain Integration Centre (AIZ), in summer 2016 Mercedes-Benz took into service one of the automotive industry's most advanced test facilities. A total of ten vehicle test rigs inside the all-new state-of-the-art building in Sindelfingen are used for such purposes as the fine tuning of engine and transmission – comfort, dynamics and agility are matched to each other. The highlights include test rigs with high-precision torque measurement directly at the wheels of the vehicle as well as a test rig with a climatic altitude chamber, which uses partial vacuum to simulate an altitude of up to 5000 metres at temperatures of down to -30°C, while the vehicle operates fully automatically on a chassis dynamometer.

The new building at the Sindelfingen Mercedes-Benz Technology Centre (MTC) houses ten vehicle test rigs for tuning vehicles and their powertrains. The new building used 16,800 m3 of concrete, equivalent to the capacity of five Olympic swimming pools. There were also 2500 tonnes of reinforcing steel. The designers of the AIZ attached great importance to energy recovery, with 98 percent of the electric braking energy produced on the test rigs being fed back into the power network. Also, the air conditioning of the test rigs is energy-neutral for two-thirds of the year, which means that no power is consumed from the joint network. With all ten test rigs in continuous operation, this would be the same as supplying around 7500 households with electricity.

Extension of the Mercedes-Benz Technology Centre

The new Powertrain Integration Centre is part of extensive additions and conversions to the Mercedes-Benz Technology Centre (MTC) in Sindelfingen. The new driving simulator, climatic wind tunnels and a high-tech aero-acoustic wind tunnel are already in operation. By 2018, there will also be a state-of-the-art technology centre for vehicle safety, an electronics testing centre and a computer centre. Housed on the upper floor of the AIZ, the computer centre will directly use the electricity generated downstairs on the test rigs in order to operate and cool the computers.

The MTC is home to the headquarters of the company's global Group Research and passenger car development, including design.








































Credits: Daimler AG

Copyright © 2016, Mercedes-Benz-Blog. All rights reserved.

Mercedes-AMG presents a new technological masterpiece: the AMG 4.0-litre V8 biturbo engine is a new development at the sporting heart of the new Mercedes-AMG GT car. This innovative eight-cylinder unit stands out for its sublime power delivery, the purposeful lightweight construction, as well as its high efficiency and environmental compatibility. With peak power of up to 375 kW (510 hp) and maximum torque of up to 650 Nm, the new AMG V8 delivers motorsport-inspired performance. The new sports car engine follows in an impressive V8 tradition that started in 1967 with the M100 in the legendary 300 SEL 6.8 AMG racing car and continues with trendsetting features of the future.

Powerful V8 engines have long been a core competence at AMG, the performance brand from Mercedes-Benz. Innovative and exciting high-performance engines come out of the location in Affalterbach. On this occasion, Mercedes-AMG GmbH is entirely responsible for both development and production.

Tobias Moers, Chairman of the Board of Management of Mercedes-AMG GmbH: "V8 engines are an integral part of the AMG philosophy and the brand's commitment to 'Driving Performance'. The V8 biturbo engine for our new GT is going to delight our customers!"

Christian Enderle, Head of Engine and Powertrain Development at Mercedes-AMG: "The new AMG 4.0-litre V8 biturbo sees us presenting an exciting and powerful sports car engine which, thanks to a number of measures, also represents the next step in efficiency."

First sports car engine with 'hot inside V' and dry sump lubrication

The new AMG V8 engine has two turbochargers which are not mounted on the outside of the cylinder banks but rather inside the V configuration – experts call it a 'hot inside V'. The benefits are a compact engine design, an optimum response and low exhaust gas emissions. Dry sump lubrication allows the engine to be installed lower, which moves the centre of gravity closer to the road and forms the basis for high lateral acceleration. The M178 (in-house designation) from AMG is thus the world's first sports car engine with hot inside V and dry sump lubrication. With a dry weight of 209 kg the new AMG V8 is also the lightest engine in its competitive segment.

The new AMG M178 V8 engine at a glance:


Superior power delivery and motorsport-inspired performance

As the latest member of the Mercedes-Benz BlueDIRECT engine family, the AMG M178 stands out for its superior power delivery and motorsport-inspired performance. It boasts an emotive and unmistakable AMG V8 engine sound, along with an immediate response and high pulling power. The torque curve is synonymous with good driveability: the peak of 650 Nm is available in the broad range from 1750 to 4750 rpm.

With a displacement of 3982 cc, in terms of technology the V8 is closely related to the AMG 2.0-litre turbo engine in the A 45 AMG, CLA 45 AMG and GLA 45 AMG, which is presently the most powerful, series-production four-cylinder engine in the world. Both AMG engines have the same bore/stroke ratio, guaranteeing high revving ability. Mixture formation comes courtesy of third-generation direct petrol injection with piezo injectors. The highly efficient and economical AMG 4.0-litre, V8 biturbo engine meets the Euro 6 emissions standard and the maximum particulate emissions level that takes effect in 2016.

Cylinder bore liners featuring NANOSLIDE® technology

The aluminium crankcase is produced using sand casting technology and features a closed deck design. This ensures extreme strength whilst keeping the weight as low as possible, and enables high injection pressures of up to 130 bar. The cylinder bore surfaces feature NANOSLIDE® technology which makes them twice as hard as conventional cast-iron linings.

NANOSLIDE® was developed by Daimler starting in the year 2000 and has so far been used in over 200,000 engines since 2006. The first unit with NANOSLIDE® technology was likewise an AMG V8: the extremely successful predecessor to the new AMG 4.0-litre biturbo. The application scope for this multi-award-winning technology has been continually widened. Since the start of the 2014 race season it is also being deployed in the new Mercedes F1 V6 turbo engine.

'Spectacle honing' is another measure to reduce friction and therefore consumption: in this complex process, the cylinder liners receive their mechanical surface treatment when already bolted in place. A jig resembling spectacles is bolted to the crankcase in place of the cylinder head mounted later. Any cylinder warpage that might occur during final assembly is therefore taken into account or eliminated as the cylinder liners are honed. This has advantages in terms of both durability and oil consumption. The new AMG V8 has forged aluminium pistons featuring a lightweight design and high strength. A low-friction piston ring package reduces fuel and oil consumption.

Dry sump lubrication for high lateral acceleration

Thanks to the use of dry sump lubrication, a conventional oil pan is redundant. Already installed low down, the engine could thus be dropped by a further 55 millimetres. This lowers the vehicle's centre of gravity, which is ideal for a sports car with extremely high lateral dynamics. In addition to improved agility, dry sump lubrication ensures direct oil extraction from the crankcases for optimal engine lubrication, even at high speeds on bends.

In the M178, dry sump lubrication deploys a suction pump, a pressure pump and an external oil tank with a capacity of 12 litres. The system circulates nine litres of engine oil in total. The oil suction pump extracts oil directly from the crankcases, cylinder heads and valve body assembly and delivers it to the external oil tank at a pump output of up to 250 litres per minute. Lubricant remains there for just five seconds before being pumped back around the high-performance engine. Efficient engine oil suction improves engine efficiency further. On-demand control of the pressure oil pump takes into account the engine rpm, temperature and load characteristics stored by the control unit. Made of plastic, the oil pan bottom section and oil tank are proof of a commitment to lightweight construction.

Cylinder heads with zirconium alloy

The cylinder heads in the AMG 4.0-litre, V8 biturbo engine are made of a zirconium alloy. The benefits are maximum temperature resistance and thermal conductivity. Four overhead camshafts control a total of 32 valves. Camshaft adjustment on the inlet and outlet side enables an excellent response and optimises the gas cycle for each operating point. Optimised valve springs and the low-friction valve gear with cam followers deliver further fuel savings.

Direct injection with spray-guided combustion

A combination of biturbocharging and direct petrol injection with spray-guided combustion increases thermodynamic efficiency, thereby reducing fuel consumption and exhaust gas emissions. Particularly fast and precise piezo injectors spray the fuel at high pressure into eight combustion chambers. Multiple injection occurs on-demand, ensuring a homogeneous fuel/air mixture. The delivery of fuel is electronically controlled and fully variable for a fuel pressure between 100 and 200 bar.

Biturbocharging with 'hot inside V'

Unlike the previous, conventional approach, both exhaust gas turbochargers in the new M178 are located inside the 'hot inside V' configuration rather than on the outside of the cylinder banks. The advantages of this layout are that the V8 engine is considerably more compact, which enables optimum weight distribution between the front and rear axle, as well as the low installation position. The 'hot inside V' also optimises the supply of fresh air to both exhaust gas turbochargers.

Electronically controlled blow-off valves ensure a very immediate and direct response. The maximum charge pressure is 1.2 bar; the turbochargers have a maximum speed of 186,000 revolutions per minute. For combustion purposes, 2.3 times more oxygen atoms are pressed into the turbocharged engine as would be the case in a naturally aspirated engine. The two firewall catalytic converters in thin-walled ceramic material positioned down from the exhaust gas turbochargers respond very quickly due to their close-coupled configuration. In conjunction with two metal, underfloor catalytic converters, the M178 delivers effective emission control.

Sports exhaust system with variable exhaust flaps

Excitement, emotive appeal and recognition value: at Mercedes-AMG engine sound is an important target during development. The new GT has a sports exhaust system with fully variable exhaust flaps. This gives the driver the ability to vary the engine sound: depending on the selected mode they may experience the new AMG V8 with a focus on comfort and relaxed, long-distance journeys or with a more emotive, motorsport-inspired touch. The M178 has its own tonal characteristics which denote the GT's membership of the AMG family but that also distinguish it from all other high-performance cars.

There is an exhaust flap on either side of the rear silencer which is actuated variably on a logic-controlled basis depending on the transmission mode, driver's power requirement and the engine speed. At low loads and engine rpm the flaps remain closed. This causes the exhaust gases to cover a longer distance and flow through an additional damping element so that the engine sound is pleasantly subdued and irritating frequencies are effectively suppressed. When the driver accelerates, the flaps progressively open so that although some of the exhaust gases cover the longer, acoustically dampened distance, most travel the shorter distance. Under full load at higher engine speeds, both flaps are fully opened, thus allowing the occupants to enjoy the powerful sound typical of an AMG V8. This means they are left in no doubt about the performance potential of the 375 kW (510 hp) eight-cylinder biturbo engine.

Efficient cooling of charge air, water and engine oil

For optimum power output even when outside temperatures are high, Mercedes-AMG uses indirect air/water intercooling. With optimum air and water flow, the charge air coolers have a separate, low-temperature water circuit.

The charge air coolers ensure that the intake air compressed by the turbochargers and heated to max. 140 degrees Celsius is cooled down effectively before it enters the combustion chambers. As a result, the charge air remains at a consistently low level of max. 25 degrees Celsius above the outside temperature, even under full load. A large radiator at the car's front end ensures controlled cooling of the water circulating in the low-temperature circuit. Extremely short charge-air ducting makes for optimum responsiveness.

The engine coolant is cooled using the particularly efficient cross-flow principle and there is a three-phase thermostat to warm coolant faster. Because the water pump is driven by a timing chain rather than the usual poly-V-belt, a simplified belt drive system is used with less clamping force. The advantages: less loss of drive power. With a rated flow of 420 litres, the water pump conveys the equivalent of more than two full bathtubs per minute.

An external engine oil cooler in the front apron of the Mercedes-AMG GT helps with heat management for the V8 engine. A two-stage, controlled oil pump circulates the engine oil: it varies the flow rate depending on load and engine speed requirement, thereby benefiting fuel economy. At high engine speeds more than 1.0 litre of engine oil per second flows through the oil lines and ducts. To save on weight numerous oil and water lines are made of aluminium.

Sophisticated solutions are also deployed on the engine's periphery:

- Separate cooling-air flow for the exhaust gas turbochargers under high thermal load

- Active engine mounts for excellent lateral dynamics with no loss of comfort

- Auxiliary units efficiently powered by two short, low-friction belts with four grooves. Intelligent positioning of auxiliary units virtually neutralises belt forces on the crankshaft.

- Two-mass flywheel with centrifugal pendulum prevents torsional vibration on the drive line for a smooth ride.

- ECO start/stop function and alternator management to save fuel

High-tech test benches for engines with over 470 kW

There are nine high-tech test stations in Affalterbach on which AMG engines with an output exceeding 470 kW and more than 1000 Nm undergo dynamic testing. These test facilities enable a very wide range of road and environmental conditions to be simulated to reproduce any conceivable type of operational scenario. Cold or hot starting, mountain passes, stop-and-go traffic or fast laps on the North Loop of the Nürburgring – the engines are required to give their utmost. Even different intake air temperatures and densities can be computer controlled.

Function and endurance benchtesting for the highest quality

The goal of the detailed bench tests is to verify the performance of all engine components, including the peripheral units. All measurement data for the engines examined is systematically compared and evaluated using reproducible test methods. The functional tests are accompanied by endurance testing. To ensure the very highest quality standards over their entire operating life, new AMG engines are required to undergo several thousand hours of endurance testing.

Extensive trials in every climatic zone on earth

Simultaneously the first test engines undergo intensive testing in practical trials. The standardised test programme at Mercedes-AMG includes all climatic zones and route profiles from the icy cold of northern Sweden to the merciless heat of Death Valley (USA), from fast laps on the North Loop of the Nürburgring and high-speed circuits in Nardo (Italy) and Papenburg to stop-and-go city traffic during rush hour. This programme makes the very highest demands on the day-to-day practicality, reliability and long-term durability of new generations of engine.

A tradition of hand-built excellence: "one man, one engine"

The AMG 4.0-litre V8 biturbo engine is being made in Affalterbach according to the "one man, one engine" principle. In the AMG engine shop, highly qualified fitters assemble the high-performance engines by hand according to the strictest quality standards. The fitter's signature on the AMG engine plate attests to this exclusive type of engine production and indicates maximum quality and technology transfer from motorsport – from Formula 1 and the DTM to customer sport activities in the SLS AMG GT3.

Long tradition of powerful AMG V8 engines

Powerful eight-cylinder engines are an inseparable part of Mercedes-AMG's history. Established in 1967, the company caused a stir with the 300 SEL 6.8 AMG which succeeded in taking second place at the 24-hour race in Spa-Francorchamps (Belgium) in 1971 for a class victory. The AMG racing saloon was technically based on the Mercedes-Benz 300 SEL 6.3 with the M100 V8 engine. With an engine output of 184 kW (250 hp) at 4000 rpm and a top speed of 220 km/h, this luxury saloon was Germany's fastest regular production car at the time. Classic tuning as well as an enlarged displacement from 6330 to 6835 cc resulted in an increase in output to 315 kW (428 hp) at 5500 rpm and in torque from 500 to 608 Nm.

Another important engine in the AMG story was the M117, its first eight-cylinder unit with a four-valve-per-cylinder design. With a displacement of 5.6 litres, 265 kW (360 hp) and 510 Nm of torque, this V8 accelerated the 300 CE 5.6 AMG to a top speed of 303 km/h. In 1987 this made the coupé the fastest German car in series production, and American AMG fans reverently christened it "The Hammer".

The supercharged AMG 5.5-litre V8 of 2001 is another milestone in the history of AMG engine development: the M113 K delivered up to 428 kW (582 hp) and 800 Nm of torque. The supercharged AMG 5.5-litre V8 of the SLR McLaren dating from 2003 was even more powerful – the M155 generated up to 478 kW (650 hp) and 820 Nm.

2005 saw the début of the naturally aspirated, high-revving AMG 6.3-litre V8 engine known as the M156, which developed up to 386 kW (525 hp) and 630 Nm depending on the model. Exclusively reserved for the SLS AMG, the likewise 6.3-litre M159 had a maximum output of 420 kW (571 hp) and maximum torque of 650 Nm. In the SLS AMG Coupé Black Series the M159 actually attained 464 kW (631 hp).

The AMG 5.5-litre V8 biturbo M157 engine delivers between 386 kW (525 hp) and 430 kW (585 hp) depending on the model, and a maximum torque of between 700 and 900 Nm. M157 is regarded as the most efficient engine in its output and displacement class.

With a high specific output of 128 hp/litre and consumption of considerably less than 10 litres/100 km (NEDC combined), the AMG 4.0-litre V8 biturbo engine leads the way in the long tradition of powerful V8 engines from Mercedes-AMG.

#MercedesBenzBlog, #MercedesBenz, #MercedesAMGGT, #MercedesAMG, #AMGGT, #MercedesAMGGTSpecial, #C190











~ Official photos and details courtesy of Mercedes-AMG GmbH ~

Copyright © 2014, Mercedes-Benz-Blog. All rights reserved.