The new Medium Duty Engine Platform for

the Commercial Vehicles in the Volvo group

Olivier LOZAR, MD Platform chief engineer
Powertrain Engineering, Group Trucks Technology

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Background
Volvo Group truck brands are present in all continents
Highest volume in the Medium Duty segments are in South East Asia
High features and low cost are required at the same time
All emissions standards certified: Euro III to Euro VI and Tier 2 to Tier 4f
Targeting a wide offering with a minimum of part numbers

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B100 certified

Euro III

Hybrid

Euro VI

MD Engine Platform - Automotive Applications - 2014

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MDE platform running two races in parallel

Fuel efficiency /CO2/Alt. Fuel / Hybrid/ Cost of Ownership

Euro VI
pPNLT
Tier4F
Stage 5

Low cost / Reliable / Robust

2013-14
Deliver
Focused BRIC markets

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2015-2021
Expand

2022->

New technologies

Euro III/IV/V
Tier2/3

MDE Platform Industrial footprint

Blainville
VNX
Ageo

VECV

Current

Bangalore

Long Block Assembly

Final Engine Assembly
Truck Assembly

Long Block Supply

Full Engine supply

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Bangkok

MDE Long block definition

CH assembly
CB assembly
Camshaft
Crankshaft
Crank train
Valve train
Piston

MDE Long block supplier base 100% in India

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Oil trap in
valve cover

SOHC 4
valves/cylinder

Rear
Gear train

Smart
actuator VNT
Deep skirt
structure
dry liner for
compactness
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Aluminum
piston
Fractured
conrod

Crankcase
ventilation:
open or close

EGR: venturi +
dP sensor

Air
compressor:
mono or twin

Gear driven
HP fuel pump
Compact
FEAD

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Air intake
throttle

Efficient oil trap

in valve cover

Engine ECU

VGT + HC
nozzle +
exhaust flap

EGR cooler

Starter motor

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Compact
FEAD

MDE key characteristics

Official engine designation
Emission level
No of Cylinders & Arrangement
Combustion system
Valve mechanism
Bore / Stroke
Displacement
Swept volume
Compression ratio
Fuel supply mode
Fuel system type
Fuel peak injection pressure
Crank Case Ventilation
Aspiration / turbocharger type
EGR
Drivelines interface
Volts

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MDE8
MDE5
Euro III / IV / V / VI and Tier 2/ 3 /4f
6 cylinders in line

4 cylinders in line

4 Stroke, Diesel, Direct Injection

SOHC 4Valves per cylinder
110mm / 135mm
7 698cc

5.132cc
1.3l (1.283l)
17.5:1

Feed pump main fuel filter on negative pressure for Euro III / IV / V
Positive pressure for Tier4F/Euro VI
Common Rail
1600 bar or 2000 bar
Open / Open extended (filter) / Closed
Euro III / IV / V: Fixed Geometry-Turbo, mechanical and controlled Waste-gate
Tier4F / Euro VI: Variable Geometry Turbocharger with electronic actuator
Euro III / IV / V: No internal EGR
Tier4F / EUVI: high pressure cooled EGR
Flywheel housing SAE1, SAE2 & SAE3
24V

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Design Concepts - Cylinder Block

360 Deg. cooling belt
On the upper area

Liner

Frame reinforcement

Deep skirt +Frame reinforcement concept for weight reduction

Dry liner concept for weight reduction and shorter bore pitch
Integrated rear flange for stiffness
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Design Concepts - Cylinder Head

Low position
Cam & Spring

Exhaust Port

Encroaching
Cam gear
position
Intake Port
OHC Design

Cross-flow Design

High PCP capability but still using gray cast iron

Shortest cylinder head as OHC design (Specific Cam gear position )

Low height design (Low position valve spring and Cam shaft)
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Valve-train, 4V SOHC
Single set per cylinder, only camshaft
variant from 6 to 4 cylinders
Rocker arm
shaft

Inlet
Rocker Arm
Bearing
cap

Lower camshaft bearing cap included into cylinder

head reducing overall engine height
Exhaust
Rocker Arm

Rocker arm roller to reduce friction

Guideless valve bridge
Light valve train not driving FIE

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Integrated Jake Brake on MDE8 engine

Solenoid
control valve

Plug-in engine
brake system

2 sets of 3 cylinders

Brake piston
acting on outer
exhaust valve
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FIE Common rail system

Euro VI / Tier4f / pPNLT:
leakless injectors
allowing maximum
injection pressure at
very low revs for an
optimized combustion
Up to 7 injection events
per stroke allowing pilot,
close post and late post
injection
Basic 1600b FIE system
for Euro III/IV/V with full
multiple injection
capability

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A VGT turbocharger coupled with

Smart
actuator VNT

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 a robust and efficient EGR system

 Robust
 EGR valve on cold side to reduce thermal stresses
 EGR pipes with bellows to better stand thermal
expansion, vibrations but also for ease of assembly
 Efficient
 EGR cooler cleaning strategy
 EGR control using a Venturi with high speed delta P
sensor and advanced SW
 Inlet manifold designed for optimized EGR distribution

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Euro VI Engine After Treatment System

One box design
DOC+SCR+DPF+ASC
One canning 2 specifications

MDE8 high ratings

MDE5 and MDE8

low ratings

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Integrated sensors
24V air assisted UDS installed on muffler
(compact design - excellent spray)
DPF Filter removable for service
All Euro VI truck and bus applications

Conclusion
The MDE platform has been deployed in all Volvo Group truck brands
All automotive emission standards are covered
Both EGR-VGT and SCR only versions developed
World class power density and benchmark product cost
Industrial footprint well positioned to serve our markets
And more to come
Continue the fuel eco race and prepare the CO2 step 2 regulation

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