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CNG: Opels Answer to Rising Fuel Prices Review

June 2006
Filed under: OPEL Car News | OPEL Headlines

- Opel Zafira CNG and Opel Combo CNG models need only 5.2/4.9 kg natural gas per 100 kilometers
- Underfloor gas tank arrangement ensures full cargo capacity
- ADAC crash test confirms outstanding safety of Opel CNG design

Paris (2006-06-10) -- The monovalentplus concept Opel has used in its natural gas-powered vehicles (CNG = Compressed Natural Gas) since 2001 is unique on the market. Among its many advantages and benefits, this concept boasts unrivalled operating costs, betters the strictest exhaust standards by up to 80 percent, enables an operating range of up to 380 kilometers in natural gas mode and guarantees unrestricted passenger and luggage compartment use. With a gasoline reserve tank operating range increases to over 500 kilometers, ensuring full everyday suitability. Opel natural gas cars feature the comprehensive manufacturer’s warranty on all vehicle components. In Germany, where Opel is the clear leader in this segment, there are currently two CNG models available: the new Zafira 1.6 CNG and the Combo 1.6 CNG.

Opel Zafira 1.6 CNG

The 1.6-liter CNG engine was developed by GM Powertrain, in close cooperation with Opel Special Vehicles GmbH (OSV), where the gas systems in Opel’s natural gas vehicles are installed. The engine is designed to run on natural gas, biogas, or any mixture of the two.


Everyday and long-distance suitability proven

A pre-production model of the new natural gas Zafira proved the everyday and long-distance suitability of CNG vehicles in November of last year in the “Eurotour 2005” test drive. The 2326 kilometer route through Germany, Austria, Italy, France, and Switzerland demonstrated not only the reliability of the environmentally-friendly compact van, but also the adequacy of the European filling station network, which has been significantly expanded over the past years.


Opel Zafira 1.6 CNG: Unique Flex7 system ensures maximum versatility

Opel introduced the new version of the best-selling natural gas vehicle in Germany last September at the International Automobile Show in Frankfurt (IAA). Just like its predecessor, more than 20,000 units of which were produced, the new Zafira features the patented Flex7 seating system, which allows it to be transformed quickly from a seven to a two-seater without cumbersome removal or storage of the seats. The intelligent underfloor arrangement of the four gas tanks around the rear axle ensures the Zafira’s versatility and spaciousness remains unaltered. The new natural gas Zafira offers even more space than the successful first edition, and the largest luggage compartment of all seven-seat compact vans, with 645 liters in the standard seating arrangement, and up to 1820 liters depending on seat configuration. Customers can order the Zafira CNG now, and market launch of the second-generation natural gas compact van takes place this summer.

The Zafira 1.6 CNG’s particular highlight is its outstanding efficiency. Average consumption of around 5.2 kg of natural gas per 100 kilometers, at the current price of 0.84 euro per kilogram (April 2006), translates into a fuel cost saving of around 30 percent compared to diesel, and as much as 50 percent compared to gasoline. Tax and insurance ratings are on the same level as those of the 1.6-liter gasoline variant. The 69 kW/94 hp natural gas van also boasts high environmental compatibility. By virtue of its propulsion unit, it produces 80 percent less nitrogen oxide than a diesel, and around 20 percent less CO2 than a gasoline model (15 percent less than diesel). The emissions are also free of soot particles.


Safety on highest level

The Zafira CNG is also ideally equipped when it comes to safety: the high-strength steel gas tanks and stainless steel gas pipes are safely located outside of the impact zone. This was also confirmed by ADAC in a crash test conducted with the first Zafira CNG in December 2004. “The gas tanks stored in a metal compartment remained in their original position during both frontal and side collisions, despite body deformation. They are therefore optimally protected against damage. The entire gas system stayed tightly sealed, also a result of the safety valves that automatically close on the tanks”, said the automobile club experts, summing up the test results.

In addition, the results clearly showed that the risk of fire with natural gas vehicles is no higher than normal. This is also due to the fact that natural gas is much less flammable than gasoline or diesel, and in the highly unlikely event of a leak, it dissipates immediately. Thanks to the physical characteristics of natural gas, the Zafira CNG can be parked in any underground car park. Just as in all Zafira models, the Zafira 1.6 CNG also features the extensive and highly efficient SAFETEC safety system integrated into the passenger cell, which is reinforced by ultra high-strength metal plates. This system played a key role in the new Zafira earning the maximum rating of five stars for adult occupant protection in Euro NCAP crash tests.


Unrestricted everyday use

The natural gas Zafira’s excellent efficiency and unrestricted everyday suitability is ensured by the innovative monovalentplus concept. The 69 kW/94 hp 1.6-liter CNG engine, which has an increased compression ratio for high efficiency (12.8:1), is specifically designed to run on natural gas, biogas, or any mixture of the two. The engine has special pistons, valves and valve-seat inserts, as well as separate injection banks for natural gas and gasoline. In addition, the engine management system was optimized for natural gas operation. A 14-liter gasoline reserve tank ensures continued mobility on routes without a natural gas filling station. Switching between fuel operating modes is via a switch on the center console, or happens automatically when the primary fuel supply is too low. Thanks to economical consumption and the four natural gas tanks' generous capacity of 21 kilograms, the Zafira CNG has a total operating range of around 530 kilometers.


Opel Combo 1.6 CNG: Full cargo volume of up to 3200 liters

Opel Combo 1.6 CNG


Available since June of last year, the Opel Combo 1.6 CNG is a spacious, multi-functional natural gas vehicle with especially economical and pro-environmental propulsion technology. With an average consumption of 4.9 kg natural gas per 100 kilometers, the 69 kW/94 hp Combo CNG boasts top efficiency. Fuel costs are around 30 percent less than diesel and as much as 50 percent less than gasoline, and just like the natural gas Zafira, the Combo produces 20 percent less CO2 emissions than a comparable gasoline engine; exhaust gas is also free of soot particles.

Thanks to the clever underfloor arrangement of the three gas tanks around the Combo's space-saving rear axle, the alternative propulsion makes no compromises in terms of practicality. Just like its conventionally powered counterparts, the compact Combo CNG offers up to 3050 liters cargo volume in its five-seat Combo, Edition, and Arizona variants, while the panel van even offers a maximum 3200 liters.

The tanks hold 19 kilograms or 110 liters of gas. Combined with a 14-liter gasoline reserve tank this enables an operating range of around 540 kilometers. Changing over from natural gas to gasoline operation is via a switch on the center console or happens automatically when the natural gas supply gets too low. Top speed is 165 km/h, and acceleration from zero to 100 km/h takes 15 seconds.

The Combo CNG’s safety is at the same high level as the gasoline version. The tanks that hold natural gas compressed to 200 bar are separately tested before installation at a pressure of 300 bar, just like the Zafira. The high-strength steel tanks are protected by underbody shields and together with the stainless steel gas pipes are located outside of the impact zone.



Chronology of Opel CNG models



§ 2001: Opel presents its first natural-gas vehicle concept with innovative monovalentplus technology

§ 2002: First Zafira 1.6 CNG’s market launch; prior to introduction of new model, 20,000 units produced, 9000 of which were for German market

§ 2003: Astra Station Wagon 1.6 CNG’s market launch; over 3600 produced before end of production, more than 2200 of which were for German market

§ 2005: Combo 1.6 CNG’s market launch, available in five-seat Combo, Edition and Arizona variants, as well as panel van

§ Summer 2006: Market launch of new Zafira 1.6 CNG

Source: Opel

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