GM's new European midsize family - New Product in Brief - Opel Vectra - Brief Article

Automotive Industries, April, 2002 by Lindsay Brooke

The Basics:

"The midsize segment has always been Opel's meat-and-potatoes," notes Carl-Peter Forster, chairman of General Motors' Adam Opel AG group. "With the launch of the new Vectra family, Opel will be the only OEM offering four bodystyles in this segment." GM hopes to recapture the sales leadership Vectra enjoyed (from 1996-'98) in the C/D) segment, and the new generation cars are critical for GM Europe's return to profitability. Based on GM's fwd Epsilon program, the Vectras represent a 1.1 billion Euro investment in plant and equipment. The cars feature very high standard content, including: five gasolineengine choices two 4-cylinder DI turbodiesels; 5-speed manual and automatic gearboxes plus a CVT; electronic stability control and brake modulation a 6-airbag array with full-size side curtains; active head restraints; and a comprensive telematics suite.

Improvements and Innovations:

Extensive computational fluid dynamics (CFD) work and wind tunnel modeling were keys to sculpting a 0.28 Cd body with excellent interior noise attenuation. The new Vectra sedan is larger than its predecessor--100mm longer overall; 60mm longer wheelbase, 52/45mm wider front/rear track, 52mm greater overall height, and a trunk that's 51 liters more voluminous. Weight reduction was a primary design bogey, with aluminum used on the hood, bumper structures and front suspension members. The cross-car beam is a magnesium casting.

Vectra's body-in-white is claimed to be 74 percent stiffer in torsion (now 18,000 Nm/degree) and 62 percent stiffer in first-order bending. GM invested big in lightweight steel grades and tailor-welded material High-strength and extra-high-strength grades now accounting for 52 percent of the car's body content (compared with only nine percent previously). To boost side-impact performance, the B-pillars are stamped in a boron-alloy steel with claimed 1,200 N/mm2 rigidity, and the side sills are a dual-phase (DP) grade that saves three pounds per vehicle. The B-pillar/roof structure uses high-strength press-hardenable steel (PHS) stampings.

An Opel-patented "pedal release system" automatically releases the brake and clutch pedals during a major frontal impact, to protect the driver's feet and legs.

Production Details:

A major element of the Vectra program is the SILS center located next to the Russelsheim assembly plant. SILS is a giant supplier park where 58 Tier 1 vendors assemble more than 70 modules and subassemblies, in line sequence. The facility employs 450 workers and is managed by Ferrostaal, a division of M.A.N. Vectra production began January 7; plant officials say a 6 to 8-week ramp-up from low volume production to the planned 60 units/hour line spe

What We Think:

The Vectors have what it takes to win customers back to the Opel fold. The upcoming Signum sportwagon is a knockout!

RELATED ARTICLE: Supplier Involvement

Bosch: Engine and body sensors

Bridgestone/Firestone: Tires

Brose: Window regulators

Cooper Standard: Metal fuel and brake lines

Faurecia: Seat assemblies

GKN: Halfshafts

Hayes Lemmerz: Steel road wheels

Hella: Headlamps

Hydro Automotive: crash boxes, bumper beam

Goodyear: Tires

JCI: Seat components, overhead syst.

Lear Carp: Door inner trim

SiemensVDO: Instrument cluster

Takata: Curtain airbags; steering wheel

TRW: ABS brake system

Valeo: HVAC system; radiator

Webasto: Sunroof system

ZF: Chassis components; clutch; steering column; engine damper

2002 Opel/Vauxhall Vectra

What it is: C/D-class 4-door sedan and 5-door GTS (2002); Signum sportwagon (2003); plus future variant (4 bodystyles total) Who's it for? Those wanting a family sedan with flair; those looking for performance, style and utility (GTS) Where it's built: Russelsheim, Germany; Ellesmere Port, UK Plant capacity (Russelsheim): 270,000/year, Ellesmere Port 150,000 Competitors: Ford Mondeo; VW Passat; Renault Laguna; Peugeot 406