Head Games: 2012 Chevy Camaro Adds Power, Saves Fuel

New cylinder head design combines key parts into single aluminum casting

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May 16, 2011, 11:53 ET

PONTIAC, Mich., May 16, 2011 /PRNewswire/ -- In auto production, more power, better fuel economy and fewer emissions rarely appear together. But the 2012 Camaro 3.6L direct injection V6 engine achieves all three by combining the exhaust manifold with the cylinder head into a single aluminum casting.

Each integrated exhaust manifold cylinder head -- a V6 has two -- replaces a cast iron exhaust manifold, six bolts, a gasket and a heat shield and three bolts. By eliminating this joint, the potential for a gasket failure is eliminated. And the change reduces engine weight by 13 lbs. or 6 kg per engine. Reducing mass helps improve fuel economy and the 2012 Camaro 2LS model is EPA estimated at 30 mpg highway.

"Reducing engine mass of this magnitude doesn't happen often," said Ameer Haider, GM assistant chief engineer for V6 engines. "Engineering usually looks for reduction in terms of grams not pounds. It's just like removing a set of golf clubs from your car when you don't need them – ultimately it saves fuel. When combined with other mass reductions, the customer will see better fuel economy over time with better performance."

Extensive simulation and bench testing was performed to perfect cylinder-head airflow. Intake airflow is improved 7 percent with the use of larger intake valves (38.3 mm v. 36.9 mm), which are primarily responsible for an increase of 11 horsepower. Exhaust flow is 10 percent better than the previous V6.

Lower emissions, narrower engine size and noise reduction round out the list of benefits for the new head design. With the catalytic converter closer to the engine exhaust point, the emissions reduction process begins sooner, resulting in lower emissions. The new cylinder heads decrease the overall width of the engine by 4.6 inches (117 mm) for significantly more packaging space in the engine bay making underhood work easier. Due to less surface area, the new design contributes to a 1 decibel reduction in engine noise at idle.

"The new, patented design benefits the customer in all the key areas without any tradeoffs, said Haider. "Emissions, performance, fuel economy, and noise all improve with the integrated exhaust manifold."

About Chevrolet -- Founded in Detroit in 1911, Chevrolet celebrates its centennial as a global automotive brand with annual sales of about 4.25 million vehicles in more than 120 countries. Chevrolet provides consumers with fuel-efficient, safe and reliable vehicles that deliver high quality, expressive design, spirited performance and value. The Chevrolet portfolio includes iconic performance cars such as Corvette and Camaro; dependable, long-lasting pickups and SUVs such as Silverado and Suburban; and award-winning passenger cars and crossovers such as Spark, Cruze, Malibu, Equinox and Traverse. Chevrolet also offers "gas-friendly to gas-free" solutions including Cruze Eco and Volt. Cruze Eco offers 42 mpg highway while Volt offers 35 miles of electric, gasoline-free driving and an additional 344 miles of extended range. Most new Chevrolet models offer OnStar safety, security and convenience technologies including OnStar Hands-Free Calling, Automatic Crash Response and Stolen Vehicle Slowdown. More information regarding Chevrolet models can be found at www.chevrolet.com.

SOURCE General Motors