2.0 and 2.2 litre HDis and TDCis, are the power sources at the heart of a wider range of cars than any others in history
Tremery is a small town near Metz in the Lorraine region of north-eastern France, just south of Luxembourg. You may well never have heard of it, a sleepy little spot well off the tourist beat, but it richly deserves a place in motoring’s roll-call of famous places. The reason for its importance is a huge factory complex located alongside the D1 road on the edge of Tremery, close to the Moselle river. Here is the world’s largest diesel engine plant, home to the most successful automotive diesel engines in history
The little town has its own heraldic coat of arms, featuring three stars and a sheep. More apt would be a rampant lion and a double chevron, symbols of Peugeot and Citroën, the two big car brands of the PSA group whose factory this is.
Such is the significance of the Tremery engine plant that I was motivated to make a pilgrimage there, a round trip of almost 800 miles in a day, to see where the vast output of engines codenamed DW10 and DW12 come from. These sibling engines, better known to us as 2.0 and 2.2 litre HDis and TDCis, are the power sources at the heart of a wider range of cars than any others in history. That includes most of the current Peugeot and Citroën ranges. So it seemed entirely appropriate to make the trip to Tremery in our Peugeot 308 HDi longtermer, taking it home to the factory where its engine was made.
Here is diesel engine production on a vast scale. The two-litre DW10 engine is manufactured at a rate of 1,200 per day, a massive 300,000 a year. The 2.2 litre DW12B comes off the production line at a rate of 600 a day, another 150,000 annually. To judge the far-reaching significance of these two engines, all you need to do is take a look at the list of cars that use them.
The 2.0 DW10 is familiar as the Peugeot-Citroën HDi and Ford Duratorq TDCi, and it was developed as a result of cooperation between PSA and Ford. It goes into Peugeot’s 307, 308, 407, 607, 807 and Expert van. It also features in the Citroën Xsara Picasso, C4, C4 Picasso, C5, C8 and Jumpy/Dispatch van. It is at the heart of Ford’s Focus, C-MAX, Mondeo, S-MAX, Galaxy and Kuga, and the Volvo C30, C70, S40, S80, V50 and V70, as well as Fiat and Lancia peoplecarriers.
The 2.2 DW12B engine, another PSA-Ford collaboration, is produced in both single and bi-turbo versions, and appears in the Peugeot 607, 807 and 4007, the Citroën C5, C6, C8 and C-Crosser, the Ford Mondeo, S-MAX and Galaxy, Land Rover Freelander, and Mitsubishi Outlander. The 1.4 and 1.6 litre HDi/ Duratorq TDCi engines, resulting from an earlier PSA-Ford agreement, are also produced at Tremery, and also feature in models right across both groups’ car ranges. The vast Tremery factory complex comprises 40 buildings on 290 acres of land, and employs some 4,100 people. Since the factory opened in 1979, the total number of engines produced there has topped 30 million. Last year alone, 1.74 million engines rolled off the production lines. As well as the hugely successful DW series of engines, other families of engines are also made there, both diesel and petrol, and from 2011 the Tremery site will also become home to a significant new family of sub-100g/km, one-litre, three-cylinder petrol engines. PSA plans to recruit 500 more production workers to build them, upping production at Tremery by another 600,000 engines a year.
But it is diesel engine production that has earned the factory its global fame within the motor industry, although it remains largely unfamiliar to the general motoring public, thousands of whom – in Britain and right across Europe – drive cars powered by Tremery engines.
Each engine comprises some 300 parts. All the most important components are manufactured at Tremery (the remainder delivered daily by suppliers) and all the assembly takes place there. Engine parts machined on the Tremery site include cylinder blocks and heads, crankshafts, connecting rods, camshafts, water and oil pumps and water outlet boxes. What makes the engines so popular? According to Jean-Paul Schneider, PSA’s Paris-based Head of DW engines, it is all down to good technology with five cycles of common-rail injection. “Here at PSA we speak about the ‘magic square’ of these engines, meaning low consumption, good torque at low speed, the low noise compared with previous diesel engines and particularly at idle, and the cleanness,” said M. Schneider. “We are very proud of them as the most successful engines ever, in terms of the number of different vehicles they go into.”
2.0-litre HDi/Duratorq TDCi
DW10 engine family architecture (1998)
134bhp at 4,000rpm
240lb ft at 2,000rpm
Cast-iron cylinder block 16-valve aluminium alloy cylinder head
Bore x stroke: 85 x 88mm S
iemens second-generation common-rail direct injection system
1,600 bar injection pressure, controlled by piezo electronic actuators
Forced induction by Garrett VGT turbocharger Intercooler
Second generation particulates filter
DW12B engine family architecture (2004)
167bhp at 4,000rpm
277lb ft at 1,500rpm
Bore x stroke: 85 x 96mm
Bosch third-generation common-rail seven-nozzle direct injection system
1,800 bar injection pressure, piezo electronic actuators
Twin variable-geometry parallel-sequential turbochargers