After an absence of nearly two decades from General Motors vehicles, a state-of-the-art all new inline six cylinder engine will be introduced for the 2002 model year as the standard engine in a new line of midsize Sport Utility Vehicles (SUV's). The new VORTEC 4200 I6 Engine (Figure 1) brings the technical sophistication of premium passenger car engines to the truck market delivering power exceeding most competitor's V8's, with exceptional low and midrange torque, yet providing best in class fuel efficiency. It is designed to provide a high level of reliability, emit low emission levels, exhibit quiet, smooth, and refined engine operation, and is lightweight. The inline configuration provides an elegant solution to meeting customer demands with premium technology. Features include dual overhead cams - four valves per cylinder, variable exhaust valve timing, all aluminum construction for the cylinder block and cylinder head, and electronic throttle control. The engine is being produced at a completely new manufacturing facility, the Flint Engine South Powertrain Plant in Flint, Michigan.
This paper provides details of the product design and specifications, an overview of the engineering processes used during development of the engine, as well as highlights of the manufacturing system and facility.