Saturday, June 19, 2010

V6 Engine Design

V6 engine

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A V6 engine is a V engine with six cylinders mounted on the crankcase in two banks of three cylinders, usually set at either a right angle or an acute angle to each other, with all six pistons driving a common crankshaft. It is the second most common engine configuration in modern cars after the inline four.[1]
The V6 is one of the most compact engine configurations, shorter than the straight 4 and in many designs narrower than the V8 engine, and is well suited to the popular transverse engine front-wheel drive layout. It is becoming more common as the space allowed for engines in modern cars is reduced at the same time as power requirements increase, and has largely replaced the inline-6, which is too long to fit in many modern engine compartments. Although it is more complicated and not as smooth as the inline 6, the V6 is more compact, more rigid, and less prone to torsional vibrations in the crankshaft. The V6 engine has become widely adopted for medium-sized cars, often as an optional engine where a straight-4 is standard, or as an economy engine where a V8 is a higher-cost option. It is also becoming a high performance engine, due to its high power and torque output like the classic V8 while still maintaining great fuel economy [1] Some examples of this are: Nissan Z-car, Infiniti G, Chevrolet Camaro and the Hyundai Genesis Coupe all in which have at least 300 horsepower at the crank.
Modern V6 engines commonly range in displacement from 2.5 to 4.3 L (150 to 260 cu in), though larger and smaller examples have been produced.



Some of the first V6-cars were built in 1905 by Marmon. Marmon was something of a V-Specialist which began with V2-engines, then built V4's and V6's, later V8's and in the 30's Marmon was one of the few car-makers of the world which ever built a V16 car. [2]
From 1908-1913 the Deutz Gasmotoren Fabrik produced benzene electric trainsets (Hybrid) which used a V6 as generator-engine.[3]
Another V6-car was designed in 1918 by Leo Goosen for Buick Chief Engineer Walter L. Marr. Only one prototype Buick V6 car was built in 1918 and was long used by the Marr family.[4]

Lancia V6
The first series production V6 was introduced by Lancia in 1950 with the Lancia Aurelia. Other manufacturers took note and soon other V6 engines were in use. In 1959, GM introduced a heavy duty 305 cubic inch (5 L) 60-degree V6 for use in their pickup trucks and Suburbans, an engine design that was later enlarged to 478 cubic inches (7.8 L) for heavy truck and bus use.
1962 saw the introduction of the Buick Special, which offered a 90 degree V6 with uneven firing intervals that shared some parts commonality with a small Buick V8 of the period. Consequently the Buick Special met consumer resistance due to its excessive vibration.[citation needed] In 1983 Nissan produced Japan's first V6 engine with the VG series.[citation needed]

 Balance and smoothness

Due to the odd number of cylinders in each bank, V6 designs are inherently unbalanced, regardless of their V-angle. All straight engines with an odd number of cylinders suffer from primary dynamic imbalance, which causes an end-to-end rocking motion. Each cylinder bank in a V6 has an odd number of pistons, so the V6 also suffers from the same problem unless steps are taken to mitigate it. In the horizontally-opposed flat-6 layout the rocking motions of the two straight cylinder banks offset each other, while in the inline-6 layout, the two ends of engine are mirror images of each other and compensate every rocking motion. Concentrating on the first order rocking motion, the V6 can be assumed to consist of two separate straight-3 where counterweights on the crankshaft and a counter rotating balancer shaft compensate the first order rocking motion. At mating, the angle between the banks and the angle between the crankshafts can be varied so that the balancer shafts cancel each other 90° V6 (larger counter weights) and the even firing 60° V6 with 60° flying arms (smaller counter weights. The second order rocking motion can be balanced by a single co-rotating balancer shaft.).
This is almost the same technique which balances an even firing 90° crossplane V8 in primary and secondary order. A 90° V8 is in primary balance because each 4-cylinder bank is in primary balance, and the secondary of the two banks can be made to cancel each other using a crossplane. However, there is no equivalent of the crossplane crankshaft for the V6, so that the vibrations from the two banks cannot be made to completely cancel each other. This makes designing a smooth V6 engine a much more complicated problem than the straight-6, flat-6, and V8 layouts. Although the use of offset crankpins, counterweights, and flying arms has reduced the problem to a minor second-order vibration in modern designs, all V6s can benefit from the addition of auxiliary balance shafts to make them completely smooth.[5]
When Lancia pioneered the V6 in 1950, they used a 60° angle between the cylinder banks and a six-throw crankshaft to achieve equally spaced firing intervals of 120°. This still has some balance and secondary vibration problems. When Buick designed a 90° V6 based on their 90° V8, they initially used a simpler three-throw crankshaft laid out in the same manner as the V8 with pairs of connecting rods sharing the same crankpin, which resulted in firing intervals alternating between 90° and 150°. This produced a rough-running design which was unacceptable to many customers. Later, Buick and other manufacturers refined the design by using a split-pin crankshaft which achieved a regular 120° firing interval by staggering adjacent crankpins by 15° in opposite directions to eliminate the uneven firing and make the engine reasonably smooth.[6] Some manufacturers such as Buick in later versions of their V6 and Mercedes Benz have taken the 90° design a step further by adding a balancing shaft to offset the primary vibrations and produce an almost fully balanced engine.
Some designers have reverted to a 60° angle between cylinder banks, which produces a more compact engine, but have used three-throw crankshafts with flying arms between the crankpins of each throw to achieve even 120° angles between firing intervals. This has the additional advantage that the flying arms can be weighted for balancing purposes.[6] This still leaves an unbalanced primary couple, which is offset by counterweights on the crankshaft and flywheel to leave a small secondary couple, which can be absorbed by carefully designed engine mounts.[7]
Six-cylinder designs are also more suitable for larger displacement engines than four-cylinder ones because power strokes of pistons overlap. In a four-cylinder engine, only one piston is on a power stroke at any given time. Each piston comes to a complete stop and reverses direction before the next one starts its power stroke, which results in a gap between power strokes and noticeable vibrations. In a six-cylinder engine (other than odd-firing V6s), the next piston starts its power stroke 60° before the previous one finishes, which results in smoother delivery of power to the flywheel. In addition, because inertial forces are proportional to piston displacement, high-speed six-cylinder engines will suffer less stress and vibration per piston than an equal displacement engine with fewer cylinders.
Comparing engines on the dynamometer, a typical even-fire V6 shows instantaneous torque peaks of 150% above mean torque and valleys of 125% below mean torque, with a small amount of negative torque (engine torque reversals) between power strokes. On the other hand, a typical four-cylinder engine' shows peaks of nearly 300% above mean torque and valleys of 200% below mean torque, with 100% negative torque being delivered between strokes. In contrast, a V8 engine shows peaks of less than 100% above and valleys of less than 100% below mean torque, and torque never goes negative. The even-fire V6 thus ranks between the four and the V8, but closer to the V8, in smoothness of power delivery. An odd-fire V6, on the other hand, shows highly irregular torque variations of 200% above and 175% below mean torque, which is significantly worse than an even-fire V6, and in addition the power delivery shows large harmonic vibrations that have been known to destroy the dynamometer.[8]

 V angles

 60 degrees

The most efficient cylinder bank angle for a V6 is 60 degrees, minimizing size and vibration. While 60° V6 engines are not as well balanced as inline-6 and flat-6 engines, modern techniques for designing and mounting engines have largely disguised their vibrations. Unlike most other angles, 60 degree V6 engines can be made acceptably smooth without the need for balance shafts. When Lancia pioneered the 60° V6 in 1950, a 6-throw crankshaft was used to give equal firing intervals of 120°. However, more modern designs often use a 3-throw crankshaft with what are termed flying arms between the crankpins, which not only give the required 120° separation but also can be used for balancing purposes. Combined with a pair of heavy counterweights on the crankshaft ends, these can eliminate all but a modest secondary imbalance which can easily be damped out by the engine mounts.[1]
This configuration is a good fit in cars which are too big to be powered by four-cylinder engines, but for which compactness and low cost are important. The most common 60° V6s were built by General Motors (the heavy duty commercial models, as well as a design used in many GM front wheel drive cars) and Ford European subsidiaries (Essex V6, Cologne V6 and the more recent Duratec V6). Other 60° V6 engines are the Chrysler 3.3 V6 engine, Nissan VQ engine and the Alfa Romeo V6 engine.

 90 degrees

90-degree V6 engines are also produced, usually so they can use the same production-line tooling set up to produce V8 engines (which normally have a 90-degree V angle). Although it is relatively easy to derive a 90-degree V6 from an existing V8 design by simply cutting two cylinders off the engine, this tends to make it wider and more vibration-prone than a 60-degree V6. The design was first used by Buick when it introduced its 198 CID Fireball V6 as the standard engine in the 1962 Special. Other examples include the Maserati V6 used in the Citroën SM, the PRV V6, Chevrolet's 4.3 L Vortec 4300 and Chrysler's 3.9 L (238 cu in) Magnum V6 and 3.7 L (226 cu in) PowerTech V6. The Buick V6 was notable because it introduced the concept of uneven firing, as a result of using the 90 degree V8 cylinder angle without adjusting the crankshaft design for the V6 configuration. These engines were often referred to by mechanics as "shakers," due to the tendency of the engine to bounce around at idle speed. More modern 90-degree V6 engine designs avoid these vibration problems by using crankshafts with offset split crankpins to make the firing intervals even, and often add balancing shafts to eliminate the other vibration problems. Examples include the later versions of the Buick V6 and the 90-degree Mercedes-Benz V6 which, although designed to be built on the same assembly lines as the V8, uses split crankpins, a counter-rotating balancing shaft, and careful acoustic design to make it as smooth and quiet as the inline-6 it replaced.

 120 degrees

120 degrees might be described as the natural angle for a V6 since the cylinders fire every 120 degrees of crankshaft rotation. Unlike the 60 degree or 90 degree configuration, it allows pairs of pistons to share crank pins in a three-throw crankshaft without requiring flying arms or split crankpins to be even-firing. However, unlike the crossplane crankshaft V8, there is no way to arrange a V6 so that unbalanced forces from the two cylinder banks will completely cancel each other. As a result, the 120° V6 acts like two straight-3s running on the same crankshaft and, like the straight-3, suffers from a primary dynamic imbalance which requires a balance shaft to offset.
The 120° layout also produces an engine which is too wide for most automobile engine compartments, so it is more often used in racing cars where the car is designed around the engine rather than vice-versa, and vibration is not as important. By comparison, the 180° flat-6 boxer engine is only moderately wider than the 120° V6, and unlike the V6 is a fully-balanced configuration with no vibration problems, so it is more commonly used in aircraft and in sports/luxury cars where space is not a constraint and smoothness is important.
Ferrari introduced a very successful 120° V6 racing engine in 1961. The Ferrari Dino 156 engine was shorter and lighter than the 65° Ferrari V6 engines that preceded it, and the simplicity and low center of gravity of the engine was an advantage in racing. It won a large number of Formula One races between 1961 and 1964. However, Enzo Ferrari had a personal dislike of the 120° V6 layout, preferring a 65° angle, and after that time it was replaced by other engines.[9]
Bombardier has designed 120° V220/V300T V6 engines for use in light aircraft. The ignition sequence is symmetrical, with each cylinder firing 120 degree after the previous cylinder resulting in smooth power delivery. A balance shaft on the bottom of the engine offsets the primary dynamic imbalance intrinsic in any V6 layout. The straight, pin-type crankshaft journals in the 120° V-6 layout allow a shorter and stiffer crankshaft than competing flat-6 engines, while water cooling results in better temperature control than air cooling. These engines have the additional advantage that they can run on automotive gasoline rather than avgas, but have been produced only in limited quantities to date.

 Other angles

Narrower angle V6 engines are very compact but can suffer from severe vibration problems unless very carefully designed. Notable V6 bank angles include:
  • The 10.6° and 15° Volkswagen VR6, which is such a narrow angle it can use a single cylinder head and double overhead camshafts for both cylinder banks. With 7 main bearings, it is more like a staggered-bank in-line six rather than a normal V6, but is only slightly longer and wider than a straight-4.
  • The 45° Electro-Motive 6 cylinder version of their model 567 Diesel locomotive engine.
  • The 54° GM/Opel V6, designed to be narrower than normal for use in small front-wheel drive cars.
  • The 65° Ferrari Dino V6. A 60° angle limited the size of the carburetors which originally used in the engine, while a 65° angle allowed larger carburetors at the expense of a slight increase in vibrations.
  • The 75° Isuzu Rodeo and Isuzu Trooper V6 of 3.2 and 3.5 liters in both SOHC and DOHC versions.

 Odd and even firing

Many older V6 engines were based on V8 engine designs, in which a pair of cylinders was cut off the front of V8 without altering the V angle or using a more sophisticated crankshaft to even out the firing interval. Most V8 engines share a common crankpin between opposite cylinders in each bank, and a 90° V8 crankshaft has just four pins shared by eight cylinders, with two pistons per crankpin, allowing a cylinder to fire every 90° to achieve smooth operation.
Early 90° V6 engines derived from V8 engines had three shared crankpins arranged at 120° from each other, similar to an inline 3-cylinder. Since the cylinder banks were arranged at 90° to each other, this resulted in a firing pattern with groups of two cylinders separated by 90° of rotation, and groups separated by 150° of rotation, causing a notorious odd-firing behavior, with cylinders firing at alternating 90° and 150° intervals. The uneven firing intervals resulting in rough-running engines with unpleasant harmonic vibrations at certain engine speeds.
An example is the Buick 231 odd-fire, which has a firing order 1-6-5-4-3-2. As the crankshaft is rotated through the 720° required for all cylinders to fire, the following events occur on 30° boundaries:
Angle 90° 180° 270° 360° 450° 540° 630°
Odd firing 1 6 5 4 3 2
Even firing 1 4 5 6 3 2
More modern 90° V6 engines avoid this problem by using split crankpins, with adjacent crankpins offset by 15° in opposite directions to achieve an even 120° ignition pattern. Such a 'split' crankpin is weaker than a straight one, but modern metallurgical techniques can produce a crankshaft that is adequately strong.
In 1977, Buick introduced the new "split-pin crankshaft" in the 231. Using a crankpin that is 'split' and offset by 30° of rotation resulted in smooth, even firing every 120°. However, in 1978 Chevrolet introduced a 90° 200/229 V6, which had a compromise 'semi-even firing' design using a crankpin that was offset by only 18°. This resulted in cylinders firing at 108° and 132°, which had the advantage of reducing vibrations to a more acceptable level and did not require strengthening the crankshaft. In 1985 Chevrolet's 4.3 (later the Vortec 4300) changed it to a true even-firing V6 with a 30° offset, requiring larger crank journals to make them adequately strong.
In 1986 the similarly-designed 90° PRV engine adopted the same 30° crankshaft offset design to even out its firing. In 1988, Buick introduced a V6 engine that not only had split crankpins, but had a counter-rotating balancing shaft between the cylinder banks to eliminate almost all primary and secondary vibrations, resulting in a very smooth-running engine.

 Racing use

The V6 engine was introduced into racing by Lancia in the early '50s. After good results with privately entered Aurelia saloons Lancia set a works competition department in 1951. Four B20 Coupes were entered in the '51 Mille Miglia and the one driven by Giovanni Bracco and Umberto Maglioli caused quite a stir by finishing second overally after the 4.1-litre Ferrari driven by Villoresi and Cassani, a car which three times more power than the Lancia. After that encouraging start Lancia decided to carry on with the endurance racing program, first with specially prepared Aurelias (called Da Corsa) and then with specially built prototypes. A D24 with a 3,102 cc (189 cu in) V6 making 230 PS (170 kW) won the 1953 Carrera Panamericana with Juan Manuel Fangio at the wheel.
After that came the Ferrari Dino V6. Alfredo Ferrari (nicknamed Dino), son of Enzo Ferrari, suggested to him the development of a 1.5 L DOHC V6 engine for Formula Two at the end of 1955. The Dino V6 underwent several evolutions, including an increased engine displacement to 2,417 cc (147 cu in), for use in the Ferrari 246 Formula One car in 1958.[10][11]
The use of a wide 120° bank angle is appealing for racing engine designers as it permits a low center of gravity. This design is even considered superior to the flat-6 in that it leaves more space under the engine for exhaust pipes; thus the crankshaft can be placed lower in the car. The Ferrari 156 built for new Formula One 1.5 L regulations used a Dino V6 engine with this configuration.[12]
The Dino V6 engine saw a new evolution in 1966 when it was adapted to road use and produced by a Ferrari-Fiat joint-venture for the Fiat Dino and Dino 206 GT (this car was made by Ferrari but sold under the brand Dino). This new version was redesigned by Aurelio Lampredi initially as a 65° 2.0 L (~122 cu in) V6 with an aluminum block but was replaced in 1969 by a 2.4 L (~146 cu in) cast-iron block version (the Dino car was renamed the 246GT).
The Fiat Dino and Dino 246GT were phased out in 1974, but 500 engines among the last built were delivered to Lancia, who was like Ferrari already under the control of Fiat. Lancia used them for the Lancia Stratos which would become one of the most successful rally cars of the decade.
The Alfa Romeo V6 was designed in the 1970s by Giuseppe Busso, the first car to use them being the Alfa Romeo 6. The over-square V6, with aluminium alloy block and heads, has seen continuous use in road vehicles, from the Alfetta GTV6 onwards. A notable use of the Bussone Sei (Busso's big Six) V6 was the Alfa Romeo 155 V6 TI. Turbocharged, it had a peak power of 490 PS (360 kW; 480 hp) at 11,900 rpm. The 164 introduced a 3.0 L (~183 cu in) V6, a 2.0 V6 turbocharged in 1991 and in 1992, a 3.0 L DOHC 24 valve version. The Alfa 156 introduced a 2.5 L DOHC 24 valve version in 1997. The engine capacity was later increased to 3.2 L (~195 cu in), where it found application in the 156 GTA, 147 GTA, 166, GT, GTV and Spider 916. Production was discontinued in 2005.
Another influential V6 design was the Renault-Gordini CH1 V6, designed by François Castaing and Jean-Pierre Boudy, and introduced in 1973 in the Alpine-Renault A440. The CH1 was a 90° cast iron block V6, similar to the mass produced PRV engine in those two respects but otherwise dissimilar. It has been suggested that marketing purposes made the Renault-Gordini V6 adopt those characteristics of the PRV in the hope of associating the two in the public's mind.
Despite such considerations, this engine won the European 2 L prototype championship in 1974 and several European Formula Two titles. This engine was further developed in a tubocharged 2 L version that competed in Sports car and finally won the 24 Hours of Le Mans in 1978 with a Renault-Alpine A 442 chassis.
The capacity of this engine was reduced to 1.5 L to power the Formula One Renault RS01. Despite frequent breakdowns that resulted in the nickname of the 'Little Yellow Teapot', the 1.5 L finally saw good results in 1979.
Ferrari followed Renault in the turbo revolution by introducing a turbocharged derivative of the Dino design (a 1.5 L 120° V6) with the Ferrari 126.[13] However, the 120° design was not considered optimum for the wing cars of the era and later engines used V angles of 90° or less.
Both Renault and Ferrari failed in their attempt to win the Drivers' Championship with V6 Turbo engines. The first turbocharged engine to win the championship was the Straight-4 BMW.
They were followed by a new generation of Formula One engines, the most successful of these being the TAG V6 (designed by Porsche) and the Honda V6. This new generation of engines were characterized by odd V angles (around 80°). The choice of these angles was mainly driven by aerodynamic consideration. Despite their unbalanced designs these engines were both quickly reliable and competitive; this is generally viewed as a consequence of the quick progress of CAD techniques in that era.
In 1989 Shelby tried to bring back the Can-Am series, using the Chrysler 3.3 L (201 cu in) V6 (not yet offered to the general public) as the powerplant in a special racing configuration making 255 hp (190 kW). This was the same year that the Viper concept was showed to the public.
Originally the plan was to produce two versions of this race car, a 255 hp (190 kW) version and a 500 hp (370 kW) model, the 255 horsepower (190 kW) version being the entry circuit. The cars were designed to be a cheap way for more people to enter auto racing. Since all the cars were identical, the winners were to be the people with the best talent, not the team with the biggest pockets. The engines had Shelby seals on them and could only be repaired by Shelby's shop, ensuring that all the engines are mechanically identical.
Only 100 of these 3.3s were ever built. Of these 100, 76 were put into Shelby Can-Am cars (the only 76 that were ever sold). No significant amount of spare parts were produced, and the unsold engines were used for parts/spares. The Shelby specific parts, such as the upper intake manifold, were never made available to the general public. According to a small article in the USA Today (in 1989), these cars were making 250 hp (190 kW) [stock versions introduced in 1990 produced 150 hp) and hitting 160 mph (260 km/h) on the track. The engine itself was not that far from a standard-production 3.3. The Shelby engine is only making about 50 horsepower (37 kW) more than the newest 3.3 factory engines from Chrysler. The Can-Am engine has a special Shelby Dodge upper intake manifold, a special Shelby Dodge throttle body, and a special version of the Mopar 3.3 PCM (which had this engine redlining at 6800 rpm).
Nissan also has a quite successful history of using V6's for racing in both IMSA and the JGTC. Development of their V6s for sports cars began in the early 1980s with the VG engine initially used in the Z31 300ZX. The engine began life as a SOHC, turbocharged 3.0L power plant with electronic fuel injection, delivering 230 PS (169 kW). The VG30ET was later revised into the VG30DETT for the Z32 300ZX in 1989. The VG30DETT sported both an additional turbocharger and an extra pair of camshafts, making the engine a genuine DOHC twin-turbo V6 producing 300 PS (221 kW). Nissan used both of these engines in its IMSA racing program through out the 1980s and 1990s each producing well over 800 hp (600 kW). In the Japan Grand Touring Car Championship, or JGTC, Nissan opted for a turbocharged version of its VQ30 making upwards of 500 hp (370 kW) to compete in the GT500 class.

 Motorcycle use

Laverda showed a 996 cc V6 engined motorcycle at the 1977 Milan show.[14] The motorcycle was raced in the 1978 Bol d'Or.


  1. ^ a b c Nunney, Light and Heavy Vehicle Technology, pp. 13-16
  2. ^ Box, The Complete Encyclopedia of Vintage Cars 1886-1940, p. 195)
  3. ^ Matschoss, Geschichte der Gasmotorenfabrik Deutz
  4. ^ Borgeson, The Golden Age of the American Racing Car, pp. 77-78)
  5. ^ Nunney, Light and Heavy Vehicle Technology, pp. 14-44
  6. ^ a b Nunney, Light and Heavy Vehicle Technology, p. 16
  7. ^ Nunney, Light and Heavy Vehicle Technology, pp. 40-41
  8. ^ Kane, Torsional Output of Piston Engines
  9. ^ Ludvigsen, Classic Racing Engines, pp. 138–141
  10. ^ Ferrari 246 F1 on
  11. ^ Ferrari engines on
  12. ^ Ferrari Dino 156 F1 on
  13. ^ Ferrari 126CK on
  14. ^ Laverda V6 on


  • Borgeson, Griffith (1998). The Golden Age of the American Racing Car (2nd ed.). Society of Automotive Engineers. ISBN 0-7680-0023-8. 
  • Box, Rob De La Rive (1998). The Complete Encyclopedia of Vintage Cars 1886 - 1940 (3rd ed.). Rebo Productions. ISBN 9-0366-1517-8. 
  • Kane, Jack (2006). "Torsional Output of Piston Engines". 2006 Advanced Engine Technology Conference (AETC): EPI, Inc.. Retrieved 2008-01-14. 
  • Ludvigsen, Karl (2001). Classic Racing Engines. Haynes Publishing. ISBN 1-85960-649-1. 
  • Matschoss, Conrad (1921). Geschichte der Gasmotorenfabrik Deutz. Berlin. 
  • Nunney, M J (2007). Light and Heavy Vehicle Technology (4th ed.). Butterworth-Heinemann. ISBN 0-7506-8037-7. 

 External links

Go here for a discussion of the inline six engine.

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