Latest gas injection system to launch at IAA

The ‘two-fuels, one nozzle’ injection technology used by Volvo in its gas-powered trucks has been updated and will be made available to other engine manufacturers with a launch at Germany’s IAA Show this Autumn.

Volvo and Canadian gas injection specialist Westport have been developing high-pressure, direct injection (HPDI) systems together since 2010. The technology uses a single nozzle to deliver a small quantity of diesel followed by a main injection of gas fuel into the combustion chamber. The burning diesel acts as a so-called ‘liquid spark’ to ignite the gas.

Rival gas-only engines use petrol-style spark ignition, necessitating the addition of an electronic ignition system complete with spark plugs and HT leads to the engine. HPDI can operate at high compression ratios, just like conventional diesel, retaining diesel torque characteristics and fuel economy.

Volvo launched its first HPDI trucks in 2018.

Cespira is a joint venture between Volvo Group and Westport, which will now offer HPDI technology to other manufacturers enabling them to convert existing diesel engines to run on a variety of gaseous fuels including methane and hydrogen with the potential for carbon-neutral long-haul trucking.

HPDI 3.0 is the latest generation of technology and will be launched at the IAA.  Earlier versions are already in use – more than 10,000 LNG-powered HPDI trucks have racked up a combined 3.3 billion km using Cespira fuel systems across more than 30 countries.

This latest generation of HPDI technology builds on that previous experience with a new fuel pressure management architecture that improves precision and reliability, reduces operational costs and delivers further improvements to the significant CO2 reductions already achieved by current HPDI fuel systems. It provides OEMs with a platform from which multiple alternative fuel engines can be developed.

Cespira will begin production of HPDI 3.0 in Q4 2026, following its adoption by Volvo Trucks for its latest generation of 13-litre gas-powered engines (Transport Operator 144). Volvo trucks equipped with HPDI 3.0 are expected to be available from early 2027. Cespira supplies the complete fuel system platform, including onboard fuel storage, pressure management, and precision fuel injection systems.

Cespira CEO Carlos Gonzalez said: “HPDI provides the heavy-duty industry something it urgently needs: a way to reduce emissions today without waiting for a complete redesign of the vehicle, the engine platform, or the operating model. For OEMs, it creates a stronger return on product investment by enabling a fuel system platform that can generate value with LNG and BioLNG today, while supporting future renewable fuel pathways such as hydrogen, methanol, and ethanol as they become commercially available. For fleets, it means they can reduce costs and emissions in long-haul operations using LNG and BioLNG without compromising the performance, range, payload, and reliability their businesses depend on.”