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Step inside the secret lab creating Maserati's future

MODENA, Italy – Driving Maserati's raucous GranTurismo MC and the effortlessly quick Levante SQ4 back to back feels like traveling through time. Horsepower doesn't go out of style, but a user interface quickly does, and the GranTurismo looks like it's from another era in that respect. Designers, engineers, and executives are busily orchestrating a transformation that will ensure the 105-year old firm's next leap forward is even more dramatic. Autoblog went behind the scenes in Maserati's Innovation Lab – which has never been opened to outsiders before – to find out how the looming metamorphosis will shape Fiat-Chrysler Automobiles' (FCA) flagship brand. Maserati is on the brink of a ground-up redesign that will take it into new segments of the market, and diversify its powertrain palette. We heard the term electrification used on many occasions during our visit, though company officials resorted to automotive omerta when we asked for additional details. An earlier product plan reveals every upcoming addition to its line-up will be available with an electric powertrain, and there will be quite a few cars to electrify. Historically a small, almost niche automaker, Maserati is on track to release five new models between 2020 and 2023, including a second SUV positioned below the aforementioned Levante, plus replacements for most of its current cars. Technology is playing a significant role in Maserati's renaissance. The company's four-year-old Innovation Lab is home to simulators capable of reproducing six months' worth of wear and tear in two weeks. Engineers can dial in a variety of situations, locations, and road conditions, ranging from a winding country road in France to a busy highway in southern California. They can digitally insert potholes, add rain or fog at the push of a button and remove either just as quickly, and put virtual prototypes on a long list of race tracks around the world, including the Nurburgring. Digital wind tunnels help the team test future cars well before they're built. This approach saves time and money, explained Luca Dusini, the man responsible for Maserati's vehicle dynamics testing and simulation. Making every dollar and each minute count is key to pulling off such an ambitious overhaul. 90% of development work is carried out on the various simulators, according to Dusini. This is significant, because Maserati is developing most of the technology it will pack into its future models from scratch.

Maserati orders explode, 22,500 through September

Last year when Maserati revealed a plan to sell 50,000 units globally by 2015, it seemed like a pretty steep goal for an automaker that had sold just 6,300 units for the entire year. It turns out that goal may be a little on the conservative side. Through September, Automotive News Europe says the Italian automaker has already racked up 22,500 orders mainly on the backs of the redesigned Quattroporte and the all-new Ghibli, and there are still more new products in the pipeline.
Back in August, we heard that demand in China was playing a strong role in Maserati's big numbers in 2013, and this doesn't even include the upcoming Levante SUV, which Maserati CEO Harald Wester expects to add as many as 25,000 units to the mix when it goes on sale in 2015. According to the ANE report, the Quattroporte is still the most popular model with almost 10,000 orders so far this year, while the smaller and more affordable Ghibli is performing quite well with almost 8,000 orders; the aging, but soon-to-be-replaced, GranTurismo models have about 5,000 orders.

FCA inline-six rumored to be real, headed for Jeep Wagoneer

In September, Allpar reported that that clues being dropped at Fiat- Chrysler headquarters, in the carmaker's factories, and on engineer resumes pointed to the development of an inline six-cylinder engine. The site has just proclaimed the rumor is reality, writing that the straight-six, "turbocharged to meet or beat 5.7 Hemi power ratings, with a smoother torque curve, is on the way." The motor's first outing is expected to be either the next-generation Jeep Grand Cherokee, debuting perhaps next year, or the Jeep Wagoneer, debuting in 2020 or 2021. "Tornado" is the purported codename for the power plant said to be just under three liters in displacement, expanding the family begun with the Global Medium Engine 2.0-liter turbo codenamed Hurricane. Engine bay constraints and a long use horizon mean engineers won't simply add two more cylinders to the GME, however. Allpar says the brief is to keep the Tornado GME-T6 — the alphanumeric for "turbocharged six" — no more than three inches longer than the Tigershark 2.4-liter four-cylinder. That means "major design changes" that could include a space-saving head, more closely spaced cylinders, and no cylinder liners. An FCA division called Comau could be called on for its "SmartSpray" plasma lining technology. Allpar muses that the standard version of the engine for Chrysler, Dodge, Jeep, and Ram could get a single twin-scroll turbocharger. Performance trims for Alfa Romeo and Maserati could get different heads and maybe twin turbos, an SRT version might also get both those tweaks. History shows that the Italian versions would make changes to the block, as well. Even so, the Tornado would be less expensive than any Ferrari-supplied V6. A straight-six would put FCA in company with current adopters BMW and Mercedes-Benz, future users like Jaguar, and perhaps Aston Martin. The engine would span the widest range of use cases in the U.S. carmaker's portfolio, though. Potential applications include being a base engine for Ram trucks, serving double duty as a base engine and 5.7-liter Hemi replacement for the Dodge Charger and Challenger, working in the high-end Jeeps, and as a properly hot trim — with Ferrari-designed heads — in the luxury Italian sports cars. The Alfa Romeo Giulia begs for just such motivation to fill the gap between the 280-hp, $42,695 Ti Sport RWD and the 505-hp, $73,700 Giulia Quadrifoglio RWD. And a twin-turbo inline-six in a Maserati Alfieri would stack up nicely with the Germans.