Stellantis' Hurricane Engine: How a Downsized Twin-Turbo Six-Cylinder Matches V-8 Power While Slashing Emissions

Stellantis is making a bold move in the internal combustion engine space with its new Hurricane twin-turbo I-6, a 3.0-liter powerplant designed to challenge the conventional wisdom that bigger always means better performance. The engine delivers something of a contradiction: exceptional efficiency paired with V-8 levels of horsepower and torque.

Breaking the Performance-Efficiency Tradeoff

The Hurricane achieves what many thought impossible – delivering more than 500 horsepower in its high-output variant while maintaining fuel efficiency comparable to engines three-quarters its size. The standard output version produces more than 400 horsepower with 450 lb.-ft. of torque, while the high-output variant reaches 500+ horsepower with 475 lb.-ft., all while being up to 15% more efficient than conventional larger engines.

This dual-variant architecture reflects Stellantis’ engineering strategy. The SO (Standard Output) model prioritizes everyday fuel economy through cooled exhaust gas recirculation, while the HO (High Output) variant is tuned for demanding applications like towing without sacrificing efficiency during heavy loads.

The Twin-Turbo Advantage

Rather than relying on a single large turbocharger, Stellantis engineered two low-inertia turbochargers operating in parallel – each feeding three cylinders. This design delivers several benefits: faster throttle response, lower rpm boost engagement, and superior power delivery across the entire rpm range compared to conventional single-turbo configurations.

The turbochargers feed compressed air through an engine-mounted water-to-air charge cooler, which reduces temperature and increases air density. Cooler, denser air enables more aggressive combustion timing and better in-cylinder temperature management. An electric coolant pump continues circulating after shutdown, extending turbo durability through active cooling.

Advanced Fuel Injection Meets Precision Engineering

At the heart of the Hurricane’s efficiency gains sits a high-pressure direct injection system running at 5,075 psi (350 bar), with centrally mounted injectors spraying fuel directly into the combustion chamber. This configuration provides ultra-fine fuel atomization and exacting control over fuel delivery, translating to higher power output and reduced tailpipe emissions.

Complementing the fuel system are dual overhead camshafts with fully independent variable valve timing. This allows the engine to optimize valve overlap across different operating conditions, maximizing efficiency during light throttle inputs and enabling maximum performance during acceleration.

Revolutionary Cylinder Coating Technology

Perhaps the most innovative aspect of the Hurricane is its cylinder bore treatment. Instead of traditional cast-iron liners, Stellantis applies a Plasma Transfer Wire Arc (PTWA) coating – a process borrowed from aerospace manufacturing. The process melts steel alloy wire at 2,300 degrees Celsius, spraying microscopic particles onto cylinder walls at high velocity, where they cool and bond metallurgically to the aluminum bore.

The result is a ultra-thin wear surface with 10 times the wear resistance of conventional cast-iron liners, while reducing friction and weight. This single innovation contributes significantly to both the engine’s efficiency and durability.

Environmental Commitment Through Advanced Engineering

Stellantis’ Hurricane engine represents more than just engineering achievement – it’s a crucial component of the company’s sustainability roadmap. By delivering V-8 performance from a downsized six-cylinder package, the Hurricane twin-turbo reduces carbon emissions while enabling customers to maintain performance expectations during the company’s transition toward electrification.

The engine supports Stellantis’ commitment to reduce carbon emissions by 50% by 2030 and achieve carbon neutrality by 2038. As the company targets a 50% battery-electric vehicle sales mix by 2030, advanced internal combustion powerplants like the Hurricane will serve as a bridge technology, minimizing environmental impact during the energy transition period.

First vehicles equipped with the Hurricane engine reached dealership showrooms in 2022, with applications expanding across multiple Stellantis brands.