Diesel To Hydrogen Conversion Technology For Commercial Vehicles Unveiled

Hydrogen conversion takes spotlight at Cenex Expo

Metier Technologies and MAHLE Powertrain will showcase a hydrogen-powered commercial vehicle at the CENEX Expo this September. The project highlights diesel-to-hydrogen conversion technology that could speed up the move to zero-emission transport.

The demonstrator is based on a DAF LF220 platform. Under the cab sits a 6.7-litre, 6-cylinder engine that has been reworked to run entirely on hydrogen. The conversion uses specialised injectors and MAHLE Powertrain’s Flexible ECU software platform to handle mapping and calibration for hydrogen combustion.

Practical route for fleet operators

“This project will demonstrate what can be achieved when engineering expertise meets urgent environmental needs,” said James Budgett, Managing Director of Metier Technologies. “Working with Mahle Powertrain’s established control technology, we’ve proven that existing diesel trucks can be rapidly converted to hydrogen power, offering depot-based fleet operators a practical, commercially viable pathway to zero-emission transport without waiting for entirely new vehicle platforms.”

The focus is on commercial vehicles where battery-electric options struggle. Long duty cycles and heavy payloads make hydrogen a more viable solution. The retrofit process also means operators can adapt trucks they already own rather than waiting for new platforms.

Engineering expertise behind the project

MAHLE Powertrain has been central to the engine conversion. Its control system manages the precise requirements of hydrogen combustion while meeting safety standards. Development and testing took place at the company’s new heavy-duty hydrogen test bed in Northampton.

At the expo, Mike Bassett, Engineering Director at MAHLE Powertrain, will outline the company’s work on hydrogen internal combustion design. He will also discuss Jet Ignition technology, which is designed to improve efficiency and performance.

Plans for rollout

Metier Technologies is targeting regions such as Scotland and Southwest England where hydrogen infrastructure is already emerging. The plan is to begin proof-of-concept fleet trials in 2026. Commercial deployment is scheduled to follow in early 2027.

The engine conversion process involves hydrogen injection hardware, remapping via MAHLE’s control software, and safety systems specific to hydrogen use. Partnerships with hydrogen suppliers, fleet operators and leasing companies are being developed to support adoption at scale.

Conclusion

The Cenex Expo will run from September 3-4 at UTAC Millbrook in Bedfordshire. The event is expected to draw strong interest from fleet operators looking for zero-emission solutions that fit operational demands.

Metier Technologies is a UK-based specialist in hydrogen powertrain solutions for commercial vehicles. MAHLE Powertrain, part of the MAHLE Group, operates technical centres in the UK, Germany and China.

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