by technology

Turbocharging Systems for Passenger Cars

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The Challenges Are Growing. And with us, so will your success.

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Although its been over a hundred years since the automobile was invented, the technological advances being made today are producing more surprises than ever. In serving the automotive industry, BorgWarner Turbo Systems is right in the vanguard of these developments with forward-looking concepts, products and solutions that meet real market needs. The requirements that have to be met in building passenger cars today are diverse and the demands are steadily increasing. High standards of safety and comfort are a must, but thats not all. Low fuel consumption, minimal pollutant emissions, durable quality, and long life are also essential. And further down the road, you can expect the challenges to keep on growing. In particular, its crucial to continue developing better engines. And turbocharging holds enormous potential for clearing many of the hurdles involved.

The challenges are magnified by the need to get new products to market faster. This makes it more important than ever for engine developers to cooperate closely with parts suppliers. No one is more acutely aware of these needs than we are. We therefore offer you considerably more than the best possible products. Were also committed to helping you get your new engines and vehicles to market more quickly than ever. To achieve this, we work with you intensively to optimize product development processes and secure you a decisive competitive edge in the marketplace. Enabling your success is a challenge that we welcome. Count on us to meet your needs. From our companys top management down to every single employee, were dedicated to serving you. For the market and the engines of tomorrow.

BorgWarner Turbo Systems is a technological leader offering turbocharging systems for both gasoline and diesel engines.

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W h e r e v e r Yo u A r e , W e l l C o m e t o Yo u . But even more important is our commitment to putting you first.

Ultra modern developing procedures such as Rapid Prototyping reduce developing time and cut costs.

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Turbocharging is playing an increasingly vital role in developing engines for today and tomorrow. But to ensure perfect interplay of all components, we have to work together very closely. Which is why we do everything we can at BorgWarner Turbo Systems to efficiently and effectively support you. To deal with todays highly complex technologies and meet the need to develop products faster and faster, we set up project groups devoted specifically to achieving your aims. These then cooperate closely with your own teams. We even go as far as assigning resident engineers to your facilities, where they provide you with constant on-site support. We make a point of putting together our project teams so theyll work as competently and quickly as

humanly possible to achieve their and your goals. This starts right in the initial phase of engine development. Seasoned application engineers with in-depth knowledge of combustion and turbocharging technology get together with experienced designers, backed by manufacturing, purchasing, quality control, and development specialists. The ability to exchange product data fast and completely with you is another vital requirement for successful cooperation. So in addition to advanced development tools, when expedient we install and use the same IT systems as you to ensure seamless cooperation based on consistent data models and smoothly conduct our cross-company projects.

In addition to ProEngineer, we use the same development systems as you.

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A Good Supplier T h i n k s f o r Yo u . A better supplier thinks ahead.

Complete systems, turbochargers with electric actuators, turbochargers able to withstand 1050C, the eBooster: solutions from BW TS help drive progress in engine development.

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Being a key technology, turbocharging calls for a high level of know-how, competence, and innovativeness. That is why BorgWarner Turbo Systems has consistently attached high priority to development. High quality of our employees, innovation potential and a wide variety of alliances render BW TS a competent partner in the automotive industry. We offer a dialogue to our customers which may be decisive, in terms of competition, for the development of future engine concepts. This is why many of our customers ask for our advice already at the inception phase, not only when series production is due to start. We thus achieve optimal results.

To support you and boost our innovative ability, we have established one of the worlds most advanced turbocharger development centers. Its state-of-the-art engine and gas test rigs, high-end CAD systems, and cutting-edge simulation tools help make BW TS the development partner of choice for many vehicle manufacturers. BorgWarner Turbo Systems keeps setting new standards with innovative solutions. You too can benefit from our broad expertise on turbocharging products and systems. Massed knowledge that we like to put at our customers disposal.

Cutting-edge test stands are deployed to optimize the interplay of engines and turbochargers.

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We Offer More Than Standard Solutions: Solutions that set new standards.

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BW TS offers a wide selection of turbochargers for the output range between 20 and 250 kW: our KP, K0, K1 and K2 series. They can be adapted to different engine types, installa-

tion requirements and performance requirements, and equipped with additional components as needed.

BorgWarner Turbo Systems strives for product leadership. Therefore we not only develop turbocharging systems, but also optimally adapt them to meet your needs. Our goal is to find ideal solutions for you. In terms of technology, quality, and processes. In the passenger car category, BW TS offers you several ranges for diesel and gasoline engines that have proven themselves in practice millions of times over. To supplement these turbocharging systems, you can draw upon a broad range of standard, optimally harmonized compressors and turbines, as well as different control systems. No matter what your specifications are BW TS has the right technology. Our offering includes turbochargers with variable turbines for diesel and gasoline engines. An absolute

innovation are multistage, regulated turbocharging systems. These include the regulated, two-stage turbocharging R2S and the eBooster system, in which an electrically driven centrifugal compressor supports the turbocharger. Increasingly, turbochargers with high temperature resistance are in demand. Responding to this need, BW TS was the first to develop a range of products designed specifically for extremely high temperatures up to 1050C. At the same time, we have also met the industrys most stringent requirements and set new standards for high-performance, extremely low-emission engines with low fuel consumption.

Tu r b o c h a r g i n g S y s t e m s for Diesel Engines:

Special requirements for diesel engines: High efficiency Broad compressor maps Dynamic response Flexible design Flexible, precise control Compact packaging

Tu r b o c h a r g i n g S y s t e m s for Gasoline Engines:

Special requirements for gasoline engines: Temperature resistance up to 1050C High efficiency Flexible, precise control Dynamic response Compact packaging
Broad compressor maps Flexible design

Our Solutions:
New turbine and compressor generations to maximize specific engine output VTG range with different frame sizes and performance classes Regulated, two-stage turbocharging R2S Various control options with pneumatic and electric actuators Special design solutions depending on the available space, e.g., with integrated components such as exhaust manifolds and other parts
Engine Performance dependent on TC-Frame Size
Range Frame Size Mass Flow (kg/s) Output Range (kW) Wastegate VTG VST KP KP 31 0,09 65 KP 35 0,12 80 KP 39 0,14 100 K0 K 03 0,17 120 K 04 0,21 150 K1 K 16 0,26 175 K2 K 24 0,30 200

Our Solutions:
Specially developed range: Special designs High-quality materials Water-cooled bearing housings Enhanced systems for high-temperature applications up to 1050C New turbine and compressor generations Different turbocharging concepts for different engine strategies: Boost pressure control flaps and valves Variable turbines Twin-entry turbine housings eBooster Special design solutions depending on the available space, e.g., with integrated components such as exhaust manifolds and other parts
Engine Performance dependent on TC-Frame Size
Range Frame Size Mass Flow (kg/s) Output Range (kW Wastegate VST KP KP 39 0,14 120 K0 K 03 0,17 150 K 04 0,21 185 K1 K 16 0,26 220 K2 K 24 0,30 250

Twin-Entry Turbines 1050 C technology

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From 20 to 250 kW BW TS offers you a complete line of turbochargers that can be adapted to meet virtually any need.

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We Dont Just Te s t f o r Q u a l i t y. We design for it from the start.

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At BorgWarner Turbo Systems, all of our production processes are geared to your needs. We have the flexibility it takes to produce either small, highly tailored series or high volumes with fewer versions. This strategy gives you the freedom you need. Right from the start of the development process, we take manufacturing considerations into account. We involve and consult those responsible for project planning, purchasing and production to optimize major sections of the automotive industrys value chain. Our goal is to perfectly harmonize all routines to save time and costs. Our highly modern production systems are naturally also matched by the approach we take to work. Interdisciplinary teamwork is a matter of course, and all

participants take full responsibility for their products and processes. Our efforts focus on continually improving processes and developing new production methods and processes. Especially for launching the latest product technologies, we pay great attention to perfecting the required manufacturing methods at the same time. All these activities yield significant competitive advantages for you: quality and flexibility. Quality management at BorgWarner Turbo Systems is exemplary, as proven by certifications under ISO 9001, QS 9000 and VDA 6, and most convincingly by our growing success and the satisfaction of our customers.

In addition to delivering products with the quality BorgWarner Turbo Systems is famous for, we design efficient, cost-optimized production processes.

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BorgWarner Turbo Systems Worldwide Headquarters GmbH Marnheimer Strae 88 67292 Kirchheimbolanden/Germany Phone: ++ 49 (0) 63 52 75 3 -0 Fax: ++ 49 (0) 63 52 75 3 -99

BorgWarner Turbo Systems GmbH Marnheimer Strae 85/87 67292 Kirchheimbolanden/Germany Phone: ++ 49 (0) 63 52 4 03 -0 Fax: ++ 49 (0) 63 52 4 03 -18 66

BorgWarner Ltd. Euroway Industrial Estate Bradford BD4 6SE West Yorkshire/UK Phone: ++ 44 12 74 68 49 15 Fax: ++ 44 12 74 68 96 71

BorgWarner Turbo Systems PO Box 15075 Asheville, NC 28813/USA Phone: 00 1 828 684 40 00 Fax: 00 1 828 684 41 14

BorgWarner Brasil Ltda. Estrada da Rhodia Km 15 P.O. Box 6540 13084-970 Campinas-SP/Brasil Phone: ++ 55 19 37 87 57 00 Fax: ++ 55 19 37 87 57 01

Hitachi Warner Turbo Systems Ltd. 3085-5 Higashi Ishikawa Saikouchi, Hitachinaka-shi Ibaraki-ken 312-0052, Japan Phone: + 81 (0) 29 - 276 - 93 88 Fax: + 81 (0) 29 - 276 - 93 97 www.turbos.bwauto.com