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BorgWarner Combines Turbocharger Technologies to Deliver More Power, Lower Emissions for Diesel V-8

Thursday, December 13, 2007 - 01:00
BorgWarner's regulated two-stage (R2S) turbocharger technology is combined with variable turbine geometry (VTG) to help International Engine Group's PowerStroke 6.4-liter V-8 diesel engine meet stringent North American emission requirements without compromising increased horsepower and torque.

The powerful diesel engine is installed in Ford's F-Series heavy-duty pickup trucks, including the F-250, F-350, F-450, and F-550.

A first in the American heavy-duty pickup segment, the R2S turbocharging system consists of two turbochargers of different sizes arranged in series. The smaller, high-pressure turbocharger responds spontaneously and harmoniously at low engine speeds while the larger, low-pressure unit provides an added boost at higher engine speeds. To make the infinitely variable adaptation of the turbine side to the compressor side even more efficient in every engine operating state, a turbocharger with VTG is used in the high-pressure stage—a world premiere in combination with the R2S system. Fast and precise adjustment of the VTG guide vanes is ensured by an electric actuator motor, which BorgWarner specially developed for this turbocharger.

The two-stage system is particularly efficient at providing the high boost pressures required over a wide operating range. In order to further reduce emissions, exhaust gas recirculation (EGR) also takes place at full load, easily complying with even the strictest U.S. emissions standards. In addition, the system's compact dimensions make it possible to accommodate the entire R2S assembly in the V of the eight-cylinder diesel.

To meet growing demand for R2S turbochargers, BorgWarner Turbo & Emissions Systems has designed, built and put into operation state-of-the-art production lines for these innovative turbocharger systems at its plant in Asheville, North Carolina.

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