Powertrain Products 2 3 If everyone drives a car, Content can our air still be clean?

Powertrain Focus Areas Combustion Drivetrain Efficiency Systems Gasoline and Performance Combustion Systems Diesel Electrification Exhaust Aftertreatment

10 System Overviews 10 Gasoline Direct Injection System 12 Gasoline Port Fuel Injection System – Naturally There are two decisive factors influencing the devel- Aspirated opment of drive technologies: active climate protec- 14 Diesel Injection and Aftertreatment System tion, particularly the reduction of CO2 and exhaust emissions. And secondly, the increasing need for 16 ES – Engine Systems individual mobility, which results in various require- 18 EMS3 Engine Management System Platform ments on vehicles and drive systems. 19 ECU Gasoline Port Fuel Injection 20 ECU Gasoline Port Fuel Injection Ready-to-use EasyU Under the guiding concept of “Clean Power,” the 21 ECU Gasoline Solenoid Direct Injection Powertrain Division is developing innovative solu- 22 ECU Gasoline SDI Ready-to-use EasyU tions both for gasoline and diesel engines and for 23 ECU Bi-Fuel Ready-to-use EasyU electrical drive sys- 24 ECU Gasoline SDI and TCU tems. These not only If you were 25 ECU Diesel Piezo Common Rail 0.005 mm to split a make driving more en- human hair one hundred times, you 26 ECU Diesel PCR Ready-to-use vironmentally friendly would have the tolerance of the 27 ECU Diesel PCR Ready-to-use 12 V/ 24 V and affordable, but nozzle needle in our piezo injector. 28 ECU Diesel Platform for Commercial Vehicles This ultra-high precision enables also enhance comfort better performance with lower fuel 29 ECU Diesel Heavy Duty Engines and the fun to drive. consumption. 30 ECU Aftertreatment Control ACM2 Powertrain Products 4 5 Content

31 ES – Engine Systems 61 SYN – Synerject 31 Glow Plug Control with SCR Heater 61 Electronic Oil Pump Single or Multi Port 32 Selective Catalytic Reduction Dosing Control Unit 62 Customized Fuel Delivery Module 33 Connected Energy Manager 63 Customized Fuel Rail Assembly 34 Gasoline High Pressure Pump GHP2.5 64 Ignition Coil 35 Diesel High Pressure Pump DHP1.1 65 Oxygen Sensor 36 Diesel High Pressure Pump DHP2 37 Diesel High Pressure Pump DHP3 66 HEV – Hybrid Electric Vehicle 38 Gasoline DI XL3.1 Solenoid Injector 68 12 V Power Net System 39 Gasoline DI XL5 Solenoid Injector 69 12 V Dual Battery Manager 40 Gasoline Deka 7/9 Port Fuel Injector 70 48 V Belt-driven Starter Generator 41 Gasoline Deka 10 Port Fuel Injector 71 48 V DC/DC Converter 42 Diesel Piezo Common Rail Injector PCRs2 72 48 V Battery Management System 43 Diesel Piezo Common Rail Injector PCRs5 73 HV Axle Drive with integrated Inverter 44 Diesel Fuel Rail 74 HV Power Electronics (Inverter with DC/DC Converter) 45 Gasoline Fuel Rail Assembly 75 HV Inverter 46 LPG Liquified Petroleum Gas Injector 76 HV DC/DC Converter 47 Air Cooled SCR Injector

48 Liquid Cooled SCR Injector 78 TR – Transmission 49 Diesel Dosing Injector 50 Gasoline Turbocharger – Steel Turbine Housing 80 Control Unit for Double Clutch Transmission 51 Gasoline Turbocharger – Aluminum Turbine Housing 81 Control Unit for Double Clutch Transmission 52 SYN – Synerject 82 Control Unit for Double Clutch Transmission 53 M3A Air Module Engine Control Unit 83 Control Unit for Double Clutch Transmission 54 M3B Air Module Engine Control Unit 84 Control Unit for Double Clutch Transmission 55 M3C Engine Control Unit 85 Control Unit for Double Clutch Transmission 56 M3D Ride by Wire Engine Control Unit 86 Control Unit for Double Clutch Transmission 57 Customized Engine Control Unit 87 Control Unit for Double Clutch Transmission 58 Mechanical Throttle Body Module 88 Control Unit for Double Clutch Transmission 59 Customized Electronic Throttle Body 89 Control Unit for Double Clutch Transmission 60 Strata Air Injector 90 Control Unit for Double Clutch Transmission Powertrain Products 6 7 Content

91 TR – Transmission 120 S & A – Sensors & Actuators 91 Control Unit for Stepped Automatic Transmission 120 Digital Linear Actuator – Standard Size – Gen I 92 Control Unit for Stepped Automatic Transmission 121 Digital Linear Actuator – Standard Size – Gen II 93 Control Unit for Stepped Automatic Transmission 122 Digital Linear Actuator – Standard Size – Gen V 94 Control Unit for Stepped Automatic Transmission 123 Electrical Compressor Bypass Valve 95 Control Unit for Stepped Automatic Transmission 124 Electrical Exhaust Gas Recirculation Valve 96 Control Unit for Stepped Automatic Transmission 125 Electrical Wastegate Actuator 97 Control Unit for Continuously Automatic Transmission 126 Electronic Throttle Control ETC 12 98 Control Unit for Continuously Automatic Transmission 127 Exhaust Control Valve – High Pressure 99 Control Unit for Commercial Vehicle 128 Exhaust Control Valve – Linear 100 Control Unit for Commercial Vehicle 129 Exhaust Control Valve – Low Pressure 101 Control Unit for Double Clutch Transmission (CV) 130 Latching Valve 102 EAST Transmission Control Unit Platform 131 Linear Purge Valve 103 Control Unit for Limited Slip Coupling 132 Natural Vacuum Leak Detection (NVLD III) 104 Control Unit for Transfer Case 133 Pump – Electrical Water Pump 105 Multi Position Linear Actuator 134 Pump – Twin Drive Pump 106 Direct Shift Module 135 Turbo Purge Valve 107 Sensorcluster for Automatic Transmission Applications 136 Variable Turbine Geometry Actuator 137 Door Handle Sensor 108 S & A – Sensors & Actuators 138 Easy Trunk Access Sensor 139 Electrostatic Particulate Matter Sensor 110 Active Purge 140 Fluid Sensor – Biodiesel 111 Air Control Valve – Economy Line S11.1 141 Fluid Sensor – Flex Fuel Ethanol 112 Air Control Valve – Economy Line S11.2 142 Fluid Sensor – Oil Level Passive Electrothermic 113 Air Control Valve – Performance Line S6 143 Fluid Sensor – Oil Level Switch 114 Air Control Valve – Performance Line S6 HT 144 Fluid Sensor – Oil Level Ultrasonic 115 Air Control Valve – Perform. Line S8.6 (MD / HD Truck) 145 Fluid Sensor – Urea Concentration and Level 116 Air Control Valve – Smart ACV 146 In Cylinder Pressure Sensor 117 Brushless DC Drives – High Efficiency 147 Knock Sensor – M6 118 Canister Purge Solenoid CPS6 148 Knock Sensor – Wide Band 119 Digital Linear Actuator – Compact Size – Gen VII 149 Mass Airflow Sensor – FMT MAF SENT Powertrain Products 8 9 Content

150 S & A – Sensors & Actuators 180 FEM – Fuel & Exhaust Management 150 Mass Airflow Sensor – FMT MAF + HPT SENT 180 Fuel Level Sensor with an Open Contact System 151 Mass Airflow Sensor – MT 181 Electric Fuel Pump – EC 152 Near Field Communication External Reader 182 Electric Fuel Pump – DC 153 Position Sensor – Linear Contactless 183 Fuel Delivery Controller 154 Position Sensor – Linear Contactless 184 Tank Domain Controller 155 Position Sensor – Rotary Contactless 185 Flat Channel METALIT® (Standard Structure) 156 Pressure Sensor – Brake Booster Absolute 186 CS-Design (Crossversal Structure) 157 Pressure Sensor – Brake Booster Gauge 187 LS-Design® (Longitudinal Structure) 158 Pressure Sensor – Filter Control Gauge 188 PE-Design® (Perforated Structure) 159 Pressure Sensor – High Pressure Diesel 189 LS-Design® and PE-Design® 160 Pressure Sensor – High Pressure Gasoline 190 TS-Design® (Transversal Structure) 161 Pressure Sensor – Manifold Absolute 191 PM-METALIT® (Particulate Matter Filter) 162 Pressure Sensor – Manifold Absolute and Temperature 192 MX-Design® (Mixing Structure) 163 Pressure Sensor Manifold Gauge 193 Mantle-less Metallic Substrate 164 Pressure Sensor – Particle Filter Differential (2 Ports) 194 Exhaust Gas Recirculation Filter 165 Pressure Sensor – Particle Filter Gauge (Single Port) 195 EMICAT® Electrically Heated Catalyst 166 Pressure Sensor – Secondary Air Absolute 196 Controller for Electrically Heated Catalyst (EMICAT®)

167 Smart NOX Sensor 197 Modular Diesel Engine System 168 Smart Position Sensor – Cover 198 Closed-Coupled Exhaust Aftertreatment System 169 Temperature Sensor – Coolant / Fuel / Oil Gasoline 170 Temperature Sensor – EGR 199 Closed-Coupled Exhaust Aftertreatment System Diesel 171 Temperature Sensor – High Multiple 200 Compact SCR EHC System 172 Temperature Sensor – High Single 201 Air-assisted Urea Dosing Unit UDA 202 SCR Catalyst 174 FEM – Fuel & Exhaust Management 176 Fuel Delivery Module for Standard Applications 177 Fuel Delivery Module for High-End Applications 178 Fuel Delivery Module for Entry Level Vehicles 179 Fuel Level Sensor with a Sealed Contact System System Overviews 10 11 Gasoline Direct Injection System

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1 Engine Control Unit 13 Fuel Rail 2 Mass Airflow Sensor 14 Gasoline Direct Injection Solenoid Injector 3 Turbocharger 15 3-Way Catalyst 4 Manifold Absolute Pressure Sensor 16 Manifold Absolute Pressure Sensor with integrated 5 Electronic Throttle Control Temperature Sensor 6 High Pressure Exhaust Control Valve 17 Oil Level Sensor 7 Canister Purge Solenoid 18 Active Crankshaft Position Sensor 8 Flex Fuel Ethanol Sensor (also with Direction Detection) 9 Natural Vacuum Leak Detection (NVLD II) 19 Knock Sensor 10 Fuel Delivery Module 20 Coolant (Water) Temperature Sensor 11 Gasoline High Pressure Pump 21 Variable Lift Control Actuator and Sensor 12 Fuel High Pressure Sensor 2 2 Active Camshaft Position Sensor System Overviews 12 13 Gasoline Port Fuel Injection System – Naturally Aspirated

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1 Canister Purge Solenoid 9 Manifold Absolute Pressure Sensor 2 Flex Fuel Ethanol Sensor with integrated Temperature Sensor 3 Electronic Throttle Control 10 Gasoline Port Fuel Injector 4 Fuel Rail 11 Active Crankshaft Position Sensor (also with 5 Pressure Regulator Direction Detection) 6 Natural Vacuum Leak Detection (NVLD II) 12 Knock Sensor 7 Fuel Delivery Module 13 Coolant (Water) Temperature Sensor 8 Engine Control Unit 14 Active Camshaft Position Sensor 15 3-Way Catalyst System Overviews 14 15 Diesel Injection and Aftertreatment System

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SCR + DOC DPF 21 21 29 30 13 Fuel Delivery Module 17 14 Biodiesel Sensor 15 Diesel High Pressure Pump 18 16 Fuel Rail with High Pressure Sensor and Pressure 13 14 15 16 19 Decay Valve 17 Coolant (Water) or Cylinder Head Temperature Sensor 1 Engine Control Unit 18 Crankshaft Position Sensor 2 Mass Airflow Sensor 19 Oil Level Sensor 3 Low Pressure Exhaust Control Valve 2 0 Variable Turbine Geometry Actuator 4 Air Control Valve 21 High Temperature Sensor 5 High Pressure Exhaust Control Valve 2 2 Diesel Dosing Unit 6 Exhaust Bypass Valve 2 3 Smart NOX Sensor 7 Manifold Absolute Pressure Sensor with integrated 2 4 Deka SCR Injector Temperature Sensor 2 5 Particle Filter Differential Pressure Sensor 8 Camshaft Position Sensor 2 6 Urea Concentration and Level Sensor 9 EGR Pressure Sensor 2 7 Tank Integrated Extraction and Pump Unit 10 Swirl Control Actuator 2 8 Distributed Function Control Unit for SCR 11 Diesel Piezo Common Rail Injector 2 9 Particulate Matter Sensor 12 In-Cylinder Pressure Sensor 3 0 Exhaust Throttle Valve ES – Engine Systems 16 17 Engine Systems System Platform EMS3 Engine Management diesel, commercial vehicle. Scalable for worldwide markets. worldwide for Scalable vehicle. commercial diesel, gasoline, powertrain: for platform EMS SW and Electronic Systems –Engine ES Technical Information Benefits multicore freely distributable distributable freely multicore integration CNG fuel, flex PCR, SDI, PFI, drive: electrical › › › › › › › › › ›

ISO 26262, PowerSAR®: AUTOSAR 4.2, 4.2, AUTOSAR PowerSAR®: 26262, ISO toUp combination) in 196 (300 pins: Connector high-/low-side 16 flexible to up 60, outputs: Driver solenoid to up 8piezo, 2piezo drivers: Injector V3.1 Module (GTM) Timer Generic FlexRay, SENT, Ethernet LIN, PSI5, CAN-FD, Interfaces: and toUp 6cores 16 size flash MB function higher and consumption power Improved actuators and sensors engine various Supports and drivetrain gasoline/diesel For Euro 6+ PowerSAR® 18 otFe neto Port Fuel Injection Gasoline ECU ihsadrie hpe o aiu F nie. engines. PFI various for chipset standardized with platform SW and electronic modular, validated Scalable, Technical Information Benefits

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ihns: IP6K9K 115 pins: Connector Tightness: 34 outputs: Driver LIN CAN-WakeUP, CAN, E100 CNG, 4PFI, drivers: MHz 80 Injector Monaco/Andorra, 2MB 1.5 or MB Interfaces: size: Flash Core: Euro 6 Supports E100 capability mounted Chassis system injection fuel port Gasoline 19

ES ofgrbeoftesefegn oto nt unit. control engines. engine off-the-shelf various for Configurable SW and electronics modular Scalable, Injection Ready-to-use EasyU Fuel Port Gasoline ECU ES – Engine Systems –Engine ES Technical Information Benefits start/stop and PORT VIM, turbo, EGR, VVT, EOBD, configurations: vehicle › › › › › › › › › › ›

netrdies 4PI or 96 128 to up +105°C 40°C – range: temp. Housing pins: Connector 4PFI external or IGBT Internal Tightness: drivers: Injector driver: Ignition Interfaces: size: Flash Core: Euro 6 Supports Fast to market time various for platform SW and HW validated Mature IP67 IP6K9K, K-Line LIN, CAN, MB 1 MB/2 MB/1.5 Monaco/Andorra 20 Solenoid Direct Injection Gasoline ECU ihsadrie hpe o aiu D nie. engines. SDI various for chipset standardized with platform SW and electronic modular, validated Scalable, Technical Information Benefits LIN control / lambda turbocharger BIN, › › › › › › › › › › ›

S222 UOA . ISO26262, AUTOSAR 4.2 IP6K9K Tightness: to up 6H-bridges High-/low-side, outputs: Driver PSI5, SENT, FlexRay, LIN, CAN-FD, architecture Tricore PC Power and to up MB 2.5 16 MB Interfaces: size: Flash Core: Euro 6 Supports (SHE) protection hardware for Encryption control, lift valve variable options: multiple with ECU Connector pins: Connector drivers: Injector pt D/F to 3up 6SDI/PFI 336 Ethernet

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ES ofgrbeoftesefegn oto nt unit. control engines. engine off-the-shelf various for Configurable SW and electronics modular Scalable, ed-oueEsU Ready-to-use EasyU ECU Gasoline SDI ES – Engine Systems –Engine ES Technical Information Benefits

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onco is 10 160 to up +95°C 40°C – range: temp. Housing 2H-bridges 26, pins: Connector Tightness: 4SDI outputs: Driver drivers: Injector Interfaces: size: Flash Core: Euro 6 Supports Fast to market time production for ready configuration basic HW, SW chipset electronic Standardized platform calibration and HW, SW validated Mature

IP6K9K LIN 2 CAN, 2 MB Andorra, 120 MHz 22 C iFe Ready-to-use EasyU ECU Bi-Fuel n lcrncfrgsln F,CG P. LPG. CNG, PFI, gasoline for electronic One applications. ECU bi-fuel for modular Scalable, Technical Information Benefits o N,LG LPG CNG, for › › › › › › › › › › › ›

ihns: PKK IP6K9K 115 pins: Connector Tightness: 37 + +4IGBTs1 H-bridge outputs: Driver K-Line LIN, CAN, +4CNG 4 PFI / MHz 80 P&H injector LPG Monaco, drivers: Injector 1.5 MB Interfaces: size: Flash Core: to up Euro 5 Supports mounted Chassis box interface or unit control management Engine chipset electronic validated Standardized, platform SW and HW validated Mature

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ES Scalable, modular, validated electronic and SW platform platform engines. various for SW chipset standardized and with electronic validated modular, Scalable, ECU Gasoline SDI and TCU ES – Engine Systems –Engine ES Technical Information Benefits control transmission and injection direct › › › › › › › › › › ›

ihns: IP6K9K 196 pins: Connector Tightness: 49 +4H-bridges outputs: Driver FlexRay LIN, 2CAN, 4SDI drivers: Injector 1.5 MB TMS: MB, 2.5 EMS: TC1782 133MHz, EMS: Interfaces: size: Flash Core: Euro 6 Supports mounted Chassis control transmission automatic 6speed or CVT solenoid gasoline for unit control Combined TMS: TC1724TMS: MHz 80 24 Piezo Common Rail Diesel ECU platform engines. various for SW chipset standardized and with electronic validated modular, Scalable, Scalable, modular, validated electronic and SW platform platform SW and electronic validated modular, Scalable, Technical Information Benefits

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S222 UOA . ISO26262, AUTOSAR 4.2 magnesium or Aluminum toUp combination) in 196 (300 pins: Connector Housing: outputs: Driver FlexRay, SENT, LIN, PSI5 CAN, to up 8piezo 3piezo drivers: Injector to up 8MB MB 2.5 multicore Tricore PC Power and Interfaces: size: Flash Core: Euro 6 Supports actuators) and (sensors subsystem SCR of Control pump pressure high of Control injectors piezo servo-driven and direct- Controls architecture High-/low-side, up to 5 H-bridges 5 to up High-/low-side, 25

ES Off-the-shelf ECU for passenger and light duty vehicles. duty light and ECU passenger for Off-the-shelf engines. various for SW and electronics modular Scalable, Ready-to-use PCR Diesel ECU ES – Engine Systems –Engine ES Technical Information Benefits › › › › › › › › › › › ›

ihns: IP6K9K 115 pins: Connector Tightness: 28 + 3H-bridges outputs: Driver K-Line LIN, CAN, bank one to Up 4PCR, drivers: Injector Monaco / Andorra to Up 4MB Interfaces: size: Flash Core: SCR external Euro 6 with Supports mounted Chassis Fast to market time chipset electronic Standardized platform calibration and HW, SW validated Mature 26 Ready-to-use 12 V V/24 ECU Diesel PCR Off-the-shelf ECU for light duty vehicle engines. vehicle duty ECU light for Off-the-shelf engines. various for SW and electronics modular Scalable, Technical Information Benefits › › › › › › › › › › › ›

ihns: IP6K9K 128 pins: Connector Tightness: 32 + 1 H-bridge outputs: Driver K-Line 2CAN, bank one to Up 4PCR, TC1767 drivers: Injector 2MB Interfaces: size: Flash : Core V and Euro IV Supports mounted Chassis Fast to market time chipset electronic Standardized platform SW and HW validated Mature 27

ES for Commercial Vehicles Platform Diesel ECU vehicle engines for diesel solenoid and CNG. and solenoid diesel for engines vehicle duty heavy and medium for ECU SW and Off-the-shelf Systems –Engine ES Technical Information Benefits › › › › › › › › › › › ›

pins: Connector Tightness: outputs: Driver drivers: Injector Interfaces: size: Flash Core: Euro V and Euro IV Supports systems injection CNG Supports voltage V universal 12/24 dampers with mounted On-engine SW and electronics modular and scalable Standardized,

154 26 + 1 H-bridge banks two toUp 6 cylinders, 2 CAN 1.5 to up 4MB MB Monaco/Andorra IP6K9K

28 Heavy Duty Engines Diesel ECU engines. duty heavy and medium solenoid diesel for platform electronic validated modular, Scalable, Technical Information Benefits

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pins: Connector Tightness: outputs: Driver drivers: Injector Interfaces: size: Flash Core: SCR) with combined Euro VI+, 2010+, (EPA requirements emission current Fulfills elements damping with mounted engine On systems injection solenoid other and pump-line-nozzle and rail common amplified for management engine Diesel 141 IP67 IP69K, 21 + 1 H-bridge 12 3 CAN 2 MB TC1796 29

ES ACM2 Control Aftertreatment ECU Controller for exhaust aftertreatment systems (SCR, DPF). (SCR, systems aftertreatment exhaust for Controller Systems –Engine ES Technical Information Benefits › › › › › › › › › ›

Supports CAN based sensors (e.g. NO (e.g. sensors based CAN Supports supply V 24 12 V/ ihns: IP5K6K 62 pins: Connector Tightness: + 4high-side 19 low-side outputs: Driver 3CAN dosing HC or 3urea drivers: Injector Andorra 4MB Interfaces: size: Flash Core: hood) (under mounted Chassis X , urea quality) , urea 30 with SCR Heater Control Plug Glow Single electronic controller for glow plug and SCR heater. SCR and plug glow for controller electronic Single

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Connector pins: 17 pins: Connector IPX9KHousing sealed: lines PWM 2dedicated CAN, drivers 8high-side outputs: Driver 32 MHz Bolero, 256 KBytes Interfaces: size: Flash Core: outputs plug glow of protection for Redundancy relay power heater SCR the of Control diagnosis electrical with control on/off SCR diagnosis electrical with control PWM plug Glow

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ES Dosing Control Unit Reduction Catalytic Selective Systems –Engine ES NO for platform SW and electronic validated Standardized,

Technical Information Benefits X harness etc.) ASICs (driver, › › › › › › › › › › aftertreatment control of passenger vehicles. passenger of control aftertreatment

Housing: Plastic housing; housing; Plastic Housing: pump BLDC driver: Pump 2 driver: Heater SENT, CAN, PWM High-/low-side drivers: Injector Bolero 1 MB Interfaces: size: Flash Core: module to ECU pump and connection Direct wiring optimized enables approach 2 connector concepts electronic and Proven mechanical Connectors with 2chambers with Connectors

32 management functions. For passenger vehicles (12 vehicles For passenger V). functions. management energy connected eco-driving for unit processing Central Connected Energy Manager Technical Information Benefits powertrain control units (engine, e-motor, battery, battery, transmission) e-motor, (engine, units control powertrain › › › › › › › › › › ›

Housing: Plastic, Connectors with 2chambers with ISO26262, Connectors 4.2 Plastic, AUTOSAR High-/low-side Housing: FlexRay, SENT, LIN, Ethernet CAN, Drivers: architecture Tricore multicore to Up 16 MB Interfaces: size: Flash Core: ECU of variants number Reduces gatewayCommunications CO Enables to various request torque distributes and Calculates Connector pins: Connector 2 savings via predictive driving algorithms algorithms driving predictive via savings 68 , H-bridges 33

ES ES – Engine Systems 34 35 Gasoline High Pressure Pump Diesel High Pressure Pump GHP2.5 DHP1.1 ES

GHP optimized for Noise, Vibration, Harshness (NVH), Next generation of diesel common rail high pressure robustness and efficiency. pump. Platform is basis for future pump applications.

› Robust design for worldwide fuel compatibility › Digital Inlet Valve (DIV) supports low inlet pressure for high efficiency and low noise › Modular design for scalability and flexible packaging › Best controllability and response Benefits Benefits › Compact package and light weight › Pressure: Up to 350 bar › Digital Inlet Valve (DIV) technology › Pressure: Up to 2,500 bar › Displacement: Up to 1.18 ccm/revolution › Displacement: 0.40 ccm/revolution › Engine speed: Up to 7,500 rpm. › Weight: < 3 kg › Inlet valve currentless open › Length: < 80 mm › 600,000 start/stops › Drive: Belt, chain, gear

Technical Information Technical › Rotation: Clockwise, counter clockwise

Technical Information Technical › Radial 1-piston pump: 2 lobes/rev vehicles. vehicles. duty light and cars passenger for pump rail Common Systems –Engine ES DHP2 Pump Pressure High Diesel Technical Information Benefits

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Volume metering: metering: Volume Rotation: Drive: Length: 0.58 ccm/revolution Weight: Displacement: Pressure: Worldwide fuel compatibility High lifetime weight light and package Compact Radial 2-piston pump: 2-piston Radial 2 strokes/revolution strokes/revolution 2 (clockwise optional) (clockwise clockwise Counter optional) chain (belt, Gear < mm 80 < 4 kg bar toUp 2,200 Volumetric Control Valve (VCV) Control Volumetric 36 Diesel high pressure pump with small size and light weight weight sizes. engine common light supporting and size small with pump pressure high Diesel DHP3 Pump Pressure High Diesel Technical Information Benefits › › › › › › › › ›

Weight: 800 g 800 possible to up 4 lobes with Camshaft Weight: ccm/stroke 0.23 Displacement: bar to Up 2,500 technology Valve (DIV) Inlet Digital Pressure: technology platform proven on Based capabilities diesel worst-case Improved behavior leakage Reduced technology drive cam for design Smart 37

ES aspirated and turbocharged engines. turbocharged and aspirated natural for injector (GDI) Injection Direct Gasoline Systems –Engine ES Solenoid Injector Gasoline DI XL3.1 Technical Information Benefits with controlled solenoid injection (COSI) injection solenoid controlled with performance injection central and side for suitable engines, › › › › › › › › › › ›

Multiple injection: < 800 μs hydr. μs <800 time dwell Fs-Laser or μEDM techn.: drilling hole Nozzle Max. 7 holes technology: Multi-stream /s g 20 to Up injection: Multiple 250 at bar mg/stroke ~2.0 flow: dynamic Minimum range: flow Static Pressure: Worldwide fuel compatibility spray 6c Euro for geometry nozzle Enhanced O-Rings capable Low temperature characteristics spray of flexibility High turbocharged high for range flow linear Improved Up toUp 250 bar 38 engines and future exhaust emission legislation. legislation. emission emission exhaust exhaust future future and and engines engines turbocharged downsized and aspirated For natural Solenoid Injector Gasoline DI XL5 Technical Information Benefits connection › › › 2) (COSI › injection solenoid controlled with › › › › › › ›

utpeijcin < hydr. μs 500 time dwell Max. 7 holes technology: Multi-stream injection: Multiple flow: dynamic Minimum Pressure: Worldwide fuel compatibility engines downsized for packaging Small metal to metal or O-Rings capable temperature Low combustion and preparation mixture For improved (WLTP, RDE) capable Euro 6c+ Valve tip diameter flexibility: techn drilling hole Nozzle .: μEDM or Fs-Laser Fs-Laser or μEDM .: 6.0 mm or or mm 7.53 mm 6.0 Up toUp 350 bar 1.5 mg/stroke at at bar 200 1.5 mg/stroke 39

ES high flow range for turbocharged engines. turbocharged for range flow high 9with Deka configurations. spray and tip body, Flexible Systems –Engine ES Port Fuel Injector Gasoline Deka 7/9 Technical Information Benefits sensitivity voltage low and › › › › › › › › › ›

Fuel compatibility: Fuel compatibility: bar, Exxsol), (3 9: Deka 50 μm leakage >= Tip μl/min <1.8 7), (Deka 9) >10:1 15:1 (Deka range: flow Linear 1 to up 9bar bar size: SMD 7), (Deka g/s to up 6.0 g/s 0.95 rate: flow Static Pressure: capabilities leakage Improved performance linear high with fueling Low minimum Various spray options and configurations packaging Spray patterns: Spray Cone, bent and split and bent Cone, PZEV application for enhanced /min μl 0.5 < 9) (Deka g/s to up 8.0 g/s 0.5 Gasoline and flex fuel up to up E100 fuel flex and Gasoline 40 twin and dual port engines. port dual and twin for packaging reduced and range flow high Provides FuelInjector Deka 10 Port Gasoline Technical Information Benefits sensitivity voltage low and › › › › › › › › › › ›

Fuel compatibility: Gasoline and flex fuel fuel flex and Gasoline Fuel compatibility: split Ø: and major Standard bent 15 Cone, Flexibility slim mm, 12.5 mm patterns: Spray bar, Exxsol), (3 SMD μl/min μm <1.8 >=40 atomization: Spray to 10bar leakage: up Tip 1 bar >17:1 (SAE) to up range: flow Linear g/s 10.0 0.50 g/s rate: flow Static Pressure: applications non-automotive for 23 length mm pressures extended and leakage Improved performance linear high with fueling Low minimum up toup E100/M30 available opt. PZEV μl/min <0.5 41

ES light duty vehicles. duty light and cars passenger for injector rail common piezo Diesel Injector PCRs2 Injector Rail Common Piezo Diesel Systems –Engine ES Technical Information Benefits Euro 6/US Tier 2 emission standards Tier 2 emission Euro 6/US

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Diameter nozzle holes: ≥ 90 μm 90 ≥ holes: nozzle Diameter to Up 7 leakage: Total μs 200 ≥ separation: injection mm³/stroke Min. 0.8 ≥ injection: Multiple quantity: Minimum Pressure: meet to accuracy injection Improved CO low for leakage injector Reduced technology piezo Field-proven (shift and permanent) and (shift bar at 1,800 /min 110ml < bar 2,000 to Up 2 emissions and and emissions 42 Injector PCRs5 Injector Rail Common Piezo Diesel injector with a with injector rail common piezo servo-driven of generation New Technical Information Benefits standards Tier 2 emission Euro 6/US › › › › › › › › › › › fuel fuel consumption

Total leakage: < 30 ml /min at 2,000 bar bar 2,000 at /min ml 30 < control needle and valve servo Precise μm 90 ≥ holes: nozzle Diameter to Up 7 leakage: Total ≥150 μs separation: Min. injection mm³/stroke 0.8 ≥ injection: Multiple quantity: Minimum Pressure: capability /stop start enables leakage permanent No (NVH) Low noise meet to accuracy injection Improved CO low for leakage injector Reduced field-proven piezo technology. piezo field-proven Up to 2,500 bar toUp 2,500 (no permanent) (no 2 emissions and and emissions 43

ES for a high variety of customer specific solutions. specific customer of variety ahigh for design robust and proven flexible, with rails fuel Diesel Diesel Fuel Rail Systems –Engine ES Technical Information › › › ›

3 – 8 cylinder solutions 8cylinder – 3 option an as Valve (PDV) Decay Pressure sensor pressure high Integrated bar to up 2,500 pressure System 44 assembly for low and high pressure applications. pressure high and low for assembly rail fuel Gasoline Fuel Rail Assembly Gasoline PFI Technical Information Benefits

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E100 capability internalOptional damper to up 9bar assembly Fuel rail rails fuel steel stainless and Plastic PFI: target spray optimal for orientation injector Accurate to up 350 bar assembly Fuel rail GDI: available solutions specific Customer PFI: Pressure optional sensors architecture rail optimized Weight suspended and clamped customer solutions specific support to portfolio rail Modular GDI: GDI 45

ES applications. LPG for Injector Petroleum Gas Injector Liquefied LPG Systems –Engine ES Technical Information Benefits

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leakage: Tip Fuel compatibility: patterns: Spray range: flow Linear range: flow Static pressure: System state liquid to the due volume line fuel Reduced metering fuel liquid to appropriate due consumption fuel reduced and impact emission Low effect cooling to transition phase vapor liquid the to due efficiency engine Improved 0.15 cc / air in bar 3.8 at min LPG and fuel flex Gasoline, split bent, cones, Various 11:1 (SAE) to g/s up 5.0 g/s 0.95 toup 18 LPG in bar gasoline, in to up 4bar 3 bar 46 Key technology in the area of NO of area the in Key technology future emission legislations. Air Cooled SCR Injector Technical Information Benefits › › › › › › › › ›

Max. ambient temperature: temperature: Max. ambient temperature: tip Max. injector temp.: body Max. injector range: pressure Fluid Multiple Multiple spray configurations performance excellent spray with urea of delivery reliable and Simple system airless fluid Single Sauter Mean Diameter (SMD): Diameter Mean Sauter patterns: Spray X reduction to meet the the meet to reduction

(5 bar, AUS32) (5 160°C continuous continuous 200°C 150°C continuous to up 9bar 4 bar 130 to μm up μm 70 Cone, bent, elliptical bent, Cone, 47

ES coupled applications. coupled Liquid cooled SCR dosing unit for NO for unit dosing SCR cooled Liquid Liquid Cooled SCR Injector Systems –Engine ES Technical Information Benefits › › › › › atomizer enhanced options available) › performance spray ›

Max. ambient temperature: 200°C continuous 200°C temperature: Max. ambient Max. injector tip temperature: 200°C continuous 200°C temperature: tip Max. injector Fluid pressure range: 4 bar up to up 9bar 4bar range: pressure Fluid Sauter Mean Diameter (SMD): 60 μm up to 130 to μm up μm 60 (SMD): Diameter Mean Sauter patterns: Spray Multiple spray configurations (patented A² and (patented configurations spray Multiple Simple and reliable delivery of urea with excellent excellent with urea of delivery reliable and Simple (5 bar) (5 Cone, bent, elliptical bent, Cone, X reduction in close close in reduction 48 nology to deliver liquid diesel fuel into the exhaust path. path. exhaust intothe fuel diesel liquid to deliver nology tech- robust and asimple provides system dosing The Injector Dosing Diesel Technical Information Benefits biodiesel and increased engine durability engine increased and biodiesel of tolerance greater intervals, change oil longer NO Efficiency High › › › › › › › › › › ›

ytmmnmmplewdh 10 to up 20 ms ms width: pulse minimum System continuous 500°C temperature: nozzle spray Max. 120°C temperature: valve control Max. pressure: Fluid 75 to up μm 150 μm (SMD): Diameter Mean 0.1Sauter toup g/s 6g/s flow: of Accuracy range: mass fuel Delivery timing regeneration for flexibility of degree Higher to leads injection by post dilution oil of Avoidance technologies injection existing Uses and (DPF) Filter Particle Diesel for approach Robust X Trap (HENT) regeneration Trap (HENT) 3.5 bar up to up bar 3.5 12 bar +/–7% 49

ES Design enables a fully automated assembly process. assembly automated afully enables Design Steel Turbine Housing Turbocharger Gasoline Systems –Engine ES Technical Information Benefits electrical wastegate actuator from Continental Continental from actuator wastegate electrical efficiency charging and design › › › › › › › › actuator wastegate and › ›

Optional electrical compressor bypass valve and valve bypass compressor electrical Optional wastegatePneumatic and actuation electrical system sealing effective Highly engine of fit best for wheels specific Applications wheel compressor Milled to Up 1,050°C temperatures: gas Exhaust inertia low and performance thermodynamic High for Applicable hybrid applications design reliable and Robust Matched system performance between turbocharger between performance system Matched 50 Design enables a fully automated assembly process. process. assembly assembly automated automated afully afully enables enables Design Design design. reliable and Robust Turbine Aluminum Housing Turbocharger Gasoline Technical Information Benefits position and accurate pressure regulation pressure accurate and position closed near especially wastegate the of positioning economy fuel best and drivability thermodynamics, transient response screws tie-rod patented › › › › › › › › ›

With electrical driven wastegate faster and precise precise and faster wastegate driven electrical With wastegatePneumatic and actuation electrical system sealing effective Highly wheel compressor Milled m/s 580 speed: Maximum to Up 1,050°C temperatures: gas Exhaust edge cutting for design wheel specific Application best for technology turbine RAAX™ Optional with connection housing turbine/center Robust 51

ES SYN – Synerject 52 53 Synerject M3A Air Module Engine Control Unit SYN

Integrated solution

The Non-Automotive business provides gaso- For 1 cyl., 2 and 4 stroke engines from 50 cc up to 250 cc line Engine Management Systems (EMS) and in light motorcycles, scooters, lawn mowers, generator sets. components for Marine, Two-Wheeler, Recre- › ECU with integrated throttle body, ABV and sensors ation, Industrial, Lawn and Garden applications. › Uses Continental electronic and mechanical designs

Benefits › Easy mounting › Throttle body size: Ø 16 mm up to 34 mm › Versatile configuration, exists in stand-alone ECU

› ABV, TPS and TMAP sensor integrated › 16 bit microcontroller operating at 16 MHz › 128 KB ROM (flash), 4 KB RAM › IP66 and IP6K9K (high pressure cleaning) › Input and output with full diagnostics and protection › Operating temperature range: –20°C up to +85°C › 32 pin connector with spares for vehicle functions Technical Information Technical › K-Line interface for diagnostics and reprogramming SYN – Synerject 54 55 M3B Air Module Engine M3C Engine Control Unit Control Unit SYN

For 1 and 2 cylinder, 2 and 4 stroke engines up to 1,000 cc For 1 and 2 cyl., 2 and 4 stroke engines up to 1,000 cc in me- in motorcycles, scooters, lawn mowers, generator sets. dium to high end motorcycles, scooters, ATV, snowmobiles.

› ECU with integr. electronic throttle body and sensors › Uses Continental electronic and mechanical designs › Uses Continental electronic and mechanical designs › Extended I / O for improved functionality Benefits › Cost optimization and easy mounting Benefits › Enhanced timer module and control capability › Different size of throttle body: Ø 26 mm up to 50 mm › Robust mechanics with aluminum casing › Versatile configuration › 16 bit microcontroller operating at 16 MHz › Integrated TMAP sensor, ETC, monitoring unit › 256 KB ROM (flash), 16 KB RAM › 32 bit microcontroller operating at 40 MHz › IP67 and IP6K9K (high pressure cleaning) › 1 MB ROM (flash), 36 KB RAM › Two knock sensor inputs › IP67 and IP6K9K (high pressure cleaning) › Input and output with full diagnostics and protection › Input and output with full diagnostics and protection › Operating temperature range: – 40°C up to +85°C › Operating temperature range: – 40°C up to +85°C Technical Information Technical › 48 pin connector with spares for extended functions › 32 pin connector with spares for vehicle functions Technical Information Technical › CAN interface for diagnostics and reprogramming › CAN interface for diagnostics and reprogramming SYN – Synerject 56 57 M3D Ride by Wire Customized Engine Control Unit Engine Control Unit SYN

For 1 up to 4 cylinder, 2 and 4 stroke engines up to 1,600 cc For 1 or multiple cylinder, 2 and 4 stroke engines in all in high end motorcycles, scooters, ATV, snowmobiles. types of non-automotive applications.

› Uses Continental electronic and mechanical designs › Small, efficient ECUs for V6 engines › Drives mechanical or electrical throttle body › Uses Continental automotive electronic designs Benefits Benefits › Modular and scalable system approach › Validated to customer specific requirements or › Designed to meet Euro 5 with EOBD qualified to automotive standards

› 32 bit microcontroller operating at 40 MHz › From 24 pins up to 144 pins, automotive connector › 896 KB ROM (flash), 2 KB E2PROM and 32 KB RAM › Plastic or aluminum housing › IP67 and IP6K9k (high pressure cleaning) › For land and marine application environments › Separate safety monitoring unit for ETC system › Configurable I / Os: Analog inputs, K-Line or LIN or multiple CAN lines, › Input and output with full diagnostics and protection multiple H-bridge, high current IGBT, high current › Operating temperature range: – 40°C up to +85°C output driver, knock interface, proportional

Technical Information Technical O sensor interface, etc. Technical Information Technical › Double pocket 96 (32 + 64) pins CMC connector 2 › CAN interface for diagnostics and reprogramming SYN – Synerject 58 59 Mechanical Throttle Body Customized Electronic Module Throttle Body SYN

For medium and high-end motorcycles, scooters, ATV and For high-end motorcycles, scooters, ATV, snowmobiles. snowmobiles. Suitable for off-road and on-road applications. Compatible with M3D ECU or other ride by wire ECU.

› Integrated stepper motor, TMAP sensor and injector › Core components from Continental Gen. 8 ETC › Bore diameter from Ø 36 mm up to 50 mm › Contactless redundant magneto resistive sensor Benefits › Flexible quadrant geometry and cable interface Benefits › Master-slave concept based on automotive safety › Short bore length of 82 mm › Air channels designed to customer requirements › Optional integration with fuel injector › Integration with fuel injector is optional

› Minimum idle flow at 40 kPa ∆P: 2 kg / h › Minimum idle flow at 40 kPa ∆P: 2 kg / h › Throttle position sensor linearity: +/– 2% › Single TPS* linearity: +/- 1,5% › Bypass flow: Up to 50 kg / hr › TPS* synchronous tolerance: +/- 3% › › Load exerted on cable at idle: 6N TPS* hysteresis: < 0.1° › Response time of single throttle: < 90 ms (at 25°C) › Vibration level: 30 g › E-motor nominal supply voltage: 12 V › Tamper proof adjusting screw for idle air flow › Vibration level: 30 g › Possibility to connect canister purge Information Technical Technical Information Technical › Operating temperature range: –40°C up to +140°C › Operating temperature range: –30°C up to +110°C *Throttle Position Sensor SYN – Synerject 60 61 Strata Air Injector Electronic Oil Pump Single or Multi Port SYN

For 1 or multiple cylinder, 2 stroke engine applications. For 1 or multiple cylinder, 2 stroke engine applications. Widely used in marine applications. Widely used in marine applications.

› Electromechanical valve › Fully flexible mounting location › Combines air and metered quantities of fuel › In-tank or in-line Benefits Benefits › Superior fuel atomization › Accurate oil delivery rate › Generates spray for in-cylinder stratification › Customized oil flow rate and number of outputs › Gasoline, ethanol, kerosene, diesel, CNG compatible › Full control of flow from 0 cc/sec up to 2 cc/sec › Operating pressure: 70 kPa typical differential › Control of flow by Pulse-Width Modulation › Static flow rate (air): 0.10 g / sec up to 2.50 g / sec PWM/frequency input › Dynamic 0.10 g / sec up to 0.90 g / sec › Full performance down to – 40°C flow rate (air): at stroke, 0.05 mm up to 0.3 mm, pressure 50 kPa up to 650 kPa

› Atomization: 4 SMD up to 28 SMD (μm) and Information Technical 15 Dv up to 80 Dv, 0 up to 9 (μm)

Technical Information Technical › Coil resistance: 1.35 +/– 0.2 (27 AWG, 189 turns) › Operating Voltage: 8 V up to 18 V SYN – Synerject 62 63 Customized Customized Fuel Delivery Module Fuel Rail Assembly SYN

For 1 or multiple cylinder, 2 and 4 stroke engines in all For 1 or multiple cylinder, 2 and 4 stroke engines in all types of non-automotive applications. types of non-automotive applications.

› Metal and plastic flanges › Fully customized designs to meet any application requirements › Electrically conductive plastics › Possible to integrate pressure sensors, diagnostic Benefits › Fuel level sending units and low levels switches Benefits ports, pressure regulators or pulsation dampers › Integrated jet pump pulls fuel from hard-to-reach › Plastic, brazed assemblies, extruded or forged areas aluminum designs › Customized fuel line and electrical connector › Validated automotive components › Designed and validated to customer specific › Materials meet J1645 ESD requirements requirements › 100% leak tests all fuel rail assemblies in the factory › Can provide simple assembly as “pump-on-a-stick” › Assemblies with integrated sensors, hoses, dampers and regulators › Designed and validated to customer specific

Technical Information Technical requirements SYN – Synerject 64 65 Ignition Coil Oxygen Sensor SYN

For mopeds, scooters, light For 1 or multiple cylinder, 2 and 4 stroke engines in all motorcycles, lawn mowers, electric power generators. types of non-automotive applications.

› Small sized inductive coil › Specifically developed for 2 wheeler environments › High voltage diode integrated › A hermetic structure which uses injection current pumping method against water splash Benefits Benefits › Standard high voltage connector › Resistant to water droplets › Standard primary connector › Vibration resistance › Nominal voltage supply: 14 V + 0.5 V › Lead wire: 4 wire › Maximum primary current: 3.3 A › Cable length: 500 mm › Dwell time: < 6 ms › Body length: 35 mm › Arc duration (1,000 V Zener): 0.5 ms + 0.2 ms › Thread size: M12 › Recommended cable size: 2.0 mm2 up to 2.5 mm2 › Reference air: Self pumping › Recommended 2 2 Technical Information Technical cable overall diameter: 2.5 mm up to 3.5 mm › Heater resistance: 8.1 ohm Technical Information Technical HEV – Hybrid Electric Vehicle 66 67 Hybrid Electric Vehicle HEV – Hybrid Electric Vehicle 68 69 12 V Power Net System 12 V Dual Battery Manager HEV

Supports the 12 V board net and supplies additional Stabilizes 12 V boardnet by connecting two energy energy for stop-start, and during engine idle and coasting. storages and supports numerous functions.

› Voltage stabilization during high power needs › 4% fuel savings on top of stop-start savings › Flexible regulation of starter current or voltage or › Extended stop-start (<20 km/h) power Benefits Benefits › Recuperation › Double Layer Capacitor (DLC) energy storage for high number of load cycles › Engine-off coasting › Dampens transient pulses with fast DC/DC control › Stabilized boardnet logic and DLC › Switch Technology: MOSFET › Second power source – serial connection to vehicle › Max. voltage drop: 50 mV battery › Continuous current: 180 A › Current capability up to 1,200 A › Peak current: 1,000 A › Regeneration with integrated 150 W DC/DC › Temperature range: –40°C up to +105°C (ambient) › Energy storage with DLCs (5.2 V, 600 F) › Very low impedance of power path: 1.6 mOhm at 20°C Information Technical Technical Information Technical HEV – Hybrid Electric Vehicle 70 71 48 V Belt-driven 48 V DC/DC Converter Starter Generator HEV

Efficient electric motor with integrated inverter realizes Stabilizes and connects the 12 V and the 48 V power net advanced stop-start, coasting and electric boost. for advanced stop-start, coasting and electric boost.

› Reduces fuel consumption by 13% › Bi-directional DC/DC converter 48 V – 12 V › Integrated inverter, no external connectors and wires › 12 V board net stabilization Benefits Benefits › Fast engine start › Pre-charging function for 48 V DC link › Recuperation › Self-protection based on diagnosis und limitation › Engine-off coasting › Digital voltage and current control › Maintenance free – no slip rings, no debris › Power (buck): Up to 3 kW permanent › Induction machine, fluid cooled › Current (permanent): 215 A buck, 58 A boost › Torque: 150 Nm at crank shaft › Efficiency: > 95% › Power (mechanical): 14 kW peak › Air-cooled › Power (regen.): 16 kW peak › Speed: Up to 20,000 rpm continuous Technical Information Technical Technical Information Technical HEV – Hybrid Electric Vehicle 72 73 48 V Battery Management HV Axle Drive with System integrated Inverter HEV

System is integrated into the battery, balances and Developed for pure electric driving, also applicable in operates battery cells individually under safe conditions. full hybrid and plug-in hybrid vehicles.

› Complete circuitry on one single PCB › E-motor, inverter and differential in one housing › Measurement of voltage, current and temperature › 15% weight reduction

Benefits › Crash signal sensing and reaction Benefits › Less cables and less connectors › Contactor control and pre-charge function › Less cooling connections › Calculation of state of charge (SOC), › Available as permanent magnet or induction state of function (SOF) and state of health (SOH) machine

› Supervises up to 13 cells › High speed: Up to 12,000 rpm › Quiescent current: <100 μA › High voltage: Up to 450 V › Measurement range: › Mechanical power: 60 kW continuous, 130 kW peak – Cell voltage: 1.5 V to 5 V › Torque: 350 Nm max – Temperature: –40°C to +90°C – Battery current: +/–400 A › Light weight: 88 kg (motor, inverter, differential)

Technical Information Technical › Fluid cooling Technical Information Technical HEV – Hybrid Electric Vehicle 74 75 HV Power Electronics (Inver- HV Inverter ter with DC/DC Converter) HEV

Drives the e-machine in both motor and generator mode. Drives a High Voltage (HV) e-machine in both motor and Supplies the 12 V boardnet with electric power. generator mode.

› State of the art power electronics › Compact and low inductive mechanical design › Compact and robust design › Highly integrated driving circuit

Benefits › Very high power density Benefits › Use of Multi Core μC (ASIL D certificated) › For application in hybrid and electric vehicles › Increased robustness against EMC

› Fluid cooled system › Output power: Up to 330 kVA at 450 V › Inverter output power: Up to 250 kVA at 450 V › Voltage: 170 V to 470 V › Accurate control of motor torque and power flow › Coolant temp.: 85°C › DC/DC converter output power: 3 kW › Integrated HV EMC filter › Bi-directional link between HV traction battery › ASIL C compliant and conventional 12 V board net Technical Information Technical Technical Information Technical HEV – Hybrid Electric Vehicle 76 77 HV DC/DC Converter Powertrain Electrification Solutions

Converts voltage from High Voltage (HV) battery to 12 V board net and vice versa.

› Conversion HV to 48 V also possible › DC/DC power scalable (parallel power phases)

Benefits › Use of Multi Core μC (ASIL D certificated) › Uni- and bidirectional operation › Voltage, current and temperature monitoring › Reverse polarity protection by external fuse

› Output power: 3 kW › Current: 200 A at 14 V › Max. peak current: 275 A at 14 V, 10 sec › Input voltage: 170 V to 460 V › LV output voltage: 6 V to 10 V (buck mode) Technical Information Technical TR – Transmission 78 79 Transmission TR – Transmission 80 81 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission TR

Integrated transmission control unit for dry 7-speed Integrated transmission control unit for wet 7-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).

› Mechatronic module integrated in the gearbox › Mechatronic module integrated in the gearbox › Direct connection of actuators to the control unit › Integrated in transmission and surrounded by transmission oil Benefits › Higher reliability of the electronics due to the Benefits reduced number of internal connections › Short links to sensor systems and actuating elements › Reduced weight › Reduced harness length › Ceramic substrate technology › LTTC (Low temperature co-fired ceramics) substrate › Operating temperature: – 40°C up to +140°C for electronic components › 32-bit microcontroller › Operating temperature: – 40°C up to +145°C › Sensors: 4 gearshift position, 2 clutch position, › 32-bit microcontroller 3 speed, 1 pressure, 1 temperature › Sensors: 4 gearshift position, 2 speed, 2 pressure, › Actuators: 8 x PWM proportional solenoids 1 temperature

Technical Information Technical › Control of BLDC motor of oil pump › Actuators: 11 closed-loop controlled valves › Only one plug connection to the vehicle Information Technical TR – Transmission 82 83 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission TR

Integrated transmission control unit for wet 7-speed Integrated transmission control unit for wet 7-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).

› Front, all-wheel and hybrid drive applications › All-wheel and front-wheel drive applications › Longitudinal installation of the engine › Longitudinal installation of the engine

Benefits › Small space requirements Benefits › Fully integrated control unit contains all electronic components › Alignment of electronics and mechanics in the unit › Improved shifting performance and comfort › Short links to sensor systems and actuating elements › Ceramic substrate technology › BD-HDI substrate technology › Operating temperature: –40°C up to +145°C › Operating temperature: –40°C to +148°C › 32-bit microcontroller › 2 x 32-bit microcontroller › Sensors: 4 gearshift position, 10 position, 3 speed, › Sensors: 2 temperature, 1 motor speed, various 2 pressure, 3 temperature, 1 PLCD module external sensors › Actuators: 11 solenoids › Actuators: 9 solenoids (+ 1 optional),

hydraulic pump motor Information Technical › Vibrations up to 20 g Technical Information Technical › ASIL-D TR – Transmission 84 85 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission TR

Integrated transmission control unit for wet 7-speed Integrated transmission control unit for Double Clutch Transmission (hydraulically controlled). wet 6-speed Double Clutch Transmission.

› Module integrated in transmission › Mechatronic module integrated in the gearbox › Short links to sensor systems and actuating › Directly mounted on valve body elements Benefits Benefits › Weight reduction due to integration › Simple car wire harness › Improving shifting performance and comfort › Small space requirements › Ceramic substrate technology › Thickfilm and ceramic substrate technology › Operating temperature: –40°C up to +140°C › Operating temperature: –40°C to +145°C › 32-bit microcontroller › 32-bit microcontroller › Sensors: 4 linear position, 2 speed, 2 pressure, › Sensors: 4 gearshift, 1 parking lock, 3 speed, 2 temperature, 1 transmission range 2 temperature, 2 pressure › Actuators: 9 solenoids (4 prop. + 5 on/off) › Actuators: 10 solenoids, 1 BLDC motor for oil pump Technical Information Technical Technical Information Technical TR – Transmission 86 87 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission TR

Mechatronic actuator External transmission control unit for wet 7-speed module for dry 6-speed Double Clutch Transmission. Double Clutch Transmission (hydraulically controlled).

› Directly attached to the gearbox › Stand-alone module placed in vehicle cabin › Includes 2 BLDC motors › Controls fully automatic shifting program Benefits › Higher reliability and accuracy of control Benefits › Sports mode with improved shifting dynamics › Flexible transmission design in regards to package › Simple integration into vehicle › High dynamics of integrated gear shift actuators › Improved shift comfort › PCB substrate technology › PCB substrate technology › Operating temperature: –40°C up to +115°C › Operating temperature: –40°C up to +85°C › 32-bit microcontroller › 32-bit microcontroller › Sensors: 5 temperature, 2 shift motor position › Sensors: 3 speed (frequency), 3 pressure (analog), › Power supply for external sensors 2 temperature (analog), 4 displacement (PWM) › Actuators: 2 BLDC motors for gear changing › Actuators: 9 solenoids (7 closed loop + 2 open loop) › Integrated control for 2 external BLDC motors Technical Information Technical

Technical Information Technical › PCB screwed on aluminum plate › Modular software design TR – Transmission 88 89 Control Unit for Control Unit for Double Clutch Transmission Double Clutch Transmission TR

Universal transmission control unit for 7-speed External transmission control unit for dry 7-speed Double Clutch Transmission. Double Clutch Transmission.

› Control unit for a double clutch transmission › Compact module with small size and low weight for hybrid vehicles › Engine/passenger compartment mounted › Contains electromechanical actuation and smart Benefits Benefits › Enables smooth gear shifting actuators › Robust mechanics with aluminum casing › Stand-alone module placed in engine compartment › Optimized cooling surface › PCB-FR4 technology › 3 motor supply voltage › Operating temperature: –40°C to +105°C › Operating temperature: –40°C up to +105°C › 32-bit microcontroller › 32-bit microcontroller with internal flash memory › Sensors: 2 x 3 hall, no external sensors › Sensors: 3 x 4 motor hall, 2 select postion, 2 speed, › Actuators outputs: 2 B6 drivers for EC motor, TSG sensor 2 HS driver enable function › Actuators: 4 BLDC motors, 2 select solenoid

Technical Information Technical › Communications with 3 high speed › PCB substrate, SMD CAN connections and 1 LIN connection Information Technical › 2 CAN port, Flex-ray TR – Transmission 90 91 Control Unit for Control Unit for Stepped Double Clutch Transmission Automatic Transmission TR

Transmission control unit platform Integrated electro-hydraulic transmission control module for Double Clutch Transmission application. for 6-speed Stepped Automatic Transmission.

› AUTOSAR standard architecture › Integrated TCU including manifold and solenoids › ISO26262 ASIL C compliance › Compact module with small size and low weight Benefits › Compatible with stand-alone and attached-to Benefits › Higher reliability and reduced number of connectors concepts › Reduced calibration effort in transmission plant › Cost and weight optimized solution › Enables smooth gear shifting › PCB substrate technology › Operating temperature range: –40°C up to +110°C › Small size LTTC (low temperature co-fired ceramics) substrate for electronic components › 32-bit microcontroller › Operating temperature: –40°C up to +140°C › Up to 12 closed loop current control outputs › 32-bit microcontroller with external flash memory › BLDC control › 11 analog inputs and 7 digital inputs › Actuators: 7 integrated solenoids, 4 integrated pres- sure switches, integrated hydraulic filter elements › 4 voltage or current type frequency inputs Technical Information Technical › Plastic mechatronics with integrated lead frames

› 2 independent 5 V sensor supplys and Information Technical 2 independent 8 V sensor supplys › Integrated hydraulic manifold

TR – Transmission 92 93 Control Unit for Stepped Control Unit for Stepped Automatic Transmission Automatic Transmission TR

Integrated control unit for 7-speed Stepped Automatic External control unit for 5-speed Automatic Transmissions Transmission. in rear-wheel drive vehicles.

› Mechatronic module assembled on valve body of › Stand-alone control unit gearbox › Simple integration into vehicle › Fully integrated control unit contains all electronic Benefits Benefits components › Improved shift comfort › Short links to sensors and actuating elements › Robust plastic cover › Improved performance characteristics › PCB substrate technology › Small size BD-HDI substrate for electronic parts › Operating temperature: –40°C up to +140°C › Operating temperature: –40°C up to +140°C › 16-bit microcontroller › 32-bit microcontroller › Power output for 6 electro-mechanical hydraulic › Sensors: 3 speed, 1 temperature, 1 linear position valves › Optional plugs for external pressure sensor › Actuators: 2 valves for hydraulic of transmission, › Actuators: 8 power outputs for solenoids 3 valves for gear changing, 1 valve for bypass Technical Information Technical converter › Plastic mechatronic with solenoid fixation system Technical Information Technical › Flexible printed circuit (FPC) TR – Transmission 94 95 Control Unit for Stepped Control Unit for Stepped Automatic Transmission Automatic Transmission TR

Stand-alone transmission control unit for 6-speed Universal transmission control unit for Stepped Automatic Stepped Automatic Transmission. Transmission.

› Compact module with small size and low weight › Chassis mounted control unit › Engine/passenger compartment mounted › Flexible module with various sensor inputs and actuator outputs Benefits Benefits › Enables smooth gear shifting › Universal use › Compact size stand-alone transmission control unit › Operating temperature: –40°C up to +105°C › PCB (FR4) substrate technology › 32-bit micro processor with internal flash memory › Operating temperature: –40°C up to +105°C › 2 power supply outputs to drive solenoid › 32-bit microcontroller › 6 linear solenoid and 2 on / off solenoid driving › Sensors: External outputs › Actuators: Control of 8 PWM solenoids › 4 coded type position and sport mode inhibitor Technical Information Technical › Sealed housing switch inputs Technical Information Technical › Oil temperature sensor and 2 speed sensor inputs › K-line and 500 kbps CAN communication TR – Transmission 96 97 Control Unit for Stepped Control Unit for Continuously Automatic Transmission Variable Transmission TR

Universal transmission control unit Integrated transmission control unit for Stepped Automatic Transmission. for Continuously Variable Transmission.

› External control unit › Front wheel drive application › Flexible module with various sensor inputs and › Longitudinal installation of the engine actuator outputs Benefits Benefits › Small space requirements › Universal use › Improved performance characteristics › PCB substrate technology › Ceramic substrate technology › Operating temperature: –40°C up to +105°C › Operating temperature: –40°C up to +145°C › 64-bit microcontroller › 32-bit microcontroller › Sensors: External › Sensors: 1 temperature, 1 position motor › Actuators: Control of 10 PWM solenoids › Control of various external sensors › Sealed housing › Actuators: Control of 11 solenoids for

Technical Information Technical

Technical Information Technical transmission ratio › Vibrations up to 20 g TR – Transmission 98 99 Control Unit for Continuously Control Unit for Variable Transmission Commercial Vehicle TR

Integrated transmission control unit External transmission control module for various for Continuously Variable Transmission. commercial vehicle transmission applications.

› External module placed in passenger or engine › Control module for ultrashift and autoshift compartment applications in commercial vehicles › Stand-alone concept › Designed as AMT controller Benefits Benefits › Size and weight optimized › Stand-alone module, transmission mounted › Reduced time-to-market due to platform technology › Fuel economy and reliability benefits

› PCB substrate technology › Flex FR4 PCB substrate technology › Operating temperature: –40°C up to +95°C › Operating temperature: Up to +105°C › 32-bit microcontroller with external flash memory › 32-bit microcontroller › Sensors: 5 gearshift position, 3 gearlever control, › Sensors: 3 position, 3 speed 3 speed, 2 pressure, 1 temperature › Actuators: 4 motor control › Actuators: 6 PWM proportional solenoid › 76 way module I / O connector Technical Information Technical › Closed-loop control Information Technical › Communications via Hardwire and CAN

TR – Transmission 100 101 Control Unit for Control Unit for Double Commercial Vehicle Clutch Transmission (CV) TR

Transmission control unit for commercial vehicle TCU for 7-speed Double Clutch Transmission. automated transmission. Direct mount TCU with pass through connector.

› Control unit for automated transmissions for › Measurement of clutch speed (input shaft) heavy duty trucks › Measurement of output speed and direction › External module directly attached to pneumatic Benefits Benefits › Measurement of transmission temperature actuator, which is mounted on the gearbox › Control and measurement of clutch pressure › Improved fuel economy › Substrate Technology: PCB substrate technology › DCB (Direct Copper Bonded) and LTCC (Low Temperature Co-fired Ceramics) technology › Operating Temperature: –40°C up to +125°C › Operating temperature: –40°C up to +140°C › Microprocessor: 32 bit MPC5674F with 4 mb of RAM › Sensors: 5 speed, 1 temperature, 1 pressure, › Control of 4 gearshifts and positions 5 external sensor supply › Control of 2 safety valves › Actuators: 15 control of pneumatic valves › Control of main oil pressure Technical Information Technical

Technical Information Technical › Control of cooling oil pressure TR – Transmission 102 103 EAST Transmission Control Unit for Control Unit Platform Limited Slip Coupling TR

Transmission control unit platform for DCT-, CVT-, AMT- Control unit for limited slip coupling of 4WD control and Step-AT applications. applications.

› External module placed in passenger or engine › Unit directly attached to 4WD coupling compartment › Controls valve and feeder pump to change torque › Stand-alone concept distribution between front and rear axle Benefits Benefits › Cost and weight optimized solution › Contribution to improve traction and stability of › Reduced time-to-market due to platform technology the vehicle

› PCB substrate technology › PCB substrate technology › Operating temperature: –40°C up to +95°C › Operating temperature: –40°C up to +120°C › 32-bit microcontroller with external flash memory › 16-bit microcontroller › Sensors: 4 gearshift position, 4 gear lever position, › Sensors: 1 pressure sensor, 1 oil temperature sensor 4 speed, 2 pressure, 2 temperature › Actuators: PWM control of 2 proportional valves, › Actuators: 8 PWM proportional solenoid closed loop 1 feeder pump motor control (hydraulic version), 3 motor control (electric Technical Information Technical Technical Information Technical version) › With integrated BLDC-motor control TR – Transmission 104 105 Control Unit Multi Position for Transfer Case Linear Actuator TR

Integrated transfer case actuator (electric motor and Power transfer control unit. control unit).

› 4WD /AWD control unit with integrated motor for › Axle disconnect and AWD function wet transfer-cases, directly attached to the transfer › 1 and 2 speed system configurations case Benefits Benefits › Mounted on PTU/RDU on the axles › Integration of ECU, brushless DC motor and sensors in one mechatronic actuator unit › Covers heat stake interface to PCB › Motor terminal blades on PCB › PCB substrate technology › Operating temperature: –40°C up to +140°C (TC) › FR4 substrate › 16-bit microcontroller › Operating temperature: –40°C up to +125°C › Sensor: 1 angle position sensor › Microprocessor: FSL S12XS › Actuator: 1 BLDC motor integrated in XCU › Sensors: 8 linear hall effect (shift fork position feedback), 1 quadrature rotational encoder (motor rotation feedback), 1 temperature Technical Information Technical › Actuators: Control of 1 brushed DC motor Technical Information Technical TR – Transmission 106 107 Direct Shift Module Sensorcluster for Automatic Transmission Applications TR

DSM offers a shift-by-wire function for the PRND selection Sensor Cluster of an automatic transmission. for DCT-, CVT-, AMT- and Step-AT-Applications

› Shift-by-Wire module attached outside of the › Internal module integrated in the transmission gearbox, at the housing of the 7-speed AT torque › Can be used as stand-alone system converter (with various TCUs) Benefits Benefits › Shift-by-Wire PRND module is smaller in size › Cost and weight optimized solution compared to conventional PRND shift levers. This creates more space for other CUs. › Stand-alone sensor cluster (smart or non-smart)

› High temperature PCB › PCB substrate technology › Operating temperature: –40°C up to +120°C › Operating temperature: –40°C up to +150°C › 16-bit microcontroller › Sensors: 4 gearshift position, 2 speed, 1 temperature › Sensors: Lever angle, temperature, eccentric shaft › Provides sensor signals to separate TCU

› Actuators: 2 motors for PRND shift and emergency

shift to P function Technical Information Technical › Communications via CAN Information Technical S & A – Sensors & Actuators 108 109 Sensors & Actuators S & A – Actuators 110 111 Active Purge Air Control Valve Economy Line S11.1

Generates the flow of fuel vapors from an evaporative emis- Intake air flow and pressure control on combustion sion canister to the manifold of limited vacuum engines. engines. Supports EGR and particle filter regeneration. S & A & S › HC purging is independent from manifold vacuum › Low cost – full functional range › OBD monitoring for HC evaporative leak detection › Capable for LP EGR environment

Benefits › Pressure sensing Benefits › Low weight, small package › Low power consumption (25 W max) › Good crash behavior › Compact size for vehicle packaging › Non-contacting position sensor

› Radial pump with integrated electronics › Temperature range: –40°C up to +140°C › Purge flow: 50 SLPM min and › Response time (typ.): 110 ms (13.5 V, RT) 8 kPa at 12 V and 20°C › Pressure range: Up to 3.5 bar peak › Operating temperature: –20°C up to +125°C › TP diameter range: 40 mm to 57 mm › Brushless DC motor: 25 W max › Signal output: Analog 5 V or digital SENT › Feedback for speed and torque Technical Information Technical Information Technical S & A – Actuators 112 113 Air Control Valve Air Control Valve Economy Line S11.2 Performance Line S6

Intake air flow and pressure control on combustion Intake air flow and pressure control on combustion engines. Supports EGR and particle filter regeneration. engines. Supports EGR and particle filter regeneration. S & A & S › Low cost – full functional range › High torque – fast performance › Capable for LP EGR environment › Capable for LP EGR environment Benefits Benefits › Low weight, small package › Very good EMC performance › Non-contacting position sensor › Non-contacting position sensor

› Temperature range intake air: –40°C up to +140°C › Temp. range intake air: –40°C up to +140°C › Temperature range environm.: –40°C up to +160°C › Temp. range environment: –40°C up to +160°C › Response time (typ.): 110 ms (13.5 V, RT) › Response time (typ.): 90 ms (13.5 V, RT) › Pressure range: Up to 3.5 bar peak › Pressure range: Up to 3.5 bar peak › TP diameter range: 40 mm up to 68 mm › TP diameter range: 40 mm up to 68 mm › Signal output: Analog 5 V › Signal output: Analog 5 V Technical Information Technical or digital SENT Information Technical or digital SENT S & A – Actuators 114 115 Air Control Valve Air Control Valve – Perform. Performance Line S6 HT Line S8.6 (MD/HD Truck)

Intake air flow and pressure control on combustion Intake air flow and pressure control on combustion engines. Supports EGR and particle filter regeneration. engines. Supports EGR and particle filter regeneration. S & A & S › Capable for high temperature applications › Modular capable for 12 V and 24 V systems › High torque - fast response › Capable for big TP diameters – high flow Benefits › Very good EMC performance Benefits › Non-contacting position sensor › Capable for LP EGR environment › Temperature range: –40°C up to +140°C › Non-contacting position sensor › Response time (typ.): 90 ms (13.5 V, RT) › Temp. range intake air: –40°C up to +230°C › Pressure range: Up to 3.5 bar peak › Temp. range environment: –40°C up to +160°C › TP diameter range: 57 mm up to 100 mm › Response time (typ.): 90 ms (13.5 V, RT) › Signal output: Analog 5 V › Pressure range: Up to 3.5 bar peak

› TP diameter range: 40 mm up to 68 mm Information Technical › Signal output: Analog 5 V

Technical Information Technical or digital SENT S & A – Actuators 116 117 Air Control Valve Brushless DC Drives Smart ACV High Efficiency

Intake air flow and pressure control on combustion Best performance motors to reasonable prices for different engines. Supports EGR and particle filter regeneration. use out of a scalable, modular concept. S & A & S › Integrated control unit with processor and H-bridge › High efficiency brushless DC drives for use in for DC motor on-board double clutch, AWD-disconnect, oil pumps etc. › Easy to integrate into existing systems › Small package, low weight, low inertia Benefits Benefits › Capable for LP EGR environment › Low content of rare earth material › Non-contacting position sensor › High torque as well as high speed capability within the modular concept › Temperature range: – 40°C up to +120°C › Different performance classes: 50 W up to 900 W › Response time (typ.): 150 ms (13.5 V, RT) › Variation of diameter, length and windings › Pressure range: Up to 3.5 bar peak depending on customers’ needs › TP diameter range: 57 mm up to 80 mm › Temperature range: – 40°C up to +140°C Technical Information Technical Technical Information Technical S & A – Actuators 118 119 Canister Purge Solenoid Digital Linear Actuator CPS6 Compact Size – Gen VII

The Canister Purge Solenoid controls hydrocarbon Idle Airflow control for 2-wheeler and small engines. vapors from the canister to the intake manifold. S & A & S › Higher flow than competitive valves › Accurate and stable idle air control › Linear flow curve and fast response › Various gas (air) flow curve can be achieved Benefits Benefits › Sonic nozzle flow control › Light weighted and small sized robust design › Integrated particle trap to control contamination › Dedicated for 2W and small engine application › High resolution linear positioning against load › Integrated noise attenuation volume › Two packagings for different integration options › Flow at >30 kPa: 110 SLPM (2.3 g/s, 7.9 kg/h) › Operating voltage: 7.5 V up to 14 V › Operating voltage: 9 V up to 16 V (13.5 V optimal) › Inductance/winding: 20.7 mH › Coil resistance: 21 Ohms › Resistance/winding: 53 Ohms › OBD leakage (6.7 kPa vacuum on canister port): › Resolution: 0.042 mm/step (full step mode) < 3.0 SCCM › Total travel (typ.): 8.5 mm (204 steps) › Operating temp.: –25°C up to +125°C › Operating temp.: –30°C up to +110°C › Frequency: 5 Hz up to 32 Hz Technical Information Technical › Airflow control: Up to 41.8 kg/hr

(10 Hz recommended) Information Technical at ΔP = 600 hPa S & A – Actuators 120 121 Digital Linear Actuator Digital Linear Actuator Standard Size – Gen I Standard Size – Gen II

Accurate and precise gas/airflow. Accurate and precise gas/airflow. Linear position control against external load. Linear position control against external load. S & A & S › Accurate and stable idle air control › Accurate and stable idle air control › Various gas (air) flow curve can be achieved › Various gas (air) flow curve can be achieved

Benefits › High accuracy under severe conditions Benefits › High accuracy under severe conditions › Proven reliability and long durability › Proven reliability and long durability › High resolution linear positioning against load › High resolution linear positioning against load

› Operating voltage: 12 V (7.5 V – 14 V) › Operating voltage: 12 V (7.5 V – 14 V) › Resistance per winding: 53 Ohms › Resistance per winding: 48 Ohms › Linear resolution: 0.042 mm / full step › Linear resolution: 0.042 mm / full step › Total travel (typical): 8.5 mm (204 steps) › Total travel (typical): 8.5 mm (204 steps) › Operating temperature: –40°C up to +125°C › Operating temperature: –40°C up to +125°C › Vibration capability: Up to 40 G › Vibration capability: Up to 40 G › Life time durability: 500 hours › Life time durability: Up to 2,000 hours Technical Information Technical Technical Information Technical › Weight: ~110 g › Weight: ~90 g S & A – Actuators 122 123 Digital Linear Actuator Electrical Compressor Standard Size – Gen V Bypass Valve

Accurate and precise gas/air flow. Compressor surge prevention and turbocharger lag Linear position control against external load. reduction by opening a bypass for the compressor. S & A & S › Accurate and stable idle air control › Electromagnetic on-off solenoid › Various gas (air) flow curve can be achieved › Improved performance and size Benefits › High accuracy under severe conditions Benefits › No vacuum lines, tank, or vacuum control valve needed › Proven reliability and long durability › Fast actuation › Plastic sleeve gives lighter weight › Mounted directly on turbocharger or air duct › Operating voltage: 12 V (7.5 V – 14 V) › Nominal operating voltage: 12 V › Linear resolution: 0.042 mm / full step › Response: <50 ms at 20°C; 13.5 V › Total travel (typical): 8.5 mm (204 steps) › Operation (gas) temperature: –40°C up to +200°C › Vibration capability: Up to 35 G short term (30 min): +200°C › Life time durability: Up to 1,000 hours › Ambient temperature: –40°C up to +150°C › Travel: ≥ 5 mm; Poppet Technical Information Technical diameter 26 mm Technical Information Technical S & A – Actuators 124 125 Electrical Exhaust Gas Electrical Wastegate Recirculation Valve Actuator

Controls the amount of recirculated exhaust gas to reduce Performing waste-gate adjustment to optimize functional NOX emissions and fuel consumption. application and reduce fuel consumption. S & A & S › Electric actuation has faster response and more › Continuous adjustment of external application using control than conventional vacuum systems rotating output shaft › Eliminates vacuum regulator and connecting hoses › Ideal for use in turbocharger applications Benefits Benefits › Can be tailored to customer flow requirements › Option: Default position › Permanent feedback signal (non-contacting) › Current consumption at max. flow: 1.0 A at 20°C › Max. external load without return function: 92 Ncm › Nominal operating voltage: 12 VDC › Max current consumption: 1.5 A › Max. continuous holding torque without return function at 160°C: 144 Ncm › Nominal coil resistance: 8.0 Ohms at 20°C › Holding torque › Nominal operating frequency: 90 Hz up to 175 Hz capability at 160°C: 420 Ncm

Technical Information Technical › Position sensor supply voltage: 5 VDC › Response time less than: 140 ms/80°angle at 160°C

› Response time (total stroke): < 50 ms at 20°C, Information Technical › Operation temperature : –40°C up to +160°C 13.5 VDC S & A – Actuators 126 127 Electronic Throttle Control Exhaust Control Valve ETC 12 High Pressure

Torque/load control on gasoline combustion engines. Helps to reduce emissions of NOX and fuel consumption Supports idle speed, cruise and traction control. in gasoline and diesel engines in HP EGR loop. S & A & S › High performance throttle body actuator › Balanced rotary throttle principle for EGR control › High torque, fast response › Contactless MR Sensor, flexible output › Benefits Benefits Low weight, very small package › Provides accurate low flow precision › Low leakage, spherical bore optional › High flow EGR with low gas pressure drop › Capable for turbo and supercharged applications › Fits high temperature and pressure pulsations › Optional capable for high temperature applications › Temperature range: –40°C up to +140°C/180°C › Torque at flap: 230 Ncm › Response time (typ.): 90 ms (13.5 V, RT) › Response time (85%): < 80 ms

› Pressure range: Up to 3 bar peak › Nominal supply voltage: 12 VDC or 24 VDC › Leakage (at stop): <1.7 kg/h (52 mm) › Position sensor supply voltage: 5 VDC › TP diameter range: 40 mm up to 95 mm › Maximum flow: Up to 190 kg/h › Analog or digital (SENT) position feedback at 50 hPa › Weight: 490 g (TP 48 mm with Technical Information Technical › Exhaust temperature: Up to 700°C Technical Information Technical optimized housing) S & A – Actuators 128 129 Exhaust Control Valve Exhaust Control Valve Linear Low Pressure

Helps to reduce emissions of NOX and fuel consumption in Helps to reduce emissions of NOX and fuel consumption gasoline and diesel engines. in gasoline and diesel engines in LP EGR loop. S & A & S › Linear technology (direct position measurement) › High flow LP EGR valve with small pressure drop › Reduced friction and short response time › Non-contacting sensor, flexible output, not sensitive against magnetic fields Benefits Benefits › Low valve seat leakage › Compact, light weighted size › Compact, can be customized › Adapted to corrosion requirement for LP EGR path › Suitable for high temperature applications › Response time (t90): < 90 ms › Nominal supply voltage: 12 VDC › Nominal supply voltage: 12 VDC › Position sensor supply voltage: 5.0 VDC › Position sensor supply voltage: 5 V › Exhaust gas temperature: >500°C with DC adequate cooling › Maximum flow (at dP 20 hPa): 245 kg/h › Typical ratio of pintle Ø to lift: 4 to 1 › Internal leakage (at dP 600 hPa): ≤ 3 kg/h › Response time (t85): ≤100 ms › Exhaust gas temperature: 100°C up to 200°C Technical Information Technical Technical Information Technical Latching Valve Latching S & A–Actuators pressurized tank or isolated HC vapors in a normal tank. anormal in vapors HC isolated or tank pressurized to aseal- used valve abi-stable is valve refueling Latching Technical Information Benefits › › › › › › › › › › ›

Leak: – Leak: at pressure sccm tank <10 9 kPa pressure 35 at tank kPa sccm Leak: <3.5 pressure 20 tank kPa and 5kPa at sccm Leak: <1 43.5 kPa at relief Overpressure Flow: >115 at SLPM 1.5 kPa state valve to14 ms change <100 for pulse V DC pressure over tank fuel for function relief Passive (open/closed) position valve to determine Able restriction flow low Very draw zero current using position valve Maintains consumption energy less Significantly 130 The Linear Purge Valve controls hydrocarbon vapors from from vapors manifold. intake to the canister the hydrocarbon controls Valve Purge Linear The Linear Purge Valve Purge Linear Technical Information Benefits constant current at: 150 to Hz up Hz 200 at: current constant vapor fuel of surges conditions operating › › › › › › › › ›

Weight: Weight: circuit Control mA 500 14.0 Ohms current: Maximum resistance: Coil 70 57 at SLPM kPa 14 V voltage: Operating Typical flow: unwanted preventing control flow end low Excellent all at control flow incremental for response Fast noise operating low Very 200 g 200 131

S & A Detection (NVLD III) Natural Vacuum Leak S & A–Actuators Engine off OBD monitoring for hydrocarbon evaporative evaporative Legislation leak detection. compliance. hydrocarbon for monitoring OBD off Engine Technical Information Benefits › › › › › › › › › › ›

100 SLPM purge flow: <6 mbar ∆ pressure mbar <6 to up +85°C –40°C flow: 100 purge SLPM 21 ohms temperature: Operating resistance: coil Nominal >100%) perform.: (IUMPR monitor Ratio use in High ECU with communication serial Bit leak diameter to 0.5mm capable Detection function Timer Switch sensing sensing; Temperature capacity flow purge improved for solenoid Integrated key off after performed diagnostic leak HC OBD With integrated electronics 132 electronics cooling as well as turbocharged air cooling. air turbocharged as well as power cooling and electronics engine for demand on flow-rate Volume Electrical Water Pump – Pump Technical Information Benefits BLDC motor BLDC operation › › › › › › › › › ›

yrui oe: 10 toW up 45 W Max. 110 power: Hydraulic W to up power: 1,800 l/h Electrical 700 l/h hPa to up 900 hPa 500 pressure: Differential flow: Volume concept design Modular rotor magnet permanent Wet running commutated oriented field sensorless Electronically engine combustion from independent Operation circuit cooling main from independent Operation demand) (on management energy Supports 133

S & A S & A – Actuators 134 135 Pump – Turbo Purge Valve Twin Drive Pump

Gearboxes and combustion engines with hydraulic The Turbo Purge Valve controls HC vapors from the demand for start-stop and hybrid functions. canister to the turbo charged intake manifold. S & A & S › Combined mechanical and electrical driven › EVAP turbo system cost savings main pump › Smooth start-to-open characteristics › No need for adding electrical and mechanical power Benefits Benefits › Robust design and easy to calibrate by pinions › Multiple turbo purge system parts in one assembly › Operates simultaneously or separate in mechanical and/or electrical mode › Flexible configuration using common actuator › Highest overall efficiency in both operation modes › Incorporates check valves to protect purge system › Electronically commutated BLDC motor › Operating voltage: 9 V up to 16 V (13.5 V optimal) with/without sensor › Operating temp.: –25°C up to +125°C › Electric power: ~150 W up to 500 W › Operating pressure: Up to 400 kPa › BLDC commutation, depending on customer › Frequency: 5 Hz up to 30 Hz requirement (10 Hz recommended) › Vane-type pump

Technical Information Technical › Purge flow: 110 SLPM Techical Information Techical S & A – Actuators 136 137 Variable Turbine Geometry Door Handle Sensor Actuator

Best performance for VTG adjustment to optimize Sealed module integrating various keyless access functional application and reduce fuel consumption. functions into a door handle or exterior module. S & A & S › Continuous adjustment of external application › Easy integration of various sensors/functions for using rotating output shaft Keyless Entry System in a single sealed module › Ideal for use in VTG applications › Communication to system: Current modulation, Benefits Benefits voltage output, LIN, CAN, etc. › Permanent feedback signal (non-contacting) › Options: Default position, integrated electronic › Power consumption: ~70 µA for double zone sensor › Response time: 5 ms up to 30 ms › Max. external load without return function: 40 Ncm › Detection distance ~2 mm to 20 mm, depending (lock/unlock): on door handle type › Max. continuous holding torque without return function at 140°C: 65 Ncm › Antenna inductance: From 100 µH up to 500 µH › Response time: <150 ms at 120°C › Temperature range: –40°C up to +85°C › Operation temperature: –40°C up to +140°C Information Techical › Integrated pocket and ground light output Technical Information Technical S & A – Sensors 138 139 Easy Trunk Access Sensor Electrostatic Particulate Matter Sensor

Sealed capacitive sensor module integrated inside Sensor for on-board a bumper for keyless access to the trunk or sliding doors diagnosis of diesel particulate filters. S & A & S › Trunk/sliding door easy hands-free opening / closing › Continuous output signal for DPF diagnosis › Sensor activated with movement of leg (no need to › Lowcross-sensitivity to noise factors press a button or remote control) Benefits Benefits › Signal available down to low concentrations › Integration of capacitive sensor inside a bumper › Environmental robustness by design (no measuring › Dual electrode set to prevent false activations ceramic)

› Detection distance: Up to 15 cm (tunable to › Diagnosis functions compliant with latest OBD application) regulations › Quiescent current: 2.5 mA (no low power mode), › Measuring range: 0 mg/m³ up to 50 mg/m³ 250 μA (low power mode) › Repeatability +/– 10% of sensor signal › Temperature range: –40°C up to +85°C (reference bench): above 5 mg/m³ › LIN, ON/OFF voltage or current output › Gas temperature: Up to 950°C › Vehicle integration guidelines available for specific › Data link: CAN 2.0 or SAE-J-1939 Technical Information Technical Technical Information Technical configurations (trailer hitch, US radars, etc.) › Mechanical interface: M22x1.5 (spinning nut) S & A – Sensors 140 141 Fluid Sensor Fluid Sensor Biodiesel Flex Fuel Ethanol

Detection of biodiesel content in diesel fuel. Detects ethanol concentration in gasoline /ethanol fuel mixture. S & A & S › Designed to accurately compensate for differences › Highly accurate prediction of ethanol concentration in worldwide biodiesel feed stocks › Enables ethanol detection before injection / › Outputs biodiesel concentration and fuel combustion Benefits Benefits temperature within 500 ms after start up › Outputs ethanol concentration and fuel temperature › Self diagnostic capability, supports OBD-II within 250 ms after start-up › Self diagnostic capability › Measurement principle: Capacitive-based on Flex Fuel Technology › Measurement principle: › Accuracy: +/– 5% (Americas and Europe) Capacitive (0% up to 100% ethanol content) +/–7% (Worldwide feed stocks) › Accuracy: +/– 5% ethanol concentration › Pressure range: <10 bar › Pressure range: <10 bar (145 psi) › Fuel temp. range: –40°C up to +125°C › Fuel temp. range: –40°C up to +90°C › Environmental temp.: –40°C up to +125°C

Technical Information Technical › Environmental temp.: –40°C up to +150°C

Technical Information Technical S & A – Sensors 142 143 Fluid Sensor – Oil Level Fluid Sensor Passive Electrothermic Oil Level Switch

Sensor monitors correct engine oil level to avoid overfill or Level switch to monitor engine oil level below minimum underfill during driving or at key-on. threshold. S & A & S › Overfill and low level indication › Low oil level detection › Absolute measurement of oil level in static and › Different connectors possible dynamic conditions Benefits Benefits › Simple on /off output › Replacement of oil dipstick › Market proven › Different mounting positions › Measuring principle: Magnetic reed switch › Temperature measurement optional › Different switch heights possible › Measuring principle: Thermo resistive heated wire › Normally on (switch closed) › Measuring range: 100 mm between min. and max. › Tolerance: +/–1 mm › Accuracy approx.: +/–3 mm › First measurement: Available 0.6 s after key-on

› Measuring interval: >10 s Information Technical › Operating temp.: –40°C up to +160°C Technical Information Technical S & A – Sensors 144 145 Fluid Sensor – Oil Level Fluid Sensor – Urea Ultrasonic Concentration and Level

Best price-performance ratio sensor to monitor correct Urea Concentration and Level Sensor helps to fulfill emis- engine oil level. sion legislation and OBD requirements for SCR systems. S & A & S › Replacement of oil dipstick › Fast and accurate measurement of urea › Detection of low level and overfill concentration (AdBlue®/DEF) in the SCR system › Additional measurement of urea level and Benefits › Absolute measurement of oil level static/dynamic Benefits temperature › Low power consumption › Flexible mounting positions › Temperature measurement optional (in-tank, in-extraction unit, in-line) › Measuring principle: Ultrasonic echo › Proven sensor technology › Measuring range: 18 mm up to 150 mm › Measuring principle: Ultrasonic › Accuracy: +/–2 mm › Output signal: PWM / CAN / SENT › Operating temperature: –10°C up to +150°C (level) – 40°C up to +150°C (temp.) › Measuring range: – Concentration: 0% up to 50% urea mass › First measurement: Available after 0.4 sec. above freezing point › Measuring interval: 1 sec. – Level: 20 mm up to 500 mm Technical Information Technical › Interface: PWM › Measuring interval: 1 sec. Technical Information Technical S & A – Sensors 146 147 In Cylinder Pressure Sensor Knock Sensor – M6

Real-time combustion sensing, providing in-cylinder Measures structural vibrations in internal combustion combustion pressure information. engine to continuously adjust ignition parameters. S & A & S › Tolerance compensation (injection, airpath, engine, › Optimization of ignition timing for max. efficiency fuel, etc.): Combustion stability control › High sensitivity › System cost improvement: Intake/exhaust models Benefits Benefits › Small design with M6 bolt for space and weight › Airpath accuracy and dynamic control savings › Enables alternative combustion control (HCCI) › Increased engine power, decreased fuel consumption › Fits for automotive, two wheelers and others › Embedded electronic using direct analog path – no time delay › Acceleration sensor based on piezo ceramic › Independent of glow plug, improved robustness technology with a range of: 0 g up to 400 g and signal › Frequency range: 3 kHz up to 25 kHz › Large bandwidth suitable for diesel and gasoline › Possible integration of discharge resistor › Output signal: 0 V up to 5 V (ratiometric) › Glue and nut designs available › Measurement range: 0 bar up to 200 bar

Technical Information Technical › Compatible with current ECU designs › Temperature range: –40°C up to +150°C Technical Information Technical S & A – Sensors 148 149 Knock Sensor – Wide Band Mass Airflow Sensor FMT MAF SENT

Measures structural vibrations in the combustion engine Measurement of the intake to continuously adjust ignition parameters. airflow for the engine management system. S & A & S › Optimized ignition timing for maximum efficiency › High flow measurement accuracy and signal stability › High sensitivity › Integral protection against water and contamination Benefits Benefits › Compact design, nested bolt possible › Excellent performance with intake airflow pulsation › Increase engine power › Enhanced EMC performance › Decrease fuel consumption › Options for humidity and pressure sensors

› Acceleration sensor based on piezo ceramic › Sensing technology: Next generation MEMS technology › Flow range: 4.5 kg/h up to 900 kg/h › Frequency range: 3 kHz up to 25 kHz (62 mm tube) › Possible integration of discharge resistor › New-part tolerance: 1.3% › Integrated connector or cable version › Supply voltage: 5 V +/– 0.5 V › Glue and nut designs available › Supply current: 5 mA maximum

Technical Information Technical Information Technical › Output signal: SENT V4 S & A – Sensors 150 151 Mass Airflow Sensor Mass Airflow Sensor FMT MAF + HPT SENT MT

Measurement of the intake airflow humidity, pressure and Measurement of the intake airflow for the engine temperature for the engine management system. management system. S & A & S › High flow measurement accuracy › High flow measurement accuracy and signal stability › Integral protection against water and contamination › Integral protection against water and contamination Benefits Benefits › Excellent performance with intake airflow pulsation › Excellent performance with intake airflow pulsation › Enhanced EMC performance › Customer specific programmable output characteristic › Options for humidity and pressure sensors › Sensing technology: Hot-film bi-directional MEMS › Sensing technology: Next generation MEMS › Flow range: 5 kg/h up to 800 kg/h › Flow range: 4.5 kg/h up to 900 kg/h (62 mm tube) (62 mm tube) › New-part tolerance: 1.5% › New-part tolerance: 1.3% › Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V › Supply current: 8 mA maximum › Output signal: SENT V4

Technical Information Technical › Output signal: Frequency or SENT digital Technical Information Technical › Intake air temperature sensor optional S & A – Sensors 152 153 Near Field Communication Position Sensor External Reader Linear Contactless

Hall Effect Technology

Sealed module integrating in it and multi zone capacitive Sensor mainly used for gear neutral and all gear sensor, sensor into a door handle or exterior module. clutch master cylinder, pedal, fork position sensor. S & A & S › Enables car access with smart phone and › Small sensor size information download/configuration upload › Through aluminum wall measurement › Enables smart car sharing and remote access Benefits Benefits › High air-gap › Easy integration of various functions for Keyless › Compatible with Ferrite Magnets Entry System: NFC reader and capacitive lock/unlock › Fully sealed module; Smart door handle integration › Overall accuracy: Min. +/–2% › Target: Magnet › NFC protocols ISO/IEC 14443a, ISO/IEC 18092:2013 › Measurement: Linear up to 60 mm › NFC range: ~40 mm, depend. on door handle type › Air gap: Up to 11 mm › Dark current: 240 uA for NFC, 70 uA for dual zone capacitive sensor › Operating temp. range: –40°C up to +150°C › Temp. range: –40°C up to +85°C › Operating voltage: 5 V +/– 0.5 V

› Communication to system: Information Technical › Output signal: Analog, PWM, SPI or SENT Current modulation, voltage output, LIN, CAN, etc.

Technical Information Technical › X-Y measurement possible S & A – Sensors 154 155 Position Sensor Position Sensor Linear Contactless Rotary Contactless

Inductive Inductive Technology Technology

Sensor mainly used for Park /No park, CMC, Sensor used for PRND, rotary valve position (EGR, ETC, linear actuators, PRND, fork position sensor. ACV, water valve, etc.), general purpose rotary actuators. S & A & S › Metallic target (Al, Fe, etc.), no magnet needed › Metallic target, no magnet › Immune versus low frequency magnetic field › Immune to low frequency magnetic field, (electric motor, starter current, etc.), no pollution by no pollution by iron particles Benefits Benefits iron particles › Single or redundant configuration › Single or redundant output › ASIC available

› Measuring range: 6 mm up to 60 mm › Measuring range: Up to 360° › Overall accuracy: +/–2% › Overall accuracy: +/–1% › Air gap: Up to 5 mm › Air gap: Up to 5 mm › Linearity: <+/–1% full scale › Linearity: <+/–1% full scale › Operating temperature range: –40°C up to +160°C › No hysteresis › No hysteresis › Operating temperature range: –40°C up to +160°C Technical Information Technical

› Output signal: Analog, PWM or SENT Information Technical › Output signal: Analog, PWM or SENT › Flat or cylindrical shape targets › End of shaft or off axis configuration S & A – Sensors 156 157 Pressure Sensor Pressure Sensor Brake Booster Absolute Brake Booster Gauge

Pressure measurement for Start-Stop applications. Direct measurement of vacuum inside brake booster. S & A & S › Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels › Precision programmable clip levels Benefits › Internal and output diagnostic capability Benefits › Internal and output diagnostic capability › High accuracy and temperature stability › High accuracy and temperature stability › Fulfills toughest EMC requirements › Flexible housing, connector, and mounting designs

› Pressure range: 10 kPa up to 120 kPa › Pressure range: –105 kPa up to 40 kPa (gauge) › Accuracy: 1% full scale (10°C up to 85°C) › Accuracy: 1% full scale (10°C up to 85°C) › Temperature range: –40°C up to +140°C › Temperature range: –40°C up to +125°C › Supply voltage: 5 V +/– 0.5 V › Supply voltage: 5 V +/– 0.5 V › Supply current at 5 V: 10 mA maximum › Supply current at 5 V: 10 mA maximum › Output signal: Analog or SENT › Load resistance: >4.7 kOhms Technical Information Technical Technical Information Technical › Output signal: Analog or SENT S & A – Sensors 158 159 Pressure Sensor Pressure Sensor Filter Control Gauge High Pressure Diesel

Relative measurement of pressure downstream of air filter. Direct measurement of pressure in diesel fuel rail. S & A & S › Flexible calibration of transfer functions › High accuracy and temperature stability › Precision programmable clip levels › High vibration robustness (low / high frequencies) › Benefits Internal and output diagnostic capability Benefits › Modular design for connector and mounting › High accuracy and temperature stability › Flexible calibration of transfer functions › Fulfills toughest EMC requirements › Internal and output diagnostic capability › Flexible housing, connector, and mounting design › Adjustable characteristic via electronic calibration › Pressure range: 0 bar up to 2,500 bar › Pressure range: 0 kPa up to 10 kPa › Temperature range: –40°C up to +140°C › Operating temp.: –40°C up to +125°C › Supply: 5 V, 10 mA › Supply voltage: 5 V +/– 0.25 V › Output signal: Analog or SENT › Output signal: Analog or SENT › Accuracy: 0.5% full scale output › Transfer function: Linear, ratiometric (analog version) › Response time: <1 ms › Accuracy over Technical Information Technical Technical Information Technical full-scale: 3% full span (10°C up to 85°C) S & A – Sensors 160 161 Pressure Sensor Pressure Sensor High Pressure Gasoline Manifold Absolute

MAP TMAP BAP

Direct measurement of pressure in gasoline fuel rail. Direct measurement of pressure in manifold. S & A & S › High accuracy and temperature stability › Flexible calibration of transfer functions › High vibration robustness (low / high frequencies) › High accuracy and temperature stability

Benefits › Modular design for connector and mounting Benefits › Low cost design and high quality › Flexible calibration of transfer functions › Fulfills toughest EMC requirements › Internal and output diagnostic capability › Flexible housing, connector, and mounting design

› Pressure range: 0 bar up to 500 bar › Pressure range: 40 kPa up to 120 kPa (for BAP) › Temperature range: –40°C up to +140°C › Pressure range: 7 kPa up to 500 kPa (for MAP and Turbo MAP) › Supply: 5 V, 10 mA › Accuracy: 1% full scale (10°C up to 85°C) › Output signal: Analog or SENT › Temperature range: –40°C up to +140°C › Accuracy: 0.5% full scale output › Output signal: Analog or SENT › Response time: <1 ms Technical Information Technical Information Technical S & A – Sensors 162 163 Pressure Sensor – Manifold Pressure Sensor Absolute and Temperature Manifold Gauge

MAP with integrated temperature sensor directly Relative measurement of pressure or vacuum in the measures the pressure and temperature in the manifold. intake manifold. S & A & S › Flexible calibration of transfer functions › Flexible calibration of transfer functions › High accuracy and temperature stability › Precision programmable clip levels Benefits › Low cost design and high quality Benefits › Internal and output diagnostic capability › Fulfills toughest EMC requirements › High accuracy and temperature stability › Flexible housing, connector, and mounting design › Fulfills toughest EMC requirements

› Pressure range: 40 kPa up to 120 kPa (for TBAP) › Pressure range: –105 kPa up to 40 kPa (gauge) › Pressure range: 7 kPa up to 500 kPa › Accuracy: 1% full scale (10°C up to 85°C) (for TMAP and Turbo TMAP) › Temperature range: –40°C up to +125°C › Accuracy: 1% full scale (10°C up to 85°C) › Supply voltage: 5 V +/– 0.5 V › Temperature range: –40°C up to +140°C › Supply current at 5 V: 10 mA maximum › Output signal: Analog or SENT › Load resistance: >4.7 kOhms Technical Information Technical Technical Information Technical S & A – Sensors 164 165 Pressure Sensor – Particle Pressure Sensor – Particle Filter Differential (2 Ports) Filter Gauge (Single Port)

Differential pressure measurement across a diesel Relative measurement of exhaust pressure before particulate filter or low pressure EGR system. or after the DPF. S & A & S › Direct measurement of pressure › Flexible calibration of transfer functions › Flexible calibration of transfer functions › Precision programmable clip levels Benefits › Precision programmable clip levels Benefits › Internal and output diagnostic capability › Internal and output diagnostic capability › High accuracy and temperature stability › High accuracy and temperature stability › Fulfills toughest EMC requirements › Pressure range: 0 kPa up to 100 kPa – P1 (downstream port): 0 kPa up to 50 kPa › Pressure range: 0 kPa up to 125 kPa – P2 (upstream port): 0 kPa up to 150 kPa › Accuracy: 1% full scale (10°C up to 85°C) › Supply voltage: 5 V › Temperature range: –40°C up to +125°C › Operating voltage: Programmable › Supply voltage (Vs): 5 V +/– 0.5 V (0.2 V up to 4,800 V) › Supply current at 5 V: 10 mA maximum › Output signal: Analog › Load resistance: > 4.7 kOhms Technical Information Technical › Accuracy: 0.8% FSS (0°C up to 70°C) Technical Information Technical › Temperature range: –40°C up to +125°C › Response time: < 2 ms S & A – Sensors 166 167

Pressure Sensor Smart NOX Sensor Secondary Air Absolute

Direct measurement of pressure in secondary air flow. NOX measurement, upstream or downstream SCR. Optimizes urea injection. S & A & S › Flexible calibration of transfer functions › Real time high accuracy measurement › High accuracy and temperature stability › Sensor performance independent of catalyst or ECU supplier and engine management system Benefits Benefits › Low cost design and high quality › Modular “Stand-alone” NO sensor enabling › Fulfills toughest EMC requirements X EU / US /Japan emission standards compliancy › Flexible housing, connector, and mounting design › Measuring principle: ZrO2-based multilayer sensor › Pressure range: 50 kPa up to 150 kPa (for SAA) with integrated heater and 3 oxygen pumps

› Accuracy: 1% full scale (10°C up to 85°C) › Triple output signal NOX, binary λ, linear λ or O -concentration › Temperature range: –40°C up to +140°C 2 › Supply voltage: 12 V or 24 V › Supply voltage: 5 V +/– 0.5 V › Data link: CAN 2.0 or SAE-J-1939 › Supply current at 5 V: 10 mA maximum › Operating gas temp.: 100°C up to 800°C

› Load resistance: >4.7 kOhms Information Technical Technical Information Technical S & A – Sensors 168 169 Smart Position Sensor Temperature Sensor Cover Coolant / Fuel / Oil

Smart Position Sensor used for controlling Temperature measurement in several liquid media General Purpose Electrical Actuators. (coolant water, oil, fuel).

S & A & S › Inductive position sensor with ASIC › Clip or screw-in design › Immune to low frequency magnetic fields › Wide range of applications (metal target, no magnet) Benefits Benefits › High accuracy › H-bridge driver for DC motor (ASIC) › Short response time › Microcontroller for position control › High temperature operation › Long-term stability › Sensor measuring range: Up to 360° › Oil, water, fuel, temperature measurement – Engine coolant: –40°C up to +140°C › Sensor accuracy: +/–1%, no hysteresis – Engine oil: –40°C up to +150°C › End of shaft or off axis sensor configuration – Fuel: –40°C up to +140°C › H-bridge driver with 4 Amp current capability › Accuracy: +/–1°C (at 0°C) › 16-bit MCU with embedded PID control › Response time: Up to 3 s › Operating temperature: Up to 140°C › Built in protections: O/L, O/T, O/V, U/V CAN, Technical Information Technical Technical Information Technical LIN or PWM interface S & A – Sensors 170 171 Temperature Sensor Temperature Sensor EGR High Multiple

Temperature measurement in EGR system, EGR bypass Temperature acquisition for closed loop aftertreatment valve function diagnostic and thermal protection. control (DPF, SCR. DeNOX / LNT). S & A & S › Temperature measurement of EGR systems › Smart sensor with digital output, high accuracy › Connector design for EGR temperatures › System price benefit up to 450°C Benefits Benefits › Stable signal over lifetime › Resistant to exhaust gases and other relevant › Proven high temperature robustness chemicals at EGR applications › Fast response due to small thermal inertia › Robust stainless steel cup › Thermocouple sensor technology, Type N › RTD or NTC sensor technology › Response time: 7 s at 10 m/s flow (4 s at 20 m/s) › Different Pt curves possible (Pt200, Pt1000) › Sensing temp.: –40°C up to +1,000°C › Measuring tolerance: +/–7°C over lifetime › Working temp. › Response time (T ): <13 sec. at air speed 10 m/s 63 electronics: –40°C up to +140°C › Temperature range: –40°C up to +450°C; › Accuracy: < 500°C +/– 5°C over lifetime up to +600 °C (peak 60 sec.) > 500°C +/–1% over lifetime Technical Information Technical Technical Information Technical S & A – Sensors 172 173 Temperature Sensor Powertrain Drivetrain High Single Efficiency Solutions

Sensor with proven high temperature robustness turbocharger protection.

› Smart sensor with digital output, high accuracy › System price benefit

Benefits › Stable signal over lifetime › Fast response due to small thermal inertia

› Sensing technology: Thermocouple › Response time: 8 sec. at 10 m/s flow (6 sec. at 20 m/s) › Temperature range: in production (diesel) – 40°C up to + 900°C in development –40°C up to +1150°C › Working temp. electron.: –40°C up to +145°C

Technical Information Technical › Accuracy: –40°C up to +500°C: +/– 5°C >500°C: +/–1% › Output: SENT Interface FEM – Fuel & Exhaust Management 174 175 Fuel & Exhaust Management FEM – Fuel & Exhaust Management 176 177 Fuel Delivery Module Fuel Delivery Module for Standard Applications for High-End Applications

In-tank Fuel Delivery Module for gasoline and diesel with the opportunity to integrate various functions.

› Cost effective modular design to cover various › Developed for high performance customer requirements vehicles › Constant flow or demand regulated › Applicable for complex tank geometries Benefits Benefits › Multiple jet-pump and fuel level sensor solutions FEM › Brushless EC pumps or brushed-type DC pumps › Dual pump configurations › Optional integrated: Fuel level sensor, filter, pressure regulator, electronics, vent valves and tank leakage › Brushless EC pumps or brushed-type DC pumps detection sensor › Hydraulic performance: >280 l/h at 6.5 bar Technical Information Technical Technical Information Technical FEM – Fuel & Exhaust Management 178 179 Fuel Delivery Module Fuel Level Sensor with for Entry Level Vehicles a Sealed Contact System

MAPPS (MAgnetic Passive Position Sensor)

Fuel Level Sensor with a fully capsulated sensor element.

› Very cost effective solution due to high flange › Hermetically sealed contacts assure robust integration protection against corrosion › Suitable for compact tanks with low flow › Longer life time (>10 million cycles) because of a Benefits Benefits

requirements wear free measurement system FEM › Also applicable for two-wheelers and recreational › Electromagnetic compatibility vehicles › Measuring range: Up to 90° › Low module weight › Operating current: Up to 20 mA › Integrated vent valve › Resolution: 1.7 degree /pad › Serviceable elements › Max. resistor tolerance: +/–1% › Operating temperature: –40°C up to +80°C Technical Information Technical Technical Information Technical FEM – Fuel & Exhaust Management 180 181 Fuel Level Sensor with an Electric Fuel Pump – EC Open Contact System

Bracket with Three Finger Contacts

Gasoline Pump Diesel Pump

Cost effective sensor In-tank fuel pump with with open contact system. brushless electronically commutated (EC) motor.

› Redundant contacts › Improved quality, reliability and durability (less parts, no commutation wear) › Various contact materials for different technical requirements and market specific fuel compositions › Higher efficiency Benefits Benefits › Electromagnetic compatibilty FEM › Measuring range: Angle up to 100° › Body born noise reduction › Operating current: 1 up to 20 mA › Resolution: 1.25 degree /pad › Gerotor and turbine pump principles › Max. resistor tolerance: +/–1% › Pressure: Up to 700 kPa › Operating temperature: –40°C up to +80°C › Flow, typ.: 330 l/h at 500 kPa › Efficiency, typ.: 35%

Technical Information Technical › Size: 38 mm, 43 mm, 50 mm › Media: Gasoline (up to E100),

Technical Information Technical diesel (incl. RME) FEM – Fuel & Exhaust Management 182 183 Electric Fuel Pump – DC Fuel Delivery Controller

Gasoline Pump Diesel Pump

In-tank fuel pump with brush-type direct current motor. Electronics for demand regulation of fuel delivery modules.

› Most cost-effective solution for non-electronically › Reduced consumption of electrical energy regulated systems › Enhanced lifetime › Stand-alone (electronics not required) Benefits Benefits › Reduced vibration and noise level FEM › Gerotor and turbine pump principles › Stand-alone device or integrated in fuel module › Pressure: Up to 700 kPa › Operating voltage: 6 V up to 16 V › Flow, typ.: 230 l/h at 500 kPa › Electrical power: 100 W up to 200 W › Efficiency, typ.: 30% › Operating temperature: –40°C up to +85°C › Size: 28 mm, 38 mm, 43 mm › Control input /output signal: PWM › Media: Gasoline (up to E100), › Degree of protection: IP6K7 and IP44

Technical Information Technical diesel (incl. RME) Technical Information Technical › Weight: Approx. 130 g and up FEM – Fuel & Exhaust Management 184 185 Tank Domain Controller Flat Channel METALIT® (Standard Structure)

Electronics for demand Metal substrate regulation of fuel delivery modules. for catalytic converter.

› Reduced consumption of electrical energy › Larger surface area than ceramic substrates › Enhanced lifetime › Improved cold-start performance

Benefits › Reduced vibration and noise level Benefits › Lower backpressure FEM › Processing of other signals (e.g. fuel level sensor, › Smaller package space pressure sensor, leakage detection) › Combustion engine exhaust emission control › Operating voltage: 6 V up to 16 V › Three-way catalyst for gasoline engines › Electrical power: 100 W up to 200 W › Cell density: 50 cpsi up to 1600 cpsi › Operating temperature: –40°C up to +85°C › Foil thickness: 25 μm up to 110 μm › Control input /output signal: CAN (1.0 mil up to 4.3 mil) › Degree of protection: IP6K7 and IP44

› Weight: Approx. 130 g and up Information Technical Technical Information Technical without penalty in back pressure. back in penalty without efficiency to increase design substrate metallic New (Crossversal Structure) (Crossversal CS-Design Management –FuelFEM &Exhaust Technical Information Benefits diesel engines › › › › › › › › ›

Variance of cell densities and foil thicknesses foil and densities cell of Variance NO DOC, engines gasoline for catalyst Three-way control emission exhaust engine Combustion catalysts standard against advantage Backpressure transfer mass by improved compensation GSA saving cost and Weight layer foil flat of Elimination layer foil flat without foils corrugated Skew X -adsorber and SCR catalyst for for catalyst SCR and -adsorber 186 for catalytic converter. catalytic for substrate Metal (Longitudinal Structure) (Longitudinal LS-Design® Technical Information Benefits structure diesel engines › › › › › › › › › ›

Foil thickness: 40 μm up to 80 μm μm 80 to up μm 40 thickness: Foil cpsi to up 400/800 cpsi 100/200 density: Cell NO DOC, engines gasoline for catalyst Three-way control emission exhaust engine Combustion Cost advantage advantage package and Backpressure light-off-performance improved material, Less Turbulence corrugation secondary generating channel to flat compared efficiency Increased X -adsorber and SCR catalyst for for catalyst SCR and -adsorber (1.6 mil) to up 3.2 mil 187

FEM FEM – Fuel & Exhaust Management –FuelFEM &Exhaust (Perforated Structure) (Perforated PE-Design® for catalytic converter. catalytic for substrate Metal Technical Information Benefits › › › › › › › › › ›

Foil thickness: thickness: Foil density: Cell NO engines gasoline for catalyst Three-way control emission exhaust engine Combustion improvement concentration and/or Flow- inhomogeneities of case in Improvement homogenization flow Low backpressure, performance light-off improved material, Less weight light in results Perforation X -adsorber for diesel engines diesel for -adsorber

40 40 cpsi to up 400/800 cpsi 100/200 (1.6 mil) to up 3.2 mil µ m up to 80 80 to up m µ m 188 LS-Design® and PE-Design® and LS-Design® for catalytic converter. catalytic for substrate Metal Technical Information Benefits › › › › › › › › › ›

Foil thickness: thickness: Foil density: Cell engines diesel for catalyst SCR and DOC engines gasoline for catalyst Three-way control emission exhaust engine Combustion improvement utilization and Performance Turbulence corrugation secondary generating homogenization flow Internal PE-Design® in layer Flat LS-Design® in layer Corrugated

40 40 cpsi to up 400/800 cpsi 100/200 (1.6 mil) to up 3.2 mil µ m up to 80 80 to up m µ m 189

FEM for catalytic converter. catalytic for substrate Metal FEM – Fuel & Exhaust Management –FuelFEM &Exhaust (TransversalStructure) TS-Design® Technical Information Benefits

› › › › › › › › ›

Foil thickness: thickness: Foil density: Cell NO DOC, engines gasoline for catalyst Three-way control emission exhaust engine Combustion space package Smaller Backpressure advantage efficiency same for costs and material Less channels to flat compared efficiency Increased diesel engines X -adsorber and SCR catalyst for for catalyst SCR and -adsorber

40 40 cpsi 100 to up 500 cpsi (1.6 mil) to up 4.3 mil µ m up to to 110up m µ m 190 particulate matter filter. matter particulate diesel Metal (Particulate Matter Filter) PM-METALIT® Technical Information Benefits

› › › › › › › › › ›

EU/China IV/ V, Tier 4i/f and similar regulations similar and V, Tier 4i/f IV/ EU/China 2004 since retrofit and applications serial Multiple proven Offroad buses and trucks duty heavy in milage Highest vehicles duty light and cars in Installation oil and fuel engine appropriate with Maintenance-free window temperature operating wide in Regeneration possible measures by engine regeneration Active by NO regeneration soot Passive in LS-Design® in DOC with combination in operation Optimized 2 from DOC from 191

FEM for catalytic converter. catalytic for substrate Metal (Mixing Structure) (Mixing MX-Design® Management –FuelFEM &Exhaust Technical Information Benefits › › › › › › › › › › › ›

Foil thickness: 65 μm Foil thickness: cpsi 40 density: Cell foil flat perforated with Combined system shovel density Low cell together catalyst and Evaporator engines diesel for catalyst Hydrolysis control emission exhaust engine Combustion downstream formation deposits of risk Reduced SCR for to ammonia conversion urea Improves SCR for improvement Low load/operation injection Adblue® increased significantly Enables surface coated on droplets AdBlue® of Catch 192 metallic substrate. metallic Mantle-less Metallic Substrate Metallic Mantle-less Mantle-less Mantle-less Technical Information Benefits motorcycle applications engines control emission exhaust engine combustion for formulations process production › › › › › › ›

Available in a variety of dimensions; Well-suited for for Well-suited dimensions; of variety a in Available gasoline for catalyst three-way as Application catalyst various with coated be can substrates Metal automatic fully high-volume, for Designed release heat to prevent canning Adjusted weight Lowest technology substrate metallic proven and Robust 193

FEM charger from ceramic particles due to DPF regeneration. to DPF due particles ceramic from charger turbo- to protect efficiency highest with EGR-filter Lifetime Filter Recirculation Gas Exhaust Management –FuelFEM &Exhaust Technical Information Benefits and engine and › › › › › › › ›

High mechanical durability High mechanical efficiency filter Optimized (GKD) structure Evolvent weaving mesh 2-layer TELA-wire efficient high of Usage soot-sensor for Replacement OBD DPF for Utilization turbocharger gas exhaust for protection Component Optimum engine dynamics 194 catalyst including a high effective support catalyst. support effective ahigh including catalyst heated Electrically Electrically heated heated Electrically Catalyst Heated Electrically EMICAT® Technical Information Benefits › › › › › › › › › › › › ›

Diameter: 50 mm up to up 264 50 mm mm W 500 toW up 4,000 Diameter: 1,000 toW up 7,200 48 at Power V: W W toW up 3,600 300 24 at Power V: at Power 12 V: 12 V V/48 V/24 voltage: Operation challenges RDE of Support energy recuperation of Use power heating lower for activation Intelligent SCR low-temperature Improved liquids of vaporization supports energy Additional reduction metal precious for Potential phases no-load during cooling catalyst Reduced time less in reached temperature off light Catalyst 195

FEM (EMICAT®), based on a 32 bit microcontroller unit. a32 on microcontroller bit based (EMICAT®), catalyst heated electrically the for control Power Heated Catalyst (EMICAT®) Electrically for Controller Management –FuelFEM &Exhaust Technical Information Benefits › › › › › › › › › › › › ›

Ambient temperature: –40°C up to up +120°C –40°C temperature: Ambient 120 x 100 flanges: x34 incl. mm Dimensions IP6K9K connectors, power M6 MX Molex connector 150 communication 1 kW output, PWM 10 frequency base Hz 100 current: A continuous Max. power: Electrical Voltage: switch Redundancy design compatible EMC output protected Electrically CAN via tools development and Diagnostic Communication with ECU and SCR controller via CAN via controller ECU SCR with and Communication 12 V (48 V in development) development) 12in V V(48 196 System Engine Diesel Modular isloiainctls /NO catalyst oxidation Diesel for lowest emission diesel cars. diesel emission lowest for Technical Information Benefits outlet parts canning DPF regeneration position closed-coupled › › › › › › ›

Closed-coupled position directly at turbocharger at directly position Closed-coupled LS-Design® with substrate metal perfomance High usage package Optimum and substrate same utillizing by effective Cost during NSC and DOC for control temperature Better in light-off fast to due emissions Lowest Catalyst integrated temperature sensor (SensorKat™) sensor temperature integrated Catalyst X storage catalyst substrate substrate catalyst storage 197

FEM FEM – Fuel & Exhaust Management 198 199 Closed-Coupled Exhaust After- Closed-Coupled Exhaust treatment System Gasoline Aftertreatment System Diesel

Three-way catalyst substrate for Oxidation catalyst substrate lowest emission gasoline cars. for lowest emission diesel cars.

› Closed-coupled position, fast light-off › Closed-coupled position, fast light-off › Lowest catalyst material enabled by LS-Design® › Lowest catalyst material enabled by LS-Design®

Benefits › CompactCat canning Benefits › CompactCat canning FEM › Optimum exhaust gas temperature utilization › Optimum exhaust gas temperature utilization › Same substrate and canning parts for gasoline › Same substrate and canning parts for gasoline and diesel and diesel › High-performance metal substrate with LS-Design® › High-performance metal substrate with LS-Design® › Catalyst-integrated lambda-sensor (Lambdasondenkat™) › Optimum flow distribution to directly connected DPF › Optimized engine control response and accuracy › CompactCat: Hot gas circulating the catalyst surfaces › CompactCat: Hot gas circulating the catalyst surfaces › Closed-coupled position directly at turbocharger › Closed-coupled position directly at turbocharger outlet

Technical Information Technical outlet Technical Information Technical FEM – Fuel & Exhaust Management 200 201 Compact SCR EHC System Air-assisted Urea Dosing Unit UDA

Oxidation catalyst in combination with electrically heated Air assisted AdBlue® (DEF) metering pump unit in combi- catalyst and reverse AdBlue® injection. nation with a passive working two-phase nozzle

› Closed-coupled position, fast light-off › Robust and proven frame mounted pump unit › Lowest catalyst material enabled by LS-Design® › Low consumption of compressed air

Benefits › CompactCat canning Benefits › Fine spray quality due to air-atomization of urea FEM › Reverse AdBlue® injection on heating disc › Designed for heavy duty trucks, NRMM and retrofit › NH3 formation at lowest temperatures with › Injection into high pressure exhaust (pre-turbo) EMICAT® support › Pump Capacity: 7.5 l/h › High-performance metal substrate with LS-Design® › Operating pressure: nominal 3 bar up to 6 bar › CompactCat: Hot gas circulating the catalyst › Integrated electronic control surfaces › Master, slave and stand alone modes › Closed-coupled position directly at turbocharger outlet › Compressed air control and mixing inside › Electrical heated catalyst (EMICAT®) › Precise urea metering by membrane pump

for 12 V up to 48 V/0.3 kW up to 7.2 kW Information Technical Technical Information Technical FEM – Fuel & Exhaust Management 202 203 SCR Catalyst Powertrain Exhaust Aftertreatment Solutions

NOX emission reduction on high efficient catalyst surface using ammonia formed out of injected AdBlue® (DEF).

› Turbulence generating structures › Reduced volume, lower space requirements

Benefits › Low backpressure for optimum fuel consumption › Applicable for cars, trucks and Non-Road Mobile Machinery (NRMM)

› Wide variety of round and non-round geometries available › Serial production diameter up to 450 mm › Cell density and foil structure optimized to application Technical Information Technical www.continental-automotive.com 0 49 941 - + Phone 790 ·Germany 93055 Regensburg 12Siemensstrasse Division Powertrain GmbH Automotive Continental © Continental Automotive GmbH Automotive © Continental notice. prior without changes technical as well as availability in changes to make right the reserve We contract. of terms the in agreed expressly if exist only shall characteristics tive respec the to provide obligation An durability. guarantee for a particular quality or particular special a be to intended or meant not is mation infor This product. the of description technical a merely is information This products. the of development further of result a as change may which or use actual of case in described as apply always not do which characteristics, performance or descriptions general only tains con brochure this in provided information The Legal notice

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Printed in Germany · 09/2015 · EN · 5.0 k · Order no.: 46-03-0103EN