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Content Development Trends in Passenger Introduction of FEV Motorentechnik DI Diesel Role of Passenger Car Diesel

Performance Data Development Trends Dr. Ernst Scheid Future Design Features FEV Motorentechnik Aachen, Germany Emission Behavior and Reduction Potential

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FEV Corporate Profile Overview FEV Motorentechnik Headquarter, Aachen, Germany

Development of Engines, Engine Components and Vehicle Application

Installation of Test Cells Delivery of Test and Instrumentation Systems

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Presentation at AVECC 2001 1 FEV Application Center, Alsdorf, Germany Passenger Car Sales and Diesel Share

70 Change in % From 1994 – 2006 Complete: + 25% 60 61 : + 20% 50 57 Diesel: + 46% 52 49 40

30 Vehicles in Mio. 20

10 Diesel share 17% 18% 20% 20% 0 1994 1998 2002 2006 Year

Diesel vehicles Gasoline vehicles

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Passenger Car Sales and Diesel Share in Western Europe Fuel Consumption of European

, SI engines , IDI - Diesel Engines , DI - Diesel Engines

16 80

15 70 14 Weightless Frictionless 14 60 12 Luxury & 13 50 Executive Class 10

12 40 Share [%] 8 [millions] 11 30 Car 6 10 20

Diesel 4 3.0 l/100 km 9 10 Number of Passenger Cars 2 SmartLupo 8 0 1980 1985 1990 1995 2000 2005 Fuel Consumption [Liters/100 km] Year 750 1000 1250 1500 1750 2000 Vehicle Curb Weight [ kg ]

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Presentation at AVECC 2001 2 Specific Power Output of HSDI Diesel Engines HSDI Peak Trend

200 Future HSDI 80 Turbo Charged Diesel Engines Diesel Engines SI Engines 100 naturally aspirated 180 turbocharged (TC) 4V-SI Engines 60 TC-intercooled 80 160 60 40

40 140 20 2V-SI Engines Specific Power [hp/l] Specific Power [kW/l] 20 120 0 0 1930 1940 1950 1960 1970 1980 1990 2000 2010 Cylinder Peak Pressure (bar) 100 Model Year 1980 1990 2000 2010

9 Year10

Specific Full Load Air Mass Flow vs. Specific Power Future HSDI Features (Design & Layout)

Light-Weight Design Demand-Controlled 350 Accessories HSDI Diesel Engines Advanced Enhanced HSDI Engine(low vol. prod.) 1999 Cooling Concept 300

1999 Displacement 250 1999 1999 On Demand 1992 1998 1986 1993 naturally aspirated 200 1989 ISG

150 1995 Spec. Air Mass Flow [ kg/h/l] 1984 Valve 100 active non-active 20 30 40 50 60 Specific Power Output [ kW/l ]

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Presentation at AVECC 2001 3 Future HSDI Diesel Engine Features (Power, Emissions) Fuel Consumption Reduction Potential

Improved Cylinder Advanced Head Concept Piezo CR-System Exh. Aftertreatment 120.0 Incr. Spec. Power, Adv. FIE, Adv. Boosting [ % ] Friction/Light-Weight (-33%) Intelligent Cooling Concept

MVEG 110.0 Cyl. Deactivation Adv. FIE/Fut. Comb. System Flex. EGR Cooling 100.0

90.0 -22% Enhanced Exhaust Improvement 2-Stage Turbocharging Aftertreatment System 80.0 9.7 ltr./100 km 70.0

60.0 V-8 Engine Fuel Consumption IWC: 1930-2040 kg Base: 50 kW/l, EU-III; 500cc/cyl.

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Roadmap FIE / Charging / Combustion Roadmap EGR & Exhaust Aftertreatment / Miscellaneous

FIE 2nd Gen. Diesel Particulate Filter FIE 3rd Gen. EGR DeNOx-Measures Improved Nozzle Hydraulic Efficiency & FIE Electrical EGR Exhaust Flexible Injection Event Aftertreatment Cooled EGR Variable Nozzle Hole Intelligent EGR-Cooling VNT Electrical Actuator EMV/VVT Electrical-Assisted Charger Charging Variable 2-Stage Turbocharging Next Gen. ECU/Model-Based Control Variable Next Gen. ECU/Model-Based Control Miscelleanous Integrated -Generator Upgrade Fuel Advanced Glow Plugs Combustion HCCI (partly) Cylinder Deactivation HCCI (strongly) EURO III EURO IV EURO V EURO III EURO IV EURO V 2000 2005 2008 (t.b.v.) 2000 2005 2008 (t.b.v.) 15 16

Presentation at AVECC 2001 4 Type Approval Data Diesel Passenger Cars on NEDC NOx Emission Advantages Due to Excellent EGR Acceptance

0.10 Type Approval Data acc. 2.0

[g/km] KBA, Flensburg FEV Concept: Model Year 1997 Ø 500 cc/cyl. 2.0bar @ 2000 rpm 0.08 Model Year 1998 Ø 50 kW/ltr 1.5 Ø CR-2nd Gen. Model Year 2000 Ø WG-TC Ø EU-IV

Particulates 0.06 EURO 3 1.0 0.04 VW Lupo TDI 1.2L “3 Liter Vehicle“ (Inertia Weight 910 kg) EURO 4 0.5 A2 TDI 1.2L 0.02 (Inertia Weight 910 kg) FEV Concept

Spec. PM Emissions [g/kWh] BSFC=325 g/kWh PSA 607 2.2L with DPF System (Inertia weight 1590 kg) 0.00 0.0 0.0 0.2 0.4 0.6 0.8 1.0 0 5 10 15 20 25 30 35 40 45 50 HC + NOx [g/km] EGR-Rate [%] 17 18

Actual Example of Emission Behaviour EU IV Concept EU IV Combustion Tuning / Emission Calibration

0,10 0.10 FEV-Concept (500cc/Zyl.;CR 2ndGen.;WG; 50kW/ltr.) 680kg/ltr.;13.6 kg/KW FEV Combustion System/Cal., DOC only 0,08 Engine Power: 50kW/l w/ Waste Gate TC [g/km] 0.08 German Homologation Data, MY 2000 1360 kg Inertia Mass Class 0,06 EU-III 0.06 Euro 3

Emissions 0,04 -

PM [g/km] 0.04 EU-IV 0,02 Euro 4 0.02 Particulate 0,00 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0.00 NOx-Emissions [g/km] 0.0 0.2 0.4 0.6 0.8 HC + NOx [g/km] 19 20

Presentation at AVECC 2001 5 Summary

Role of Passenger Car Diesel Engine Increasing in Europe

Diesel Engine Establishing in High Class Vehicles With Market Share of More Than 50%

Power Output Exceeding 65 kW / l

Further Potential for Fuel Consumption Reduction

EURO IV Emission Concepts Under Development

High-Tech Components Utilized for Aggressive Targets

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Presentation at AVECC 2001 6