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## engine group 

The Engine Group develops strategies and products to manage engines for fuel efficiency, reduced emissions and enhanced performance. BorgWarner’s expertise in engine timing systems, boosting systems, air and noise management, cooling and controls is the foundation for this collaboration. 

## 2004 Highlights 

Strong demand boosted Engine Group sales 19% with an 18% increase in earnings before interest and taxes. The group continues to benefit from European and Asian automaker demand for turbochargers, timing systems and emission products, and from stronger commercial vehicle production in both Europe and North America. During the year, the group expanded its presence in Korea to manufacture engine timing systems for Hyundai’s high-volume gasoline engines and formed a joint venture for the manufacture and sale of turbochargers. New business awards from Asian and European automakers expanded the group’s customer base. The acquisition of a major stake in Beru in January 2005 further enhances the group. 

## Growth Drivers and Opportunities 

• Stricter emission regulations for Europe, North America and Asia 

• Continued growth of diesel engines in European passenger cars 

• Tighter emission regulations related to commercial diesels 

• Engine downsizing for improved fue l consumption and em issions in gasoline engines 

• Electronic controls and growth of “smart systems” 

• Engine timing systems moving from belts to chains 

• Development of variable cam timing systems 

• Growth of overhead cam engines 

• Systems integration; alternative technologies 

## Key Technologies 

Chain Products Global leader in the design and manufacture of automotive chain systems for engine timing, automatic transmission and torque transfer including four- and all-wheel drive applications. Fully integrated timing chain system supplier including chains, sprockets, tensioners, control arms and guides, and variable cam timing phasers. 

Boosting Systems Leading designer and manufacturer of turbochargers and boosting systems for the passenger car and commercial vehicle markets. 

Emissions and Thermal Systems Leading designer and supplier of components and systems for engine air and thermal management designed to control emissions and reduce fuel consumption. 

Beru Technologies World’s leading supplier of diesel cold-start technology and a leading European supplier of ignition technology for gasoline vehicles. Electronics and sensing technology is focused on creating intelligent sensor products for various engine and vehicle functions. 

## Production Plants and Technical Centers 

## Americas 

Asheville, North Carolina ✦ ✴ Auburn Hills, Michigan ✴ Cadillac, Michigan ✦ Campinas, Brazil ✦ Civac-Jiutepec, Mexico  ✦ GLYPH<127> Cortland, New York ✦ Dixon, Illinois ✦ Fletcher, North Carolina ✦ Guadalajara, Mexico ✦ Ithaca, New York ✦ Marshall, Michigan ✴ Sallisaw, Oklahoma ✦ Simcoe, Ontario, Canada ✦ Water Valley, Mississippi ✦ 

## Asia 

Aoyama, Japan ✦ Changwon, South Korea ✦ Chennai, India ✦ Chennai, India (JV) ✦ Chungju-City, South Korea (JV) ✦ GLYPH<127> Hitachinaka City, Japan (JV) ✦ Kakkalur, India (JV) ✦ Nabari City, Japan ✦ ✴ Ningbo, China (JV) ✦ Pune, India (JV) ✦ GLYPH<127> Pyongtaek, South Korea ✦ Shihung-City, South Korea ✦ GLYPH<127> Tainan Shien, Taiwan ✦ 

## Europe 

Arcore, Italy ✦ ✴ Biassono, Italy ✦ GLYPH<127> Bretten, Germany ✦ GLYPH<127> Bradford, England ✦ Chazelles, France ✦ GLYPH<127> Diss, England ✦ GLYPH<127> Kandel, Germany (JV) ✦ GLYPH<127> Kirchheimbolanden, Germany ✦ ✴ La Ferté-Macé, France ✦ GLYPH<127> Ludwigsburg, Germany ✦ ✴ GLYPH<127> Markdorf, Germany ✦ ✴ Muggendorf, Germany ✦ GLYPH<127> Neuhaus, Germany ✦ GLYPH<127> Oroszlany, Hungary ✦ Rijswijk, Netherlands (JV) ✦ GLYPH<127> Tiszakécske, Hungary ✦ GLYPH<127> Tralee, Ireland ✦ GLYPH<127> Vitoria, Spain ✦ GLYPH<127> 

PRODUCTION PLANTS TECHNICAL CENTERS BERU LOCATIONS ✦ ✴ GLYPH<127> 

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## Diesel Engine Timing 

## Variable Cam Timing 

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## Secondary Air Pump 

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## Air Flow Systems 

## Beru Tire Pressure Monitoring Systems 

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Our chain timing systems prolong engine life, increase fuel efficiency and reduce emissions in today’s demanding new diesel applications. 

Our patented variable cam timing system uses camshaft oscillation to achieve twice the emissions reduction and three times the fuel efficiency improvement in the federal EPA cycle than competitive technologies. 

BorgWarner’s air pump technology reduces hydrocarbon emissions by as much as 41%. Our air pumps are available in a full range of flow capa- bilities, are compact in size, and can be engine or vehicle mounted. 

Visctronic thermal management technology for engine cooling is a patented, revolutionary system which utilizes precision electronic controls to improve engine cooling and fuel economy in light, medium, heavy-duty and off-highway vehicles. 

Direct tire pressure monitoring systems measure temperature and pressure inside the tire and transmit the data to the driver. Legislation is mandating their use in North America for enhanced vehicle stability. 

## SALES 

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## Gasoline Turbochargers 

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## Exhaust Gas Recirculation 

## Diesel Turbochargers 

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## Gasoline Engine Timing 

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## Beru Diesel Cold-Start Technology 

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BorgWarner’s boosting systems for gasoline engines, including new direct injected systems, provide power, pickup and real driver enjoyment with fuel economy improvement up to 15%. 

BorgWarner provides exhaust gas recirculation technology to support the most stringent emissions reductions. Our EGR valve offers a wide range of integration and high temperature solutions. 

Our boosting systems for diesel engines are key enabling technolo- gies for modern, high-performing clean diesel engines. Advances include new variable geometry turbine designs and regulated two-stage devices. 

We bring increased power and durability, noise reduction and more compact packaging to the growing market for both single and double overhead cam timing in gasoline engines. 

Glow plugs are a standard feature in modern passenger car diesels. With the Beru Instant Start System (ISS), diesel engines start more quickly and safely than ever before thanks to optimized glow plugs and an electronic controller which individually regulates each plug. 

