TDI reloaded

For more than 20 years, the letters TDI have stood for powerful acceleration and sensationally low consumption in Volkswagen vehicles. Although the diesel engine has long since developed into a highly cultivated high-tech unit, today’s turbodiesels still hold a great deal of optimization potential. The new 85 cubic inch (1.4 liter) and 122 cubic inch (2.0 liter) TDI engines from Volkswagen, which are equipped with ultra-modern BorgWarner turbocharging systems, represent the latest examples of this.
First VTG turbocharger in a 3-cylinder TDI
Volkswagen has been using the latest turbocharging technologies in its TDI engines for many years. Indeed, even the smaller engines come with innovative and technically sophisticated VTG turbochargers with variable turbine geometry. BorgWarner’s VTG technology is now being used in a three-cylinder turbodiesel for the first time. The new, extremely efficient 85 cubic inch (1.4 liter) diesel unit is available in two versions: one with 75 bhp and one with 90 bhp. Both units comply with the Euro 6 emissions standard and set new records in terms of fuel efficiency. Compared with their predecessors, it has been possible to reduce fuel consumption by up to 21%. The 75 bhp turbodiesel is celebrating its premiere in the new VW Polo, where it impresses with average standard fuel consumption of 75 mpg US (91 mpg UK). The VTG turbocharger with adjustable turbine vanes in the S-vane design makes a key contribution to the excellent efficiency of the new engine. The developers at BorgWarner went to great lengths to optimize the efficiency of the impellers and turbines. As a result, this turbocharging system from BorgWarner significantly improves the engine’s response, while also increasing its efficiency (particularly in the low rev range), which leads to better fuel consumption and emissions figures. The compact 55 bhp engine delivers maximum torque of 155 lb-ft (210 Nm), which is available from just 1,500 rpm. The new turbodiesel is an important unit in the modular engine range of the Volkswagen Group. Following its deployment in the Polo, the engine will also be available in many other vehicles from Audi, Seat, Škoda and Volkswagen.
Power Passat with R2S system
While the 85 cubic inch (1.4 liter) engine represents the entry level model of the advanced TDI technology, the new 122 cubic inch (2.0 liter) turbodiesel from Volkswagen sits at the top end of the performance scale. Delivering 240 bhp and 368 lb-ft (500 Nm) of torque, the engineers at VW and BorgWarner were able to extract extremely impressive performance from such a small displacement through use of the latest exhaust gas turbocharging technologies. With a top speed of 147 mph (238 kph) and a 0 – 60 mph time of just over 6 seconds, the new engine offers boundless driving pleasure in the new Passat 2.0 TDI SCR – together with exceptional fuel consumption of 44 mpg US (53 mpg UK). Of course, the 122 cubic inch (2.0 liter) TDI also complies with the Euro 6 emissions standard and produces just 140 grams of CO2 per kilometer. At the heart of the new engine sits a regulated two-stage turbocharging system (R2S), comprising one VTG turbocharger for the high-pressure stage and one larger, water-cooled B03 turbocharger for the low-pressure stage. BorgWarner employs a milled impeller wheel with a special protective coating in both turbochargers, so that they can handle the extreme loads and corrosive components associated with low-pressure exhaust gas recirculation more effectively. Controlled by an electrical actuator, the turbine vanes of the VTG turbocharger are adapted to the engine speed and the volume of exhaust gas available in a fraction of a second. This results in extremely fast boost pressure build-up for virtually lag-free acceleration. As the engine speed then increases, the B03 low-pressure stage begins to take effect, ultimately assuming all boost duties at high revs. The two new 85 cubic inch (1.4 liter) and 122 cubic inch (2.0 liter) TDI engines from Volkswagen impressively complete the top and bottom end of the company’s turbodiesel engine portfolio. For BorgWarner Turbo Systems, the drives represent an excellent opportunity to once again position itself as a qualified development partner to the well-known automotive manufacturer.
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