"A lot of validation effort and fine-tuning is needed to get everything to work right and survive in the field," he says. "All of the changes have come from lessons learned from previous field experience and during the development of the new turbocharger. These lessons applied to the 2007 turbo highlight the latest technology."
The VTG linkage in the turbocharger connects the actuator to the VTG mechanism, according to Reinke, and is developed with a ball-joint linkage. This reduces friction and increases the corrosion resistance of the linkage.
Reinke says that the linkage is an external part to the system that is often exposed to the salt spray and a changing engine environment.
But Reinke says that continuous validation testing on the turbochargers will improve performance and durability on the final product. He says that the development from concept to production takes about three years, but the validation process typically takes about two years to complete.
"A combination of technology improvements and lessons learned have improved the turbocharger system from previous generations," says Reinke.
"VTG technologies have been available for a few years now, and BorgWarner's technology highlights a more robust and durable product for 2007."
More on troubleshooting '02 EGR and ACERT engines from the Technology & Maintenance Council.