MAHLE Powertrain's downsizing demonstration vehicle.

1. MAHLE Advanced Downsizing Demonstrator Engine – Second Generation
Gasoline engine downsizing is now recognized as one of the
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most viable approaches to meet future CAFE requirements, with
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increasing degrees of downsizing being applied in the market
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place. The approach involves the combination of displacement
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reduction to improve fuel economy, together with high boost
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turbocharging to maintain acceptable power and torque outputs.
The reduced engine displacement enables lower friction losses,
lower weight and reduced gas exchange losses to be achieved.
As the degree of downsizing increases, greater demands are
made on the key engine systems and components to achieve the
optimum benefits.
MAHLE Powertrain is a recognized specialist in advanced
gasoline engine downsizing and the MAHLE technology
demonstrator engine is now an established industry benchmark.
MAHLE Product Information 10/2010 1
©MAHLE Powertrain LLC, 2010

2. MAHLE Advanced Downsizing Demonstrator Engine – Second Generation
Displacement / Confign.: 1.2 L / 3 cyl in-line
Bore / stroke: 83.0 mm / 73.9 mm
Charging: BMTS turbo
Fuel system: Central GDI, Bosch 7 hole solenoid
Compression ratio: 9.25 : 1
Maximum power output: 120 kW (161 hp)
Maximum power speed: 4,750 - 6,000rpm
Peak torque: 285 Nm
Peak torque speed: 1,600 - 3,750rpm
Minimum BSFC: 235 g/kWh
BSFC @ 2,000rpm/4 bar: 295 g/kWh
Weight 275 lbs
Fuel Economy Simulation Results
3300lb sedan 6spd manual US mpg City / Highway
2.0L GTDI Reference 23.9 / 31.7 (actual 23/32)
1.2L MAHLE 29.4 / 37.7 (actual TBD)
In order to conduct research into the requirements for
advanced downsizing engines MAHLE, Bosch, and
Bosch MAHLE Turbo Systems (BMTS) collaborated to
produce a demonstrator vehicle, bringing together the
core competencies of each company to achieve the best
overall system solution.
This involved a further development of the existing 1.2
liter, 3-cylinder downsizing demonstrator engine but with
a single rather than twin sequential turbochargers, to
demonstrate a cost effective, near term solution.
The engine repeats the 30 bar peak BMEP but with a
peak power reduction to 120 kW, allowing it to maintain
excellent vehicle dynamic performance in a medium-
sized passenger car weighing 3500lbs, combined with
excellent fuel consumption.
Currently undergoing a rigorous calibration program, the
vehicle package will be further developed to optimize the
driveability across a wide range of environmental
conditions. NVH levels, whilst already acceptable, will be
further reduced.
Through this project, MAHLE, Bosch and BMTS have
demonstrated their detailed understanding of advanced
downsizing technologies.
MAHLE Product Information 10/2010 2
©MAHLE Powertrain LLC, 2010