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Powertrain Products 09
Benets and Technical Information
Powertrain Products
Mobility and nature in harmony

The Powertrain Division integrates innovative and efcient system solutions for vehicle powertrains within the automotive supplier Continental AG. These systems increase performance and driving comfort while at the same time lowering consumption and emissions. As a partner of the automotive industry, the division develops and produces a comprehensive range of products at more than 60 sites around the world. These include gasoline and diesel injection systems, engine management, transmission control units including sensors & actuators and fuel supply systems as well as components and systems for hybrid & electric drives.
Content
Passenger Car Application Light and /or Medium, Heavy Duty Commercial Vehicles Application
System Overview
8 Gasoline Piezo Stratied Direct Injection 10 Gasoline Solenoid Direct Injection 12 Gasoline Port Injection Flex Fuel 14 Diesel Piezo Common Rail Injection
16 Engine Systems ES
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Diesel Piezo Common Rail Injector Diesel New Generation Injector Diesel High Pressure 2-Piston Pump ECU Diesel Piezo Common Rail DEKA SCR Injector DEKA Injector for Diesel Dosing into Exhaust Gas Gasoline Piezo Injector Gasoline DI XL2 Solenoid Injector Gasoline DI XL3 Solenoid Injector Gasoline DEKA VII Fuel Injector Gasoline High Pressure Single-Piston Pump Gasoline High Pressure Multi-Piston Pump Gasoline Turbocharger ECU Gasoline Piezo Direct Injection ECU Gasoline Solenoid Direct Injection Engine Control Unit Gasoline Easy-U 3
Powertrain Products
Content
Engine Systems ES
34 35 36 37 38 29 Light Duty ECU for Emerging Markets Light & Medium Duty ECU for Emerging Markets ECU for Light & Medium Duty Applications Medium & Heavy Duty Motor Control Module ECU for Heavy Duty Applications Control Unit for Exhaust Gas Aftertreatment
60 Sensors & Actuators S & A 62 Actuators

62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Air Control Valve (ACV) Canister Purge Solenoid (CPS) Digital Linear Actuator for Idle Control Valve Digital Linear Actuator for Idle Control Valve Electronic Throttle Control Exhaust By-pass Valve (EBV) Exhaust Control Valve (ECV-3) Exhaust Control Valve Low Pressure Exhaust Throttle Valve General Purpose Actuator (GPA) Linear Purge Valve (LPV) Mini Electric EGR (EEGR) Natural Vacuum Leak Detection (NVLD II) Smart Air Control Valve (Smart ACV) Smart Coolant Pump (SCP) Transmission Oil Pump (TOP) Variable Valve Train Actuator (Brushless DC) Variable Valve Train Actuator
40 Hybrid Electric Vehicle HEV

42 43 44 45 46 47 Power Electronics Modular Li-Ion Energy Storage System High Voltage Electric Motor High Voltage Side-Mounted Starter Generator High Voltage Axel Drive System 14 V Modular Power Net System
48 Transmission TR
50 51 52 53 54 55 56 57 Mechatronic Transmission Module Electro-Hydraulic Control Module Control Unit for Double Clutch Transmissions External Transmission Control Unit Transfer Case Control Unit All-Wheel Drive Control Unit East TCU Platform Transmission Control Unit for Commercial Vehicles 58 External Transmission Control Unit for Commercial Vehicles 4
80 Sensors
80 81 82 83 84 85 86 Door Fluid Fluid Fluid Fluid Fluid Fluid Handle Sensor Level Oil Level Switch Level Sensor Active Electrothermic Level Sensor Active QLT Level Sensor Active Ultrasonic Level Sensor Passive Electrothermic Quality Flex Fuel Sensor 5
Powertrain Products
Content
Sensors & Actuators S & A
87 In Cylinder Pressure Sensors: Glow Plug Pressure Sensor & Stand Alone Pressure Sensor 88 Knock Sensor New Design 89 Mass Airow Sensor 90 Position Sensor Clutch Master Cylinder 91 Position Sensor Contactless Angular 92 Position Sensor Fork Linear 93 Position Sensor Linear Contactless 94 Position Sensor Neutral Position 95 Position Sensor Park, no Park 96 Position Sensor Rotary Covers 97 Position Sensor Variable Valve Train 98 Position Sensor 360 Angle Contactless 99 Pressure Sensor Brake Pressure 100 Pressure Sensor Diesel Particle Filter 101 Pressure Sensor Differential Manifold Vacuum 102 Pressure Sensor High Pressure 103 Pressure Sensor Manifold Absolute Family 104 Pressure Sensor Truck Application MAP 105 Pressure Sensor Relative 106 Pressure Switches 107 Smart NOx Sensor 108 Temperature Sensor Coolant / Fuel / Oil 109 Temperature Sensor Cylinder Head 110 Temperature Sensor High Temperature 111 Temperature Sensor Intake Air 112 Temperature Sensor Intake Air (High EGR) 113 Temperature Sensor Outside Air
114 Fuel Supply FS

116 117 118 119 120 121 Modular Fuel Supply Unit EC Fuel Pump G50D / EC Code Description for Names of Fuel Pumps Modular Fuel Level Sensor with MAPPS Fuel Supply Electronics Modular Function Carrier (MFC)
122 Catalytic Converters CC

124 125 126 127 128 129 130 131 METALIT (3-Way-Cat) NO X -Adsorber Pre Turbo METALIT TM Compact Cat PM-METALIT SCRi-System LS-Design PE-Design
System Overview
10 11
Gasoline Piezo Stratied Direct Injection System

21 22 23 24 25
Lambda Sensor Catalyst
SCR (optional LNT)
No. Technology 10 11 12 13 14 15 116 17 18 19 20 21 22 23 24 25 Dual Variable Camphaser Active Camshaft Position Sensor Canister Purge Solenoid Low Pressure Fuel Pump (PWM-controlled) Gasoline High Pressure Pump with Flow Control Valve (Single Piston) Fuel Pressure Sensor Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Active Electrothermic Oil Level Sensor Coolant (Water) Temperature Sensor Knock Sensor Active Crankshaft Position Sensor (also with Direction Detection) Turbo Charger Linear O2 Sensor High Temperature Sensor DEKA SCR-Injector NOX Sensor 9
12
13
14 15
16
17 18 19
20
No. Technology 1 2 3 4 5 6 7 8 9 8 Mass Airow-Sensor with integrated Temperature Sensor (Frequency Output) Turbo Speed Sensor Manifold Air Pressure Sensor Electronic Throttle Control Electrical Exhaust Gas Recirculation Valve (EEGR) Exhaust Bypass Valve Piezo Injector In-Cylinder Pressure Sensor (Optional) Single Coil Ignition with Diagnosis Feedback
System Overview
Gasoline Solenoid Direct Injection System
3-Way Catalyst
10
20
11 12 13 14 15 16 17 18 19 No. Technology 1 2 3 4 5 6 7 8 9 10 10 Manifold Air Pressure Sensor Electronic Throttle Control Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Electrical Exhaust Gas Recirculation Valve SMART NVLD 2 Canister Purge Solenoid Fuel Supply Unit Flex Fuel Sensor (Optional) Gasoline High Pressure Pump with Flow Control Valve (Single Piston) Fuel Pressure Sensor No. Technology 11 12 13 14 15 16 17 18 19 20 Active Crankshaft Position Sensor (also with Direction Detection) Variable Valvelift 2-step Knock Sensor Coolant (Water) Temperature Sensor Solenoid Injector Single Coil Ignition with Diagnosis Feedback Dual Variable Camphaser Active Camshaft Position Sensor Turbo Charger Binary O2 Sensor 11
System Overview
Gasoline Port Injection System Flex Fuel
3-Way Catalyst
15
10 11 12 13 14
No. Technology 1 2 3 4 5 6 7 Electronic Throttle Control Manifold Air Pressure Sensor with integrated Temperature Sensor Integrated Intake Manifold SMART NVLD 2 Canister Purge Solenoid Fuel Supply Unit Flex Fuel Sensor (Optional)
No. Technology 8 9 10 11 12 13 14 15 Active Crankshaft Position Sensor (also with Direction Detection) DEKA VII Multipoint Injector Knock Sensor Coolant (Water) Temperature Sensor Ignition Coil Dual Variable Camphaser Active Camshaft Position Sensor Binary O2 Sensor
12
13
System Overview
Diesel Piezo Common Rail Injection System
Oxidation Catalyst
Diesel Particulate Filter
SCR (optional LNT)
17 18 No. Technology 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
19 20 21 22
19 23
24
10 11 12 No. Technology 1 2 3 4 5 6 7 8 9 14
13 14 15 16
Mass Airow Sensor Turbo Speed Sensor Air Control Valve Electrical Exhaust Gas Recirculation Valve (EEGR) Manifold Absolute Pressure Sensor with Integrated Temperature Sensor Exhaust Bypass Valve Active Camshaft Position Sensor Diese Piezo Common Rail Injector Glow Plug Pressure Sensor
Fuel Supply Unit Diesel High Pressure Pump Fuel Pressure Sensor Engine Coolant or Cylinder Head Temperature Sensor Active Electrothermic Oil Level Sensor Knock Sensor Active Crankshaft Position Sensor (also with Direction Detection) Pre Turbo Cat General Purpose Actuator High Temperature Sensor Diesel Dosing Injector Linear/Binary O2 Sensor Relative Pressure Sensor DEKA SCR-Injector NOX Sensor 15
Engine Systems ES
Engine Systems ES
16
17
ES
Engine Systems ES
Diesel Piezo Common Rail Injector
Diesel New Generation Injector

ES
q High speed piezo actuator for a faster & more

exible injection control q Extra ne fuel atomization & minimized pressure loss in the hydraulic system q Excellent multiple injection accuracy & lifetime stability even for smallest quantities
q Excellent multiple injection stability due to needle

direct drive and needle closed loop control
q Reduced CO2 emissions q Fulll future emission standards Euro 6 / US Tier 2 q Piezo inline design for optimized injector
packaging
q Outstanding low noise (NVH)

Technical Information
q Pressure q Min. quantity

with quantity drift correction
up to 2,000 bar 0.80 mm 3 0.65 mm 3 7 100 s 35 ml /min > 90 m
q Max. no. of injections q Min. injection separation q Continuous leakage q Diameter nozzle holes
18
q Pressure q Min. quantity q Max. no. of injections q Min. injection separation q Total leakage q Diameter nozzle holes
2,000 bar and above 0.65 mm 3 /shot 7 no hydraulic dwell 10 ml / min > 90 m 19
Engine Systems ES
Diesel High Pressure 2-Piston Pump
ECU Diesel Piezo Common Rail

ES
q Minimized pump leakage for reduced fuel

consumption and CO2 emissions q Weight and package optimized high pressure pump
q Engine Control Unit for Diesel Piezo Common Rail

Injection Systems
q Standardized scalable and modular electronic

hardware
q Chassis mounted q Supporting Euro 5

up to 2,000 bar 0.596 up to 0.795 cm3/rev 7.5 mm 9 mm 4,000 rpm
q Pressure q Displacement q Piston (max. ) q Stroke (max.) q Max. speed at full load
q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing
TC1796, 150 MHz 2 MB CAN bus: 1 incl. wake up 4, single bank 24 sealed IP5k9k, connector 154 pin 21
20
Engine Systems ES
DEKA SCR Injector
DEKA Injector for Diesel Dosing into Exhaust Gas

ES
q Optimized design for airless SCR dosing systems q Reliable delivery of urea with excellent spray
performance q Frost-proof (no emptying of dosing system at shutdown) q Part of Continentals approach to SCR systems
q Robust approach for

Diesel Particle Filter (DPF) regeneration
q Avoidance of oil dilution by post injection q Uses existing injection technologies q Improved fuel economy
q Nominal ow
Qs = 1.7 g /s, Qd = 3.8 mg / stroke (5 bar, AUS 32) 3.8 up to 7.5 bar < 75 m (5 bar, AUS 32)
q Nominal ow
Qs = 2 up to 6 g /s, Qd = 20 mg / stroke
q Fluid pressure range q Sauter Mean Diameter

(SMD)
3.5 up to 8 bar q Input pressure range q Sauter Mean Diameter (SMD) 50 up to 100 m (n-heptane)
Cone / 42 cone angle q Injector spray type q Max. injector temperatures 120C (injector body) >180C (injector tip) 22
q Accuracy of ow q Max. control valve temp. q Max. spray nozzle temp. q System minimum pulse width
+/ 6 % 120C 600C 10 ms 23
Engine Systems ES
Gasoline Piezo Injector
Gasoline DI XL2 Solenoid Injector

ES
q Very fast & precise injection

(up to 4 injections /combustion cycle) q Extended linear ow range, high ow capability q World wide fuel compatibility
q Improved linear ow range for turbocharged

engines
q World wide fuel compatibility q High exibility of spray characteristic to meet the
requirements of each target engine
q O-Ring or metal-to-metal sealing

50 up to 200 bar > 50 > 35 g /s 14.5 mg / injection 10% at 0.4 ms PW < 2 mg /stroke ~ 15 m 150 s 94/ 98 4 30 up to +140C
q System pressure q Working ow range q Static ow q Dynamic ow
q System pressure q Working ow range q Static ow range q Min. dynamic ow q SMD size q Opening / Closing q Cone angle range q Bent angle range
40 up to 150 bar > 20 5 up to 17 g/s (at 100 bar at 70C) < 4 mg /stroke < 15 m min. 300 s 35 up to 90 0 up to 30 25
24
q Min. dynamic ow q SMD size q Opening / Closing time q Spray angle q Temperature range
Engine Systems ES
Gasoline DI XL3 Solenoid Injector
Gasoline DEKA VII Fuel Injector
q Improved linear ow range for high-turbocharged

engines q World wide fuel compatibility q High exibility of spray characteristics to meet the requirements of side or central mounted engines q O-Ring or metal-to-metal sealing q Multiple injection capability q No needle bouncing
q Fast opening/closing, various packaging options q Flexible orice congurations q Low pulse width with high linear performance
and low voltage sensitivity
q Fuel pressure range 1 up to 6 bar q Fuel compatibility Gasoline & Flex Fuel
(up to E100)
* Depending on calibration constrains
26
q System pressure q Working ow range q Static ow range q Min. dynamic ow q Max. functioning pressure q Multiple injection q Multi-stream technology q Family layout
40 up to 200 bar > 24* > 20* g /s (at 100 bar at 70 C ) < 3* mg/stroke at 40 bar 260 bar < 500 s dwell time max. 8 holes short, long, extended
q Static ow rate q SMD size q Opening time q Closing time q Min. linear pulse q Possible
spray patterns
per applic. 0.95 up to 6.0 g /s ~ 60 up to 100 m with ASQUARED < 1.10 ms > 0.70 ms 1 up to 20 ms cone spray 10 up to 30 bent stream 5 up to 25 split stream 15 up to 30
27
Engine Systems ES
Gasoline High Pressure Single-Piston Pump
Gasoline High Pressure Multi-Piston Pump

ES
q World wide fuel compatibility q Low friction due to running components in

permanent oil lling
q World wide fuel compatibility q Low friction due to running components in

permanent oil lling
q Dry run capability q Mounted on top of the camshaft

q Dry run capability

q Max. fuel pressure q Supply pressure q Temperature range q Control q Drive q Integrated (inlet) ow
up to 200 bar 4.5 up to 6 bar 40 up to +130C ow controlled cam driven control valve
q Max. fuel pressure q Supply pressure q Temperature range q Control q Drive q Maximum ow
up to 200 bar 4.5 up to 6 bar 40 up to +130C ow controlled end of camshaft or belt driven up to 240 l / h ( at 3500 rpm, depending on the # of pistons 2 up to 6) 29
q Integrated (inlet) ow control valve

28
Engine Systems ES
Gasoline Turbocharger
ECU Gasoline Piezo Direct Injection

ES
q Designed for a fully

integrated robotized assembly process q Outstanding thermodynamics q Robust and reliable design
q Engine Control Unit for Gasoline Piezo

Direct Injection
q Standardized scalable and modular electronic

hardware
q Engine compartment, option for water cooling q Supporting Euro 5

q Gasoline application up to 1050C exhaust gas

temperatures up to 90 kW per Turbo q Engine power q Turbine wheel 30 up to 39 mm max. 0,1 kg/s q Air ow max. 330,000 rpm q Speed q Integrated recirculation valve q Electric actuated wastegate control q Milled compressor wheel 30
TC1796, 150 MHz 2 MB, optional 2 MB external BSD, LIN-Bus, FlexRay, 2*CAN 8 32 sealed, IP6K4K, connector 177 pin 31
Engine Systems ES
ECU Gasoline Solenoid Direct Injection
Engine Control Unit Gasoline Easy-U
q Engine Control Unit for Solenoid Direct Injection q Standardized and modular electronic hardware q Chassis mounted q Supporting Euro 5
q Ready-to-use Gasoline Engine Management

System for worldwide applications: Europe low budget vehicle segment, Russia, China, India, ASEAN, Middle East, South America q Modular and scalable system approach to cover various engine and vehicle congurations including Euro 5 and EOBD
TC1796, 150 MHz 2 MB + 2 MB external Lin, 2*CAN 6 (8 optional) 32 sealed, IP6k9, connector 154 pin
q ECU with predened set of sensors and actuators Coral, 40 MHz q Core 1 MB q Flash size 1* CAN, 1* K-line q Interfaces q Injection drivers 4 MPI q Driver outputs 20 sealed, IPX7, q Housing
connector 32 + 64 pins 33
32
Engine Systems ES
Light Duty ECU (Emerging Markets)
Light & Medium Duty ECU (Emerging Markets)
q Engine Control Unit for Light Duty Vehicle

Applications q Chassis mounted q Supporting Euro IV
q Engine Control Unit for Light & Medium Duty

Vehicle Applications
q Cab mounted q Supporting Euro III, IV

q Core q Clock frequency q Flash size q RAM q CAN BUS q H-Bridges q Injection drivers q Driver outputs q Connector pins
34
Freescale MPC5566 (UIPER) 80 MHz 24 MBit 4 MBit 2 2 4 20 154
q Core q Clock frequency q CAN BUS q Injection drivers q Driver outputs q Connector pins
Freescale MPC555 40 MHz 2 6 15 121
35
Engine Systems ES
ECU for Light & Medium Duty Applications
Medium & Heavy Duty Motor Control Module

ES
q Engine Control Unit for Piezo Common Rail and

Amplied Common Rail Injection Systems q Engine mounted with dampers q Supporting EPA 07
q Motor Control Module for Common Rail,

Amplied Common Rail and Pump-Line-Nozzle Injection Systems q On-engine mounted with damping elements q Supporting Euro VI, EPA 10
q Core q Flash size q RAM q CAN BUS q H-Bridge output q Injection drivers q Connector pins
Green Oak 16 Mbit 32 kB 2 up to 2 up to 8 2 x 76; 1 x 36
q Core q Flash size q CAN BUS q H-Bridge output q Injection drivers q Driver outputs q Connector pins
TriCore TC1766 1,5 MB 3 1 12 21 1 x 120; 1 x 21
36
37
Engine Systems ES
ECU for Heavy Duty Applications
Control Unit for Exhaust Gas Aftertreatment
q Engine Control Unit for high pressure Solenoid

Injection System q On-engine mounted w/o damping elements q Supporting Euro V w/o SCR
q Control Unit
for Selective Catalytic Reduction (SCR)
q Chassis mounted q Supporting Euro IV, V

q Core q Flash size q RAM q CAN BUS q H-Bridge output q Injection drivers q Connector pins
Green Oak 2.5 MB 2 Mbit 3 2 8 14 x 10
q Core q Clock frequency q CAN BUS q Ubat q Connector pins
16 bit 20 MHz 1 12/24 V 62
38
39
Hybrid Electric Vehicle HEV
40
41
HEV
Power Electronics
New Generation Power Electronics
Modular Li-Ion Energy Storage System
Single DC/DC Converter
q Modular design q Control module for electric machine in hybrid electric vehicle, electric vehicle and fuel cell vehicle
q Application in hybrid, electric and fuel cell vehicles q Safety and lifetime optimized cells q Synergy effect through modular system q Variable cooling system
q Water cooling
Inverter
q Power: up to 150kW at 450V q Converts energy in both directions drive electric

machine in motor and generator mode
q Power: 18 kW 120 kW q Li-Ion ultra high power cells q Integrated battery management q Integrated safety system q Integrated cooling system
Converter
q Power: up to 3kW q Bi-directional potential free energy transport

between HV traction battery and 14V power net
q Replaces conventional 14 V generator

42 43
HEV
Single Inverter
High Voltage Electric Motor
HV Side-Mounted Starter Generator
In cooperation with ZF
q Pure electric driving (zero emission) q Permanent synchronous or induction machine q Transmission integrated
q Operates q Power q Fast start q Cold start q Speed
up to 450 V up to 75 kW < 300 ms < 800 ms up to 7.000 rpm
q High speed asynchronous machine q High power density q High efciency q Low weight q Short axial length q Cost-optimized
q High speed q High voltage q Regenerative Power
up to 18000 rpm up to 150 V 5 kW continuous, 20 kW peak
q Water-cooling q Aluminium housing q Special stator winding design

44 45
HEV
High Voltage Axle Drive System
14V Modular Power Net System
q High speed synchronous machine

(external excited) q High power density q High efciency q Cost-optimized
q Energy storage for limited regenerative braking

(up to 4% CO2 reduction)
q Provides second voltage level for high power

applications
q Support of start-stop q High number of load cycles q Modular and integrated designs available
up to 12,000 rpm up to 450 V 35 kW continuous, 70 kW peak
q High speed q High voltage q Regenerative power
q DC/DC converter 0,4k W up to 2,6 kW

Voltage level 14 V up to 60 V Efciency up to 94 % Bidirectional Potential-free and potential-connected designs available 3,6 Wh up to 50 Wh q Energy Storage Based on Double Layer Capacitors Includes active or passive balancing q Energy management & diagnosis (e.g. SOC, SOH) q CAN or LIN communication
q Water-cooling q Aluminum housing q Mechanical integration gear/e-machine
46
47
HEV
Transmission TR
Transmission TR
TR
48 49
Transmission TR
Mechatronic Transmission Module
Electro-Hydraulic Control Module
q Controls 6-speed automatic transmission q Mechatronic Module assembled in the gear box q Integration of all transmission sensors q Weight reduction due to integration q Higher reliability of the electronics due to reduced
number of internal connections
q Controls 6-speed automatic transmission q Integrated transmission control unit including

manifold and solenoids
q Monitors transmission performance and compensates for normal wear in components such as clutch plates, so transmission performance remains consistent for the life of the transmission
q E-Module based on ex technology q Position, speed and temperature sensors

integrated
q Operating temperature 40C up to +140C q 32-bit processor with external ash memory q Low temperature co-red ceramics (LTCC)
substrate for electronic components
q LTCC (Low temperature co-red ceramics)

substrate for electronic components
q Temperature range from 40C up to +143C q Powerful 32 bit microcontroller q Communication via CAN bus
50
q 14-pin vehicle interface connector system q Communication via CAN bus

51
TR
Transmission TR
Control Unit for Double Clutch Transmissions
External Transmission Control Unit
q Controls 7-speed dry double clutch transmission q Integration of all transmission sensors into the
control unit
q Controls 5-speed automatic transmission q Stand-alone concept q Control of 6 valves

q Higher reliability of the electronics due to the

reduced number of internal connections
q Weight reduction due to integration

q Direct connection of actuators to the control unit q Only one plug connection to the vehicle q Control of BLDC motor of oil pump q Operating temperature range
40C up to +140C
q 16 bit processor q Communication via CAN-Bus q Power outputs for 6 electromechanical

hydraulic valves: 2 control valves for the hydraulic of the transmission 3 control valves for the gear changing 1 valve for bypass converter
q Maximum permissible acceleration q 32 bit processor

52 53
TR
Transmission TR
Transfer Case Control Unit
All-Wheel Drive Control Unit
q Controls high/low shift and active torque

distribution of transfer cases used in Four-Wheel-Drive vehicles q For improved traction on-road and off-road
q Controls the torque distribution of All-Wheel-Drive

vehicles by actuating a limited slip coupling
q Directly attached to All-Wheel-Drive coupling

device
q Powerful 16 bit processor q Flame Retardant 4 (FR4) substrate for electronic

components
q Powerful 16 bit processor q Flame Retardant 4 (FR4) substrate for electronic

components
q Power output for one actuator motor q Protection class IP40 q Communication via CAN bus q Stand-alone housing with integrated cooling plate q Operating temperature up to 85C
54
q Power outputs for one valve and feeder pump q Protection class IP 6K9K q Communication via CAN bus q Operating temperature up to 120C q Integrated connectors for solenoid and pressure
sensor 55
TR
Transmission TR
East TCU Platform
Transmission Control Unit for CV
q Controls of stepped AT, CVT, DCT, hydraulic AMT q Stand alone concept q Reduced time-to-market thanks to existing
platform
q Controls 6-speed automatic transmission q Control unit for retarder truck applications q Control unit directly mounted on the transmission
or retarder
q Cost efcient solution

q Environment: engine or passenger compartment q 32-bit Microcontroller with internal ash memory q Flame retardant FR4 printed circuit board
substrate
q Improved performance characteristics q Higher service life q Reduced driving noise development q Reduced harness length and complexity
q Ceramic substrate and direct copper bonded

technology
q State of the art input/output stages q Communication via CAN-Bus q Start of production in 2009
56
q IP6k9 housing with overmolded leadrame q 32 bit microcontroller q 24 V/12 V capable q Temperature: 40C up to +140C q 2 x Can Bus and current control outputs (10)
57
TR
Transmission TR
External Transmission Control Unit for CV

Development of transmission control units.
q Controls 6-speed automatic transmission q External control unit q Improved shift comfort q Reduced life cycle costs q Higher reliability
q Powerful 32 bit processor q HDI organic substrate q 10 power outputs for solenoids q 3 VRS speed inputs q CAN, J1708, J1850, K-Line communication q 18 switch inputs q Operating temperature up to 105C
58 59
TR
Sensors & Actuators S & A
Sensors & Actuators S&A

S &A
60 61
S & A Actuators
Air Control Valve (ACV)
Canister Purge Solenoid (CPS)
q Non-contacting MR sensor not sensitive on

environmental inuences q Version with plastic housing lighter than aluminium q Version with electronics easy to integrate in existing ECU
feature
q Operating
temperature range
40 up to +125C (up to +160C on specic designs) 100 up to 2500 hPa (up to 3500 hPa on specic designs) < 150 ms (< 100 ms on spec. designs) > 1.0 Nm (> 1.6 Nm on spec. designs)
50 up to 85 SLPM q Flow at 500 mm Hg 14 VDC q Nominal operating voltage 17 Ohms q Coil resistance PWM q Control circuit 5 Hz up to 32 Hz q Operating frequency 40 up to +140C q Operating temperature q Total leakage at 500 mm Hg < 20 SCCM q Sonic regulated above 100 mm Hg
q Intake manifold air

pressure (absolute)
q Response time q Excess torque

62
63
S &A
q Canister regeneration with a PWM solenoid q Linear ow curve, sonic nozzle ow control q Fast response, light weight, compact size q Various mounting options available q Direct manifold mount with NVH suppression
S & A Actuators
Digital Linear Actuator for Idle Air Control Valve
Digital Linear Actuator for Idle Air Control Valve
q The idle air control system provides a consistent,

stable idle speed throughout the service life of the vehicle (maintenance free). q The air ow characteristic is tuned to the application needs by changing the pintle prole. q The actuator (DLA) can be integrated into air induction system
q The idle air control system provides a consistent,

stable idle speed throughout the service life of the vehicle (maintenance free). q The air ow characteristic is tuned to the application needs by changing the pintle prole. q The actuator (DLA) can be integrated into air induction system
12 V (7.5 V/14 V) 38 mH 48 Ohms 0.04167 mm / step 9.35 mm (224 steps) 40 up to +150C 90 g 35 up to 40 G
64
q Operating Voltage q Inductance per winding q Resistance per winding q Resolution q Total travel q Operating temperature q Weight q Vibration
q Operating Voltage q Inductance per winding q Resistance per winding q Resolution q Total travel q Operating temperature q Weight q Vibration
12 V (7.5 V/14 V) 33.5 mH 53 Ohms 0.04167 mm / step 8.5 mm (204 steps) 40 up to +125C 110 g 35 up to 40 G 65
S &A
S & A Actuators
Electronic Throttle Control
Exhaust By-pass Valve (EBV)
q Non-contacting MR sensor not sensitive on

environmental inuences; can be used in close proximity e.g. to alternators q Version with plastic housing lighter and with better crash performance than aluminium
q Design options available to t customer

requirements
q Easy integration into EGR cooler q Flexible housing design q Leakage to atmosphere < 0.5 kg / h at 3 bar q Internal MR sensor for position accuracy within 2 q Max. DC motor current draw 6 A,
running current 2 A typ.
q Operating temperature range 40 up to +125C q Storage temperature range 40 up to +140C q Intake manifold air pressure
Plastic housing 100 up to 2500 hPa (absolute) Aluminum housing 100 up to 3000 hPa (absolute)
q Operating ambient
temperature range 40 up to +140C 600C (short term 650C)
q Typical response time ( t 90, room temperature)

Plastic housing < 130 ms Aluminum housing < 90 ms
q Exhaust gas temp. q Actuator opening q Mechanical closing
design capability range 100 ms up to 1000 ms design capability range 100 ms up to 1000 ms
q Excess torque
66 Plastic housing > 1.0 Nm Aluminum housing > 2.0 Nm
q Noise level
< 60 dB
67
S &A
S & A Actuators
Exhaust Control Valve (ECV-3)
Exhaust Control Valve Low Pressure
q Provides both accurate low ow precision

(improves engine performance) and high volume ow (improves emission reduction) by maintaining low gas pressure drop q Contactless MR sensor, exible output, not sensitive against magnetic elds, well known control strategy q Compact, light weighted size and water cooled additional shaft bearing to withstand high pressure pulsation
q Provides both accurate low ow precision

(improves engine performance) and high volume ow (improves emission reduction) by maintaining low gas pressure drop q Contactless MR Sensor, exible output, not sensitive against magnetic elds, well known control strategy q Compact, light weighted size and water cooled
68
q Torque at ap: 230 Ncm q Response time (85%): < 80 ms q Nominal supply voltage: 13.5 V q Position sensor supply voltage: 5.0 V q Maximum ow: up to 190 kg / h at 50 hPa q Exhaust temperature: up to 700C
q Nom. supply voltage: 13.5 VDC q Position sensor supply voltage: 5.0 VDC q Maximum ow: up to 350 kg / h at dp 50 hPa q Valve seat leakage: max. 1,5 kg / h at dp 600 hPa q Max. differential pressure over ap: 600 kPa q Max. backpressure (p3): 900 kPa q Exhaust gas temperature: max. 500C,
permanent 400C 69
S &A
S & A Actuators
Exhaust Throttle Valve
General Purpose Actuator (GPA)
q Resistant to external aggression: stone projection,

gravel, water splashes q Resistant to corrosion using specic materials, i.e. ap housing off precision casting or welded stainless steel technology q Existing serial proven actuator portfolio
q Continuous position control of intake ap and

turbo charger applications
q More precise and independent from vacuum q Version with electronics easy to integrate in
existing ECU
q GPA technology used for actuation q Nominal supply voltage: 13.5 VDC q Position sensor supply voltage: 5.0 VDC q Maximum ow: up to 420 kg / h at dp 50 hPa q Response time
Valve opening: < 100 ms (from 0 % to 85 % of max. opening angle) Valve closing: < 100 ms (from 0 % to 15 % of max. opening angle) 70
q Available as version with integrated electronics,

or position control sensor
q Various motor sizes available q Worm gear or spur gear q Return spring for self return functionality q Typical data for M-28 GPA at room temperature
and 13.5 V: Response time (for t90 and 90 travel) 130 ms Stall torque 140 Ncm Continuous output torque 55 Ncm
q Exhaust gas temperature: 800C
71
S &A
based systems
S & A Actuators
Linear Purge Valve (LPV)
Mini Electric EGR (EEGR)
q Canister regeneration with a linear proportional

solenoid q Very low operating noise due to constant current input q Fast response for incremental ow control at all operating conditions q Excellent low end ow control to prevent unwanted surges of fuel vapor
q Electric Actuation has faster response and more

control than conventional vacuum systems
q Eliminates vacuum regulator and q Can be tailored to customer ow requirements

q Nominal operating voltage q Current consumption

at max ow
13.5 VDC 1.0 A at 20C 1.5 A 8.0 Ohms at 20C 90 Hz up to 175 Hz 5.0 VDC
q Typical ow q Operating voltage q Coil resistance q Maximum current q Control circuit

72
70 SLPM at 57 kPa 14.0 VDC 14.0 Ohms 500 mA Constant current at 150 up to 200 Hz 200 g
q Max current consumption q Nominal coil resistance q Nominal operating frequency q Position sensor supply voltage q Response time (total stroke)
q Weight
< 50 ms (open to close or close to open) 73
S &A
connecting hoses
S & A Actuators
Natural Vacuum Leak Detection (NVLD II)
Smart Air Control Valve (Smart ACV)
q Vacuum sensing switch with 2.5 0.3 mbar

calibration
q Damping feature to avoid noise q Weight approx. 100 g q Bit serial communication with ECU q Average current consumption < 50 A q High In Use Monitor Performance Ratio
(IUMPR > 100%) 74
q Integrated control unit with processor and

H-bridge for DC motor on-board
q Aluminum housing and throttle plate q Non-contacting position sensor q Temperature range 40 up to +125C q Response time
(full stroke, RT) < 150 ms 75
S &A
q With Integrated Electronic (NVLD II integrated) q Diagnostic performed after key off q Stand-alone or canister mounted versions q Temperature sensing; Switch sensing q Timer function
q Improves EGR-function by increased and /or more

exact EGR-ratio under all driving conditions. Helps to meet exhaust gas legal requirements q Avoids typical diesel engine vibration during engine shut-off by closing the air channel q Easy to integrate into existing engine management system related to simple communication
S & A Actuators
Smart Coolant Pump (SCP)
Transmission Oil Pump (TOP)
q Precise engine temperature control through

variation of coolant volume ow q Operation independent from engine for fuel economy, comfort, and advanced propulsion applications
q Continental as system supplier for all three

components
of motor, pump, and electronics in one unit
q Electronically commutated 12 V DC-motor q Integrated electronics in thick lm technology q Wet running permanent magnet rotor 9000 l / h q Volume ow 800 hPa q Differential pressure 200 W q Hydraulic power 32 A q Supply current at Pmax q Coolant temperature range 40 up to +128C
76
q EC-Motor; commutation
with or without sensor
q Electric power q Electronics ambient q Available pump types
~ 150 W up to 700 W
temperature capabilities up to 140C depending on requirements Vane-type G-Rotor 77
S &A
q E-Motor and electronics from one source q Already serial production history with integration
S & A Actuators
Variable Valve Train Actuator
Variable Valve Train Actuator
Brushless DC Motor
q Reliable and proved concept in serial production

engines
(small package)
M -42 42.6 mm 70.0 mm w/o connector 567 g 480 W 70 Ncm with current limited by the ECU 40 up to +140C
q EC motor q Diameter q Length q Weight q Max. EC motor power q Stall torque q Temperature range
78
q DC Motor q Diameter q Length q Weight q Max. DC motor power q Stall torque
M60 60.5 mm 91.0 mm 998 g 355 W 215 Ncm; current limited by the ECU 79
q Operating temperature range 40 up to +140C
S &A
q Continuous positioning of eccentric shaft q Adjusts valve lift q High dynamics (low inertia) q Closed loop control via integrated position sensor q EC-motor mounted in cylinder head
q Continuous positioning of eccentric shaft

to adjust valve lift
q Closed loop control via separate position sensor

and position control electronics
S & A Sensors
Door Handle Sensor
Fluid Level Oil Level Switch
q Easy to integrate into the door handle q Low power consumption

(< 100 A for double zone sensor)
q Low oil level detection q Different connectors possible q Simple on /off output
environment conditions (rain, fog, snow...)
q Capacitive sensor for Keyless Entry System q Detection distance 0 up to 40 mm < 5 ms up to 30 ms q Response time q Optional:
80 Capacitive switch for door locking Mechanical switch for door locking Movement sensor LED for ground / pocket illumination LF antenna integration
q Measuring principle: magnetic reed switch q Different switch heights possible q Normally on (switch closed) q Tolerance: 1 mm
81
S &A
q Reduced false detection thanks to adaptation of
S & A Sensors
Fluid Level Sensor Active Electrothermic
Fluid Level Sensor Active QLT
QLT = Quality Level Temperature
q Overll and low level indication q Absolute measurement of oil level

in static and dynamic conditions
q Overll and low level indication q Absolute measurement of oil level in static and
dynamic conditions. Replacement of oil dipstick
q Replacement of oil dipstick q Stand-alone sensor with integrated electronics

(active) q Temperature measurement optional
q Stand-alone sensor with integrated electronics

(active)
q Oil quality information (permittivity) q Extension of the oil change intervals

capacitive q Measuring principle 40 up to 120 mm q Measuring range 2 mm q Accuracy q First measurement available in 1.4 sec after key-on ~ 1 sec. q Measuring interval q Permittivity measuring range (quality): 1 up to 6 Typical value for engine oils 2 up to 3
82
q Measuring principle q Measuring range q Accuracy q First measurement q Measuring interval q Current consumption q Operating temperature q Temperature accuracy
thermoresistive heated wire 110 mm betw. min. & max. 2 mm available 0.6 s after key-on > 5 sec 200 1 mA (pulse mode) 40C up to 160C 3C
q Temperature measuring range 40 up to + 160C
83
S & A Sensors
Fluid Level Sensor Active Ultrasonic
Fluid Level Sensor Passive Electrothermic
q Overll and low level indication q Absolute measurement of oil level in static
and dynamic conditions
q Overll and low level indication q Absolute measurement of oil level in static and
dynamic conditions
(active)
q Low power consumption q Temperature measurement optional

q Measuring principle q Measuring range q Accuracy q First measurement available q Measuring interval q Operating temperature
84 Level Temperature
ultrasonic echo 18 mm up to 163 mm 2 mm 0.3 sec after key-on ~ 1 sec. 40 up to + 160C 10 up to + 150C 40 up to + 160C
q Measuring principle q Measuring range q Accuracy
thermoresistive heated wire 110 mm betw. min. & max. approx. 3 mm
available 0.6 s after key-on q First measurement > 5 sec q Measuring interval q Current consumption max. ~200 1 mA (pulse mode)
q Operating temperature 40C up to 160C q Temp. measurement optional with NTC ( 2C)
85
S &A
q Replacement of oil dipstick q Stand-alone sensor with integrated electronics
q Replacement of oil dipstick q Different mounting positions q Temperature measurement optional
S & A Sensors
Fluid Quality Flex Fuel Sensor
In Cylinder Pressure Sensors
q In-line sensor mounted between fuel tank and

engine q Meets OBD II functional requirements q Allows usage of saddle tanks on ex fuel vehicles q Provides safe car operation (no engine stall) q Active temperature and conductivity compensation q Simple Compact design, proven, safe and reliable q Various connector interfaces available
1 Glow Plug Pressure Sensor 2 Stand Alone Pressure Sensor
q Easy to integrate q Allows closed-loop combustion control q Reduces emissions q Increases engine power q Reduces fuel consumption q Simple and robust solution
q Measures Ethanol content of Ethanol / Gasoline mix 5% on Ethanol q Accuracy q Frequency output based on percent
Ethanol PWM output
q Cylinder pressure measurement during

compression and combustion stroke accuracy: 3.5%
q Integrated in the glow plug or stand-alone sensor

40C up to +125C 9 up to 18 V 400 l / h (80 g/s)
86
q Operating temperature q Supply voltage q Maximum ow
q Active sensor q Small size sensor: M8 thread

87
S &A
S & A Sensors
Knock Sensor New Design
Mass Airow Sensor
1 2 1 In-Tube MAF Sensor 2 Plug-In MAF Sensor
characteristic
q Acceleration sensor based on piezo ceramic

technology with a range of: 0 up to 400 g
q Excellent performance with intake airow pulsation q Low power consumption and fast start-up time q Flow range adaptable for secondary airow (SAF)
and fuel cell applications
q Frequency range: 3 up to 25 kHz q Possible integration of discharge resistor q Integrated connector or cable version
88
q Sensing technology Hot-lm bi-directional MEMS 5 up to 800 kg/h (62 mm tube) q Flow range q New-part tolerance 1.5% 5 0.5 V q Supply voltage 10 mA maximum q Supply current Frequency or SENT digital q Output signal q Integrated intake air temperature sensor optional
89
S &A
q High sensitivity q Compact design, nested bolt possible q Increases engine power q Decreases fuel consumption
q High ow measurement accuracy and exceptional

signal stability
q Integral protection against water and contamination q Customer specic programmable output
S & A Sensors
Position Sensor Clutch Master Cylinder
Position Sensor Contactless Angular
q Some mechanical interface for either dual switch

or linear position sensor conguration q Small sensor package to t in small environment q Best cost magnetic system (sensor + magnet)
q Contactless sensors, no wear q High performance and best cost q Possible re-calibration to compensate for
q Non contacting technology q 23 to 36 mm range q Dual switch (start of course, end of course)
conguration ( 1 mm accuracy) or linear position sensor conguration ( 3% accuracy with possibility to reach 1.5% with on clutch calibration)
q Magnetic technology q Measurement range up to 360C q Temperature range 40 up to 150C q Analog, PWM or digital output q Through-wall (aluminum, plastic) possible
measurement
q Accuracy of 3% for linear position,

1 mm for switch
q Compensated for airgap and temperature

variations
90
q Temperature 40C up to 150C q Magnet integrated in piston
q Stand alone sensor, can include the magnet

target 91
S &A
mechanical tolerances
S & A Sensors
Position Sensor Fork Linear
Position Sensor Linear Contactless
q Measures the fork position to enable fork

actuation in Dual Clutch Transmission, Automatic Transmission or Step Automated Transmission q Automatic Transmission Fluid compatible design q Mechanical interface compatible with transmission modules q Robust and proven magnetic design
on the mechanics
q Hall effect technology q Operation temperature 40C up to 150C q Supply voltage q Measurement range q Airgap q Ratiometric output
92 4.5 V up to 5.5 V 23 mm 4.5 mm
q Magnetic technology q Measurement range from 10 mm up to 55 mm q Temperature range 40C up to 150C q Analog, PWM or digital output q Through-wall (aluminum, plastic) possible
measurement
q Compensated for airgap and temperature

variations
q Stand alone sensor, can include the magnet target

93
S &A
q Contactless sensor, no wear q High performance and best cost q Compact design, easily integrated q Possible re-calibration to allow better tolerances
S & A Sensors
Position Sensor Neutral Position
Position Sensor Park, no Park
q Detects that gear lever is in neutral

position to enable Stop & Start function with manual gearbox q Allows Stop & Start function on manual gearbox to reduce fuel consumption up to 10 % q Robust and proven magnetic design
q No magnet used: no iron particles pollution q Insensitive to low frequency magnetic elds q Best cost sensor system (sensor and target)
q Inductive technology the target is a metallic plate linear: 10 mm up to 60 mm q Measuring range

rotary: 0 up to 180
q Magnetic technology q Operation temperature q Airgap q Insensitive to gearbox

metallic debris 40C up to 150C up to 1.5 mm up to 2 gr
q Signal output q Temperature range q Supply voltage
analog, PWM 40C up to 160C 5V
94
95
S &A
S & A Sensors
Position Sensor Rotary Covers
Position Sensor Variable Valve Train
Air Control Valve Application
180 0.6% Vdd 0.15% Vdd 5V < 10 mA 50 mT 40 up to 160C
q Angular range q Linearity q Hysteresis q Power supply q Power consumption q Magnet eld requirement q Temperature range
96
q Non-Contacting Rotary Position Sensor 1% q Accuracy 0.022 q High resolution q Programmable

measuring range 0 up to 180
q Temperature range up to 160C q Based on MR technology

97
S &A
q Fully integrated MR sensor in the cover q High temperature q High accuracy q Ageing stability (MR technology) q Low cost design
q Sensor assembly inclusive magnet wheel q Easy to install q Insensitive to air gap variation q Insensitive to magnet temperature coefcient q Analog and digital interface q Calibration possible q Very robust to parasitic magnetic eld
S & A Sensors
Position Sensor 360 Angle Contactless
Pressure Sensor Brake Pressure
q Contactless rotary sensor for transmission

application with programmable Hall effect technology q Full 360 rotation q Environmentally and electrically robust design q Electrical performance stable over temperature q Locking clip xes rotor position for installation
q Direct measurement of pressure and temperature q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q Large measurement range q High accuracy and temperature stability q Excellent dynamic response
q Rotational Range q Total Error q Signal Output
360 1.5 (over 360), 1.0 over 40 PWM, analog, digital (open collector output)
q Pressure Range q Pressure Accuracy q Offset q Span q Temperature Range q Temperature Accuracy q Supply Voltage (Vs)
0 to 250 bar
2.5% full scale 0.7 up to 2.2% full scale 40C up to +125C 10C 5.00 0.5 VDC 99
q Temperature Range 40 up to 150C 4.5 up to 18 V q Supply Voltage

98
S &A
S & A Sensors
Pressure Sensor Diesel Particle Filter
Pressure Sensor Differential Manifold Vacuum
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic response q Fullls toughest EMC requirements q Flexible housing, connector, and mounting designs
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q High accuracy and temperature stability q Excellent dynamic response q Fullls toughest EMC requirements q Flexible housing, connector, and mounting designs
100
q Pressure Range q Accuracy q Temperature Range q Supply Voltage (Vs) q Supply Current at 5 V q Load Resistance q Response Time
0 up to 125 kPa 1% full scale (10 up to 85C) 40C up to +140C 5.00 0.5 VDC 10 mA maximum > 4.7 k < 2 ms
q Pressure Range q Accuracy q Temperature Range q Supply Voltage (Vs) q Supply Current at 5 V q Load Resistance
105 up to 40 kPa (gauge) 1% full scale (10 up to 85C) 40C up to +140C 5.00 0.5 VDC 10 mA maximum > 4.7 k 101
S &A
S & A Sensors
Pressure Sensor Fuel High Pressure
Pressure Sensor Manifold Absolute Family
q Direct measurement of pressure q Flexible calibration of transfer functions q Precision programmable clip levels q Internal and output diagnostic capability q Large measurement range q High accuracy and temperature stability q Fullls toughest EMC requirements q Flexible housing, connector, and mounting designs
MAP T-MAP BAP BPS EVAPO...
electrical calibration
q Modular mechanical concept allows high

mounting exibility
0 up to 2200 bar 1% full scale (10 up to 85C) 40C up to +140C 5.00 0.5 VDC 10 mA maximum > 4.7 k < 1 ms
102
q Pressure Range q Accuracy q Temperature Range q Supply Voltage (Vs) q Supply Current at 5 V q Load Resistance q Response Time
q Adjustable characteristic via electronic calibration 0,1 up to 1 bar (MAP, BAP) q Pressure range
0,2 up to 3 bar (Turbo MAP)
q Temperature range 40 up to 125C

(storage: 135C)
q Supply voltage q Transfer function
5 V 0.5 V linear to applied pressure, ratiometric, adjustable
103
S &A
q High pressure signal accuracy over life time q Low cost design and high quality q Customer specic output characteristics by
S & A Sensors
Pressure Sensor Truck Application MAP
Pressure Sensor Relative
Truck Applications
Tank Leakage Control & Air Filter Diagnosis
by electrical calibration
by electrical calibration

mounting exibility

mounting exibility
q Adjustable characteristic via electronic calibration up to 5,2 bar absolute q Pressure range q Operating temperature 40 up to 125C 5 V 0.25 V q Supply voltage linear, ratiometric q Transfer function q Accuracy over full-scale 1% full span
(10 up to 85C) 104
q Adjustable characteristic via electronic calibration 0 up to 100 mbar diff. q Pressure range q Operating temperature 40 up to 125C 5 V 0.25 V q Supply voltage linear, ratiometric q Transfer function q Accuracy over full-scale 3% full span
(10 up to 85C) 105
S &A
q High pressure signal accuracy over life time q Low cost design and high quality q Customer specic output characteristics
q High pressure signal accuracy over life time q Low cost design and high quality q Customer specic output characteristics
S & A Sensors
Pressure Switches
Smart NOx Sensor
q Various designs available q Stable over life-time

q Switching points q Burst pressure q Switch characteristics q Applications
0.1 up to 100 bar < 150 bar Normally open and closed Oil, air and brake pressure
Modular Stand-Alone NOx Sensor q Standardized electronic interface with CAN-Bus q Independent of catalyst supplier, ECU supplier and engine management system q All Electronics including heater control and drivers integrated in the sensor q Self diagnosis capability regarding shortcut and open wire Calibrated High Accuracy Smart NOx Sensor Technical Information
q Measuring principle ZrO2-based multilayer sensor

with integrated heater and 3 oxygen pumps
q Triple output signal NOx, binary , linear

or O2-conc.
106
q Supply voltage 12 V or 24 V q Data link CAN 2.0 or SAE-J-1939 q Operating gas temperature: 100 up to 800C
107
S &A
S & A Sensors
Temperature Sensor Coolant / Fuel / Oil
Temperature Sensor Cylinder Head
q Clip or screw-in design q Wide range of applications q High accuracy q Short response time q Long-term stability q Certied quality q High worldwide volume production q Plastic variant available for each type
q Temperature Measurement of cylinder head

and other solid media
q Oil, water, fuel, temperature measurement

Engine coolant 40 up to 150C Engine oil 40 up to 150C Fuel 40 up to 140C
q Different NTC curves possible q Cylinder-head temperature: 40 up to 230C
108
109
S &A
q Short response time q High accuracy q Stainless steel design q Robustness q Certied quality
S & A Sensors
Temperature Sensor High Temperature
Temperature Sensor Intake Air
q Active sensor for the comparable price as an

passive q High accuracy (ECU will get the data digital, no further corruption of the signal at acquisition) q Price benet for costumer at ECU-system (no ADC, no precise pull-up) q One design for various application: catalyst monitoring, turbocharger monitoring, DPF, EGR, Selective Catalytic Reduction
q Clip, screw design or twist lock design q Wide range of applications q High resolution q Short response time q Long-term stability q Certied quality q High worldwide volume production
q Temperature monitoring of exhaust gas

temperatures in vehicles
q Intake air temperature measurement q Intake air temperature: 40 up to 150C
110
q Response time: up to 7 s (10 m/s gas ow) q Temperature range: 40C up to 1100C q Accuracy low temp. (< 500C): 2C + 0,75% FSO q Accuracy high temp. (> 500C): 7,5C q Supply voltage: 5 V DC (12 V DC, 24 V DC option)
111
S &A
S & A Sensors
Temperature Sensor Intake Air (High EGR)
Temperature Sensor Outside Air
q Measures intake air with high EGR rates q Clip or screw design q Very robust q Wide range of applications q Short response time q Certied quality q No chemical and soot impact on NTC
q Overpressure up to 4 bar q Response time T63,2 < 7 s (5 m / s air ow)
q Outside air temperature measurement q Outside air temperature: 40 up to 120C q Slash-proof plastic housing q Different NTC curves possible
112
113
S &A
q Snap-in design q High accuracy q Short response time q Long-term stability q Certied quality q High worldwide volume production
Fuel Supply FS
Fuel Supply FS
114
115
FS
Fuel Supply FS
Modular Fuel Supply Unit
EC Fuel Pump G50D/EC
q Various customer specic

designs possible based on modular concept q Flange geometry can be adapted to customer requirements q Integrated tank management q Variants: constant ow or ow controlled
q In-tank fuel pump with electronically commutated

(EC) motor
q Twin channel turbine pump principle q Emission reduction

q Performance data at 12 V:
Pressure, KPa 400 / 600 Flow, l / h typ. 325 / 250
q Different fuel pumps ( 38 mm /43 mm)

with EC (electronically commutated) or DC (direct current) motor
Current, A typ. 11.3/13.8
q Integrated lifetime fuel lter q Integrated pressure regulator q MAPPS ( MAgnetic Passive Position Sensor)
fuel level sensor
q Media q Weight q Volume
Premium, regular, leaded, unleaded, tropical, Flex Fuel 385 g 175 cm 3
116
117
FS
Fuel Supply FS
Code Description for Names of Fuel Pumps

stands for the pump motor resp. the pump commutation = Copper Commutator = Carbon Commutator = Electronic Commutator (brushless)
Modular Fuel Level Sensor with MAPPS
/ EC
/ Cu
/ Cu
M ## P [ P..] f [ f..] /C
stands for special features
MAPPS ( MA gnetic Passive Position Sensor)
/C
p lastic pump
(one f for each special feature)
s hort fuel
pump
stage
D ouble turbine
(one P for each pump stage, main stage on first position)
stands for the pump principle
q Redundant contacts q Best EMC because of passive system q Longer life time ( > 10 million cycles) because of
wear-resistant measurement system
G erotor
T urbine
q Hermetically sealed contacts assure perfect protection against contamination of all types of fuel
stands for the diameter
stands for the media
q Measuring range q Operating current q Resolution q Max. total error of resistor q Interface
B io Diesel F lex Fuel
Angle up to 86 1 up to 20 mA 1.7 ~ 2% = 1% 2-wire resistance signal, 50 up to 1000 linear voltage at ADC 40C up to + 125C 200 m/s (0 Hz...1 kHz) 119
28 mm
38 mm
43 mm
G asoline
T ropical
D iesel
L PG
50 mm
##
118
q Operating temperature q Dynamic strength
FS
Fuel Supply FS
Fuel Supply Electronics
Modular Function Carrier (MFC)
q Enhanced fuel pump lifetime in comparison

to systems without demand control q Reduced consumption q Noise and emission reduction
q Suitable for almost all tank designs q Integrated carbon canister (optional) q Reduction of permeation
q Integrated in the ange of the fuel supply unit

or stand-alone
DC (direct current) fuel pump to provide only the amount of fuel to the engine which is currently demanded
q Retaining vapor with integrated carbon canister

(optional)
q Processing of fuel level sensor signals (optional) q Integrated theft protection (optional)
120
121
FS
q Enables an EC (electronically commutated) or
q Operating ventilation q Refueling ventilation (optional) q Roll over function
Catalytic Converters CC
122
123
CC
METALIT (3-Way-Cat)
NO X-Adsorber
Leading metallic substrate technology Technical Information
NOX-adsorption catalysts: Technology for lean-mixture Otto-DI and Diesel engines Technical Information
q Low heat capacity for quick light-off q Foil thicknesses from 20 up to 110 m q Structured foils for enhanced efciency
are possible
q Capacity and regeneration are important for

overall efciency and fuel economy
q High cell densities help to improve mass transfer

and therefore conversion efciency
q Cell densities 50 up to 1600 cpsi
q Enhanced functionality due to included

NOX Sensor
q Additional storage volume after the sensor
124
125
CC
increases safety margin
Pre Turbo METALIT TM
Compact Cat
Excellent Cold Start Performance Technical Information
Compact design for close coupled applications with optimized heat management Technical Information
q Use of higher exhaust gas temperature q Increases HC/CO efciency (turbulent ow) q Reduces the needed Diesel Oxidation Catalyst
volume
q Compact design for close coupled applications

especially for Diesel applications
q Mounted directly to the turbocharger for

fast light-OFF
q Signicant system cost reduction possible

(Preturbo Catalyst + Diesel Oxidation Catalyst)
q High efciency due to optimized heat management q Potential for cost savings by volume reduction
126
127
CC
PM-METALIT
SCRi -System
Urea
Oxicat
PMMETALIT
SCR-Cat
LS- & PE-DesignTM
PM-METALIT
LS-Design
Partial ow deep bed lter for ultrane particulate matter Technical Information
Catalyst system with integrated particle reduction and turbulent substrates Technical Information
q Particulates are deviated in the shovel and

deposed in the eece layer
q Future lter strategies have to be adapted to

changing particulate sizes
q In conjunction with NO2 from the oxidation

catalyst continuous particle reduction
q Continuously working particle system without

regeneration
q Side-ow system guarantees discruption-free

engine operation through deep-bed ltration
q Above-average elimination in smallest particles q High performance reduction catalyst turbulence

generating LS/PE-Design with optimized coating allows volume reduction
q EU 4/ 5 without urea
128
129
CC
LS-Design
PE-Design TM
Turbulent Catalyst Technical Information Longitudinal Structure Design
Turbulent Catalyst Technical Information Perforated Metal Foil Design
q Reduction of material / weight q Improvement of cold start performance q Increased mass transfer q Catalyst efciency
q Lower backpressure q Faster light off q Improved turbulent mass transfer
130
131
CC
Continental Automotive GmbH Siemensstrasse 12 93055 Regensburg Germany Phone + 49 941 790 - 0 Fax + 49 941 790 -14 www.continental-corporation.com
Printed in Germany 04/2009 EN 2.0 k
The information provided in this brochure contains only general descriptions or performance characteristics, which do not always apply as described in case of actual use or which may change as a result of further development of the products. This information is merely a technical description of the product. This information is not meant or intended to be a special guarantee for a particular quality or particular durability. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. We reserve the right to make changes in availability as well as technical changes without prior notice. Continental Automotive GmbH

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Powertrain Products 09

Benets and Technical Information

Mobility and nature in harmony

60 Sensors & Actuators S & A 62 Actuators

40 Hybrid Electric Vehicle HEV

114 Fuel Supply FS

122 Catalytic Converters CC

Gasoline Piezo Stratied Direct Injection System

Lambda Sensor Catalyst

SCR (optional LNT)

Gasoline Solenoid Direct Injection System

Gasoline Port Injection System Flex Fuel

Diesel Piezo Common Rail Injection System

Diesel Particulate Filter

SCR (optional LNT)

Diesel Piezo Common Rail Injector

Diesel New Generation Injector

q High speed piezo actuator for a faster & more

q Excellent multiple injection stability due to needle

q Outstanding low noise (NVH)

q Pressure q Min. quantity

up to 2,000 bar 0.80 mm 3 0.65 mm 3 7 100 s 35 ml /min > 90 m

Diesel High Pressure 2-Piston Pump

ECU Diesel Piezo Common Rail

q Minimized pump leakage for reduced fuel

q Engine Control Unit for Diesel Piezo Common Rail

q Standardized scalable and modular electronic

q Chassis mounted q Supporting Euro 5

q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing

DEKA SCR Injector

DEKA Injector for Diesel Dosing into Exhaust Gas

q Robust approach for

q Fluid pressure range q Sauter Mean Diameter

Gasoline Piezo Injector

Gasoline DI XL2 Solenoid Injector

q Very fast & precise injection

q Improved linear ow range for turbocharged

q O-Ring or metal-to-metal sealing

q System pressure q Working ow range q Static ow q Dynamic ow

Gasoline DI XL3 Solenoid Injector

Gasoline DEKA VII Fuel Injector

q Improved linear ow range for high-turbocharged

Gasoline High Pressure Single-Piston Pump

Gasoline High Pressure Multi-Piston Pump

q World wide fuel compatibility q Low friction due to running components in

q World wide fuel compatibility q Low friction due to running components in

q Dry run capability q Mounted on top of the camshaft

q Dry run capability

q Integrated (inlet) ow control valve

ECU Gasoline Piezo Direct Injection

q Designed for a fully

q Engine Control Unit for Gasoline Piezo

q Standardized scalable and modular electronic

q Engine compartment, option for water cooling q Supporting Euro 5

q Gasoline application up to 1050C exhaust gas

q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing

ECU Gasoline Solenoid Direct Injection

Engine Control Unit Gasoline Easy-U

q Ready-to-use Gasoline Engine Management

q Core q Flash size q Interfaces q Injection drivers q Driver outputs q Housing

Light Duty ECU (Emerging Markets)

Light & Medium Duty ECU (Emerging Markets)