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COMPLETE SOLUTIONS FOR THE DESIGN AND MANUFACTURE OF ENGINES AND TRANSMISSIONS TO GLOBAL CUSTOMERS
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<a href="company/company.htm">Powertrain</a> Ltd designs, manufacturers and markets the award winning <a href="product/k-series.htm">K
Series</a> petrol engines, the <a href="product/L-series.htm">L Series</a> turbo diesel engine and the <a href="product/pg1.htm">PG1</a> transmission.
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The process of engine and transmission production, from design through cylinder head and block casting to manufacturing and logistics, is driven by engineering and by the skills of <a href="company/company.htm">Powertrain</a>'s Birmingham based workforce.
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We value this team of talented and passionate people who are the driving force behind our business development. They are the strength that make us the supplier of choice.
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Our continued success is based on cost competitiveness and quality performance combined with technical competence, efficiency, flexibility and strong operational controls.
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We provide complete solutions at the highest levels of quality and value to all our customers.
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<a href="company/company.htm">Powertrain</a> Ltd is a British company based in the West Midlands, producing engines and transmissions to a wide client portfolio. It has immense expertise and flexibility that allows a quick reaction to new market opportunities. Applications for its engines extend to: racing cars, 4 x 4’s, sports cars, sports saloons, exclusive sedans, family hatchbacks, vans and even hovercraft. <a href="company/company.htm">Powertrain</a> Ltd is a subsidiary of <a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> and supplier of the award winning <a href="product/k-series.htm">K
Series</a> petrol engine, <a href="product/L-series.htm">L Series</a> diesel engine and <a href="product/pg1.htm">PG1</a> transmission.
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Recent developments include two turbo-charged versions of the 1.8 <a href="product/k-series.htm">K
Series</a> engine developing outputs of 150Ps and 160Ps respectively for <a href="product/eng_app.htm">Rover</a> 75 and <a href="product/eng_app.htm">MG</a> ZT. With outstanding fuel economy these engines give class leading CO2 ratings of 193g/km for <a href="product/eng_app.htm">Rover</a> 75 and 194 g/km for the <a href="product/eng_app.htm">MG</a> ZT making them most attractive for the tax conscious motorist.
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<a href="company/company.htm">Powertrain</a> also developed the 2.5L <a href="product/kv6.htm">KV6</a> engine, fitted to Land <a href="product/eng_app.htm">Rover</a>’s Freelander, to meet North American emission legislation.
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A further initiative has been the engineering of LPG (Liquefied Petroleum Gas) conversions to take advantage of lower fuel costs and where appropriate an exemption from congestion charges. <a href="company/company.htm">Powertrain</a> engineers have put a programme in place to produce LPG versions across the whole <a href="product/k-series.htm">K
Series</a> range.
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<a href="company/company.htm">Powertrain</a>’s client portfolio already boasts many famous motoring names and the business is set to expand both in Europe and further a field. The company has a true global perspective and in addition to mainstream automotive business it is also working on exploring non-automotive market potential. What distinguishes <a href="company/company.htm">Powertrain</a> from other suppliers is its willingness to work openly with new customers and get its highly skilled engineers involved at an early stage.
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Commenting on the future, Fraser Winton, managing director of <a href="company/company.htm">Powertrain</a> Ltd said, “Both the 1.8 Turbo and LPG programmes demonstrate the breadth of skills within <a href="company/company.htm">Powertrain</a>. Looking ahead we are developing our diesel product and working on programmes that will provide improved refinement, lower emissions and reduced fuel consumption. A number of new business projects are also being pursued and our client portfolio may soon widen into more non-European markets.”
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The Vehicle Certification Agency (VCA) is a leading European approval and quality/environmental management system certification body. VCA is itself accredited by UKAS, the United Kingdom Accreditation Service and <a href="company/company.htm">Powertrain</a> Ltd are certified by VCA against both ISO9001 and ISO14001.
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<a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> Ltd is an independent, medium-sized, British-owned company with 6,500 employees. From its Longbridge International Headquarters in Birmingham, at the core of the UK’s engineering and manufacturing heartlands, the company engineers, produces, and markets cars that proudly carry the <a href="product/eng_app.htm">MG</a> and <a href="product/eng_app.htm">Rover</a> brands. It also owns <a href="company/company.htm">Powertrain</a> Limited, which produces engines and transmissions for <a href="product/k-series.htm">K
Series</a> petrol engines for <a href="product/eng_app.htm">Rover</a>, <a href="product/eng_app.htm">MG</a>, Land <a href="product/eng_app.htm">Rover</a>, Lotus and many other companies.
Today’s <a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a> is very different from the sprawling company that existed before the acquisition in May 2000.
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All car production has been brought together on one site. The process of consolidating production at Longbridge was a major operation, involving such major technical and logistical challenges as the transfer of the <a href="product/eng_app.htm">Rover</a> 75 production line from its previous base at Oxford. This and other projects were all completed on time and on budget.
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<a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a>’s car models include the <a href="product/eng_app.htm">Rover</a> 25, <a href="product/eng_app.htm">Rover</a> 45 and <a href="product/eng_app.htm">Rover</a> 75 series, which have carved out more than respectable positions in their market segments. And the <a href="product/eng_app.htm">MG</a>F is Britain’s top-selling roadster. In addition, the introduction of new models – from the <a href="product/eng_app.htm">Rover</a> 75 Tourer variant to the powerful and sporting new <a href="product/eng_app.htm">MG</a> Saloons - <a href="product/eng_app.htm">MG</a> ZR, ZS, ZT and sports wagon ZT-T - are in line with the overall strategy of developing or replacing models on an ongoing basis.
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Financially, <a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a> has been in a position of strength ever since take-over negotiations were completed in May 2000. The company started its life with a debt-free net asset balance sheet valued at around £740 million and benefited from the fact that the previous owners had made around £3 billion of investments in the company, all of which was included in the acquisition.
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Today, <a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> Ltd revenue streams range from car sales to parts and accessories. Outside the United Kingdom, <a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a> owns sales companies in main European markets and operates through local import agents in over 70 other countries.
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In its first year alone, <a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> Ltd exceeded its production, cost and sales targets. In addition, the company established its own parts business and signed a 10-year partnership with Caterpillar Inc for logistics support. Agreements were also made with major financial services providers, such as First National Finance – part of the Abbey National Finance Bank – to provide dealer financial services in the UK. Similar agreements with other providers of vehicle financing have been reached in other major markets.
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In May 2001 <a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> Ltd reached an agreement with BMW Group to settle the Completion Accounts in connection with the sale of <a href="product/eng_app.htm">Rover</a> Cars. As part of this agreement the previously owned BMW "<a href="company/company.htm">Powertrain</a>" plant in Longbridge transferred to <a href="company/mgrov_fact.htm">Phoenix
Venture Holdings</a> Ltd ownership. "<a href="company/company.htm">Powertrain</a>" now produces engines and transmissions for itself and third party customers.
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In June 2001 <a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a> announced that it had entered into an agreement to purchase the assets of the Italian subsidiary of Qvale Automotive Group. At the Frankfurt motor show the <a href="product/eng_app.htm">MG</a> X80 was revealed to the worlds media for the first time. The new <a href="product/eng_app.htm">MG</a> X80, styled by world-renowned design director Peter Stevens, utilises the outstanding chassis and engineering of the Qvale Mangusta project, coupled to a 4.6 litre V8 engine producing upto 380Ps.
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Frankfurt also saw the unveiling of the new <a href="product/eng_app.htm">MG</a> ZT XPOWER 385, <a href="product/eng_app.htm">MG</a> ZT 260 and the concept "Monogram" programme which allows buyers to personalise their car in a wide combination of exterior colour, interior trims and technical components. All available during 2002.
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The "K" Series engine has its roots in the 1980s when it won government funding from politicians renowned for their dislike of state support for the manufacturing industry. The elegance of its design, with one set of bolts clamping the whole engine together, is still considered to be world class in many respects.
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The major components of the unit – the four "Cs" – are largely produced in-house. Castings for the cylinder block and cylinder head are made from raw aluminium billets using the LPS (Low-Pressure Sand) process in the Foundry. The transformation of these raw castings into machined components also takes place on-site in East Works. Forged blanks are bought in as the starting point for crankshafts and camshafts. Precision turning, grinding and finishing transforms these blanks into the heart and soul of the engine. Following these parts through the assembly process is not as easy as you might think. There are two assembly tracks running side-by-side. One of these does a subterranean "U" turn half way through. Between and around the lines are sub-assembly loops for manifolds and cylinder heads obscuring the overall pattern.
Sophistication in the process takes many forms. Automatic assembly of valve train components hides behind unassuming metal panels. Selection of different grades of bearing to suit individual combinations of crankshaft, cylinder block and connecting rods ensures the highest level of refinement. Mechanical and electrical tests ensure no faults pass forward down the lines. Continuous improvement of assembly line facilities and tooling ensures that the quality of the product has continually improved since its first shift in 1989. A very high proportion of engines are produced "right first time".
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More amazing than its manufacture is the power output of this unit. What started out as a weight - and strength - optimised 1400cc with 1100cc younger brother has grown up through 1600cc and 1800cc variants to become the <a href="product/vvc.htm">VVC</a> (Variable Valve Control) unit developing more than twice as much power than originally planned. This goes some way towards explaining why "K" Series engines have been adopted for so many small high performance vehicles such as the Lotus Elise.
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Following its successful production debut, the "K" Series engine donated many of its internal components and geometry to the <a href="product/kv6.htm">KV6</a>, which followed it through the engineering test beds. This engine successfully justified its transformation into a volume product when it replaced the V6 engine bought from Honda for the <a href="product/eng_app.htm">Rover</a> 800.
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In volume and overall length terms, it is one of the smallest on the market: a fact which makes it admirably suitable for front wheel drive vehicles. The methods used for the production of its major components have evolved from those used on the "K" Series engine and remain predominantly "in-house". Final assembly takes place on a dedicated asynchronous track running in an easy to follow circle. Units earmarked for rectification by in process validation are diverted onto loops like railway sidings. The whole process is supported by a sophisticated pallet system. Since 2001 the <a href="product/kv6.htm">KV6</a> has now been allowed to shine in uprated forms as the power behind the new <a href="product/eng_app.htm">MG</a>-ZS and ZT models.
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Longest serving in the current <a href="company/company.htm">Powertrain</a> product line-up is the <a href="product/pg1.htm">PG1</a> gearbox. With its roots in the Honda-designed HX5MT unit
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supplied for the original <a href="product/eng_app.htm">Rover</a> 800, the gearbox has benefited from continuous improvement over the years resulting in progressively higher levels of customer satisfaction.
Only a few small components are still sourced from Japan. The aluminium casings come in as raw castings. Most of the gears and both shafts come in as rough forgings to be machined, heat-treated and finished by in-house processes.
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Compared to the engines, the gearbox assembly process is a short and sweet affair involving barely half a dozen stations. Sophistication comes in the form of acoustic test rigs, which check all finished assemblies to make sure none exceed the noise standards set for the vehicles. In the last twelve months this product has been specified for use in the <a href="product/eng_app.htm">MG</a>-ZS and the <a href="product/eng_app.htm">MG</a>F 1600cc.
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A manufacturing unit of approximately 5,000 square metres, which is situated South of the main Longbridge Site at the Cofton Hackett end of East Works.
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LPS has been in production since 1988 manufacturing major aluminum components for <a href="product/k-series.htm">K
Series</a> Engines, including Cylinder Heads and Cylinder Blocks for K4 and <a href="product/vvc.htm">VVC</a> Engines and Cylinder Heads for <a href="product/kv6.htm">KV6</a>.
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The facility is organised into 4 major processes:-
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Core Shop<br>
Casting Area <br>
Heat Treatment <br>
Finishing <br>
<a href="company/company.htm">Powertrain</a>’s LPS (Low Pressure Sandcasting) Foundry was conceived in response to a demand for a casting process that could supply the thin-walled, lightweight, aluminium cylinder head and block on which the <a href="product/k-series.htm">K
Series</a> Engine family concept was based.
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Both the process and facilities were designed and developed to be at the forefront of foundry technology, without which the engine designers’ visions could not have become reality.
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The casting process involves the use of a special electromagnetic pump to fill precision sand moulds under closely controlled process conditions leading to enviable levels of quality and efficiency.
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The process has also proved itself to be extremely versatile, accommodating over the years since the original introduction of <a href="product/k-series.htm">K
Series</a> numerous design changes and new product introductions. Alongside Cylinder Heads and Blocks for the complete K4 Engine range, including <a href="product/vvc.htm">VVC</a>, the Foundry also produces the Cylinder Heads for the <a href="product/kv6.htm">KV6</a> family of engines. At other times during its life, clutch housings for transmission products have been produced as have complex prototype and pre-series cylinder heads for BMW.
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Located as it is, less than a hundred metres from a local residential area, environmental considerations have been at the forefront of activity in the foundry with the result being the complete satisfaction of the requirements of regulatory authorities.
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So, after many of years of volume production which have seen the evolution of both the products and processes within the facility, the LPS foundry remains an integral part of the <a href="product/k-series.htm">K
Series</a> story.
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The award winning <a href="product/k-series.htm">K
Series</a> engine is an all aluminum unit utilising through bolt technology and is available in four capacity variants: 1.1 litre, 1.4 litre, 1.6 litre and 1.8 litre.
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The engines are 4 cylinder water cooled naturally aspirated with 4 valves per cylinder and utilising multi-point fuel injection with sequential operating capability.
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The block and liner construction is common across the range with the 1.6 litre and 1.8 litre using thinner section liners to increase bore size and hence capacity.
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All have direct acting overhead camshafts and hydraulic tappets, toothed belt driver via an auto tensioning system arrangement.
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The 1.8 litre engine offers a variable valve control derivative giving full performance potential from camshaft variables.
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The L-Series power unit commenced production in January 1995 and was the first in-house designed and manufactured d.i. Diesel for use in <a href="product/eng_app.htm">Rover</a> Cars applications. The unit is extremely versatile and has been fitted in the Land <a href="product/eng_app.htm">Rover</a> Freelander.
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The current engine is intercooled and has an electronically controlled injection system that uses Bosch injection equipment. It is this version that is used in the <a href="product/eng_app.htm">Rover</a> 25, 45 and <a href="product/eng_app.htm">MG</a> ZR, ZS.
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The engine is extremely environmentally friendly in terms of its emissions. Firstly it is quiet in operation owing to its two stage fuel injection & ECU controlling fuel and timing. Secondly the engine currently satisfies ECD IIl derogated Diesel emissions legislation when installed with an appropriate specified oxidation catalyst. Sensors around the engine consistently give feedback to the ECU regarding injection timing, engine speed, load, fuel and coolant temperature, boost pressure etc to ensure that optimum running conditions are maintained.
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The core engine is a conventional four cylinder with 2 valves per cylinder operated by a single overhead camshaft and hydraulic tappets. The block is cast iron with aluminium alloy head and sump. An Allied Signal GT15 turbo charger supplies boosted air. A fully modulated, water cooled, Exhaust Gas Recirculation (EGR) system is incorporated into the intake/exhaust system.
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All ancillaries (PAS, aircon, water pump, vac pump, alternator) are all driven off a single poly-vee-belt drive with autotensioner. Camshaft and injection pump drive is via multi-toothed belts and manual tensioners.
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<a href="product/pg1.htm">PG1</a> Gearbox is a five-speed constant mesh gearbox, which employs helical gears for speed transmission and final drive.
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The transmission casings are of a full aluminium construction and all other components optimised for improved weight. (37kg dry).
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The gearbox can be supplied with either a standard open differential or a Limited Slip Differential presently Torsen, the name which is derived from TORque SENsing.
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Due to the modular design of the gearbox various final drive ratio and 1st to 5th gear ratio combinations have been used. Including both present and past an overall total of 21 ratio combinations, 5 speedometer gear ratios; and 7 clutch lever designs for both hydraulic and cable operation can be called on to ensure the customers requirements are met.
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The gearbox in its two types of standard (rated to 216Nm) and uprate (rated to 240Nm) is presently supplied to various companies including <a href="product/eng_app.htm">MG</a> <a href="product/eng_app.htm">Rover</a>, Land <a href="product/eng_app.htm">Rover</a>, Honda and Lotus for vehicles such as <a href="product/eng_app.htm">Rover</a> 25 and 45, <a href="product/eng_app.htm">MG</a>F, <a href="product/eng_app.htm">MG</a> ZR, <a href="product/eng_app.htm">MG</a> ZS, Land <a href="product/eng_app.htm">Rover</a> Freelander and Lotus Elise.
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Providing impressive combination of performance and economy, yet reducing levels of exhaust emissions, the K4 <a href="product/vvc.htm">VVC</a> is the ultimate in the <a href="company/company.htm">Powertrain</a> K4 family.
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It utilises the common base structure configuration of the K4 family and adds a sophisticated cylinder head system generating infinitely variable camshaft period.
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This in turn gives greater engine flexibility and performance and improves the combustion dynamics.
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The ignition and fuelling systems are controlled on the K-series units by a sophisticated management system, which allows the engine to meet all current emissions legislation, when used in conjunction with a three way catalytic converter.
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The <a href="product/k-series.htm">K
Series</a> 1.8 litre Turbo-charged engine was launched in 2002, delivering performance and economy in a small package. The engine produces the outstanding combination of 150Ps power, 215Nm of torque from 2100rpm and competitively low 193g/km CO2 emissions. This 4 cylinder engine weighs in at just 114kg and holds many advantages over the competition including the lightweight construction, which provides exceptional levels of responsiveness and drive.
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The engine boasts a tax-beating CO2 rating of 193 g/km, thus reducing the 2002/03 UK company car tax liability to 20% of list price plus lower running costs through enhanced fuel economy.
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At the same time, the 1.8T performs well with good acceleration. 60mph passes from a standstill in 9.1 seconds and in gear performance in fourth gear between 30-50mph and 50-70mph in fourth gear can be achieved in 7.1 and 7.4 seconds, respectively. This 'have your cake and eat it' result follows a very intensive and carefully-judged engineering programme to produce the first ever turbo-charged production version of the lightweight <a href="product/k-series.htm">K
Series</a> engine.
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