BorgWarner’s Locally Produced Plug Top Ignition Coils with Integrated Electronics Enhance Engine Performance, Improve Fuel Economy and Reduce Emissions

BorgWarner produces plug top ignition coils with integrated electronics at its plant in Ramos-Arizpe, Mexico, for Volkswagen’s third generation 2.0- and 1.8-liter DOHC I4 engines built in Mexico. These engines power the Volkswagen Jetta and Beetle as well as other models designated for the U.S. market. Specifically designed for modern downsized engines, BorgWarner’s compact plug top technology delivers more ignition energy and higher voltage than conventional plug top or pencil ignition coils.

“BorgWarner’s plug top technology facilitates more complete combustion to enhance engine performance, improve fuel economy and reduce emissions,” said Brady Ericson, President and General Manager, BorgWarner Emissions Systems. “We are pleased to provide Volkswagen’s modern gasoline engines with our advanced ignition technology. By offering localized production in North America as well as Europe and Asia, we can respond to our customer’s needs and react to changing market conditions quickly.”

BorgWarner’s lightweight plug top technology achieves an energy output of up to 100 milli-Joules. For engines that employ exhaust gas recirculation (EGR) to reduce emissions, this high-energy output enables EGR rates of up to 15 to 20 percent without misfires. An integrated electronic insulated gate bipolar transistor (IGBT) communicates with the engine control unit (ECU) to continuously provide diagnostic data, and an optimized magnetic circuit offers compact packaging to meet the tight installation specifications inside modern downsized engines. New synthetic materials reduce weight, and an innovative, secure component connection technology inside the body of the ignition coil improves reliability and durability. In addition, the ignition technology’s modular construction offers rapid customization and allows the energy output to be adjusted according to customer specifications.


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