BorgWarner and Volkswagen has developed a new DSG (Direct Shift Gearbox) gearbox codenamed DQ200 which will succeed it’s current DG250 6-speed DSG gearbox from BorgWarner. One major difference relevant to the consumer would be it’s 7-gears compared to the first generation DSG’s 6-speeds.

The new 7-speed DSG now uses twin dry clutches, while the 6-speed DSG uses oil-submerged clutches. The new gearbox uses a pair of dry, organic bonded friction linings that do not require cooling, making the drivetrain more efficient through the extra ratio and the fact that less power is required for the gear selection and clutch servo system. The new 7-speed DSG weighs 79kg, compared to 75kg for the 6-speed unit, however despite being heavier, it is smaller. Oil volume has been reduced by 75% from 7 litres to 1.7 litres, thanks to the new dry clutches. This oil travels in two different circuits – one for the gear teeth, and the other feeds the gear actuators.

Since there are now more ratios to play with, the first gear of the new 7-speed DSG has had it’s ratio increased to provide stronger acceleration from a standstill, while the 7th gear acts as a high ratio overdrive to help ease on the fuel consumption on highway drives. Another feature would be the ability for the DSG gearbox to be mounted transversely. Thanks to it’s compact size, the DSG gearbox can now be mounted into smaller Volkswagens like the Polo as well as it’s larger siblings.

The new gearbox will first debut in 1.4 litre TSI and 1.9 litre TDI equipped Volkswagens. It only handles power outputs up to 170 PS and 250Nm of torque, so don’t expect it to appear in the more high performance models such as the Golf GTI.

In other Volkswagen news, the staple 1.6 litre FSI engine will be replaced by the recently announced 1.4 litre Turbo FSI engine. This is not the same as the 1.4 litre TSI engine – it only has a turbocharger without a supercharger and produces 122 PS maximum power and 200Nm of torque from as low as 1,500rpm, compared to the 1.4 litre TSI’s 140 PS and 170 PS ratings. All models using the 1.6 FSI engine will be replaced with a 1.4 Turbo FSI model, including the Golf, Golf Plus, Golf Estate, Jetta, Passat, and others.

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1.4 Turbo FSI Specifications

# 90 kW / 122 PS power between 5,000 and 6,400 rpm.
# 200 Nm maximum torque from 1,500 to 3,500 rpm.
# 80 percent of maximum torque starting at 1,250 rpm
# Maximum torque 30 percent greater than in the 1.6 FSI.
# 66 percent more torque at 1,500 rpm.
# Fuel consumption is about six percent lower.
# Specific torque of 144 Nm per litre.
# 16V in-line four cylinder of the EA111 engine series.
# 1,390 cm3 displacement.
# Cylinder spacing: 82 millimeters.
# Bore and stroke: 76.5 and 75.6 millimeters.
# Compression 10:1.
# Electronic gasoline direct injection.
# Electronic-map ignition with cylinder-selective anti-knock control.
# Advanced combustion process.
# New intake port without charge movement flaps.
# Turbocharger (max. 1.8 bar)
# 220,000 rpm as maximum rpm of the turbocharger.
# Electrically-controlled divert-air valve for turbocharger.
# Water-cooled charge air in intake port.
# Fuel: Super unleaded (95 ROZ).
# Reduced friction losses.
# Total engine weight per DIN: 131 kilograms.