# Light

- Duty Technology Cost Analysis

Report on Additional Case Studies

# EPA-420-R-10-010

April 2010 

# Assessment and Standards Division

Office of Transportation and Air Quality

U.S. Environmental Protection Agency

Prepared for EPA by

FEV, Inc.

EPA Contract No. EP-C-07-069

Work Assignment No. 1-3 

# Light

- Duty Technology Cost Analysis

Report on Additional Case Studies

NOTICE

This technical report does not necessarily represent final EPA decisions or

positions. It is intended to present technical analysis of issues using data

that are currently available. The purpose in the release of such reports is to

facilitate the exchange of technical information and to inform the public of

technical developments.

# i CONTENTS

Section Page

Executive Summary.............................................................................................................. ...........1

1 Introduction ................................................................................................................. ....... 1-1

1.1 Objectives ................................................................................................................. 1-1

1.2 Study Methodology .................................................................................................. 1-2

1.3 Manufacturing Assumptions..................................................................................... 1-5

1.4 Subsystem Categorization ........................................................................................ 1-6

2 Case Study Results........................................................................................................... .. 2-1

2.1 Case Study #0102 Results............................................................................................ 2-2

2.2 Case Study #0104 Results............................................................................................ 2-7

2.3 Case Study #0802 Results.......................................................................................... 2-10

2.4 Case Study #0902 Results.......................................................................................... 2-13

3 GLOSSARY OF TERMS .................................................................................................. 3-1

# ii LIST OF APPENDICES



# A. Powertrain Package Specification Proformas

B. System Cost Model Analysis Templates (CMATs)

C. Subsystem Cost Model Analysis Templates (CMATs)

# iii LIST OF FIGURES

Number Page

Figure 1-1: Cost Analysis Process Flow Steps and Document Interaction ................................. 1-4

Figure 2-1: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs

Roll Up for V6 to I4, Turbo, GDI Downsizing, Case Study #0102 ..........................2-5

Figure 2-2: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs

Roll Up for V8 to V6, Turbo, GDI Downsizing, Case Study #0104.........................2-8

Figure 2-3: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs

Roll Up for a 6-Speed Automatic Transmission compared to a 5-Speed Automatic

Transmission............................................................................................................ 2-12

Figure 2-4: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs

Roll Up for a 6-Speed Wet DCT compared to a 6-Speed Automatic Transmission2-15

# iv LIST OF TABLES

Number Page

Table ES-0-1: Increment Unit Cost Impact – Five (5) New Technology Configurations.............. 2

Table 1-1: Vehicle Class a nd Corresponding Downsized, Turbocharged, Stoichiometric, GDI

Engine Case Study Evaluated ....................................................................................1-1

Table 1-2: Engine System, Subsystem and Sub-Subsystem Classification................................. 1-6

Table 1-3: Transmission System, Subsyste m and Sub-Subsystem Classification....................... 1-7

Table 2-1: Location of System and Subsystem CMATs within Appendix ................................ 2-2

Table 2-2: Cost for Adding Turbocharging a nd GDI to a 2.0L, I4, NA, PFI engine and the

Estimated Credit for Downsizing from a Conventional 3.0L V6 to 2.0L I4. ............ 2-6

Table 2-3: Cost for Adding Tu rbocharging and GDI to a 3.5L, V6, NA, PFI engine and the

Estimated Credit for Downsizing from a Conventional 5.4L V8 to 3.5L V4............ 2-9

# Report FEV 07-069-203

March 26, 2010



# 1 

# Light-Duty Technology Cost Analysis – Report on Additional Case Studies

Executive Summary

The United States Environmental Protection Agency (EPA) contracted with FEV, Inc. to

d e te r mine the incremental direct manufacturing costs for a set of advanced, light-duty

vehicle technologies. The technologies selected are on the leading edge for reducing

emissions of greenhouse gases in the future, primarily in the form of tailpipe carbon

dioxide (CO 2 

# ).

This report, the second in a series of reports, addresses the direct incremental

manufacturing cost of four (4) new powertrain configurations, relative to four (4) existing

baseline configurations, with comparable driver performance metrics. The complete

costing methodology used in the analysis of these configurations, as well as the pilot case

study, is described in “Light-Duty Technology Cost Analysis Pilot Study (EPA-420-R-09-

020)”.

The four (4) new powertrain technology configurations analyzed are:

• 2.0L, I4, 4-valve, dual overhead cam (DOHC), dual variable valve timing (dVVT), turbocharged, gasoline direct injection (GDI) engine, compared to an

equivalent conventional 3.0L, V6, 4-valve, DOHC, d-VVT, naturally aspirated

(NA), port fuel injected (PFI) engine.

• 3.5L, V6, 4-valve, dual overhead cam (DOHC), d-VVT, turbocharged, GDI

engine, compared to an equivalent conventional 5.4L, V8, 3-valve, single overhead

cam (SOHC), VVT, NA, PFI engine.

• A 6-speed automatic transmission, compared to an equivalent 5-speed automatic

transmission

• A 6-speed wet dual clutch transmission (DCT), compared to an equivalent 6-speed

automatic transmission

The results for the four (4) case studies are shown in Table ES- 0-1 

# along the results

pre v iously published for case study #0101.

# 2 Table ES-0-1: 

# Increment Unit Cost Impact – Five (5) New Technology C onfigurations

Case

Study

Reference Technology

Definition Vehicle

Class Base

Technology New

Technology Incremental

Unit Cost

0101 Downsized

Turbocharged

Gasoline Direct

Injection (Engine) Compact/

Budget/

Economy Car,

Passenger. 2-4 CS# B0101

2.4L, I4, 4-V

DOHC, d-VVT

NA, PFI, CS# N0101

1.6L, I4, 4-V

DOHC, d-VVT,

Turbo, GDI $531.57

0102 Downsized

Turbocharged

Gasoline Direct

Injection (Engine) Mid to Large

Size Car,

Passenger 4-6 CS# B0102

3.0L, V6, 4-V,

DOHC, d-VVT,

NA, PFI CS# N0102

2.0L, I4, 4-V,

DOHC, d-VVT

Turbo, GDI $68.68

0104 Downsized

Turbocharged

Gasoline Direct

Injection (Engine) Passenger +

Midsize

Towing

Capabilities

Truck & SUV CS# B0104

5.4L V8, 3-V,

SOHC, VVT,

NA, PFI CS# N0104

3.5L V6, 4-V,

DOHC, d-VVT

Turbo, GDI $846.26

0902 6-Speed Dual Clutch

Transmission

Replacing a 6-Speed

Automatic

Transmission Mid to Large

Size Car,

Passenger 4-6 CS# B0801

6-Speed

Automatic

Transmission CS# N0801

6-Speed Wet

Dual Clutch

Transmission ($147.34)

0802 6-Speed replacing a

5-Speed Automatic

Transmission Mid to Large

Size Car,

Passenger 4-6 CS# B0802

5-Speed

Automatic

Transmission CS# N0802

6-Speed

Automatic

Transmission ($105.53) (1)



# (1) 

# The 6-speed automatic transmission evalua ted incorporated a Ravigneaux gear set

design, a major factor in the reduction of ha rdware and complexity in the 6-speed design

over the 5-speed design. As such the 6-speed transmission was calculated to be less

costly to manufacture than the 5-speed automatic transmission.

# 1-1 

# 1 Introduction

1.1 Objectives



# The objective of this work assignment was to determine the incremental direct

manufacturing costs for four (4) new advanced light-dut y vehicle technology

configurations using the co sting methodology, databases, and supporting worksheets

developed in the previously concluded pilot study (Light-D uty Technology Co st Analysis

Pilot Study [EPA-420-R-09-020]).

For the downsized, turbocharged, stoichio metric GDI engine case studies, careful

consideration was given to the selection of vehicle classes an alyzed to ensure that the

developed costing models, at any analysis level (com ponent, sub-subsystem, or

subsystem) could be interpolated or extrapolated to other classes, configurations and/or

content levels.

Table 1-1 

# exhibits the five (5) vehicle classes considered in this work assignment and

identifies those vehicles classes with actual teardown-based cost studies.

Table 1-1: Vehicle Class a nd Corresponding Downsized, Tur bocharged, Stoichiometric,

GDI Engine Case Study Evaluated

Vehicle Class Vehicle Class Description Completed

Analysis

Small Car subcompact or compact car typically powered by an

in-line 4 cylinder engine Case Study #0101

(2.4L I4 » 1.6L I4)

( ≈ 175 hp)

(Pilot Study)

Midsize Car 

# midsize or large passenger car typically powered

by a V6 engine Case Study #0102

(3.0 V6 » 2.0L I4)

( ≈ 225 hp)

Large

Multipurpose

Vehicle minivan or large cross-over vehicle with a large frontal

area, typically powered by a V6 engine, capable of

carrying ~ 6 or more passengers (Large V6»Small V6)

Potential to scale

costs from #0102 &

#0104

Small Truck small or mid-sized sports-utility or cross-over vehicle,

or a small pickup truck, powered by a V6 or V8 engine Case Study #0104

(5.4L V8 » 3.5L V6)

( ≈ 330 hp)

Large Truck large sports-utility vehicles and large pickup trucks,

typically powered by a V8 engine (Large V8»Small V8)

Potential to scale

costs from #0104

# 1-2 1.2 Study Methodology



# The first report published, “Light-Duty Te chnology Cost Analysis Pilot Study (EPA-420-

R-09-020)”, covers in great detail the overa ll costing methodology used to calculate an

incremental cost delta between various te chnology configurations. In summary, the

costing methodology is heavily based on tear downs of both new a nd baseline technology

configurations having similar driver performan ce metrics. Only components identified as

being different, within the selected new and baseline technology c onfigurations, as a

result of the new technology adaptation are ev aluated for cost. Component costs are

calculated using a ground-up co sting methodology analogous to that employed in the

automotive industry. All incremental cost s for the new technology are calculated and

presented using transparent cost models c onsisting of eight (8) core cost elements:

material, labor, manufacturing overhead/burden, end item scra p, SG&A (selling general

and administrative), profit, ED&T (engineeri ng, design and testing) and packaging.

Information on how additional associated manuf acturing fixed and variable cost elements

(e.g. shipping, tooling, OEM indirect costs) ar e accounted for within the cost analysis are

also discussed in the initial report (EPA-420-R-09-020).

Listed below, with the aid of Figure 1-1, is a high level summary of the ten (10) major

steps taken during the cost analysis process. For additional information concerning the

terminology used within the ten (10) steps, please reference the glossary of terms found

at the end of this report.

Step 1 : Using the Powertrain-Vehicle Class Summary Matrix (P-VCSM) , a technology

is selected for cost analysis.

Step 2 : Existing vehicle models are identified for teardown to provide the basis for

detailed incremental cost calculations.

Step 3 : Pre-teardown Comparison Bills of Materials (CBOM) are developed, covering

hardware that exists in the new and base technology configurati ons. These high level

CBOM’s are informed by the team’s understandi ng of the new and ba se technologies and

serve to identify the major systems and components targeted for teardown.

Step 4 : Phase 1 (high level) teardown is conducte d for all subsystems identified in Step

3 and the assemblies that comprise them. Using Design Profit® software , all high level

processes (e.g. assembly process of the hi gh pressure fuel pump onto the cylinder head

assembly) are mapped during the disassembly.

# 1-3 Step 5 : A cross functional team (CFT) reviews all the data generated from the high level

teardown and identifies which components a nd assumptions should be carried forward

into the cost analysis. The CBOMs are updated to reflect the CFT input.

Step 6 : Phase 2 (component/assembly level) teardowns are initiated, based on the

updated CBOM’s. Components and assemblie s are disassembled, and processes and

operations are mapped in full detail. Th e process mapping generates key process

information for the quote worksheets. Several databases containing critical costing

information provide support to the mapping process.

Step 7 : Manufacturing Assumption and Quote Summary (MAQS) worksheets are

generated for all parts undergoing the cost analysis. The MAQS details all cost elements

making up the final unit costs: material, la bor, burden, end item sc rap, SG&A, profit,

ED&T, and packaging.

Step 8 : Parts with high or unexpected cost results are subjected to a marketplace crosscheck, such as comparison with supplier pr ice quotes or wider consultation with

company and industry resources (i.e. subject matter experts) beyond the CFT.

Step 9 : All costs calculated in the MAQS worksh eets are automatically inputted into the

Subsystem Cost Model Analysis Templates (CMAT) . The Subsystem CMAT is used to

display and roll up all the differe ntial costs associated with a subsystem. All parts in a

subsystem that are identified for costing in the CBOM are entered into the Subsystem

CMAT. Also both the base a nd new technology confi gurations are included in the same

CMAT to facilitate differential cost analysis.

Step 10 : The final step in th e process is creating the System CMAT which rolls up all

the subsystem differential costs to establish a final system unit co st. The System CMAT,

similar in function to the subsystem CMAT, is the document used to display and roll-up

all the subsystem costs associat ed within a system as defi ned by the CBOM. Within the

scope of this cost analysis, the System CMAT provides the botto m line incremental unit

cost between the base and new tec hnology configurations under evaluation

# 1-4 Figure 1-1: Cost Analysis Process Fl ow Steps and Document Interaction 1. Technology

Selection

Powertrain Vehicle

Class Summary Matrix

(P-VCSM)



# 2. Hardware

Selection

Powertrain Package

Proforma



# 3A. Generate Bill of

Materials – Phase 1

Comparison Bill of

Materials (C-BOM) 

# Databases (Material, Labor, Manufacturing

Overhead, Mark-up, & Packaging)

5. Cross Functional

Team (CFT)

Reviews 7. Generate

Manufacturing

Assumption and

Quote Summary

(MAQS)

Worksheets

9. Subsystem Cost

Roll Up

Subsystem Cost Model

Analysis Template

(Subsystem CMAT)



# 10. System Cost

Roll Up

System Cost Model

Analysis Template

(System CMAT) 

# 4. System/Subsystem

Disassembly and

Process Mapping –

Phase 1

( Design Profit®)



# 6. Component/

Assembly

Disassembly &

Process Mapping –

Phase 2

( Design Profit®)



# 3B. Update Bill of Materials – Phase 2

Comparison Bill of Materials (C-BOM) 

# 8. Market Place

Cross-check



# Process Flow

Manual & Automated

Document Links

# 1-5 1.3 Manufacturing Assumptions



# When conducting the cost analysis for the various technology conf igurations, a number

of assumptions are made in orde r to establish a consistent framework for all costing. The

manufacturing assumptions can be broken into generic and specific case study

assumptions.

The generic manufacturing assumptions appl y to all technology c onfigurations under

analysis and are carry-over from the pilot study. Listed below are the fundamental

assumptions:

1) Manufacturing rates are considered high volume (>450K Units/Year) and

maintained throughout the product life. In the four (4) case studies which follow,

a yearly capacity planning volume (CPV) of 450,000 units was assumed.

2) All OEM and supplier manufacturing loca tions are in North America, unless

otherwise stated. This serves to make the resulting costs conservative to the

extent that OEMs use offshore suppliers to reduce costs.

3) OEMs and suppliers have manufacturi ng equipment and facilities capable of

handling required manufacturi ng processes and capacities unless otherwise stated.

4) All manufacturing processes and operati ons are based on standard/mainstream

industrial practices.

5) Supplier and OEM manufacturing costs (mater ial costs, labor rates, manufacturing

overhead/burden rates) are based on 2008/2009 economics.

6) Supplier mark-up rates (end-item scrap, SG&A, profit, and ED&T) are based on

mature technology and manufacturing met hods (e.g. mature product designs, high

production volumes, significant market place competition, and established

manufacturing processes) unless otherwise specified.

7) All OEM mark-up will be applied using i ndirect cost (IC) mu ltipliers. These are

not within the scope of this analysis but should be separately determined and

applied to the results of this analys is to obtain total (direct + indirect)

manufacturing costs.

The specific case study assumptions are those unique to a given te chnology and hardware

configuration. Listed below are some of the case study specific considerations:

1) Manufacturing site for define d operation or process; OEM, Tier 1 or Tier 2/3.

2) Intellectual property expense.

# 1-6 3) Neighboring system costs as a resu lt of new technology adaptation.

4) A new or modified, maintenance and/or end-of-life expense.

5) Availability of significant material cost reductions (MCRs).

6) Performance and/or cost implications of alternative new technology advances

(NTAs).

1.4 Subsystem Categorization



# As with the first case study analysis, a desi gn based classification system was used to

group the various components and assemblie s making up the technol ogy configurations.

In general, every vehicle system (e.g. engine system, transmission system, etc) is made

up of several subsystems levels (e.g. the engi ne system includes a crank drive subsystem,

cylinder head subsystem, lubr ication subsystem, air inducti on subsystem, etc), which inturn, is made up of several sub-subsystem levels (e.g. the air induction subsystem may

include the following sub-subsystems: turboc harger, heat exchange r, pipes, hoses, and

ducting). The sub-subsystem is the smallest classification level in which all components

and assemblies are binned.

Adding new technology to a system will also affect the primary subsystem(s). Also

impacted are the neighboring s ubsystems which require additi ons and/or modification for

successful integration of the new technology in to the system. For example, to add a

turbocharged air inducti on subsystem to a naturally aspira ted engine, as many as ten (10)

additional subsystems may be affected rela tive to cost, some in the positive direction

(added cost), others in the negative direc tion (cost savings). Tabl e 1-2 and Table 1-3

provide an overview of the major subsyste ms and sub-subsystems included for each

system (e.g. engine and transmission) evaluated within this analysis. In Section 2, Case

Study Results, costs are presented for both the engine and transmissi on evaluations using

these design subsystem categorizations.

# 1-7 Table 1-2: Engine System, Subsyste m and Sub-Subsystem Classification

Subsystem Sub-Subsystem

Engine Frames, Mountings & Brackets Engine Frames, Engine Mountings, Hanging Hardware

Crank Drive Crankshaft, Flywheels/Flexplat es, Connecting Rods, Pistons,

Bearing Elements

Counter Balance Dynamic Part s, Static Parts, Drives

Cylinder Block Cylinder Block, Crankshaft B earing Caps, Bedplate, Piston

Cooling

Cylinder Head Cylinder Head, Valve Guides & Seats, Guides for Valvetrain,

Camshaft Bearing Housing, Ca mshaft Sensors, Camshaft

Carrier, Cylinder Head Covers.

Valvetrain Camshaft, Intake Valves, E xhaust Valves, Valve Springs,

Spring Retainers & Keepers & Seats,

Timing Drives Timing Wheels, Tens ioners, Guides, Belts, Chains

Accessory Drives Pulleys, Tensioners, Guides, Belts

Intake Intake Manifold, Air Filter Box, Air Filters, Throttle Housing

Assembly & Supplies, Pipes/Hoses/Ducting

Fuel Induction Fuel Rails, Fuel Injectors, Pressure Regulators & Sensors, Fuel

Injection Pumps, Pipes/Hoses, Brackets

Exhaust Exhaust Manifold, Collector Pi pes, Catalysts, Silencers

(Mufflers), Oxygen Sensors, Pipes/Hoses, Brackets

Lubrication Oil Pans, Oil pumps, Pressure Re gulators& Sensors, Oil Filters,

Pipes/Hoses, Sealing Elements, Heat Exchangers

Cooling Water Pumps, Thermostat Housing, Heat Exchangers, Pressure

Regulators, Pipes/Hose s/Ducting, Brackets

Induction Air Charging Turbochargers, Heat Excha ngers, Pipes/Hoses/Ducting,

Brackets

Breather Oil/Air Separator, Valv es, Adapters, Pipes/Hoses/Ducting

Electronic and Electrical Engine Management, Engine Electronic, Engine Electrical (e.g.

Wiring, Ignition, Plugs, Coils, Powertrain Control Module)

Accessory Starter Motors, Alternators, Power Steering Pumps, Air

Conditioning Compressors

# 1-8 Table 1-3: Transmission System, Subsystem and Sub-Subsystem Classification

Subsystem Sub-Subsystem

Externally Mounted Com ponent Lift Eye, Vent Cap, Bracket, Bolting

Case(s) Transaxle Case, Transaxle Housing, Covers, Bearing

Race, Plug, Actuator

Gear Train Input Shaft, Output Shaft, Transfer Shaft, Sun Gear,

Planetary Gear, Ring Gear, Counter Gear, Differential

Gear, Bearing (Roller, Needle)

Internal Clutch Sprag Clutch, Clutch & Br ake Hub, Disc and Plate,

Piston, Snap Ring, Bearing (Roller, Needle),

Synchronizer

Launch Clutch Torque Converter, Clutch Assembly, Flexplate, Flywheel

Oil Pump and Filter Oil pump, Cover, Oil Filter, Oil Cooler, Oil Squirter,

Pipes/Tubes

Mechanical Control Valve Body Assembly, Mechanical Controls (e.g. Shift

Forks), Sealing Elements, Bearing Elements, Plugs &

Cups

Electrical Control Controller, Solenoid, Sensor, Switches, Wiring Harness

Park Mechanism Rod/Shaft/Pin, Spring, Pawl, Bracket, Bolt

# 2-1 

# 2 Case Study Results

The results for the four (4) cas e studies analyzed within this work assignment. For each

case study, a brief description of the technology and its associat ed hardware is provided.

Additional general specifications for each cas e study can also be found in the Powetrain

Packaging Specification Proformas in Appendix A. A scaled-down version of the System

Cost Model Analysis Template (CMAT) is provided, summarizing the incremental direct

manufacturing costs for each major subsystem th at was affected by adaptation of the new

technology.

The full System CMATs for each case study can be found in Appendix B. The

supporting Subsystem CMATs for each case st udy, which roll-up all the component and

assembly costs for each subsystem, can be found in Appendix C. Table 2-1 provides a

cross reference between each case study a nd the associated system and subsystem

CMATs.

Because each case study consists of a larg e quantity of component and assembly

Manufacturing and Assumption Quote Summa ry (MAQS) worksheets, approximately

200 pages per case study, hard copies were not included as part of this report. However,

electronic copies of the MAQS worksheets , as well as all other supporting case study

documents (e.g. CBOMs, Subsystem CMATs, System CMATs), can be accessed at

http://www.epa.gov/otaq/

.

# 2-2 Table 2-1: Location of System a nd Subsystem CMATs within Appendix

Case

Study

Numbers Case Study Description System

CMAT

Appendi

x

Section Subsystem

CMAT

Appendix

Section

N0102

B0102 2.0L, I4, 4-valve, dual overhead cam (DOHC), dual

variable valve timing (d-VVT), turbocharged,

gasoline direct injection (GDI) engine, compared to

an equivalent conventi onal 3.0L, V6, 4-valve,

DOHC, d-VVT, naturally aspirated (NA), port fuel

injected (PFI) engine. a 

# B1 C1

N0104

B0104 3.5L, V6, 4-valve, dual overhead cam (DOHC), dVVT, turbocharged, GDI engine, compared to an

equivalent conventional 5. 4L, V8, 3-valve, single

overhead cam (SOHC), VVT, NA, PFI engine. B2 C2

N0802

B0802 A 6-speed automatic transm ission, compared to an

equivalent 5-speed automatic transmission B3 C3

N0902

B0902 A 6-speed wet dual clutch transmission (DCT),

compared to an equivalent 6-speed automatic

transmission. B4 C4

a For the purpose of these case studies, “equivalent ” means similar performance and/or capability

# 2-2 2.1 Case Study #0102 Results



# (V6 Downsizing to I4)

Case Study #0102 analyzed the direct increm ental manufacturing cost for downsizing

from a conventional 3.0L, V6, 4-V, DOHC, d-VVT , NA, PFI engine to a 2.0L, I4, 4-V,

DOHC, d-VVT, turbocharged, GDI engine. The performance specifications for both

engine configurations were c onsidered to be equivalent w ith a maximum power output of

approximately 225 hp and maximum torque of approximately 210 lb-ft.

Note that in this analysis, neither the new or base engine actual hardware had d-VVT.

Both sets of hardware only consisted of intake-VVT. Ho wever, as part of the overall

study assumptions, both technologies were assumed to have d-VVT.

For the conventional/baseline e ngine configuration, a 2008 Ford Cyclone Duratec 35 (i.e.

3.5L V6) engine was used in combinati on with a 2008 Ford Mondeo Duratec 30 (i.e.,

3.0L V6) engine. The 3.5L Duratec engine wa s the principal hardware referenced in this

analysis, with the 3.0L Duratec engine prim arily used to support size and weight scaling

of the 3.5L V6 engine to a 3. 0L V6 equivalent. This approach was taken for two main

reasons: 1) the 3.5L Duratec is a relativ e new engine (launched in 2007 timeframe,

winner of 2007 Ward’s Top 10 Best Engines) and, as such, is considered to contain some

of the latest design and manuf acturing advances for conven tional V6 engines; and 2)

much of this same base engine cost anal ysis could be reused in Case Study #0104 (5.4L

V8, NA, PFI downsized to a 3.5L V6, Tur bo, GDI engine), reducing analysis time.

For the new technology configuration, the 2007 BMW/PSA Peugeot C itroën Prince 1.6L

I4, Turbo, GDI engine (used in the 2008 Mi ni Cooper, S) was selected as the lead

hardware, scaled up to a 2.0L I4, Turbo, GDI equivalent. Both the Chrysler GEMA 2.4L,

I4, NA, PFI engine and GM Fa mily II, Ecotec, 2.0L, I4, Tur bocharged, GDI engine were

used for size and weight sca ling (e.g. pistons, connecting rods, cylinder head), feature

counts (e.g. valve cover fasteners, oil sump fasteners), as well as for costing selected

items not captured within the 1.6L I4 BOM (e .g. balance shaft). Because the 1.6L I4,

Prince engine was used in a previous study (i.e. case study #0101), selected cost models

for this previously completed work coul d be reprocessed with updated function and

performance specifications, reducing analysis time.

Features of the 2.0L I4, Turbo, GDI fuel induction subsystem include a direct rotary

drive, swash plate, high pressure fuel pum p assembly servicing four (4) side-mounted

solenoid injectors (7-hole type) with a maxi mum operating pressure of 150 bar. The air

induction subsystem includes a twin-scroll tu rbocharger assembly, featuring a vacuumactuated waste gate actuator, electronically-act uated anti-surge valve, along with a watercooled, pressure-lubricated bearing housing. The maximum exhaust gas temperature

permitted at the turbine inle t is 950°C. Compressed air leaving the turbocharger

assembly is cooled via an air-to-air heat exch anger prior to reaching the intake manifold.

# 2-3 In this cost analysis, as well as in the V8 to V6 Turbo, GDI, engine downsizing analysis,

no additional intellectual property expens es were identified beyond the typical

contribution included in the selling, general a nd administrative (SG&A) expense. It is

acknowledged that each supplier currently ma nufacturing air inducti on components (e.g.

Honeywell-Garret, BorgWarner, Cummins) and/ or high pressure fuel system components

(e.g. Bosch, Continental, De lphi) will have a large number of patents to protect their

intellectual property. Because of these pa tents, market-leading suppliers can recover

some of their development costs in the short term. However the approach of this cost

analysis assumes that a competitive supplier base will develop similar components

(which do not infringe on the original devel oper’s patents), and th at the value of the

originator’s intellectual property will dimini sh, resulting in more modest intellectual

property allowances as the technology mature s. This allowance is captured by the

assigned SG&A rate.

As with the first pilot case study (#0101 ), new technology advances (NTAs) were

identified as possible performance upgrades to the physical hardware of the turbocharged

engines. These NTAs included the following: variable geometry tu rbochargers, water-toair charge air coolers, electric water pump (replacing the conventional mechanical water

pump) paired with a smaller auxiliary after-r un pump. At this tim e, these alternative

technologies are recorded and identified (and may be evaluated at a later date when

representative hardware is available), but are not included in the cost analysis.

Many material cost reduction (MCR) ideas we re identified in case study #0102, and these

MCRs were incorporated at the beginning of this analysis. For example, certain

manufacturing processes are sometimes bette r suited to lower-vol ume products due to

lower tooling costs. An example of this would be a part manufac tured using a powdered

metal process; at low production volumes, this may result in the lowest cost, but at high

production volumes, a fine bl anking process may make be tter financial sense..

Generally, anywhere a component design or manufacturing method was originally

adopted based on low volume production, a re vised design assumpti on and/or process

suitable for high volume mass production was selected. A second example of where

MCRs were directly implemente d into the analysis was in the selection of “best practice”

or “upward trending” manufacturi ng processes. An example of this is the replacement of

a sandcast aluminum cylinder block with a diecas t cylinder block. In this particular case

study, the actual block for the 3.0L, V6, Ford Duratec block was sandcast, whereas the

3.5L block was diecast. For this reason, the 3.5L, V6, Ford Duratec diecast cylinder

block was evaluated for cost and scal ed down to a 3.0L V6 equivalent.

In all of the turbo, GDI, engine downs izing studies (case studies #0101, #0102, and

#0104), this same approach to NTA’s and MCRs was utilized.

Figure 2-1 shows the net incremental direct manufacturing cost of $68.68 for downsizing

from a 3.0L V6, NA, PFI conventional engine to a 2.0L I4, Turbo, GDI engine. In

# 2-4 addition to the subsystem cost breakdowns s howing their net contribution to costs, the

contribution from each cost elemen t is also captured. Major incremental cost factors for

the new technology were the fuel inducti on subsystem ($84.76) and air induction

subsystem ($280.70). Major incremental co st savings for the new technology due to

downsizing were the cylinder head subsys tem ($158.70) and the valvetrain ($122.71).2-5Figure 2-1: System Cost Model Analysis Template Illustrating the Incremental SubsystemCosts Roll Up for V6 to I4,Turbo, GDI Downsizing, Case Study #0102

# 2-6 An alternative method of binning component a nd assembly incremental costs is based on

their contribution to cost relative to downsiz ing, GDI, or turbocharging categories. In

Table 2-2, the incremental subsystems costs ar e broken out into these three (3) alternative

categories. The combined subsystems co st of adding GDI to a 2.0L I4 over a

conventional PFI subsystem is $213. The combined subsystems cost for adding

turbocharging to an I4 engine over a conve ntional NA subsystem is $403. Lastly, the

credit for downsizing from a conventiona l V6 to a conventional I4 is $547.

Table 2-2: Cost for Adding Turbocharging a nd GDI to a 2.0L, I4, NA, PFI engine and

the Estimated Credit for Downsizing from a Conventional 3.0L V6 to 2.0L I4.

Combine

Subsystem

Incremental

Impact Direct Subsystem

Incremental

Contribution Indirect

Subsystem

Incremental

Contribution

GDI $213 $85 $128

Turbo $403 $281 $122

Downsizing (-$547)

Net Incremental Cost $69

# 2-7 2.2 Case Study #0104 Results



# (V8 Downsizing to V6)

Case Study #0104 analyzed the direct increm ental manufacturing cost for downsizing

from a conventional 5.4L, V8, 3-V, SOHC, VVT, NA, PFI engine to a 3.5L V6, 4-V,

DOHC, d-VVT, turbocharged, GDI engine.

For the conventional/baseline e ngine configuration, a 2008 Ford Modular 5.4L V8 engine

was selected. Standard features of this engine include a cast iron block, forged

crankshaft, aluminum heads, variable va lve timing and hydraulic, roller finger valve

lifters. The maximum power output rating is 300 hp @ 5000 rpm with a maximum torque

of 365 lb.-ft. @ 3750 rpm.

For the new technology configur ation, a 2008 Ford Cyclone Duratec 35 (i.e. 3.5L V6)

base engine was selected for the foundation of the analysis. Utilizing the project team’s

expertise, published data on Tu rbo, GDI, V6 engine archite ctures, surrogate component

data from existing benchmarking evaluations, and previously co mpleted cost studies (i.e.,

case study #0101 and #0102), the project team deve loped a 3.5L V6, Turbo, GDI engine

Bill of Materials (BOM). In regards to a target performance specification, the Ford

EcoBoost engine (3.5L V6, 4- V, DOHC, i-VVT, Turbo, GDI, engine) specification was

used as a surrogate; maximum 355 hp @ 5000 rpm and 350 lb.-ft. @ 3500 rpm.

Features of the 3.5L V6, Turbo, GDI fuel induction subsystem incl ude a direct rotary

drive, swash plate design, high-pressure fuel pump servicing six (6) side-mounted

solenoid injectors (7-hole type), with a maxi mum operating pressure of 150 bar. The air

induction subsystem features twin, single-scroll turbocharger assemblies. Each

turbocharger assembly has a vacuum-actuate d waste gate, an electronically-actuated antisurge valve, and a water-cooled, pressure-l ubricated bearing hous ing. The maximum

exhaust gas inlet temperature permitted at th e turbine inlet is 950°C. Compressed air

leaving the turbocharger assemblies is cooled prior to reaching the intake manifold via an

air-to-air heat exchanger.

Figure 2-2 shows the net incremental di rect manufacturing cost of $846.26 for

downsizing from a 5.4L V8, NA, PFI conventi onal engine to a 3.5L V6, Turbo, GDI

engine. Major incremental cost factors fo r the new technology were the fuel induction

subsystem ($124.59) and air induction subsystem ($448.79). The downsizing of many

subsystems (e.g. intake, crank drive, cylinder block) resulted in a cost savings of $155.2-8Figure 2-2: System Cost Model Analysis Template Illustrating the Incremental SubsystemCosts Roll Up for V8 to V6,Turbo, GDI Downsizing, Case Study #0104

# 2-9 Similar to the V6 to I4 dow nsizing analysis, Table 2-3 breaks down the incremental

component and subsystems cost s into downsizing, GDI, and tu rbocharging categories. As

shown in the table, the combined subsys tem cost for adding GDI to a V6 (over a

conventional PFI subsystem) is $321. The combined subsystem costs for adding

turbocharging to a V6 engine over a conve ntional NA subsystem is $681. Lastly, the

credit for downsizing from a conventional V8 to a conventional V6 is $155.

Table 2-3: Cost for Adding Turbocharging a nd GDI to a 3.5L, V6, NA, PFI engine and

the Estimated Credit for Downsizing from a Conventional 5.4L V8 to 3.5L V4.

Combine

Subsystem

Incremental

Impact Direct Subsystem

Incremental

Contribution Indirect

Subsystem

Incremental

Contribution

GDI $321 $125 $196

Turbo $681 $449 $232

Downsizing (-$155)

Net Incremental Cost $846

# 2-10 2.3 Case Study #0802 Results



# (6-Speed versus 5-Speed Automatic Transmission)

Case Study #0802 analyzed the direct incremental manufacturing cost for updating from

a conventional 5-speed automatic transmissi on to a next generation 6-speed automatic

transmission.

The 5-speed automatic transm ission selected for the analysis was the Toyota U151E

FWD transmission. This tr ansmission was used in various applications including the

Toyota Camry through the 2005-2006 timeframe . The main construction of the

transmission includes three (3) full planetary gear sets. The front and rear planetary gear

sets are positioned in series along a common intermediate shaft assembly. Adjacent to

the front and rear planetary sets, and mounted in series to the counter shaft assembly, is a

third underdrive planetary set. The transm ission contains a total of nine (9) shift

elements, four (4) disc clutches, three (3) di sc brakes, and two (2) one-way-clutches. The

hydraulic valve body assembly, c ontaining a total of seven (7) shift solenoid valves is

controlled directly by the e ngine control module (ECM). The total weight of the

transmission, including Automatic Transmission Fluid (ATF), is approximately 221 lbs.

The maximum output torque rating for the U151E is 258 lb-ft.

The 6-speed automatic transmission selected for the analysis was the replacement

transmission to the Toyota 5-speed. Th e Toyota 6-speed FWD transmission (U660E)

was a complete redesign of the existing U 151E transmission, which launched in the 2007

timeframe. Employing a Ravign eaux and underdrive planetary gear set, positioned along

a common intermediate shaft assembly, the U660E gear driveline is much simpler

compared to its predecessor. On ly six (6) shift elements ar e required for operation of the

transmission; two (2) disc clutches, three (3 ) disc brakes, and one (1) one-way-clutch.

The U660E valve body assembly also contains a total of seven (7) shift solenoid valves

interfacing with an exterior-mount transm ission control module (TCM), which in-turn

communicates with the engine control m odule (ECM). The total weight of the

transmission, including ATF, is 208 lbs. The maximum output torque rating for the

U660E is 295 lb.-ft.

As discussed in the initia l report (EPA-420-R-09-020), the costing methodology employs

an exclusion approach to costing. Follo wing completion of the comparison bill of

materials (CBOMs), the cross functional t eam began the process of rationalizing

similarities and differences between hard ware on the five (5) and six (6) speed

transmissions. A combination of component function and content ex clusion analysis was

conducted, eliminating the majority of compone nts which required costi ng. Since the 5-

speed transmission contained more hardware (i.e., approximately 150 more parts), and

was generally more complex, the 6-speed es tablished a zero cost baseline from which an

incremental cost for the 5-speed was established. The ma jority of incremental cost

# 2-11 increase of the five 5-speed over the 6-speed was associated with the two (2) additional

clutch packs, the need for a counter shaft assembly, and some additional gearing.

According to the SAE Technical Pa per 2006-01-0847 (“Toyot a’s New 6-Speed

Automatic Transaxle U660E for FWD Vehicl es”), the U660E’s transmission geartrain

structure, consisting of a Ra vigneaux gear set and simpler planetary set, was Toyota’s

original invention. As such, there was no pa tent royalty fee penalization assessed against

the 6-speed design. The patent rights for similar 6-speed transmission designs (e.g.

Lepelletier) are due to expire in 2010. Theref ore we do not expect r oyalty fees to be a

significant part of the cost for 6-speed transmissions.

For the 6-speed automatic tran smission, there were no NTA or MCR ideas identified as

part of the cost analysis. It was obvious from the transmission teardown assessment that

in addition to Toyota’s goal for improving overall performance with their new 6-speed

automatic transmission relative to the 5-speed pr edecessor, keeping costs at or below the

existing manufacturing cost was a key metric . In regard to th e 5-speed automatic

transmission, many of innovative ideas implem ented into the 6-speed automatic could

have been incorporated into a new 5-speed if it were to be redesigned). The most

obvious NTA would be adopti ng a similar Ravigneaux gear train design, which could

conceivably have the same financial benef it recognized by the 6-speed automatic. As

part of this analysis, no additional work wa s conducted to determine what the financial

impact would be on the 5-speed automatic by employing some of these NTA and MCRs

concepts. As such, th e net incremental direct manufacturing cost shown below is solely

based on the physical hardware evaluated.

Figure 2-3 shows the net incremental direct manufacturing cost between the six (6) and

five (5) speed automatic transmissions. In evaluating the physical hardware, the 6-speed

automatic was analyzed to be less expensiv e to manufacture by a pprox $105. Note that

when the 6-speed transmission was redesigne d, several other functional and performance

updates not driven by the added 6 th 

# -gear ratio were incorporated (e.g. modified hydraulic

control strategy, spool valve material, and fri ction discs, as well as a newly-developed

torque converter). These modifi cations were not costed in the analysis since they are

independent of the gear ratio addition and modifications.2-12Figure 2-3: System Cost Model Analysis Template Illustrating the Incremental SubsystemCosts Roll Up for a 6-SpeedAutomatic Transmission compared toa 5-Speed Automatic Transmission

# 2-13 2.4 Case Study #0902 Results



# (6-Speed Wet Dual Clutch Transmission versus 6-Speed Automatic Transmission)

Case Study #0902 analyzed the direct increm ental manufacturing cost for updating from

a conventional 6-speed automatic transmi ssion to a 6-speed, wet, dual clutch

transmission.

The baseline technology configuration selected for the analysis was the Toyota 6-speed

automatic transmission (U660E) of case study #0802. General design parameters of the

U660E transmission can be found in section 2.3 of this report.

The new technology configurati on selected for the analysis was the Volkswagen (VW)

six 6-speed, wet, dual clutch transmission (DCT); model number DQ250. Other industry

naming conventions for this technology configuration incl ude twin-clutch gearbox or

dual shift gearbox (DSG). The basic component s of the DCT include a twin clutch pack

assembly driving two (2) coaxial input shafts . Power from the engine is transmitted to

the input shafts through a dual-mass flywheel wh ich is connected in series to the twinclutch pack. Each input shaft, dependent on the selected gear, is designed to mesh with

one (1) of two (2) output shafts. Upon revers e gear selection, there is an intermediate

shaft which engages with both input shaft one (1) and output shaft two (2). There are

four (4) shift forks, two (2) on each output sh aft, hydraulically activated into one of two

positions from their neutral home position. The controls for the DCT, which include the

hydraulic controls, electronic controls, and va rious sensors and actuators, are integrated

into a single module VW refers to as a Mech atronic unit. The total weight of the

transmission module, including the dual-mass fl ywheel, is approximately 207 lbs. The

maximum output torque rating for the DQ250 transmission is 258 lb.-ft.

Relative to intellectual property costs, no a dditional allowances we re provided, outside

the general allowance covered as part of th e selling, general and administrative (SG&A)

expense, for protecting intellectual property. It is acknowledged that each supplier

currently making a version of a DCT (e.g. BorgWarner, Getrag, ZF, LuK) will have a

large number of patents on their own technology. Because of these patents, suppliers

who are considered to be market leaders in DCT technology will certainly recover some

of their development costs in the short term. However, it is assumed that as the supplier

base and associated technologies mature, th e value (i.e. function/cost) each supplier

provides will begin to equalize, resulting in a diminishing intellectual property cost

allowance for each design.

As part of the hardware review and evalua tion, no NTA or MCR ideas were considered

in the final cost analysis. The evaluation te am felt that in general, both transmissions

were robustly designed, with each consisti ng of a high level of component and function

integration, which resulted in two financially competitive solutions.

# 2-14 In this analysis, approximately seventy-five (75) percent of the components on both the

6-speed automatic transmission and 6-speed we t DCT were evaluated for cost. This

level of analysis was required due to the inherent differences between the automatic

versus DCT components. Th e only subsystems identified as common in function and

cost between the two (2) transmissions were the oil pump, filter, park mechanism, and

external components.

Figure 2-4 shows the net, incremental, direct manufacturing cost between the 6-speed wet

DCT and 6-speed automatic transmissions. In evaluating the physic al hardware, the 6-

speed wet DCT was analyzed to be less expensive to ma nufacture by approx $147. The

major cost increment of the 6-speed wet DCT was the launch clutch system ($64.79),

which included a dual-mass flywheel and twin clutch assembly. Th e major incremental

cost savings for the new technology were the internal clutches ($132.35) and the

geartrain ($38.04).2-15Figure 2-4: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs Roll Up for a 6-Speed WetDCT compared to a 6-SpeedAutomatic Transmission

# 3-1 

# 3 GLOSSARY OF TERMS

Assembly: generally refers to a group of interdep endent components joined together to

perform a defined function (e.g. turbocha rger assembly, high pressure fuel pump

assembly, high pressure fuel injector assembly).

Buy: is the terminology used to identify thos e components or assemblies as ones in

which a manufacturer would purchase versus manufacture. All parts designated as a

“buy” part, within the analysis, only have a net component cost pr esented. Typically

these types of parts are considered commod ity purchase parts havi ng industry established

pricing.

CBOM (Comparison Bill of Materials): is a system bill of materials, identifying all the

subsystems, assemblies and components associ ated with the technology configurations

under evaluation. The CBOM records all the high level details of the technology

configurations under study, identif ies those items which have cost implications as a result

of the new versus base t echnology differences, documents the study assumptions, and is

the primary document for capturing input from the cross functional team.

Component: is the lowest level part w ithin the cost analysis. An assembly is typically

made up of several components acting together to perform a functi on (e.g. the turbine

wheel in a turbocharger assembly). Howe ver, in some cases a component can act

independently performing a func tion within a sub-subsystem or subsystem (e.g. exhaust

manifold within the exhaust subsystem).

Cost Estimating Models : are cost estimating tools, external to the Design Profit®

software, used to calculate operation and pr ocess parameters for primary manufacturing

processes (e.g. injection molding, die cas ting, metal stamping, forging). Key

information calculated from the costing estima ting tools (e.g. cycle times, raw material

usage, equipment size) is inputted into th e Lean Design® process maps supporting the

cost analysis. The Excel ba se cost estimating models ar e developed and validated by

Munro & Associates.

Costing Databases : refer to the five (5) core databa ses which contain all the cost rates

for the analysis. The material database lists all the materials used throughout the analysis

along with the estimated price/pound for each. The labor database captures various

automotive, direct labor, manufacturing jobs (supplier and OEM), along with the

associated mean hourly labor rates. The manufacturing overh ead rate database contains

the cost/hour for the various pieces of manufacturing equipmen t assumed in the analysis.

A mark-up database assigns a percentage of ma rk-up for each of the four (4) main markup categories (i.e. end-item scrap, SG&A, profit, and ED&T), based on the industry,

supplier size, and complexity classification. The fifth database, th e packaging database,

contains packaging options and costs for each case.

# 3-2 Lean Design® (a module within the Design Profit® software): is used to create

detailed process flow charts/process maps. Lean Design® uses a series of standardized

symbols, each base symbol representing a group of similar manuf acturing procedures

(e.g. fastening, material modifications, in spection). For each group, a Lean Design®

library/database exists containing standard ized operations along with the associated

manufacturing information and specifications for each operation. The information and

specifications are used to generate a ne t operation cycle time. Each operation on a

process flow chart is represented by a base symbol, operation desc ription, and operation

time, all linked to a Lean Design® library/database.

Make: is the terminology used to identify thos e components or assemblies as ones in

which a manufacturer would produce internally versus purchase. All parts designated as

a “make” part, within the analys is, are costed in full detail.

MAQS (Manufacturing Assumption and Quote Summary) Worksheet : is the

standardized template used in the an alysis to calculate the mass production

manufacturing cost, including supplier mark -up, for each system, subsystem and

assembly quoted in the analysis . Every component and assembly costed in the analysis

will have a MAQS worksheet. The worksheet is based on a standard OEM (original

equipment manufacturer) quote sheet modified for improved costing transparency and

flexibility in sensitivity studies . The main feeder documents to the MAQS worksheets

are process maps and the costing databases.

MCRs (Material Cost Reductions): is a process employed to identify and capture

potential design and/or manufacturing optim ization ideas with the hardware under

evaluation. These savings could potentially reduce or increase the differential costs

between the new and base technology configurations, depending on whether an MCR

idea is for the new or the base technology.

Net Component/Assembly Cost Impact to OEM : is defined as the net manufacturing

cost impact per unit, to the OEM, for a defined component, asse mbly, subsystem or

system. For components produced by the supplier base, the net manufacturing cost

impact to the OEM includes total manufacturing costs (material, labor, and

manufacturing overhead), mark-up (end-item scrap costs, selling, general and

administrative costs, profit, and engineeri ng design and testing co sts) and packaging

costs. For OEM internally manufactured co mponents, the net manufacturing cost impact

to the OEM includes total manufacturing cost s and packaging costs; mark-up costs are

addressed through the application of an indirect cost multiplier.

NTAs (New Technology Advances): is a process employed to identify and capture

alternative advance technology ideas which coul d be substituted for some of the existing

hardware under evaluation. These advanc ed technologies, thr ough improved function

# 3-3 and performance, and/or cost reductions, coul d help increase the overall value of the

technology configuration.

Powertrain Package Proforma : is a summary worksheet comparing the key physical

and performance attributes of the technol ogy under study with those of the corresponding

base configuration.

Process Maps : are detailed process flow charts used to capture the operations and

processes, and associated key manufactur ing variables, invol ved in manufacturing

products at any level (e.g. vehicle, sy stem, subsystem, assembly, component).

P-VCSM (Powertrain–Vehicle Cl ass Summary Matrix): records the technologies

being evaluated, the applicable vehicle classes for each technology, and key parameters

for vehicles or vehicle systems that have been selected to repr esent the new technology

and baseline configurations in each vehicle class to be costed.

Quote: refers to the analytical process of establishing a cost for a component or

assembly.

Sub-subsystem: refers to a group of interdepende nt assemblies and/or components,

required to create a functioning sub-subsystem. For example, the air induction subsystem

contains several sub-subsyste ms including the following: tur bocharging, heat exchangers,

and pipes, hoses and ducting.

Subsystem: refers to a group of interdependent sub-subsystems, assemblies and/or

components, required to create a functioning s ubsystem. For example, the engine system

contains several subsystems including the following: crank drive subsystem, cylinder

block subsystem, cylinder head subsystem, fuel induction subsystem, and air induction

subsystem.

Subsystem CMAT (Cost Model Analysis Templates): is the document used to display

and roll up all the sub-subsystem, assembly and component incremental costs associated

with a subsystem (e.g. fuel induction, ai r induction, exhaust), as defined by the

Comparison Bill of Material (CBOM).

Surrogate part : refers to a part similar in fit, fo rm and function as the part required for

the cost analysis. Surrogate parts are sometim es used in the cost analysis when actual

parts are unavailable. The cost of a surrogate pa rt is considered equivalent to the cost of

the actual part.

System: refers to a group of interdependent subsystems, sub-subsystems, assemblies

and/or components, working t ogether to create a vehicle primary function (e.g. engine

system, transmission system, brake syst em, fuel system, suspension system).

# 3-4 System CMAT (Cost Mode l Analysis Template): is the document used to display and

roll up all the subsystem incremental costs associated with a sy stem (e.g. engine,

transmission, steering), as defined by the CBOMs.

# A-0 APPENDIX A

POW ERTRAIN PACKAGE PROFORMAS

The Powertrain Package Proforma is summary worksheet comparing the key

physical and performance attributes of th e technology under study with those of

the corresponding base configuration.

• Appendix A.1: Powertrain Package Pr oforma for Case Study #0102, 3.0L,

V6, 4-V, DOHC, d-VVT, NA, PFI engi ne compared to a 2.0L, I4, 4-V,

DOHC, d-VVT, turboc harged, GDI engine

• Appendix A.2: Powertrain Package Pr oforma for Case Study #0104, 5.4L,

V8, 3-V, SOHC, VVT, NA, PFI engi ne compared to a 3.5L V6, 4-V,

DOHC, d-VVT, turbocharg ed, GDI engine

• Appendix A.3: Powertrian Packag e Proforma for Case Study #0802,

conventional 5-speed automatic transmission comp ared to a next generation

6-speed automatic transmission

• Appendix A.4: Powertrain Packag e Proforma for Case Study #0902,

conventional 6-speed automatic transmission co mpared to a 6-speed, wet,

dual clutch transmissionAPPENDIX A.1 -POWERTRAIN PACKAGE SPECIFICATION PROFORMACASE STUDY #0102Printed: 3/29/2010ItemCharacteristicsBaseline Technology PackageNew Technology Package1 Engine Name/Code2008Ford Mondeo Duratec 30Theoretical engine scaled off Prince/N14B16(Mini Cooper S Engine)2 Engine TypeV6, 4 Valve, DOHCI4, 4-Valve, DOHC3 Displacement, cc (CID)3.0L2.0L4 AspirationNaturally AspiratedTurbocharged (Twin Scroll, Wastegate)5 Compression Ratio10:110:16 Variable Valve Timing (VVT)Hardware: Intake -VVT, Study Assumption: Dual-VVTDual-VVT7 Variable Valve LiftNoNo8 Multi Displacement SystemNoNo9 Variable Intake ManifoldNoNo10 Bore (mm)8985.911 Stroke (mm)79.585.912 Fuel SystemSequential multi-port electronic injectionDirect Injection, Side Mounted Solenoid (7 Hole), < 150 bar13 Block MaterialHardware: Aluminum Sand Castr, Study Assumption: Aluminum Diecast Aluminum Die Cast14 Cylinder Head MaterialAluminumAluminum15 Cylinder Liner MaterialCast IronCast Iron16 Connecting Rod MaterialPM Steel Forged/CrackedPM Steel Forged/Cracked17 Intake Manifold MaterialComposite (Aluminum & Glassed Reinforced Nylon)Glass Reinforced Nylon18 Horse Power @ RPM221 @ 6250Est. 225 @ 4000/600019 Torque (lb-ft) @ rpm (normal)205 @ 4750 rpmEst. 205 @ 2000/400020 TransmissionElectronic 6-speed automatic with overdriveElectronic 6-speed automatic with overdrive21 Fuel Economy (City/Highway)18/26NA22 Emission CertificationTier 2, Bin 4 / LEV-2 ULEVTier 2, Bin 5 / LEV-2 (Based on Mini Cooper S)23 Fuel OctaneUnleaded regular/E8587/91 (Based on Mini Cooper S)24 North American ApplicationsFord Fusionn/a25 ManufacturerFord Motor Companyn/a26 Plant LocationsMexicon/a27 Annual Engine VolumeActual: Approximately 300K, Study Assumption 450K450KCASE STUDY: 0102TECHNOLOGY:Downsized, turbocharged, gasoline directinjection (GDI) Engine versusPort-fuelinjected, 4-valve, naturally aspirated gasolineengine.VEHICLE CLASS:Mid to Large Size Passenger CarPassenger Seating: 4 -6Surrogate Image of Duratec 3.0 V6 EngineMini Cooper S, 1.6L I4, Turbo GDIFile:PT Package Spec. Proforma 032610.xlsEPA Contract: EP-C-07-069 WA1-3Apdx. A.1 PT-Pkge.Proforma 0102, Page 1 of 4Author: G. Kolwich(248) 373-6000, Ext.2411APPENDIX A.2 -POWERTRAIN PACKAGE SPECIFICATION PROFORMACASE STUDY #0104Printed: 3/29/2010ItemCharacteristicsBaseline Technology PackageNew Technology Package1 Engine Name/CodeTriton / 5.4L 3V NATheoretical engine based off Ford EcoBoost / 3.5L GTDI iVCT2 Engine Type5.4L 3-valve SOHC V83.5L EcoBoostTM 24-valve DOHC V63 Displacement, cc (CID)5,407.7 cc (330)3500 cc (213.5)4 AspirationNaturally AspiratedTwin-Turbocharged5 Compression Ratio9.8:110.0:16 Variable Valve Timing (VVT)VVTActual Hardware: Intake-VVT, Study Assumption: Dual-VVT7 Variable Valve LiftNoNo8 Multi Displacement SystemNoNo9 Variable Intake ManifoldNoNo10 Bore (mm)90.1792.511 Stroke (mm)105.9288.712 Fuel SystemSequential multi-port electronic injectionDirect Injection13 Block MaterialCast IronAluminum14 Cylinder Head MaterialAluminumAluminum15 Cylinder Liner MaterialSteelCast Iron16 Connecting Rod MaterialPM Steel Forged/CrackedPM Steel Forged/Cracked17 Intake Manifold MaterialCompositeCast Aluminum (costed as composite)18 Horse Power @ RPM310 @ 5000 rpm355 @ 5700 rpm19 Torque (lb-ft) @ rpm (normal)390 @ 3500 rpm350 @ 3500 rpm20 TransmissionElectronic 6-speed automatic with overdrive6-speed electronically controlled automatic overdrive with paddle activation21 Fuel Economy (City/Highway)4x2 14/20, 4x4 14/1817/25 (AWD standard equipment)22 Emission CertificationLEV-2LEV-223 Fuel OctaneUnleaded regular/E8591 Octane (recommended)24 North American Application(s)Ford F-Series Light Duty TruckFord Flex and Taurus SHO and Lincoln MKS and MKX25 ManufacturerFord Motor CompanyFord Motor Company26 Plant LocationsFord Windsor Engine Plant I, Windsor, ONTFord Cleveland Engine Plant I, Brook Park, OH27 Annual Engine VolumeActual: 2008 Approximately 410K, Study Assumption: 450KStudy Assumption: 450KCASE STUDY: 0104TECHNOLOGY:Downsized, turbocharged, gasoline directinjection (GDI) Engine versusPort-fuelinjected, 3-valve, naturally aspirated gasolineengine.VEHICLE CLASS:Mid to Large Car and Light Duty TruckPassenger Seating: 4 -5Ford EcoBoost 3.5L, V6, Turbo, GDIFord Triton 5.4L, V8, NA, PFIFile:PT Package Spec. Proforma 032610.xlsEPA Contract: EP-C-07-069 WA1-3Apdx. A.2 PT-Pkge.Proforma 0104, Page 2 of 4Author: G. Kolwich(248) 373-6000, Ext.2411APPENDIX A.3 -POWERTRAIN PACKAGE SPECIFICATION PROFORMACASE STUDY #0802Printed: 3/29/2010ItemCharacteristicsBaseline Technology PackageNew Technology Package1 Transmission Name / Code2004/2006 Toyota 5-Speed Automatic Transmission, U151E2007-Present, Toyota 6-Speed Automatic Transmission, U660E2 Transmission Type5-Speed Automatic Transmission for FWD Mid to Large Size PassengerVehicles6-Speed Automatic Transmission for FWD Mid to Large Size PassengerVehicles3 Control SystemElectric-HydraulicElectric-Hydraulic4 Geartrain3 Planetary Sets: Front, Rear and UnderdriveOne Ravigneaux Planetary and One Underdrive Planetary5 Internal Clutches4 Disc Clutches, 3 Disc Brakes, and 2 Sprags all Electro-HydraulicallyControlled.2 Disc Clutches, 3 Disc Brakes, and 1 Sprag all Electro-HydraulicallyControlled.6 Launch Clutch SubsystemElectro-Hydraulically Controlled Torque Converter with Lock-up Clutch Electro-Hydraulically Controlled Torque Converter with Lock-up Clutch7 Engine ConnectionFlex Plate AssemblyFlex Plate Assembly8 Gear Ratios(Ratio Data Published per SAE 2002-01-0936)(Ratio Data Published per SAE 2006-01-0847)First3.9383.300Second2.1941.900Third1.4111.420Fourth0.9731.000Fifth0.7030.713Sixthn/a0.608Reverse3.1414.148Final In/an/aFinal IIn/an/a9 Maximum Torque Capacity258 lb-ft295 lb-ft10 Approximate Weight (with Automatic Transmission Fluid) 221 lbs208 lbs11 North American Application(s)Camry, Solara, Sienna, AvalonCamry, Lexus ES-350, Avalon12 Annual Case Study Volume Assumption:450K450KCASE STUDY: 0802TECHNOLOGY:6-Speed Automatic Transmission compared toan equivalent 5-Speed Automatic TransmissionVEHICLE CLASS:Mid to Large Size Passenger CarPassenger Seating: 4 -6File:PT Package Spec. Proforma 032610.xlsEPA Contract: EP-C-07-069 WA1-3Apdx. A.3 PT-Pkge.Proforma 0802, Page 3 of 4Author: G. Kolwich(248) 373-6000, Ext.2411APPENDIX A.4 -POWERTRAIN PACKAGE SPECIFICATION PROFORMACASE STUDY #0902Printed: 3/29/2010ItemCharacteristicsBaseline Technology PackageNew Technology Package1 Transmission Name / Code2007-Present, Toyota 6-Speed Automatic Transmission, U660EVolkswagen Direct Shift Gearbox (DSG)/Dual Clutch Transmission, DQ2502 Transmission Type6-Speed Automatic Transmission for FWD Mid to Large Size PassengerVehicles6-Speed, Twin Wet Clutch Transmission for FWD Mid Size PassengerVehicles3 Control SystemElectric-HydraulicElectric-Hydraulic4 GeartrainOne Ravigneaux Planetary and One Underdrive PlanetaryTwo Coaxial Input Gear Shaft Assemblies, Two Output Gear ShaftAssemblies, and a Intermediate Gear Shaft Assembly for Reverse Gear.5 Internal Clutches2 Disc Clutches, 3 Disc Brakes, and 1 Sprag all Electro-HydraulicallyControlledFour Electro-Hydraulically Controlled Shift Fork and Synchronizer GearAssemblies6 Launch Clutch SubsystemElectro-Hydraulically Controlled Torque Converter with Lock-up ClutchTwo Eectro-Hydraulically Controlled, Oil-Cooled Multi-PlateClutches7 Engine ConnectionFlex Plate AssemblyDual-mass Flywheel assembly8 Gear Ratio(Ratio Data Published per SAE 2006-01-0847)(Calculated Ratios)First3.303.36Second1.902.09Third1.421.47Fourth1.001.10Fifth0.711.09Sixth0.610.92Reverse4.153.99Final In/a3.94Final IIn/a3.149 Maximum Torque Capacity295 lb-ft258 lb-ft10 Approximate Weight (with Transmission Fluid)208 lbs20711 North American Application(s)Camry, Lexus ES-350, AvalonJetta Sports Wagon12 Annual Case Study Volume Assumption:≥450K≥450KCASE STUDY: 0902TECHNOLOGY:6-Speed Wet Dual Clutch Transmissioncompared to an equivalent 6-Speed AutomaticTransmissionVEHICLE CLASS:Mid to Large Size Passenger CarPassenger Seating: 4 -6File:PT Package Spec. Proforma 032610.xlsEPA Contract: EP-C-07-069 WA1-3Apdx. A.4 PT-Pkge.Proforma 0902, Page 4 of 4Author: G. Kolwich(248) 373-6000, Ext.2411

# B-0 APPENDIX B

SYSTEM COST MODEL A NALYSIS TEMPLATES

The System Cost Model An alysis Template (CMAT) is the document used to display

and roll up all the subsystem incremental co sts associated with a system (e.g. engine,

transmission, steering), as defined by the CBOM.



# • Appendix B.1: System CMAT for Case Study #0102, 3.0L, V6, 4-V,

DOHC, d-VVT, NA, PFI engine compar ed to a 2.0L, I4, 4-V, DOHC, dVVT, turbocharged, GDI engine

• Appendix B.2: System CMAT for Ca se Study #0104, 5.4L, V8, 3-V,

SOHC, VVT, NA, PFI engine compared to a 3.5L V6, 4-V, DOHC, d-VVT,

turbocharged, GDI engine

• Appendix B.3: System CMAT for Ca se Study #0802, co nventional 5-speed

automatic transmission compared to a next generation 6-speed automatic

transmission

• Appendix B.4: System CMAT for Ca se Study #0902, co nventional 6-speed

automatic transmission compared to a 6-speed, wet, dual clutch

transmissionAPPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem-$-$-$-$-$-$-$-$-$-$203 Crank Drive Subsystem50.89$24.65$65.62$141.16$1.50$6.27$6.27$2.12$16.15$0.60$157.91$304 Counter Balance Subsystem10.37$6.22$ 10.89$27.47$0.84$3.16$2.92$0.91$7.83$0.05$35.36$405 Cylinder Block Subsystem81.47$25.86$ 135.54$242.87$7.83$ 11.75$12.61$2.89$35.07$1.14$279.08$506 Cylinder Head Subsystem91.27$18.16$ 108.15$217.58$4.33$7.37$8.10$2.25$22.05$0.48$240.12$607 Valvetrain Subsystem83.52$15.83$59.40$158.75$0.51$6.24$6.01$2.41$15.17$0.26$174.18$708 Timing Drive Subsystem10.10$-$-$10.10$-$-$-$-$-$-$10.10$809 Accessory Drive Subsystem29.00$-$-$29.00$-$-$-$-$-$-$29.00$910 Intake Subsystem11.04$0.92$2.15$14.11$0.07$0.92$0.85$0.35$2.19$0.18$16.48$1011 Fuel Subsystem37.51$18.45$55.50$111.46$1.15$ 11.45$11.48$4.41$28.48$0.25$140.19$1112 Exhaust Subsystem144.60$31.84$98.14$274.57$11.06$17.24$16.27$6.94$51.51$0.59$326.67$1213 Lubrication Subsystem11.91$6.43$ 12.74$31.08$0.14$2.15$1.76$0.49$4.55$0.33$35.96$1314 Cooling Subsystem18.49$6.29$ 10.55$35.33$0.20$2.40$2.48$1.06$6.15$0.11$41.59$1415 Induction Air Charging Subsystem98.15$51.97$73.38$223.50$7.36$ 20.61$20.71$7.75$56.44$0.76$280.70$1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis-$-$-$-$-$-$-$-$-$-$-$1617 Breather Subsystem9.14$2.42$7.38$18.94$0.06$1.23$0.82$0.21$2.32$0.05$21.31$1760 Engine Management, Engine Electronic and Electrical Subsystems51.36$22.00$38.90$112.26$0.62$8.11$7.47$3.11$19.30$0.07$131.64$1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)3.44$2.55$7.45$13.45$0.09$1.35$1.10$0.30$2.84$0.09$16.38$19-$-$-$-$-$-$-$-$-$-$-$20-$-$-$-$-$-$-$-$-$-$-$742.58$ 233.59$ 685.46$1,661.62$35.75$ 100.23$98.83$ 35.19$270.01$4.99$1,936.62$SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item SubsystemSubsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: System CMAT- RPT2-032009.xlsEPAContract:EP-C-07-069 WA1-3Appendix B.1 (CS#0102), , Page: 1 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/26/20100100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem203Crank Drive Subsystem304 Counter Balance Subsystem405 Cylinder Block Subsystem506 Cylinder Head Subsystem607 Valvetrain Subsystem708 Timing Drive Subsystem809 Accessory Drive Subsystem910 Intake Subsystem1011 Fuel Subsystem1112 Exhaust Subsystem1213 Lubrication Subsystem1314 Cooling Subsystem1415 Induction Air Charging Subsystem1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis1617 Breather Subsystem1760 Engine Management, Engine Electronic and Electrical Subsystems1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)1920SUBSYSTEM ROLL-UP

Item SubsystemSubsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$56.77$32.52$90.55$179.84$1.11$7.91$7.86$2.67$19.56$0.91$200.31$-$-$-$-$-$-$-$-$-$-$-$97.26$21.04$ 119.50$237.81$6.95$ 11.06$12.04$2.98$33.02$0.74$271.57$148.96$31.81$ 182.67$363.44$6.61$ 11.63$12.70$3.59$34.53$0.86$398.82$120.32$31.27$ 115.65$267.24$0.97$ 11.97$11.54$4.65$29.13$0.52$296.90$49.34$5.99$ 11.58$66.90$0.59$1.56$1.04$0.24$3.43$0.38$70.71$22.00$-$-$22.00$-$-$-$-$-$-$22.00$21.72$4.31$ 12.04$38.07$0.18$2.37$2.19$0.91$5.65$0.42$44.15$8.16$9.17$ 28.18$45.51$0.34$3.83$3.94$1.66$9.77$0.15$55.43$135.37$43.46$ 121.81$300.63$7.63$ 18.81$18.08$7.84$52.36$0.98$353.97$14.77$2.87$ 18.14$35.77$0.18$2.35$2.14$0.87$5.54$0.32$41.63$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.21$0.43$0.59$2.23$0.00$0.09$0.06$0.02$0.17$0.02$2.42$40.21$23.22$32.81$96.24$0.42$6.34$5.16$1.85$13.77$0.07$110.07$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$715.90$ 206.07$ 733.66$1,655.63$24.98$ 77.91$ 76.76$ 27.28$206.92$5.38$1,867.93$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.1 (CS#0102), , Page: 2 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/26/20100100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem203Crank Drive Subsystem304 Counter Balance Subsystem405 Cylinder Block Subsystem506 Cylinder Head Subsystem607 Valvetrain Subsystem708 Timing Drive Subsystem809 Accessory Drive Subsystem910 Intake Subsystem1011 Fuel Subsystem1112 Exhaust Subsystem1213 Lubrication Subsystem1314 Cooling Subsystem1415 Induction Air Charging Subsystem1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis1617 Breather Subsystem1760 Engine Management, Engine Electronic and Electrical Subsystems1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)1920SUBSYSTEM ROLL-UP

Item SubsystemSubsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$(5.88)$(7.87)$ (24.93)$(38.68)$0.38$(1.64)$(1.60)$(0.56)$(3.41)$(0.31)$(42.40)$10.37$6.22$ 10.89$27.47$0.84$3.16$2.92$0.91$7.83$0.05$35.36$(15.80)$4.82$ 16.04$5.06$0.88$0.69$0.57$(0.09)$2.04$0.40$7.51$(57.68)$(13.65)$(74.52)$(145.85)$(2.28)$(4.26)$(4.60)$(1.34)$(12.48)$(0.37)$(158.70)$(36.81)$(15.43)$(56.25)$(108.49)$(0.47)$(5.72)$(5.53)$(2.24)$(13.96)$(0.26)$(122.71)$(39.24)$(5.99)$ (11.58)$(56.80)$(0.59)$(1.56)$(1.04)$(0.24)$(3.43)$(0.38)$(60.61)$7.00$-$-$7.00$-$-$-$-$-$-$7.00$(10.69)$(3.38)$(9.89)$(23.96)$(0.11)$(1.45)$(1.34)$(0.56)$(3.46)$(0.24)$(27.66)$29.35$9.28$ 27.31$65.94$0.81$7.62$7.53$2.75$18.71$0.10$84.76$9.22$(11.62)$(23.67)$(26.06)$3.43$(1.57)$(1.80)$(0.91)$(0.85)$(0.39)$(27.30)$(2.86)$3.56$(5.40)$(4.69)$(0.04)$(0.20)$(0.38)$(0.37)$(0.99)$0.02$(5.66)$18.49$6.29$ 10.55$35.33$0.20$2.40$2.48$1.06$6.15$0.11$41.59$98.15$51.97$73.38$223.50$7.36$ 20.61$20.71$7.75$56.44$0.76$280.70$-$-$-$-$-$-$-$-$-$-$-$7.93$1.99$6.80$16.71$0.06$1.14$0.76$0.19$2.15$0.03$18.89$11.16$(1.22)$6.09$16.03$0.21$1.76$2.31$1.25$5.53$0.01$21.57$3.44$2.55$7.45$13.45$0.09$1.35$1.10$0.30$2.84$0.09$16.38$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$26.67$ 27.51$(48.19)$5.99$10.77$ 22.33$ 22.08$7.91$63.08$(0.39)$68.68$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.1 (CS#0102), , Page: 3 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem-$-$-$-$-$-$-$-$-$-$-$203 Crank Drive Subsystem70.67$33.19$96.75$200.61$2.22$8.86$8.78$3.02$22.88$0.83$224.31$304 Counter Balance Subsystem-$-$-$-$-$-$-$-$-$-$-$405 Cylinder Block Subsystem105.58$21.77$ 128.38$255.72$7.11$ 12.65$13.21$3.04$36.02$0.80$292.55$506 Cylinder Head Subsystem161.65$32.63$ 210.03$404.31$7.37$ 12.73$13.96$3.91$37.96$0.86$443.13$607 Valvetrain Subsystem120.77$31.34$ 115.98$268.10$0.98$ 12.06$11.62$4.69$29.36$0.52$297.98$708 Timing Drive Subsystem29.50$5.72$ 11.39$46.61$0.58$1.36$0.90$0.23$3.07$0.38$50.06$809 Accessory Drive Subsystem33.00$-$-$33.00$-$-$-$-$-$-$33.00$910 Intake Subsystem56.49$3.78$5.66$65.93$0.16$1.64$1.88$0.47$4.15$1.11$71.20$1011 Fuel Subsystem52.08$25.81$79.08$156.98$1.55$ 15.81$15.79$6.05$39.21$0.39$196.58$1112 Exhaust Subsystem76.95$3.47$ 14.41$94.83$3.98$6.16$6.96$3.38$20.48$0.29$115.60$1213 Lubrication Subsystem44.25$16.54$39.30$100.09$0.37$5.03$4.52$1.75$11.67$1.26$113.02$1314 Cooling Subsystem24.98$7.54$ 12.56$45.08$0.25$3.07$3.14$1.31$7.78$0.18$53.04$1415 Induction Air Charging Subsystem146.26$76.44$ 106.36$329.41$17.87$38.21$40.86$16.27$113.21$6.17$448.79$1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis-$-$-$-$-$-$-$-$-$-$-$1617 Breather Subsystem15.99$4.24$ 12.92$33.14$0.11$2.15$1.44$0.36$4.05$0.05$37.25$1760 Engine Management, Engine Electronic and Electrical Subsystems75.20$32.70$58.06$165.95$0.92$ 11.98$11.08$4.63$28.61$0.11$194.68$1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)4.11$2.92$8.67$15.69$0.11$1.62$1.32$0.37$3.41$0.11$19.22$19-$-$-$20-$-$-$######## 297.96$ 900.20$2,216.05$43.60$ 133.46$ 135.56$49.49$362.11$13.08$2,591.24$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item SubsystemSubsystem DescriptionManufacturingSUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: System CMAT- RPT2-032009.xlsEPAContract:EP-C-07-069 WA1-3Appendix B.2 (CS#0104), Page: 4 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem203Crank Drive Subsystem304 Counter Balance Subsystem405 Cylinder Block Subsystem506 Cylinder Head Subsystem607 Valvetrain Subsystem708 Timing Drive Subsystem809 Accessory Drive Subsystem910 Intake Subsystem1011 Fuel Subsystem1112 Exhaust Subsystem1213 Lubrication Subsystem1314 Cooling Subsystem1415 Induction Air Charging Subsystem1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis1617 Breather Subsystem1760 Engine Management, Engine Electronic and Electrical Subsystems1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)1920SYSTEM & SUBSYSTEM DESCRIPTION

Item SubsystemSubsystem DescriptionSUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$75.77$38.48$ 109.25$223.50$1.43$ 10.32$10.20$3.51$25.46$1.06$250.01$-$-$-$-$-$-$-$-$-$-$-$96.03$19.85$ 164.51$280.40$7.10$ 11.63$12.90$3.29$34.93$1.46$316.79$170.31$30.32$ 193.96$394.60$8.04$ 13.91$15.24$4.27$41.46$0.86$436.92$183.67$18.74$70.32$272.73$0.63$7.87$7.50$2.88$18.88$0.27$291.87$40.60$5.72$ 11.39$57.71$0.69$1.48$0.99$0.25$3.41$0.38$61.50$22.00$-$-$22.00$-$-$-$-$-$-$22.00$76.05$6.48$ 10.63$93.16$0.35$3.49$3.99$1.00$8.83$1.15$103.13$11.04$11.29$36.58$58.92$0.45$5.03$5.21$2.20$12.89$0.18$71.99$21.97$2.77$ 13.61$38.35$1.18$2.30$2.12$0.88$6.48$0.35$45.18$7.70$1.39$6.29$15.38$0.07$0.94$0.87$0.36$2.24$0.18$17.79$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.21$0.43$0.59$2.23$0.00$0.09$0.06$0.02$0.17$0.02$2.42$42.49$23.81$41.91$108.22$0.50$7.29$6.10$2.27$16.16$0.15$124.52$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$748.84$ 159.29$ 659.78$1,567.91$20.44$ 64.39$ 65.24$ 20.95$171.02$6.05$1,744.98$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.2 (CS#0104), Page: 5 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100100 ENGINE SYSTEM102 Engine Frames, Mountings & Brackets Subsystem203Crank Drive Subsystem304 Counter Balance Subsystem405 Cylinder Block Subsystem506 Cylinder Head Subsystem607 Valvetrain Subsystem708 Timing Drive Subsystem809 Accessory Drive Subsystem910 Intake Subsystem1011 Fuel Subsystem1112 Exhaust Subsystem1213 Lubrication Subsystem1314 Cooling Subsystem1415 Induction Air Charging Subsystem1516 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis1617 Breather Subsystem1760 Engine Management, Engine Electronic and Electrical Subsystems1870Accessories Subsystem (Starter Motors, Alternators, PowerSteering Pumps, etc)1920SYSTEM & SUBSYSTEM DESCRIPTION

Item SubsystemSubsystem DescriptionSUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$(5.10)$(5.29)$ (12.50)$(22.89)$0.79$(1.45)$(1.43)$(0.49)$(2.58)$(0.23)$(25.70)$-$-$-$-$-$-$-$-$-$-$-$9.55$1.91$(36.13)$(24.67)$0.01$1.02$0.31$(0.25)$1.09$(0.66)$(24.24)$(8.66)$2.31$ 16.07$9.71$(0.67)$(1.18)$(1.29)$(0.36)$(3.49)$(0.01)$6.21$(62.89)$12.60$45.66$(4.63)$0.35$4.20$4.12$1.81$10.48$0.26$6.11$(11.10)$-$-$(11.10)$(0.11)$(0.13)$(0.08)$(0.02)$(0.34)$-$(11.44)$11.00$-$-$11.00$-$-$-$-$-$-$11.00$(19.56)$(2.70)$(4.96)$(27.23)$(0.18)$(1.85)$(2.11)$(0.53)$(4.67)$(0.03)$(31.94)$41.04$14.52$42.50$98.06$1.11$ 10.78$10.58$3.85$26.32$0.21$124.59$54.98$0.70$0.80$56.49$2.80$3.86$4.84$2.50$14.00$(0.06)$70.43$36.55$15.16$33.00$84.71$0.30$4.09$3.65$1.38$9.43$1.08$95.22$24.98$7.54$ 12.56$45.08$0.25$3.07$3.14$1.31$7.78$0.18$53.04$146.26$76.44$ 106.36$329.41$17.87$38.21$40.86$16.27$113.21$6.17$448.79$-$-$-$-$-$-$-$-$-$-$-$14.78$3.80$ 12.33$30.91$0.10$2.06$1.38$0.34$3.88$0.03$34.83$32.70$8.88$ 16.15$57.73$0.43$4.69$4.98$2.35$12.46$(0.04)$70.15$4.11$2.92$8.67$15.69$0.11$1.62$1.32$0.37$3.41$0.11$19.22$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$268.64$ 138.78$ 240.51$648.28$23.16$ 69.00$ 70.27$ 28.54$190.97$7.02$846.27$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.2 (CS#0104), Page: 6 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.-$-$-$-$-$-$-$-$-$-$-$202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.-$-$-$-$-$-$-$-$-$-$-$303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.-$-$-$-$-$-$-$-$-$-$-$404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.-$-$-$-$-$-$-$-$-$-$-$505 LAUNCH CLUTCHES: Torque Converter-$-$-$-$-$-$-$-$-$-$-$606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.-$-$-$-$-$-$-$-$-$-$-$707 MECHANICAL CONTROLS-$-$-$-$-$-$-$-$-$-$-$808 ELECTRICAL CONTROLS-$-$-$-$-$-$-$-$-$-$-$909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers-$-$-$-$-$-$-$-$-$-$-$1010 MISCELLANEOUS:-$-$-$-$-$-$-$-$-$-$-$1112######## 297.96$ 900.20$2,216.05$43.60$ 133.46$ 135.56$49.49$362.11$13.08$2,591.24$SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item SubsystemSubsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)File: System CMAT- RPT2-032009.xlsEPAContract:EP-C-07-069 WA1-3Appendix B.3 (CS#0802), Page: 7 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.505 LAUNCH CLUTCHES: Torque Converter606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.707 MECHANICAL CONTROLS808 ELECTRICAL CONTROLS909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers1010 MISCELLANEOUS:1112SUBSYSTEM ROLL-UP

Item SubsystemSubsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$0.83$0.53$4.68$6.03$-$-$-$-$-$-$6.03$1.83$4.69$ 13.67$20.19$0.14$1.45$1.64$0.81$4.05$-$24.24$19.46$8.87$ 34.46$62.80$0.47$4.27$4.28$1.90$10.91$0.26$73.98$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.17$0.52$0.50$1.19$0.00$0.04$0.03$0.01$0.07$0.02$1.28$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$22.23$ 14.46$ 53.42$90.11$0.62$ 5.78$ 5.99$ 2.74$15.13$0.28$105.53$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.3 (CS#0802), Page: 8 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.505 LAUNCH CLUTCHES: Torque Converter606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.707 MECHANICAL CONTROLS808 ELECTRICAL CONTROLS909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers1010 MISCELLANEOUS:1112SUBSYSTEM ROLL-UP

Item SubsystemSubsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$(0.83)$(0.53)$(4.68)$(6.03)$-$-$-$-$-$-$(6.03)$(1.83)$(4.69)$ (13.67)$(20.19)$(0.14)$(1.45)$(1.64)$(0.81)$(4.05)$-$(24.24)$(19.46)$(8.87)$ (34.46)$(62.80)$(0.47)$(4.27)$(4.28)$(1.90)$(10.91)$(0.26)$(73.98)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.17)$(0.52)$(0.50)$(1.19)$(0.00)$(0.04)$(0.03)$(0.01)$(0.07)$(0.02)$(1.28)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(22.29)$ (14.61)$ (53.32)$(90.22)$(0.61)$ (5.76)$ (5.95)$ (2.71)$(15.04)$(0.28)$(105.53)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.3 (CS#0802), Page: 9 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.-$-$-$-$-$-$-$-$-$-$-$202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.64.85$7.28$ 13.09$85.22$4.05$5.30$4.89$0.81$15.05$0.95$101.21$303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.57.31$25.22$75.67$158.20$0.93$9.31$ 10.64$2.66$23.55$2.45$184.21$404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.10.81$15.21$29.71$55.73$0.26$3.35$3.09$0.51$7.20$0.55$63.48$505 LAUNCH CLUTCHES: Torque Converter46.61$28.52$61.55$136.68$0.99$7.94$7.48$1.31$17.71$0.72$155.11$606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.-$-$-$-$-$-$-$-$-$-$-$707 MECHANICAL CONTROLS23.85$23.71$42.44$90.00$0.96$5.68$5.12$0.83$12.61$0.63$103.23$808 ELECTRICAL CONTROLS95.75$6.38$8.95$111.09$0.01$0.11$0.10$0.02$0.23$0.01$111.33$909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers0.10$0.85$0.76$1.71$0.01$0.11$0.13$0.10$0.35$-$2.06$1010 MISCELLANEOUS:-$-$-$-$-$-$-$-$-$-$-$1112299.27$ 107.18$ 232.17$638.62$7.21$ 31.81$ 31.45$6.24$76.70$5.30$720.63$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item SubsystemSubsystem DescriptionManufacturingSUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02- Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: System CMAT- RPT2-032009.xlsEPAContract:EP-C-07-069 WA1-3Appendix B.4 (CS#0902) , Page: 10 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.505 LAUNCH CLUTCHES: Torque Converter606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.707 MECHANICAL CONTROLS808 ELECTRICAL CONTROLS909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers1010 MISCELLANEOUS:1112SYSTEM & SUBSYSTEM DESCRIPTION

Item SubsystemSubsystem DescriptionSUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02- Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$59.04$10.47$45.95$115.46$0.55$7.18$6.62$2.76$17.11$0.56$133.12$47.93$42.72$91.92$182.57$2.92$ 16.39$14.85$2.35$36.51$0.69$219.77$54.86$37.85$67.45$160.16$1.57$ 16.17$16.15$4.81$38.70$2.81$201.67$89.44$0.46$0.83$90.74$-$-$-$-$-$-$90.74$-$-$-$-$-$-$-$-$-$-$-$15.44$31.49$41.23$88.16$0.59$7.66$7.07$1.18$16.50$0.26$104.92$104.86$3.94$6.01$114.82$0.02$0.24$0.22$0.04$0.51$0.01$115.34$0.30$1.02$0.72$2.03$0.01$0.12$0.14$0.10$0.38$-$2.41$-$-$-$-$-$-$-$-$-$-$-$0371.87$ 127.95$ 254.12$753.94$5.67$ 47.76$ 45.05$ 11.24$109.71$4.32$867.97$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.4 (CS#0902) , Page: 11 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100200 TRANSMISSION SYSTEM101EXTERNAL COMPONENTS: Consists of installation of oil coolers,lift eyes, vent caps.202CASE(S): Includes pressed in components (i.e., bearing races),plugs, and associated hardware.303GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential andall associated gears and bearings on the shaft.404INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,etc.505 LAUNCH CLUTCHES: Torque Converter606OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.707 MECHANICAL CONTROLS808 ELECTRICAL CONTROLS909PARK MECHANISM: Includes Park & Lock Pawl Mechanism andActuating Levers1010 MISCELLANEOUS:1112SYSTEM & SUBSYSTEM DESCRIPTION

Item SubsystemSubsystem DescriptionSUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02- Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$5.82$(3.19)$ (32.86)$(30.24)$3.49$(1.88)$(1.73)$(1.94)$(2.06)$0.39$(31.91)$9.38$(17.50)$(16.25)$(24.37)$(1.99)$(7.08)$(4.20)$0.31$(12.96)$1.76$(35.57)$(44.06)$(22.63)$(37.74)$(104.43)$(1.32)$ (12.82)$(13.06)$(4.30)$(31.49)$(2.26)$(138.19)$(42.83)$28.06$60.71$45.94$0.99$7.94$7.48$1.31$17.71$0.72$64.37$-$-$-$-$-$-$-$-$-$-$-$8.41$(7.79)$1.21$1.83$0.37$(1.98)$(1.95)$(0.34)$(3.89)$0.37$(1.69)$(9.12)$2.44$2.94$(3.73)$(0.01)$(0.13)$(0.12)$(0.02)$(0.28)$0.00$(4.01)$(0.20)$(0.16)$0.04$(0.32)$(0.00)$(0.01)$(0.01)$(0.01)$(0.03)$-$(0.34)$-$-$-$-$-$-$-$-$-$-$-$(72.60)$ (20.77)$ (21.95)$(115.32)$1.54$(15.95)$ (13.60)$(4.99)$(33.00)$0.98$(147.34)$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: System CMAT- RPT2-032009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix B.4 (CS#0902) , Page: 12 of 12Author: G. Kolwich(248)373-6000 Ext. 2411

# C-0 APPENDIX C

SUBSYSTEM COST MODEL ANALYSIS TEMPLATES

The Subsystem Cost Model Analysis Temp late (CMAT) is the document used to

display and roll up all the sub-subsystem, assembly and comp onent incremental

costs associated with a subs ystem (e.g. fuel induction, ai r induction, exhaust), as

defined by the Compar ison Bill of Material.

• Appendix C.1: Subsystem CMATs for Case Study #0102, 3.0L, V6, 4-V,

DOHC, d-VVT, NA, PFI engine compar ed to a 2.0L, I4, 4-V, DOHC, dVVT, turbocharged, GDI engine

• Appendix C.2: Subsystem CMATs for Ca se Study #0104, 5.4L, V8, 3-V,

SOHC, VVT, NA, PFI engine compared to a 3.5L V6, 4-V, DOHC, d-VVT,

turbocharged, GDI engine

• Appendix C.3: Subsystem CMATs for Case Study #0802, conventional 5-

speed automatic transmission compar ed to a next generation 6-speed

automatic transmission

• Appendix C.4: Subsystem CMATs for Case Study #0902, conventional 6-

speed automatic transmission compared to a 6-speed, wet, dual clutch

transmissionAPPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0103 Crank Drive Subsystem101 Crank Shaft28.70$9.08$ 24.94$62.72$0.24$2.44$2.79$0.70$6.17$0.14$69.03$202 Flywheels-$-$-$-$-$-$-$-$-$-$-$303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)5.25$6.40$ 16.09$27.74$0.14$1.80$1.66$0.69$4.30$0.07$32.12$404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)5.43$6.16$ 18.98$30.57$1.11$2.03$1.81$0.73$5.68$0.38$36.64$505 Drive for Accessory Drives (Down force, Flywheel side)-$-$-$-$-$-$-$-$-$-$-$606 Drive for Timing Drive (Down force, Flywheel side)-$-$-$-$-$-$-$-$-$-$-$765 Adaptors-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings: Connecting-Rod Bolts-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290Bearing Elements (Connecting Rod Bearing Shells, Connecting RodBushing)-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1500 Engine & Vehicle Assembly11.52$3.01$5.60$20.13$-$-$-$-$-$-$20.13$50.89$ 24.65$ 65.62$141.16$1.50$ 6.27$ 6.27$ 2.12$16.15$0.60$157.91$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Crank Drive, Page: 1 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100103 Crank Drive Subsystem101 Crank Shaft202Flywheels303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)505 Drive for Accessory Drives (Down force, Flywheel side)606 Drive for Timing Drive (Down force, Flywheel side)765 Adaptors870 Pipes, Hoses, Ducting975 Brackets1080 Boltings: Connecting-Rod Bolts1185 Sealing Elements1290Bearing Elements (Connecting Rod Bearing Shells, Connecting RodBushing)1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D32.74$11.49$39.80$84.04$0.30$2.95$3.38$0.84$7.47$0.14$91.65$-$-$-$-$-$-$-$-$-$-$-$6.70$9.60$ 24.14$40.44$0.20$2.63$2.43$1.01$6.27$0.19$46.90$7.31$7.81$ 20.64$35.77$0.62$2.33$2.06$0.82$5.82$0.58$42.17$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$10.02$3.61$5.96$19.59$-$-$-$-$-$-$19.59$56.77$ 32.52$ 90.55$179.84$1.11$ 7.91$ 7.86$ 2.67$19.56$0.91$200.31$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Crank Drive, Page: 2 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100103 Crank Drive Subsystem101 Crank Shaft202Flywheels303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)505 Drive for Accessory Drives (Down force, Flywheel side)606 Drive for Timing Drive (Down force, Flywheel side)765 Adaptors870 Pipes, Hoses, Ducting975 Brackets1080 Boltings: Connecting-Rod Bolts1185 Sealing Elements1290Bearing Elements (Connecting Rod Bearing Shells, Connecting RodBushing)1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(4.04)$(2.42)$ (14.86)$(21.32)$(0.05)$(0.51)$(0.59)$(0.15)$(1.30)$-$(22.62)$-$-$-$-$-$-$-$-$-$-$-$(1.45)$(3.20)$(8.05)$(12.70)$(0.06)$(0.83)$(0.76)$(0.32)$(1.97)$(0.12)$(14.79)$(1.88)$(1.65)$(1.66)$(5.20)$0.50$(0.30)$(0.25)$(0.09)$(0.14)$(0.19)$(5.53)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.50$(0.60)$(0.36)$0.54$-$-$-$-$-$-$0.54$(5.88)$ (7.87)$ (24.93)$(38.68)$0.38$(1.64)$ (1.60)$ (0.56)$(3.41)$(0.31)$(42.40)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Crank Drive, Page: 3 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0104 Counter Balance Subsystem101 Dynamic Parts8.53$5.83$ 10.18$24.54$0.84$3.16$2.92$0.91$7.83$0.05$32.42$202 Static Parts-$-$-$-$-$-$-$-$-$-$-$303 Drives-$-$-$-$-$-$-$-$-$-$-$465 Adapters-$-$-$-$-$-$-$-$-$-$-$570 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$675 Brackets-$-$-$-$-$-$-$-$-$-$-$780 Connecting Elements-$-$-$-$-$-$-$-$-$-$-$885 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$990 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1095 Tools-$-$-$-$-$-$-$-$-$-$-$1199 Misc.-$-$-$-$-$-$-$-$-$-$-$1200 Vehicle and Engine Assembly1.83$0.39$0.71$2.93$-$-$-$-$-$-$2.93$10.37$6.22$ 10.89$27.47$0.84$ 3.16$ 2.92$ 0.91$7.83$0.05$35.36$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Counter Balance, Page: 4 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100104 Counter Balance Subsystem101 Dynamic Parts202 Static Parts303 Drives465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Connecting Elements885 Sealing Elements990 Bearing Elements1095 Tools1199 Misc.1200 Vehicle and Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Counter Balance, Page: 5 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100104 Counter Balance Subsystem101 Dynamic Parts202 Static Parts303 Drives465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Connecting Elements885 Sealing Elements990 Bearing Elements1095 Tools1199 Misc.1200 Vehicle and Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D8.53$5.83$ 10.18$24.54$0.84$3.16$2.92$0.91$7.83$0.05$32.42$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.83$0.39$0.71$2.93$-$-$-$-$-$-$2.93$10.37$6.22$ 10.89$27.47$0.84$ 3.16$ 2.92$ 0.91$7.83$0.05$35.36$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Counter Balance, Page: 6 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0105 Cylinder Block Subsystem101 Cylinder Block45.55$11.14$80.67$137.36$4.65$6.45$7.20$1.74$20.05$0.57$157.98$202 Crankshaft Bearing Caps-$-$-$-$-$-$-$-$-$-$-$303 Bedplates21.68$10.10$48.15$79.94$3.12$4.31$4.75$1.13$13.32$0.48$93.74$404 Piston Cooling2.60$0.64$3.61$6.85$0.04$0.86$0.58$-$1.48$0.04$8.38$565 Crankcase Adaptor-$-$-$-$-$-$-$-$-$-$-$666 Water Jacket-$-$-$-$-$-$-$-$-$-$-$767 Cylinder Barrel-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings/Dowel Pins/Plugs/Studs Etc-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290 Bearing Elements: Crankshaft bearing shells-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous0.68$0.37$0.87$1.91$0.01$0.11$0.08$0.02$0.22$0.05$2.17$1500 Engine & Vehicle Assembly10.96$3.61$2.24$16.81$-$-$-$-$-$-$16.81$81.47$ 25.86$ 135.54$242.87$7.83$ 11.75$ 12.61$2.89$35.07$1.14$279.08$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Block, Page: 7 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100105 Cylinder Block Subsystem101 Cylinder Block202 Crankshaft Bearing Caps303 Bedplates404 Piston Cooling565 Crankcase Adaptor666 Water Jacket767 Cylinder Barrel870 Pipes, Hoses, Ducting975 Brackets1080 Boltings/Dowel Pins/Plugs/Studs Etc1185 Sealing Elements1290 Bearing Elements: Crankshaft bearing shells1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D77.42$13.17$ 106.22$196.81$6.88$9.54$ 10.64$2.57$29.64$0.57$227.02$3.49$1.50$4.99$9.98$0.01$0.75$0.70$0.12$1.57$0.12$11.67$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$4.05$2.16$5.48$11.68$0.06$0.76$0.70$0.29$1.81$0.05$13.54$12.31$4.21$2.82$19.34$-$-$-$-$-$-$19.34$97.26$ 21.04$ 119.50$237.81$6.95$ 11.06$ 12.04$2.98$33.02$0.74$271.57$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Block, Page: 8 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100105 Cylinder Block Subsystem101 Cylinder Block202 Crankshaft Bearing Caps303 Bedplates404 Piston Cooling565 Crankcase Adaptor666 Water Jacket767 Cylinder Barrel870 Pipes, Hoses, Ducting975 Brackets1080 Boltings/Dowel Pins/Plugs/Studs Etc1185 Sealing Elements1290 Bearing Elements: Crankshaft bearing shells1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(31.87)$(2.03)$ (25.55)$(59.45)$(2.23)$(3.09)$(3.44)$(0.83)$(9.59)$-$(69.04)$(3.49)$(1.50)$(4.99)$(9.98)$(0.01)$(0.75)$(0.70)$(0.12)$(1.57)$(0.12)$(11.67)$21.68$10.10$48.15$79.94$3.12$4.31$4.75$1.13$13.32$0.48$93.74$2.60$0.64$3.61$6.85$0.04$0.86$0.58$-$1.48$0.04$8.38$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(3.37)$(1.79)$(4.61)$(9.77)$(0.05)$(0.64)$(0.62)$(0.27)$(1.59)$(0.00)$(11.37)$(1.35)$(0.60)$(0.58)$(2.53)$-$-$-$-$-$-$(2.53)$(15.80)$4.82$ 16.04$5.06$0.88$ 0.69$ 0.57$(0.09)$2.04$0.40$7.51$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Block, Page: 9 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0106 Cylinder Head Subsystem101 Cylinder Head57.25$13.00$92.13$162.38$4.22$5.91$6.75$1.69$18.57$0.27$181.22$202 Valve Guides. Valve Seats-$-$-$-$-$-$-$-$-$-$-$303 Guides for Valve Train-$-$-$-$-$-$-$-$-$-$-$406 Camshaft Bearing Housing-$-$-$-$-$-$-$-$-$-$-$507 Cam Shaft Speed Sensor-$-$-$-$-$-$-$-$-$-$-$608 Camshaft Carrier-$-$-$-$-$-$-$-$-$-$-$709 Other Parts for Cylinder Head-$-$-$-$-$-$-$-$-$-$-$820 Cylinder Head Covers13.15$1.85$7.41$22.41$0.11$1.46$1.34$0.56$3.47$0.22$26.10$965 Adapter-$-$-$-$-$-$-$-$-$-$-$1070 Pipes-$-$-$-$-$-$-$-$-$-$-$1175 Brackets-$-$-$-$-$-$-$-$-$-$-$1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold-$-$-$-$-$-$-$-$-$-$-$1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....-$-$-$-$-$-$-$-$-$-$-$1490 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1595 Tools-$-$-$-$-$-$-$-$-$-$-$1699 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1700 Vehicle and Engine Assembly24.26$3.01$5.53$32.79$-$-$-$-$-$-$32.79$94.65$ 17.86$ 105.07$217.59$4.33$ 7.37$ 8.10$ 2.25$22.05$0.48$240.12$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Head, Page: 10 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100106 Cylinder Head Subsystem101 Cylinder Head202Valve Guides. Valve Seats303 Guides for Valve Train406 Camshaft Bearing Housing507 Cam Shaft Speed Sensor608 Camshaft Carrier709 Other Parts for Cylinder Head820 Cylinder Head Covers965 Adapter1070 Pipes1175 Brackets1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Vehicle and Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D80.85$23.63$ 149.18$253.66$6.40$8.97$ 10.25$2.56$28.18$0.54$282.38$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$22.83$3.97$ 14.13$40.93$0.20$2.66$2.46$1.02$6.34$0.32$47.59$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$45.28$4.21$ 19.36$68.85$-$-$-$-$-$-$68.85$148.96$31.81$ 182.67$363.44$6.61$ 11.63$ 12.70$3.59$34.53$0.86$398.82$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Head, Page: 11 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100106 Cylinder Head Subsystem101 Cylinder Head202Valve Guides. Valve Seats303 Guides for Valve Train406 Camshaft Bearing Housing507 Cam Shaft Speed Sensor608 Camshaft Carrier709 Other Parts for Cylinder Head820 Cylinder Head Covers965 Adapter1070 Pipes1175 Brackets1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Vehicle and Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(23.60)$(10.63)$(57.05)$(91.28)$(2.18)$(3.06)$(3.49)$(0.87)$(9.61)$(0.27)$(101.16)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(9.68)$(2.12)$(6.72)$(18.52)$(0.09)$(1.20)$(1.11)$(0.46)$(2.87)$(0.10)$(21.49)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(21.02)$(1.20)$ (13.83)$(36.05)$-$-$-$-$-$-$(36.05)$(54.30)$ (13.95)$ (77.60)$(145.85)$(2.28)$ (4.26)$ (4.60)$ (1.34)$(12.48)$(0.37)$(158.70)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cylinder Head, Page: 12 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0107 Valvetrain Subsystem101 Intake Valves9.20$-$-$9.20$-$-$-$-$-$-$9.20$202 Exhaust Valves26.00$-$-$26.00$-$-$-$-$-$-$26.00$303 Valve Springs4.80$-$-$4.80$-$-$-$-$-$-$4.80$404 Spring Retainers & Keepers, Spring Seats9.12$-$-$9.12$-$-$-$-$-$-$9.12$505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...12.80$-$-$12.80$-$-$-$-$-$-$12.80$606 Camshafts6.06$4.57$ 17.21$27.84$1.40$2.87$2.65$0.90$7.82$0.08$35.75$708 Camshaft Phaser and/or Cam Sprockets12.20$5.23$ 17.43$34.85$0.17$2.27$2.09$0.87$5.40$0.10$40.35$865 Adapters-$-$-$-$-$-$-$-$-$-$-$970 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1075 Brackets-$-$-$-$-$-$-$-$-$-$-$1180 Boltings0.30$-$-$0.30$-$-$-$-$-$-$0.30$1285 Sealings: e.g. Valve-stem, Seals-$-$-$-$-$-$-$-$-$-$-$1390 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1495 Tools-$-$-$-$-$-$-$-$-$-$-$1599 Miscellaneous3.97$2.38$9.52$15.87$0.11$1.11$1.27$0.63$3.13$0.08$19.08$1600 Engine and Vehicle Assembly-$ 3.61$ 13.18$16.79$-$-$-$-$-$-$16.79$84.44$ 15.79$ 57.34$157.58$1.68$ 6.25$ 6.01$ 2.41$16.35$0.26$174.19$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Valvetrain, Page: 13 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100107 Valvetrain Subsystem101 Intake Valves202Exhaust Valves303 Valve Springs404 Spring Retainers & Keepers, Spring Seats505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...606 Camshafts708 Camshaft Phaser and/or Cam Sprockets865 Adapters970 Pipes, Hoses, Ducting1075 Brackets1180 Boltings1285 Sealings: e.g. Valve-stem, Seals1390 Bearing Elements1495 Tools1599 Miscellaneous1600 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D12.48$-$-$12.48$-$-$-$-$-$-$12.48$27.24$-$-$27.24$-$-$-$-$-$-$27.24$7.20$-$-$7.20$-$-$-$-$-$-$7.20$13.68$-$-$13.68$-$-$-$-$-$-$13.68$19.20$-$-$19.20$-$-$-$-$-$-$19.20$7.97$8.44$ 31.49$47.89$2.34$5.05$4.66$1.58$13.62$0.16$61.68$25.31$10.85$36.15$72.30$0.36$4.70$4.34$1.81$11.21$0.20$83.71$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.60$-$-$0.60$-$-$-$-$-$-$0.60$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$7.94$4.76$ 19.05$31.75$0.22$2.22$2.54$1.27$6.25$0.16$38.16$-$7.22$ 25.73$32.95$-$-$-$-$-$-$32.95$121.61$31.27$ 112.41$265.29$2.92$ 11.97$ 11.54$4.65$31.08$0.52$296.89$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Valvetrain, Page: 14 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100107 Valvetrain Subsystem101 Intake Valves202Exhaust Valves303 Valve Springs404 Spring Retainers & Keepers, Spring Seats505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...606 Camshafts708 Camshaft Phaser and/or Cam Sprockets865 Adapters970 Pipes, Hoses, Ducting1075 Brackets1180 Boltings1285 Sealings: e.g. Valve-stem, Seals1390 Bearing Elements1495 Tools1599 Miscellaneous1600 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(3.28)$-$-$(3.28)$-$-$-$-$-$-$(3.28)$(1.24)$-$-$(1.24)$-$-$-$-$-$-$(1.24)$(2.40)$-$-$(2.40)$-$-$-$-$-$-$(2.40)$(4.56)$-$-$(4.56)$-$-$-$-$-$-$(4.56)$(6.40)$-$-$(6.40)$-$-$-$-$-$-$(6.40)$(1.91)$(3.87)$ (14.27)$(20.05)$(0.94)$(2.18)$(2.01)$(0.67)$(5.80)$(0.08)$(25.93)$(13.11)$(5.62)$ (18.73)$(37.45)$(0.19)$(2.43)$(2.25)$(0.94)$(5.80)$(0.10)$(43.35)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.30)$-$-$(0.30)$-$-$-$-$-$-$(0.30)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(3.97)$(2.38)$(9.52)$(15.87)$(0.11)$(1.11)$(1.27)$(0.63)$(3.13)$(0.08)$(19.08)$-$(3.61)$ (12.55)$(16.16)$-$-$-$-$-$-$(16.16)$(37.17)$ (15.48)$ (55.07)$(107.71)$(1.24)$ (5.72)$ (5.53)$ (2.24)$(14.73)$(0.26)$(122.70)$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Valvetrain, Page: 15 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0108 Timing Drive Subsystem101 Timing Wheels (Sprockets)1.60$-$-$1.60$-$-$-$-$-$-$1.60$202 Tensioners-$-$-$-$-$-$-$-$-$-$-$303 Guides-$-$-$-$-$-$-$-$-$-$-$405 Belts, Chains8.50$-$-$8.50$-$-$-$-$-$-$8.50$506 Covers-$-$-$-$-$-$-$-$-$-$-$665 Adaptors-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings-$-$-$-$-$-$-$-$-$-$-$1085 Sealings-$-$-$-$-$-$-$-$-$-$-$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1295 Tools-$-$-$-$-$-$-$-$-$-$-$1399 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1400 Engine Assembly-$-$-$-$-$-$-$-$-$-$-$10.10$-$ -$10.10$-$ -$ -$ -$-$-$10.10$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Timing Drives, Page: 16 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100108 Timing Drive Subsystem101 Timing Wheels (Sprockets)202Tensioners303 Guides405 Belts, Chains506 Covers665 Adaptors770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealings1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$26.00$-$-$26.00$-$-$-$-$-$-$26.00$-$-$-$-$-$-$-$-$-$-$-$12.00$-$-$12.00$-$-$-$-$-$-$12.00$9.75$4.18$9.77$23.70$0.59$1.56$1.04$0.24$3.43$0.38$27.51$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.59$1.81$1.81$5.20$-$-$-$-$-$-$5.20$49.34$5.99$ 11.58$66.90$0.59$ 1.56$ 1.04$ 0.24$3.43$0.38$70.71$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Timing Drives, Page: 17 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100108 Timing Drive Subsystem101 Timing Wheels (Sprockets)202Tensioners303 Guides405 Belts, Chains506 Covers665 Adaptors770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealings1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D1.60$-$-$1.60$-$-$-$-$-$-$1.60$(26.00)$-$-$(26.00)$-$-$-$-$-$-$(26.00)$-$-$-$-$-$-$-$-$-$-$-$(3.50)$-$-$(3.50)$-$-$-$-$-$-$(3.50)$(9.75)$(4.18)$(9.77)$(23.70)$(0.59)$(1.56)$(1.04)$(0.24)$(3.43)$(0.38)$(27.51)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(1.59)$(1.81)$(1.81)$(5.20)$-$-$-$-$-$-$(5.20)$(39.24)$(5.99)$ (11.58)$(56.80)$(0.59)$ (1.56)$ (1.04)$ (0.24)$(3.43)$(0.38)$(60.61)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Timing Drives, Page: 18 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0109 Accessory Drive Subsystem101 Pulleys29.00$-$-$29.00$-$-$-$-$-$-$29.00$202 Tensioners-$-$-$-$-$-$-$-$-$-$-$303 Guides-$-$-$-$-$-$-$-$-$-$-$405 Belts-$-$-$-$-$-$-$-$-$-$-$565 Adaptors-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$785 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$890 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$995 Tools-$-$-$-$-$-$-$-$-$-$-$1099 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1100 Engine & Vehicle Assembly-$-$-$-$-$-$-$-$-$-$-$29.00$-$ -$29.00$-$ -$ -$ -$-$-$29.00$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Accessory Drives, Page: 19 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100109 Accessory Drive Subsystem101 Pulleys202 Tensioners303 Guides405 Belts565 Adaptors670 Pipes, Hoses, Ducting785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D22.00$-$-$22.00$-$-$-$-$-$-$22.00$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$22.00$-$ -$22.00$-$ -$ -$ -$-$-$22.00$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Accessory Drives, Page: 20 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100109 Accessory Drive Subsystem101 Pulleys202 Tensioners303 Guides405 Belts565 Adaptors670 Pipes, Hoses, Ducting785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D7.00$-$-$7.00$-$-$-$-$-$-$7.00$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$7.00$-$ -$7.00$-$ -$ -$ -$-$-$7.00$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Accessory Drives, Page: 21 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0110 Intake Subsystem101 Intake Manifolds11.04$0.92$2.15$14.11$0.07$0.92$0.85$0.35$2.19$0.18$16.48$202 Air Filter Box-$-$-$-$-$-$-$-$-$-$-$303 Air Filters-$-$-$-$-$-$-$-$-$-$-$405 Throttle Housing Assembly; including Supplies-$-$-$-$-$-$-$-$-$-$-$565 Adapters: Flanges for Port Shut-off-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Bolting & Clamps-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Engine and Vehicle Assembly-$-$-$-$-$-$-$-$-$-$-$11.04$0.92$ 2.15$14.11$0.07$ 0.92$ 0.85$ 0.35$2.19$0.18$16.48$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Intake, Page: 22 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100110 Intake Subsystem101 Intake Manifolds202Air Filter Box303 Air Filters405 Throttle Housing Assembly; including Supplies565 Adapters: Flanges for Port Shut-off670 Pipes, Hoses, Ducting775 Brackets880 Bolting & Clamps985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D21.42$3.71$ 11.32$36.45$0.18$2.37$2.19$0.91$5.65$0.42$42.52$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.30$0.60$0.72$1.62$-$-$-$-$-$-$1.62$21.72$4.31$ 12.04$38.07$0.18$ 2.37$ 2.19$ 0.91$5.65$0.42$44.15$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Intake, Page: 23 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100110 Intake Subsystem101 Intake Manifolds202Air Filter Box303 Air Filters405 Throttle Housing Assembly; including Supplies565 Adapters: Flanges for Port Shut-off670 Pipes, Hoses, Ducting775 Brackets880 Bolting & Clamps985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(10.39)$(2.78)$(9.17)$(22.34)$(0.11)$(1.45)$(1.34)$(0.56)$(3.46)$(0.24)$(26.04)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.30)$(0.60)$(0.72)$(1.62)$-$-$-$-$-$-$(1.62)$(10.69)$(3.38)$ (9.89)$(23.96)$(0.11)$ (1.45)$ (1.34)$ (0.56)$(3.46)$(0.24)$(27.66)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Intake, Page: 24 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0111 Fuel Induction Subsystem101 Fuel Rails11.17$1.81$4.04$17.01$0.05$1.02$0.68$0.17$1.92$0.08$19.02$204 Fuel Injectors8.75$5.88$ 23.89$38.53$0.41$4.47$4.77$1.91$11.55$0.05$50.13$306 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$407 Fuel Injection Pumps16.99$8.01$ 24.95$49.94$0.68$5.88$5.97$2.32$14.84$0.11$64.90$565 Adaptors-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses: Low Pressure, High Pressure0.39$0.34$0.71$1.44$0.00$0.09$0.06$0.01$0.16$0.01$1.61$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Bolting-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Engine Assembly0.21$2.41$1.91$4.53$-$-$-$-$-$-$4.53$37.51$ 18.45$ 55.50$111.46$1.15$ 11.45$ 11.48$4.41$28.48$0.25$140.19$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Fuel Induction, Page: 25 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100111 Fuel Induction Subsystem101 Fuel Rails204Fuel Injectors306 Pressure Regulators407 Fuel Injection Pumps565 Adaptors670 Pipes, Hoses: Low Pressure, High Pressure775 Brackets880 Bolting985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D1.85$2.24$3.25$7.33$0.02$0.44$0.29$0.07$0.83$0.08$8.24$6.20$5.73$ 24.10$36.03$0.32$3.39$3.65$1.59$8.94$0.07$45.04$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.12$1.20$0.83$2.15$-$-$-$-$-$-$2.15$8.16$ 9.17$ 28.18$45.51$0.34$ 3.83$ 3.94$ 1.66$9.77$0.15$55.43$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Fuel Induction, Page: 26 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100111 Fuel Induction Subsystem101 Fuel Rails204Fuel Injectors306 Pressure Regulators407 Fuel Injection Pumps565 Adaptors670 Pipes, Hoses: Low Pressure, High Pressure775 Brackets880 Bolting985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D9.32$(0.43)$0.79$9.68$0.03$0.58$0.39$0.10$1.09$(0.00)$10.77$2.56$0.16$(0.22)$2.50$0.10$1.08$1.12$0.32$2.61$(0.02)$5.10$-$-$-$-$-$-$-$-$-$-$-$16.99$8.01$ 24.95$49.94$0.68$5.88$5.97$2.32$14.84$0.11$64.90$-$-$-$-$-$-$-$-$-$-$-$0.39$0.34$0.71$1.44$0.00$0.09$0.06$0.01$0.16$0.01$1.61$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.09$1.20$1.08$2.38$-$-$-$-$-$-$2.38$29.35$9.28$ 27.31$65.94$0.81$ 7.62$ 7.53$ 2.75$18.71$0.10$84.76$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Fuel Induction, Page: 27 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0112 Exhaust Subsystem101 Exhaust Manifold29.60$3.30$ 11.02$43.92$3.70$3.08$2.84$1.18$10.81$0.06$54.80$204 Collector Pipes24.63$8.21$ 21.89$54.73$0.27$3.56$3.28$1.37$8.48$0.20$63.41$305 Catalysts64.73$12.95$51.78$129.45$6.91$8.82$8.14$3.39$27.26$0.20$156.91$406 Particle Filters-$-$-$-$-$-$-$-$-$-$-$507 Silencers (Mufflers)-$-$-$-$-$-$-$-$-$-$-$608 Oxygen Sensors11.62$2.32$9.30$23.25$0.16$1.63$1.86$0.93$4.58$0.10$27.93$765 Adapters-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses: Low Pressure, High Pressure-$-$-$-$-$-$-$-$-$-$-$975 Brackets1.21$0.24$0.97$2.42$0.01$0.16$0.15$0.06$0.38$0.03$2.83$1080 Bolting-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1500 Engine and Vehicle Assembly12.80$4.81$3.18$20.79$-$-$-$-$-$-$20.79$144.60$31.84$ 98.14$274.57$11.06$ 17.24$ 16.27$6.94$51.51$0.59$326.67$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Exhaust, Page: 28 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100112 Exhaust Subsystem101 Exhaust Manifold204Collector Pipes305 Catalysts406 Particle Filters507 Silencers (Mufflers)608 Oxygen Sensors765 Adapters870 Pipes, Hoses: Low Pressure, High Pressure975 Brackets1080 Bolting1185 Sealing Elements1290 Bearing Elements1395 Tools1499 Miscellaneous1500 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D6.09$6.09$ 18.26$30.43$0.15$1.98$1.83$0.76$4.72$0.12$35.27$30.78$10.26$27.36$68.41$0.34$4.45$4.10$1.71$10.60$0.20$79.21$65.98$13.20$52.78$131.95$6.80$8.97$8.28$3.45$27.51$0.40$159.86$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$23.25$4.65$ 18.60$46.50$0.33$3.25$3.72$1.86$9.16$0.20$55.86$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.19$0.24$0.96$2.39$0.01$0.16$0.14$0.06$0.37$0.06$2.82$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$8.08$9.03$3.85$20.95$-$-$-$-$-$-$20.95$135.37$43.46$ 121.81$300.63$7.63$ 18.81$ 18.08$7.84$52.36$0.98$353.97$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Exhaust, Page: 29 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100112 Exhaust Subsystem101 Exhaust Manifold204Collector Pipes305 Catalysts406 Particle Filters507 Silencers (Mufflers)608 Oxygen Sensors765 Adapters870 Pipes, Hoses: Low Pressure, High Pressure975 Brackets1080 Bolting1185 Sealing Elements1290 Bearing Elements1395 Tools1499 Miscellaneous1500 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D23.52$(2.79)$(7.24)$13.49$3.55$1.10$1.02$0.42$6.09$(0.06)$19.53$(6.16)$(2.05)$(5.47)$(13.68)$(0.07)$(0.89)$(0.82)$(0.34)$(2.12)$-$(15.80)$(1.25)$(0.25)$(1.00)$(2.50)$0.11$(0.15)$(0.14)$(0.06)$(0.25)$(0.20)$(2.95)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(11.62)$(2.32)$(9.30)$(23.25)$(0.16)$(1.63)$(1.86)$(0.93)$(4.58)$(0.10)$(27.93)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.21$0.24$0.97$2.42$0.01$0.16$0.15$0.06$0.38$0.03$2.83$-$-$-$-$-$-$-$-$-$-$-$(1.19)$(0.24)$(0.96)$(2.39)$(0.01)$(0.16)$(0.14)$(0.06)$(0.37)$(0.06)$(2.82)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$4.72$(4.21)$(0.67)$(0.16)$-$-$-$-$-$-$(0.16)$9.22$(11.62)$ (23.67)$(26.06)$3.43$(1.57)$ (1.80)$ (0.91)$(0.85)$(0.39)$(27.30)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Exhaust, Page: 30 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0113 Lubrication Subsystem101 Oil Pans (Oil Sump)2.31$1.13$1.72$5.15$0.03$0.33$0.31$0.13$0.80$0.09$6.04$202 Oil Pumps-$-$-$-$-$-$-$-$-$-$-$305 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$406 Oil Filter2.93$2.23$4.61$9.77$0.09$1.35$1.14$0.36$2.94$0.16$12.87$565 Adapter for Oil Filters-$-$-$-$-$-$-$-$-$-$-$670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.1.69$1.61$3.79$7.09$0.02$0.47$0.31$-$0.81$0.08$7.98$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Boltings & Clamps-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements: Oil Pan Gasket,...-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous3.75$-$-$3.75$-$-$-$-$-$-$3.75$1300 Engine & Vehicle Assembly1.23$1.46$2.63$5.32$-$-$-$-$-$-$5.32$11.91$6.43$ 12.74$31.08$0.14$ 2.15$ 1.76$ 0.49$4.55$0.33$35.96$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Lubrication, Page: 31 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100113 Lubrication Subsystem101 Oil Pans (Oil Sump)202Oil Pumps305 Pressure Regulators406 Oil Filter565 Adapter for Oil Filters670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.775 Brackets880 Boltings & Clamps985 Sealing Elements: Oil Pan Gasket,...1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D13.53$2.87$ 18.14$34.54$0.18$2.35$2.14$0.87$5.54$0.32$40.39$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.24$-$-$1.24$-$-$-$-$-$-$1.24$14.77$2.87$ 18.14$35.77$0.18$ 2.35$ 2.14$ 0.87$5.54$0.32$41.63$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Lubrication, Page: 32 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100113 Lubrication Subsystem101 Oil Pans (Oil Sump)202Oil Pumps305 Pressure Regulators406 Oil Filter565 Adapter for Oil Filters670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.775 Brackets880 Boltings & Clamps985 Sealing Elements: Oil Pan Gasket,...1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(11.23)$(1.74)$ (16.42)$(29.38)$(0.15)$(2.01)$(1.83)$(0.74)$(4.74)$(0.23)$(34.35)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$2.93$2.23$4.61$9.77$0.09$1.35$1.14$0.36$2.94$0.16$12.87$-$-$-$-$-$-$-$-$-$-$-$1.69$1.61$3.79$7.09$0.02$0.47$0.31$-$0.81$0.08$7.98$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.75$-$-$3.75$-$-$-$-$-$-$3.75$(0.00)$1.46$2.63$4.08$-$-$-$-$-$-$4.08$(2.86)$3.56$(5.40)$(4.69)$ (0.04)$ (0.20)$ (0.38)$ (0.38)$(0.99)$0.02$(5.66)$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Lubrication, Page: 33 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0114 Cooling Subsystem101 Water Pumps15.15$1.78$3.51$20.43$0.19$1.88$2.14$1.06$5.26$0.06$25.76$202 Thermostat Housing-$-$-$-$-$-$-$-$-$-$-$304 Heat Exchangers-$-$-$-$-$-$-$-$-$-$-$405 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$506 Expansion Tanks-$-$-$-$-$-$-$-$-$-$-$665 Adapters-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting2.60$2.57$3.54$8.71$0.02$0.52$0.35$-$0.89$0.04$9.64$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings & Clamps-$-$-$-$-$-$-$-$-$-$-$1085 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1295 Tools-$-$-$-$-$-$-$-$-$-$-$1399 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1400 Engine and Vehicle Assembly0.74$1.94$3.50$6.19$-$-$-$-$-$-$6.19$18.49$6.29$ 10.55$35.33$0.20$ 2.40$ 2.48$ 1.06$6.15$0.11$41.59$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Cooling, Page: 34 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100114 Cooling Subsystem101 Water Pumps202Thermostat Housing304 Heat Exchangers405 Pressure Regulators506 Expansion Tanks665 Adapters770 Pipes, Hoses, Ducting875 Brackets980 Boltings & Clamps1085 Sealing Elements1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cooling, Page: 35 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100114 Cooling Subsystem101 Water Pumps202Thermostat Housing304 Heat Exchangers405 Pressure Regulators506 Expansion Tanks665 Adapters770 Pipes, Hoses, Ducting875 Brackets980 Boltings & Clamps1085 Sealing Elements1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D15.15$1.78$3.51$20.43$0.19$1.88$2.14$1.06$5.26$0.06$25.76$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$2.60$2.57$3.54$8.71$0.02$0.52$0.35$-$0.89$0.04$9.64$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.74$1.94$3.50$6.19$-$-$-$-$-$-$6.19$18.49$6.29$ 10.55$35.33$0.20$ 2.40$ 2.48$ 1.06$6.15$0.11$41.59$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Cooling, Page: 36 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)53.92$29.21$39.70$122.82$7.08$ 16.00$17.15$6.73$46.96$0.12$169.89$205 Heat Exchanger8.16$3.36$6.65$18.17$0.09$1.09$1.09$0.36$2.63$0.11$20.92$370 Pipes, Hoses, Ducting27.60$9.09$ 11.44$48.14$0.14$2.89$1.93$0.48$5.44$0.35$53.93$475 Brackets1.07$0.15$0.39$1.61$0.00$0.10$0.06$-$0.17$0.06$1.83$580 Boltings, Clamps, Misc Fastening-$-$-$-$-$-$-$-$-$-$-$699 Miscellaneous6.27$0.34$0.48$7.09$0.04$0.54$0.48$0.18$1.24$0.13$8.45$700 Engine & Vehicle Assembly1.14$9.81$ 14.72$25.67$-$-$-$-$-$-$25.67$98.15$ 51.97$ 73.38$223.50$7.36$ 20.61$ 20.71$7.75$56.44$0.76$280.70$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Induct. Air Charging, Page: 37 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)205Heat Exchanger370 Pipes, Hoses, Ducting475 Brackets580 Boltings, Clamps, Misc Fastening699 Miscellaneous700 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Induct. Air Charging, Page: 38 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)205Heat Exchanger370 Pipes, Hoses, Ducting475 Brackets580 Boltings, Clamps, Misc Fastening699 Miscellaneous700 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D53.92$29.21$39.70$122.82$7.08$ 16.00$17.15$6.73$46.96$0.12$169.89$8.16$3.36$6.65$18.17$0.09$1.09$1.09$0.36$2.63$0.11$20.92$27.60$9.09$ 11.44$48.14$0.14$2.89$1.93$0.48$5.44$0.35$53.93$1.07$0.15$0.39$1.61$0.00$0.10$0.06$-$0.17$0.06$1.83$-$-$-$-$-$-$-$-$-$-$-$6.27$0.34$0.48$7.09$0.04$0.54$0.48$0.18$1.24$0.13$8.45$1.14$9.81$ 14.72$25.67$-$-$-$-$-$-$25.67$98.15$ 51.97$ 73.38$223.50$7.36$ 20.61$ 20.71$7.75$56.44$0.76$280.70$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Induct. Air Charging, Page: 39 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0117 Breather Subsystem102 Oil/Air Separator7.10$1.42$5.68$14.19$0.05$0.96$0.64$0.16$1.81$0.05$16.05$203 Valves-$-$-$-$-$-$-$-$-$-$-$365 Adapters-$-$-$-$-$-$-$-$-$-$-$470 Pipes, Hoses, Ducting2.00$0.40$1.60$3.99$0.01$0.27$0.18$0.05$0.51$-$4.50$575 Brackets-$-$-$-$-$-$-$-$-$-$-$680 Boltings-$-$-$-$-$-$-$-$-$-$-$785 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$890 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$995 Tools-$-$-$-$-$-$-$-$-$-$-$1099 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1100 Engine and Vehicle Assembly0.05$0.60$0.11$0.76$-$-$-$-$-$-$0.76$9.14$ 2.42$ 7.38$18.94$0.06$ 1.23$ 0.82$ 0.21$2.32$0.05$21.31$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Breather, Page: 40 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100117 Breather Subsystem102 Oil/Air Separator203Valves365 Adapters470 Pipes, Hoses, Ducting575 Brackets680 Boltings785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0.67$0.13$0.53$1.33$0.00$0.09$0.06$0.02$0.17$0.02$1.52$-$-$-$-$-$-$-$-$-$-$-$0.50$-$-$0.50$-$-$-$-$-$-$0.50$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.05$0.30$0.05$0.40$-$-$-$-$-$-$0.40$1.21$ 0.43$ 0.59$2.23$0.00$ 0.09$ 0.06$ 0.02$0.17$0.02$2.42$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Breather, Page: 41 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100117 Breather Subsystem102 Oil/Air Separator203Valves365 Adapters470 Pipes, Hoses, Ducting575 Brackets680 Boltings785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D6.43$1.29$5.14$12.86$0.04$0.87$0.58$0.15$1.64$0.03$14.53$-$-$-$-$-$-$-$-$-$-$-$(0.50)$-$-$(0.50)$-$-$-$-$-$-$(0.50)$2.00$0.40$1.60$3.99$0.01$0.27$0.18$0.05$0.51$-$4.50$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.30$0.05$0.36$-$-$-$-$-$-$0.36$7.93$ 1.99$ 6.80$16.71$0.06$ 1.14$ 0.76$ 0.19$2.15$0.03$18.89$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Breather, Page: 42 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0160 Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs2.70$0.54$2.16$5.41$0.03$0.42$0.38$0.16$0.99$-$6.40$202 Engine Management Systems, Engine Electronic Systems16.06$3.21$ 12.85$32.12$0.28$2.80$3.20$1.60$7.88$-$40.00$303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)32.50$17.04$23.06$72.60$0.31$4.89$3.88$1.35$10.43$0.07$83.11$465 Adapters-$-$-$-$-$-$-$-$-$-$-$570 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$675 Brackets-$-$-$-$-$-$-$-$-$-$-$780 Boltings-$-$-$-$-$-$-$-$-$-$-$885 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$990 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1095 Tools-$-$-$-$-$-$-$-$-$-$-$1199 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1200 Engine and Vehicle Assembly0.10$1.20$0.83$2.13$-$-$-$-$-$-$2.13$51.36$ 22.00$ 38.90$112.26$0.62$ 8.11$ 7.47$ 3.11$19.30$0.07$131.64$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Electronic-Electrical, Page: 43 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100160Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs202 Engine Management Systems, Engine Electronic Systems303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Boltings885 Sealing Elements990 Bearing Elements1095 Tools1199 Miscellaneous1200 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D2.54$0.51$2.03$5.07$0.03$0.39$0.36$0.15$0.93$-$6.00$-$-$-$-$-$-$-$-$-$-$-$37.57$19.84$29.87$87.28$0.39$5.95$4.80$1.70$12.84$0.07$100.19$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.10$2.87$0.91$3.88$-$-$-$-$-$-$3.88$40.21$ 23.22$ 32.81$96.24$0.42$ 6.34$ 5.16$ 1.85$13.77$0.07$110.07$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Electronic-Electrical, Page: 44 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100160Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs202 Engine Management Systems, Engine Electronic Systems303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Boltings885 Sealing Elements990 Bearing Elements1095 Tools1199 Miscellaneous1200 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0-$-$ 0.14$0.34$0.00$0.03$0.02$0.01$0.06$-$0.40$0-$-$ 12.85$32.12$0.28$2.80$3.20$1.60$7.88$-$40.00$0-$-$(6.81)$(14.68)$(0.08)$(1.06)$(0.92)$(0.36)$(2.41)$0.01$(17.08)$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$(0.08)$(1.75)$-$-$-$-$-$-$(1.75)$-$-$ 6.09$16.03$0.21$ 1.76$ 2.31$ 1.25$5.53$0.01$21.57$BASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Electronic-Electrical, Page: 45 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0170 Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors-$-$-$-$-$-$-$-$-$-$-$202 Alternators-$-$-$-$-$-$-$-$-$-$-$303 Power Steering Pumps-$-$-$-$-$-$-$-$-$-$-$404 Vacuum Pumps3.31$1.81$6.11$11.24$0.09$1.35$1.10$0.30$2.84$0.09$14.18$505 Air Conditioning Compressors-$-$-$-$-$-$-$-$-$-$-$606 Hydraulic Pumps-$-$-$-$-$-$-$-$-$-$-$707 Ventilator-$-$-$-$-$-$-$-$-$-$-$810 Other Accessories-$-$-$-$-$-$-$-$-$-$-$965 Adapters-$-$-$-$-$-$-$-$-$-$-$1070 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1175 Brackets-$-$-$-$-$-$-$-$-$-$-$1280 Boltings-$-$-$-$-$-$-$-$-$-$-$1385 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1490 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1595 Tools-$-$-$-$-$-$-$-$-$-$-$1699 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1700 Engine & Vehicle Assembly of Accessory Components0.13$0.74$1.34$2.20$-$-$-$-$-$-$2.20$3.44$ 2.55$ 7.45$13.45$0.09$ 1.35$ 1.10$ 0.30$2.84$0.09$16.38$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)File: Subsystem CMAT, CS0102, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.1 Accessory, Page: 46 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100170Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors202 Alternators303 Power Steering Pumps404 Vacuum Pumps505 Air Conditioning Compressors606 Hydraulic Pumps707 Ventilator810 Other Accessories965 Adapters1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Engine & Vehicle Assembly of Accessory ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Accessory, Page: 47 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0102Printed: 3/25/20100170Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors202 Alternators303 Power Steering Pumps404 Vacuum Pumps505 Air Conditioning Compressors606 Hydraulic Pumps707 Ventilator810 Other Accessories965 Adapters1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Engine & Vehicle Assembly of Accessory ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:02-Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0102 ( N0102 New Technology Configuration)( B0102 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.31$1.81$6.11$11.24$0.09$1.35$1.10$0.30$2.84$0.09$14.18$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.13$0.74$1.34$2.20$-$-$-$-$-$-$2.20$3.44$ 2.55$ 7.45$13.45$0.09$ 1.35$ 1.10$ 0.30$2.84$0.09$16.38$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION2.0L I4, DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION3.0LV6, DOHC, NA, PFIFile: Subsystem CMAT, CS0102, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.1 Accessory, Page: 48 of 48Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0103 Crank Drive Subsystem101 Crank Shaft36.62$11.49$38.17$86.29$0.31$3.11$3.56$0.89$7.87$0.14$94.30$202 Flywheels-$-$-$-$-$-$-$-$-$-$-$303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)8.24$9.60$ 24.14$41.99$0.21$2.73$2.52$1.05$6.51$0.11$48.60$404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)8.53$8.48$ 28.47$45.48$1.70$3.02$2.70$1.09$8.50$0.58$54.56$505 Drive for Accessory Drives (Downforce, Flywheel side)-$-$-$-$-$-$-$-$-$-$-$606 Drive for Timing Drive (Downforce, Flywheel side)-$-$-$-$-$-$-$-$-$-$-$765 Adaptors-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings: Connecting-Rod Bolts-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290Bearing Elements: Connecting Rod Bearing Shells, Connecting RodBush-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1500 Engine & Vehicle Assembly17.28$3.61$5.96$26.85$-$-$-$-$-$-$26.85$70.67$ 33.19$ 96.75$200.61$2.22$ 8.86$ 8.78$ 3.02$22.88$0.83$224.31$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Crank Drive, Page: 1 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100103 Crank Drive Subsystem101 Crank Shaft202Flywheels303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)505 Drive for Accessory Drives (Downforce, Flywheel side)606 Drive for Timing Drive (Downforce, Flywheel side)765 Adaptors870 Pipes, Hoses, Ducting975 Brackets1080 Boltings: Connecting-Rod Bolts1185 Sealing Elements1290Bearing Elements: Connecting Rod Bearing Shells, Connecting RodBush1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D42.06$11.69$43.58$97.32$0.36$3.61$4.12$1.03$9.12$0.14$106.59$-$-$-$-$-$-$-$-$-$-$-$10.79$12.80$32.19$55.78$0.28$3.63$3.35$1.39$8.65$0.14$64.57$9.55$10.38$27.53$47.46$0.79$3.08$2.73$1.09$7.69$0.77$55.92$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$13.36$3.61$5.96$22.93$-$-$-$-$-$-$22.93$75.77$ 38.48$ 109.25$223.50$1.43$ 10.32$ 10.20$3.51$25.46$1.06$250.01$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Crank Drive, Page: 2 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100103 Crank Drive Subsystem101 Crank Shaft202Flywheels303 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)404Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins,Circlips)505 Drive for Accessory Drives (Downforce, Flywheel side)606 Drive for Timing Drive (Downforce, Flywheel side)765 Adaptors870 Pipes, Hoses, Ducting975 Brackets1080 Boltings: Connecting-Rod Bolts1185 Sealing Elements1290Bearing Elements: Connecting Rod Bearing Shells, Connecting RodBush1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(5.44)$(0.20)$(5.40)$(11.04)$(0.05)$(0.49)$(0.57)$(0.14)$(1.25)$-$(12.29)$-$-$-$-$-$-$-$-$-$-$-$(2.55)$(3.20)$(8.05)$(13.80)$(0.07)$(0.90)$(0.83)$(0.34)$(2.14)$(0.04)$(15.97)$(1.03)$(1.90)$0.95$(1.98)$0.91$(0.06)$(0.03)$(0.00)$0.81$(0.19)$(1.36)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.92$-$-$3.92$-$-$-$-$-$-$3.92$(5.10)$ (5.29)$ (12.50)$(22.89)$0.79$(1.45)$ (1.43)$ (0.49)$(2.58)$(0.23)$(25.70)$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Crank Drive, Page: 3 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0105 Cylinder Block Subsystem101 Cylinder Block79.42$13.23$ 109.26$201.91$6.98$9.68$ 10.81$2.61$30.08$0.57$232.56$202 Crankshaft Bearing Caps4.21$1.81$6.02$12.04$0.01$0.91$0.84$0.14$1.90$0.12$14.06$303 Bedplates-$-$-$-$-$-$-$-$-$-$-$404 Piston Cooling3.90$0.96$5.42$10.28$0.06$1.30$0.86$-$2.23$0.06$12.56$565 Crankcase Adaptor-$-$-$-$-$-$-$-$-$-$-$666 Water Jacket-$-$-$-$-$-$-$-$-$-$-$767 Cylinder Barrel-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings/Dowel Pins/Plugs/Studs Etc-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290 Bearing Elements: Crankshaft bearing shells-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous4.11$2.16$5.48$11.74$0.06$0.76$0.70$0.29$1.82$0.05$13.61$1500 Engine & Vehicle Assembly13.94$3.61$2.20$19.75$-$-$-$-$-$-$19.75$105.58$21.77$ 128.38$255.72$7.11$ 12.65$ 13.21$3.04$36.02$0.80$292.55$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Block, Page: 4 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100105 Cylinder Block Subsystem101 Cylinder Block202 Crankshaft Bearing Caps303 Bedplates404 Piston Cooling565 Crankcase Adaptor666 Water Jacket767 Cylinder Barrel870 Pipes, Hoses, Ducting975 Brackets1080 Boltings/Dowel Pins/Plugs/Studs Etc1185 Sealing Elements1290 Bearing Elements: Crankshaft bearing shells1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D71.51$13.88$ 150.31$235.70$7.03$9.84$ 11.25$2.81$30.93$1.29$267.92$4.21$1.81$6.02$12.04$0.01$0.91$0.84$0.14$1.90$0.12$14.06$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$5.41$2.37$5.80$13.58$0.07$0.88$0.81$0.34$2.10$0.05$15.73$14.89$1.81$2.38$19.08$-$-$-$-$-$-$19.08$96.03$ 19.85$ 164.51$280.40$7.10$ 11.63$ 12.90$3.29$34.93$1.46$316.79$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Block, Page: 5 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100105 Cylinder Block Subsystem101 Cylinder Block202 Crankshaft Bearing Caps303 Bedplates404 Piston Cooling565 Crankcase Adaptor666 Water Jacket767 Cylinder Barrel870 Pipes, Hoses, Ducting975 Brackets1080 Boltings/Dowel Pins/Plugs/Studs Etc1185 Sealing Elements1290 Bearing Elements: Crankshaft bearing shells1395 Tools1499 Miscellaneous1500 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D7.91$(0.65)$ (41.05)$(33.79)$(0.05)$(0.16)$(0.44)$(0.20)$(0.85)$(0.72)$(35.36)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.90$0.96$5.42$10.28$0.06$1.30$0.86$-$2.23$0.06$12.56$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(1.31)$(0.21)$(0.32)$(1.83)$(0.01)$(0.12)$(0.11)$(0.05)$(0.28)$0.00$(2.12)$(0.95)$1.81$(0.18)$0.67$-$-$-$-$-$-$0.67$9.55$ 1.91$(36.13)$(24.67)$0.01$ 1.02$ 0.31$(0.25)$1.09$(0.66)$(24.24)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Block, Page: 6 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0106 Cylinder Head Subsystem101 Cylinder Head96.49$23.78$ 170.58$290.85$7.16$ 10.02$11.45$2.86$31.50$0.54$322.89$202 Valve Guides. Valve Seats-$-$-$-$-$-$-$-$-$-$-$303 Guides for Valve Train-$-$-$-$-$-$-$-$-$-$-$406 Camshaft Bearing Housing-$-$-$-$-$-$-$-$-$-$-$507 Cam Shaft Speed Sensor-$-$-$-$-$-$-$-$-$-$-$608 Camshaft Carrier-$-$-$-$-$-$-$-$-$-$-$709 Other Parts for Cylinder Head-$-$-$-$-$-$-$-$-$-$-$820 Cylinder Head Covers23.17$4.08$ 14.48$41.73$0.21$2.71$2.50$1.04$6.47$0.32$48.51$965 Adapter-$-$-$-$-$-$-$-$-$-$-$1070 Pipes-$-$-$-$-$-$-$-$-$-$-$1175 Brackets-$-$-$-$-$-$-$-$-$-$-$1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold-$-$-$-$-$-$-$-$-$-$-$1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....-$-$-$-$-$-$-$-$-$-$-$1490 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1595 Tools-$-$-$-$-$-$-$-$-$-$-$1699 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1700 Vehicle and Engine Assembly48.16$4.21$ 19.36$71.73$-$-$-$-$-$-$71.73$167.82$32.07$ 204.42$404.31$7.37$ 12.73$ 13.96$3.91$37.96$0.86$443.13$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Head, Page: 7 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100106 Cylinder Head Subsystem101 Cylinder Head202Valve Guides. Valve Seats303 Guides for Valve Train406 Camshaft Bearing Housing507 Cam Shaft Speed Sensor608 Camshaft Carrier709 Other Parts for Cylinder Head820 Cylinder Head Covers965 Adapter1070 Pipes1175 Brackets1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Vehicle and Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D105.91$23.24$ 160.50$289.66$7.81$ 10.93$12.49$3.12$34.35$0.54$324.54$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$25.94$3.47$ 14.22$43.62$0.23$2.98$2.75$1.15$7.11$0.33$51.06$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$38.46$3.61$ 19.25$61.32$-$-$-$-$-$-$61.32$170.31$30.32$ 193.96$394.60$8.04$ 13.91$ 15.24$4.27$41.46$0.86$436.92$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Head, Page: 8 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100106 Cylinder Head Subsystem101 Cylinder Head202Valve Guides. Valve Seats303 Guides for Valve Train406 Camshaft Bearing Housing507 Cam Shaft Speed Sensor608 Camshaft Carrier709 Other Parts for Cylinder Head820 Cylinder Head Covers965 Adapter1070 Pipes1175 Brackets1280 Boltings: Cylinder Head, Cylinder Head Cover, Manifold1385 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Vehicle and Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(9.42)$0.53$ 10.08$1.19$(0.65)$(0.91)$(1.04)$(0.26)$(2.85)$-$(1.66)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(2.77)$0.61$0.26$(1.90)$(0.02)$(0.27)$(0.25)$(0.10)$(0.64)$(0.01)$(2.55)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$9.70$0.60$0.11$10.41$-$-$-$-$-$-$10.41$(2.50)$1.75$ 10.46$9.71$(0.67)$ (1.18)$ (1.29)$ (0.36)$(3.50)$(0.01)$6.21$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cylinder Head, Page: 9 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0107 Valvetrain Subsystem101 Intake Valves13.80$-$-$13.80$-$-$-$-$-$-$13.80$202 Exhaust Valves39.00$-$-$39.00$-$-$-$-$-$-$39.00$303 Valve Springs7.20$-$-$7.20$-$-$-$-$-$-$7.20$404 Spring Retainers & Keepers, Spring Seats-$-$-$-$-$-$-$-$-$-$-$505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...19.20$-$-$19.20$-$-$-$-$-$-$19.20$606 Camshafts9.18$8.50$ 31.52$49.20$2.51$5.15$4.75$1.61$14.02$0.16$63.38$708 Camshaft Phaser and/or Cam Sprockets25.31$10.85$36.15$72.30$0.36$4.70$4.34$1.81$11.21$0.20$83.71$865 Adapters-$-$-$-$-$-$-$-$-$-$-$970 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1075 Brackets-$-$-$-$-$-$-$-$-$-$-$1180 Boltings0.60$-$-$0.60$-$-$-$-$-$-$0.60$1285 Sealings: e.g. Valve-stem, Seals-$-$-$-$-$-$-$-$-$-$-$1390 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1495 Tools-$-$-$-$-$-$-$-$-$-$-$1599 Miscellaneous7.94$4.76$ 19.05$31.75$0.22$2.22$2.54$1.27$6.25$0.16$38.16$1600 Engine and Vehicle Assembly-$ 7.22$ 25.73$32.95$-$-$-$-$-$-$32.95$122.22$31.33$ 112.44$265.99$3.09$ 12.07$ 11.63$4.69$31.48$0.52$297.99$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Valvetrain, Page: 10 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100107 Valvetrain Subsystem101 Intake Valves202Exhaust Valves303 Valve Springs404 Spring Retainers & Keepers, Spring Seats505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...606 Camshafts708 Camshaft Phaser and/or Cam Sprockets865 Adapters970 Pipes, Hoses, Ducting1075 Brackets1180 Boltings1285 Sealings: e.g. Valve-stem, Seals1390 Bearing Elements1495 Tools1599 Miscellaneous1600 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D17.14$-$-$17.14$-$-$-$-$-$-$17.14$25.64$-$-$25.64$-$-$-$-$-$-$25.64$9.94$-$-$9.94$-$-$-$-$-$-$9.94$-$-$-$-$-$-$-$-$-$-$-$108.00$-$-$108.00$-$-$-$-$-$-$108.00$6.10$6.16$ 28.74$41.00$0.34$4.42$4.08$1.34$10.18$0.09$51.27$12.58$5.39$ 17.97$35.94$0.18$2.34$2.16$0.90$5.57$0.10$41.61$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.30$-$-$0.30$-$-$-$-$-$-$0.30$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.97$2.38$9.52$15.87$0.11$1.11$1.27$0.63$3.13$0.08$19.08$-$4.81$ 14.08$18.90$-$-$-$-$-$-$18.90$183.67$18.74$ 70.32$272.73$0.63$ 7.87$ 7.50$ 2.88$18.88$0.27$291.87$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Valvetrain, Page: 11 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100107 Valvetrain Subsystem101 Intake Valves202Exhaust Valves303 Valve Springs404 Spring Retainers & Keepers, Spring Seats505Valve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...606 Camshafts708 Camshaft Phaser and/or Cam Sprockets865 Adapters970 Pipes, Hoses, Ducting1075 Brackets1180 Boltings1285 Sealings: e.g. Valve-stem, Seals1390 Bearing Elements1495 Tools1599 Miscellaneous1600 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(3.34)$-$-$(3.34)$-$-$-$-$-$-$(3.34)$13.36$-$-$13.36$-$-$-$-$-$-$13.36$(2.74)$-$-$(2.74)$-$-$-$-$-$-$(2.74)$-$-$-$-$-$-$-$-$-$-$-$(88.80)$-$-$(88.80)$-$-$-$-$-$-$(88.80)$3.08$2.34$2.78$8.20$2.17$0.73$0.67$0.27$3.83$0.08$12.11$12.73$5.45$ 18.18$36.36$0.18$2.36$2.18$0.91$5.64$0.10$42.10$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.30$-$-$0.30$-$-$-$-$-$-$0.30$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.97$2.38$9.52$15.87$0.11$1.11$1.27$0.63$3.13$0.08$19.08$-$2.41$ 11.65$14.05$-$-$-$-$-$-$14.05$(61.45)$12.59$ 42.13$(6.74)$2.46$ 4.20$ 4.12$ 1.81$12.60$0.26$6.12$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Valvetrain, Page: 12 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0108 Timing Drive Subsystem101 Timing Wheels (Sprockets)3.50$-$-$3.50$-$-$-$-$-$-$3.50$202 Tensioners-$-$-$-$-$-$-$-$-$-$-$303 Guides-$-$-$-$-$-$-$-$-$-$-$405 Belts, Chains14.00$-$-$14.00$-$-$-$-$-$-$14.00$506 Covers8.59$3.91$9.59$22.09$0.58$1.36$0.90$0.23$3.07$0.38$25.54$665 Adaptors-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings-$-$-$-$-$-$-$-$-$-$-$1085 Sealings-$-$-$-$-$-$-$-$-$-$-$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1295 Tools-$-$-$-$-$-$-$-$-$-$-$1399 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1400 Engine Assembly3.41$1.81$1.81$7.02$-$-$-$-$-$-$7.02$29.50$5.72$ 11.39$46.61$0.58$ 1.36$ 0.90$ 0.23$3.07$0.38$50.06$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Timing Drives, Page: 13 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100108 Timing Drive Subsystem101 Timing Wheels (Sprockets)202Tensioners303 Guides405 Belts, Chains506 Covers665 Adaptors770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealings1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D5.00$-$-$5.00$-$-$-$-$-$-$5.00$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$24.00$-$-$24.00$-$-$-$-$-$-$24.00$10.61$3.91$9.59$24.11$0.69$1.48$0.99$0.25$3.41$0.38$27.90$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.99$1.81$1.81$4.60$-$-$-$-$-$-$4.60$40.60$5.72$ 11.39$57.71$0.69$ 1.48$ 0.99$ 0.25$3.41$0.38$61.50$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Timing Drives, Page: 14 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100108 Timing Drive Subsystem101 Timing Wheels (Sprockets)202Tensioners303 Guides405 Belts, Chains506 Covers665 Adaptors770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealings1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(1.50)$-$-$(1.50)$-$-$-$-$-$-$(1.50)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(10.00)$-$-$(10.00)$-$-$-$-$-$-$(10.00)$(2.02)$-$-$(2.02)$(0.11)$(0.13)$(0.08)$(0.02)$(0.34)$-$(2.36)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$2.42$-$-$2.42$-$-$-$-$-$-$2.42$(11.10)$-$ -$(11.10)$(0.11)$ (0.13)$ (0.08)$ (0.02)$(0.34)$-$(11.44)$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Timing Drives, Page: 15 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0109 Accessory Drive Subsystem101 Pulleys33.00$-$-$33.00$-$-$-$-$-$-$33.00$202 Tensioners-$-$-$-$-$-$-$-$-$-$-$303 Guides-$-$-$-$-$-$-$-$-$-$-$405 Belts-$-$-$-$-$-$-$-$-$-$-$565 Adaptors-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$785 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$890 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$995 Tools-$-$-$-$-$-$-$-$-$-$-$1099 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1100 Engine & Vehicle Assembly-$-$-$-$-$-$-$-$-$-$-$33.00$-$ -$33.00$-$ -$ -$ -$-$-$33.00$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Accessory Drives, Page: 16 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100109 Accessory Drive Subsystem101 Pulleys202 Tensioners303 Guides405 Belts565 Adaptors670 Pipes, Hoses, Ducting785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D22.00$-$-$22.00$-$-$-$-$-$-$22.00$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$22.00$-$ -$22.00$-$ -$ -$ -$-$-$22.00$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Accessory Drives, Page: 17 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100109 Accessory Drive Subsystem101 Pulleys202 Tensioners303 Guides405 Belts565 Adaptors670 Pipes, Hoses, Ducting785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D11.00$-$-$11.00$-$-$-$-$-$-$11.00$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$11.00$-$ -$11.00$-$ -$ -$ -$-$-$11.00$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Accessory Drives, Page: 18 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0110 Intake Subsystem101 Intake Manifolds16.69$2.23$4.56$23.47$0.16$1.64$1.88$0.47$4.15$1.10$28.72$202 Air Filter Box-$-$-$-$-$-$-$-$-$-$-$303 Air Filters-$-$-$-$-$-$-$-$-$-$-$405 Throttle Housing Assembly; including Supplies39.00$-$-$39.00$-$-$-$-$-$0.02$39.02$565 Adapters: Flanges for Port Shut-off-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Bolting & Clamps-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Engine and Vehicle Assembly0.80$1.55$1.10$3.45$-$-$-$-$-$-$3.45$56.49$3.78$ 5.66$65.93$0.16$ 1.64$ 1.88$ 0.47$4.15$1.11$71.20$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Intake, Page: 19 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100110 Intake Subsystem101 Intake Manifolds202Air Filter Box303 Air Filters405 Throttle Housing Assembly; including Supplies565 Adapters: Flanges for Port Shut-off670 Pipes, Hoses, Ducting775 Brackets880 Bolting & Clamps985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D32.46$3.02$6.38$41.86$0.29$2.93$3.35$0.84$7.41$1.10$50.37$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$39.00$-$-$39.00$-$-$-$-$-$0.02$39.02$-$-$-$-$-$-$-$-$-$-$-$3.59$1.56$2.86$8.02$0.06$0.56$0.64$0.16$1.42$0.03$9.47$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.00$1.90$1.38$4.28$-$-$-$-$-$-$4.28$76.05$6.48$ 10.63$93.16$0.35$ 3.49$ 3.99$ 1.00$8.83$1.15$103.13$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Intake, Page: 20 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100110 Intake Subsystem101 Intake Manifolds202Air Filter Box303 Air Filters405 Throttle Housing Assembly; including Supplies565 Adapters: Flanges for Port Shut-off670 Pipes, Hoses, Ducting775 Brackets880 Bolting & Clamps985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(15.78)$(0.79)$(1.82)$(18.39)$(0.13)$(1.29)$(1.47)$(0.37)$(3.26)$-$(21.65)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(3.59)$(1.56)$(2.86)$(8.02)$(0.06)$(0.56)$(0.64)$(0.16)$(1.42)$(0.03)$(9.47)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.20)$(0.35)$(0.28)$(0.82)$-$-$-$-$-$-$(0.82)$(19.57)$(2.70)$ (4.96)$(27.23)$(0.18)$ (1.85)$ (2.11)$ (0.53)$(4.67)$(0.03)$(31.94)$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Intake, Page: 21 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0111 Fuel Induction Subsystem101 Fuel Rails16.03$3.07$7.01$26.11$0.08$1.57$1.04$0.26$2.95$0.16$29.21$204 Fuel Injectors13.13$8.83$ 35.83$57.79$0.62$6.70$7.15$2.86$17.33$0.08$75.20$306 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$407 Fuel Injection Pumps21.23$10.01$31.19$62.43$0.85$7.34$7.47$2.89$18.55$0.14$81.12$565 Adaptors-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses: Low Pressure, High Pressure0.94$0.69$1.69$3.32$0.01$0.20$0.13$0.03$0.36$0.02$3.69$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Bolting-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Engine Assembly0.75$3.22$3.37$7.34$-$-$-$-$-$-$7.34$52.08$ 25.81$ 79.08$156.98$1.55$ 15.81$ 15.79$6.05$39.19$0.39$196.56$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Fuel Induction, Page: 22 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100111 Fuel Induction Subsystem101 Fuel Rails204Fuel Injectors306 Pressure Regulators407 Fuel Injection Pumps565 Adaptors670 Pipes, Hoses: Low Pressure, High Pressure775 Brackets880 Bolting985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D2.54$2.45$3.61$8.61$0.03$0.52$0.34$0.09$0.97$0.08$9.66$8.26$7.63$ 32.14$48.03$0.42$4.51$4.87$2.12$11.92$0.10$60.05$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.24$1.20$0.83$2.27$-$-$-$-$-$-$2.27$11.04$ 11.29$ 36.58$58.92$0.45$ 5.03$ 5.21$ 2.20$12.89$0.18$71.99$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Fuel Induction, Page: 23 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100111 Fuel Induction Subsystem101 Fuel Rails204Fuel Injectors306 Pressure Regulators407 Fuel Injection Pumps565 Adaptors670 Pipes, Hoses: Low Pressure, High Pressure775 Brackets880 Bolting985 Sealing Elements1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D13.49$0.62$3.39$17.50$0.05$1.05$0.70$0.17$1.98$0.07$19.55$4.87$1.19$3.69$9.76$0.20$2.19$2.28$0.75$5.41$(0.02)$15.15$-$-$-$-$-$-$-$-$-$-$-$21.23$10.01$31.19$62.43$0.85$7.34$7.47$2.89$18.55$0.14$81.12$-$-$-$-$-$-$-$-$-$-$-$0.94$0.69$1.69$3.32$0.01$0.20$0.13$0.03$0.36$0.02$3.69$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.51$2.01$2.54$5.06$-$-$-$-$-$-$5.06$41.04$ 14.52$ 42.50$98.06$1.11$ 10.78$ 10.58$3.85$26.30$0.21$124.57$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Fuel Induction, Page: 24 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0112 Exhaust Subsystem101 Exhaust Manifold64.58$2.98$ 12.45$80.01$3.95$5.84$6.67$3.34$19.79$0.23$100.04$204 Collector Pipes305Catalysts406 Particle Filters-$-$-$-$-$-$-$-$-$-$-$507 Silencers (Mufflers)-$-$-$-$-$-$-$-$-$-$-$608 Oxygen Sensors765Adapters-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses: Low Pressure, High Pressure-$-$-$-$-$-$-$-$-$-$-$975 Brackets1080 Bolting-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements2.45$0.49$1.96$4.90$0.02$0.32$0.29$0.05$0.69$0.06$5.65$1290 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1395 Tools-$-$-$-$-$-$-$-$-$-$-$1499 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1500 Engine and Vehicle Assembly9.92$-$-$9.92$-$-$-$-$-$-$9.92$76.95$3.47$ 14.41$94.83$3.98$ 6.16$ 6.96$ 3.38$20.48$0.29$115.60$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Exhaust, Page: 25 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100112 Exhaust Subsystem101 Exhaust Manifold204Collector Pipes305 Catalysts406 Particle Filters507 Silencers (Mufflers)608 Oxygen Sensors765 Adapters870 Pipes, Hoses: Low Pressure, High Pressure975 Brackets1080 Bolting1185 Sealing Elements1290 Bearing Elements1395 Tools1499 Miscellaneous1500 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D16.77$2.53$ 12.66$31.96$1.17$2.14$1.98$0.82$6.11$0.29$38.36$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.19$0.24$0.96$2.39$0.01$0.16$0.14$0.06$0.37$0.06$2.82$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$4.00$-$-$4.00$-$-$-$-$-$-$4.00$21.97$2.77$ 13.61$38.35$1.18$ 2.30$ 2.12$ 0.88$6.48$0.35$45.18$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Exhaust, Page: 26 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100112 Exhaust Subsystem101 Exhaust Manifold204Collector Pipes305 Catalysts406 Particle Filters507 Silencers (Mufflers)608 Oxygen Sensors765 Adapters870 Pipes, Hoses: Low Pressure, High Pressure975 Brackets1080 Bolting1185 Sealing Elements1290 Bearing Elements1395 Tools1499 Miscellaneous1500 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D47.81$0.45$(0.20)$48.06$2.78$3.69$4.69$2.51$13.68$(0.06)$61.68$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.26$0.25$1.00$2.51$0.01$0.16$0.15$(0.01)$0.32$-$2.83$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$5.92$-$-$5.92$-$-$-$-$-$-$5.92$54.98$0.70$ 0.80$56.49$2.80$ 3.86$ 4.84$ 2.50$14.00$(0.06)$70.43$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Exhaust, Page: 27 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0113 Lubrication Subsystem101 Oil Pans (Oil Sump)13.43$2.87$ 18.14$34.44$0.18$2.34$2.14$0.86$5.52$0.32$40.28$202 Oil Pumps-$-$-$-$-$-$-$-$-$-$-$305 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$406 Oil Filter2.94$2.23$4.61$9.78$0.07$1.08$0.90$0.26$2.31$0.16$12.26$565 Adapter for Oil Filters-$-$-$-$-$-$-$-$-$-$-$670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.20.03$3.34$8.04$31.41$0.12$1.59$1.46$0.61$3.78$0.78$35.98$775 Brackets-$-$-$-$-$-$-$-$-$-$-$880 Boltings & Clamps-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements: Oil Pan Gasket,...0.04$0.12$0.17$0.32$0.00$0.02$0.02$0.01$0.05$0.00$0.38$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1195 Tools-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous6.50$-$-$6.50$-$-$-$-$-$-$6.50$1300 Engine & Vehicle Assembly1.30$7.98$8.35$17.63$-$-$-$-$-$-$17.63$44.25$ 16.54$ 39.30$100.09$0.37$ 5.03$ 4.52$ 1.75$11.67$1.26$113.02$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Lubrication, Page: 28 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100113 Lubrication Subsystem101 Oil Pans (Oil Sump)202Oil Pumps305 Pressure Regulators406 Oil Filter565 Adapter for Oil Filters670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.775 Brackets880 Boltings & Clamps985 Sealing Elements: Oil Pan Gasket,...1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D6.77$1.39$6.29$14.45$0.07$0.94$0.87$0.36$2.24$0.18$16.87$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.93$-$-$0.93$-$-$-$-$-$-$0.93$7.70$ 1.39$ 6.29$15.38$0.07$ 0.94$ 0.87$ 0.36$2.24$0.18$17.79$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Lubrication, Page: 29 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100113 Lubrication Subsystem101 Oil Pans (Oil Sump)202Oil Pumps305 Pressure Regulators406 Oil Filter565 Adapter for Oil Filters670Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.775 Brackets880 Boltings & Clamps985 Sealing Elements: Oil Pan Gasket,...1090 Bearing Elements1195 Tools1299 Miscellaneous1300 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D6.67$1.48$ 11.85$19.99$0.11$1.40$1.27$0.50$3.28$0.14$23.41$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$2.94$2.23$4.61$9.78$0.07$1.08$0.90$0.26$2.31$0.16$12.26$-$-$-$-$-$-$-$-$-$-$-$20.03$3.34$8.04$31.41$0.12$1.59$1.46$0.61$3.78$0.78$35.98$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.04$0.12$0.17$0.32$0.00$0.02$0.02$0.01$0.05$0.00$0.38$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$6.50$-$-$6.50$-$-$-$-$-$-$6.50$0.37$7.98$8.35$16.70$-$-$-$-$-$-$16.70$36.55$ 15.16$ 33.00$84.71$0.30$ 4.09$ 3.65$ 1.38$9.43$1.08$95.22$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Lubrication, Page: 30 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0114 Cooling Subsystem101 Water Pumps18.90$2.22$4.37$25.50$0.23$2.33$2.64$1.31$6.51$0.08$32.08$202 Thermostat Housing-$-$-$-$-$-$-$-$-$-$-$304 Heat Exchangers-$-$-$-$-$-$-$-$-$-$-$405 Pressure Regulators-$-$-$-$-$-$-$-$-$-$-$506 Expansion Tanks-$-$-$-$-$-$-$-$-$-$-$665 Adapters-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting4.41$3.38$4.68$12.47$0.02$0.75$0.50$-$1.27$0.10$13.85$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings & Clamps-$-$-$-$-$-$-$-$-$-$-$1085 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1295 Tools-$-$-$-$-$-$-$-$-$-$-$1399 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1400 Engine and Vehicle Assembly1.66$1.94$3.50$7.11$-$-$-$-$-$-$7.11$24.98$7.54$ 12.56$45.08$0.25$ 3.07$ 3.14$ 1.31$7.78$0.18$53.04$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Cooling, Page: 31 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100114 Cooling Subsystem101 Water Pumps202Thermostat Housing304 Heat Exchangers405 Pressure Regulators506 Expansion Tanks665 Adapters770 Pipes, Hoses, Ducting875 Brackets980 Boltings & Clamps1085 Sealing Elements1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cooling, Page: 32 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100114 Cooling Subsystem101 Water Pumps202Thermostat Housing304 Heat Exchangers405 Pressure Regulators506 Expansion Tanks665 Adapters770 Pipes, Hoses, Ducting875 Brackets980 Boltings & Clamps1085 Sealing Elements1190 Bearing Elements1295 Tools1399 Miscellaneous1400 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D18.90$2.22$4.37$25.50$0.23$2.33$2.64$1.31$6.51$0.08$32.08$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$4.41$3.38$4.68$12.47$0.02$0.75$0.50$-$1.27$0.10$13.85$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.66$1.94$3.50$7.11$-$-$-$-$-$-$7.11$24.98$7.54$ 12.56$45.08$0.25$ 3.07$ 3.14$ 1.31$7.78$0.18$53.04$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Cooling, Page: 33 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)103.57$55.54$69.32$228.42$17.30$31.41$34.07$13.46$96.23$5.17$329.82$202 Solenoids-$-$-$-$-$-$-$-$-$-$-$305 Heat Exchanger11.13$3.46$ 10.62$25.21$0.33$3.66$3.89$2.20$10.08$0.33$35.61$407 Pins, Dowels, Plugs and Cups-$-$-$-$-$-$-$-$-$-$-$515 Snap Rings-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting20.02$6.62$ 10.27$36.90$0.18$2.40$2.21$0.42$5.21$0.63$42.75$775 Brackets5.74$0.27$0.32$6.33$0.03$0.41$0.38$0.06$0.89$0.02$7.24$880 Boltings, Clamps, Misc Fastening-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1199 Miscellaneous5.19$-$-$5.19$0.03$0.34$0.31$0.13$0.80$0.02$6.02$1200 Engine & Vehicle Assembly0.97$ 10.55$15.83$27.35$-$-$-$-$-$-$27.35$146.61$76.44$ 106.36$329.41$17.87$ 38.21$ 40.86$ 16.27$113.21$6.17$448.79$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Induct. Air Charging, Page: 34 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)202Solenoids305 Heat Exchanger407 Pins, Dowels, Plugs and Cups515 Snap Rings670 Pipes, Hoses, Ducting775 Brackets880 Boltings, Clamps, Misc Fastening985 Sealing Elements1090 Bearing Elements1199 Miscellaneous1200 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Induct. Air Charging, Page: 35 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100115 Induction Air Charging Subsystem101 Turbo Chargers (Assemblies)202Solenoids305 Heat Exchanger407 Pins, Dowels, Plugs and Cups515 Snap Rings670 Pipes, Hoses, Ducting775 Brackets880 Boltings, Clamps, Misc Fastening985 Sealing Elements1090 Bearing Elements1199 Miscellaneous1200 Engine & Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D103.57$55.54$69.32$228.42$17.30$31.41$34.07$13.46$96.23$5.17$329.82$-$-$-$-$-$-$-$-$-$-$-$11.13$3.46$ 10.62$25.21$0.33$3.66$3.89$2.20$10.08$0.33$35.61$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$20.02$6.62$ 10.27$36.90$0.18$2.40$2.21$0.42$5.21$0.63$42.75$5.74$0.27$0.32$6.33$0.03$0.41$0.38$0.06$0.89$0.02$7.24$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$5.19$-$-$5.19$0.03$0.34$0.31$0.13$0.80$0.02$6.02$0.97$10.55$15.83$27.35$-$-$-$-$-$-$27.35$146.61$76.44$ 106.36$329.41$17.87$ 38.21$ 40.86$ 16.27$113.21$6.17$448.79$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Induct. Air Charging, Page: 36 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0117 Breather Subsystem102 Oil/Air Separator12.42$2.48$9.93$24.84$0.08$1.68$1.12$0.28$3.16$0.05$28.05$203 Valves-$-$-$-$-$-$-$-$-$-$-$365 Adapters-$-$-$-$-$-$-$-$-$-$-$470 Pipes, Hoses, Ducting3.49$0.70$2.79$6.99$0.02$0.47$0.32$0.08$0.89$-$7.88$575 Brackets-$-$-$-$-$-$-$-$-$-$-$680 Boltings-$-$-$-$-$-$-$-$-$-$-$785 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$890 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$995 Tools-$-$-$-$-$-$-$-$-$-$-$1099 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1100 Engine and Vehicle Assembly0.08$1.05$0.19$1.32$-$-$-$-$-$-$1.32$15.99$4.24$ 12.92$33.14$0.11$ 2.15$ 1.44$ 0.36$4.05$0.05$37.25$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Breather, Page: 37 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100117 Breather Subsystem102 Oil/Air Separator203Valves365 Adapters470 Pipes, Hoses, Ducting575 Brackets680 Boltings785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0.67$0.13$0.53$1.33$0.00$0.09$0.06$0.02$0.17$0.02$1.52$-$-$-$-$-$-$-$-$-$-$-$0.50$-$-$0.50$-$-$-$-$-$-$0.50$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.05$0.30$0.05$0.40$-$-$-$-$-$-$0.40$1.21$ 0.43$ 0.59$2.23$0.00$ 0.09$ 0.06$ 0.02$0.17$0.02$2.42$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Breather, Page: 38 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100117 Breather Subsystem102 Oil/Air Separator203Valves365 Adapters470 Pipes, Hoses, Ducting575 Brackets680 Boltings785 Sealing Elements890 Bearing Elements995 Tools1099 Miscellaneous1100 Engine and Vehicle AssemblySYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D11.75$2.35$9.40$23.51$0.08$1.59$1.06$0.27$2.99$0.03$26.53$-$-$-$-$-$-$-$-$-$-$-$(0.50)$-$-$(0.50)$-$-$-$-$-$-$(0.50)$3.49$0.70$2.79$6.99$0.02$0.47$0.32$0.08$0.89$-$7.88$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.03$0.75$0.14$0.92$-$-$-$-$-$-$0.92$14.78$3.80$ 12.33$30.91$0.10$ 2.06$ 1.38$ 0.34$3.88$0.03$34.83$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Breather, Page: 39 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0160 Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs4.06$0.81$3.24$8.11$0.05$0.62$0.58$0.24$1.49$-$9.60$202 Engine Management Systems, Engine Electronic Systems24.09$4.82$ 19.27$48.18$0.42$4.20$4.80$2.40$11.82$-$60.00$303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)46.95$24.66$34.29$105.90$0.46$7.16$5.71$1.99$15.31$0.11$121.32$465 Adapters-$-$-$-$-$-$-$-$-$-$-$570 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$675 Brackets-$-$-$-$-$-$-$-$-$-$-$780 Boltings-$-$-$-$-$-$-$-$-$-$-$885 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$990 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1095 Tools-$-$-$-$-$-$-$-$-$-$-$1199 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1200 Engine and Vehicle Assembly0.10$2.41$1.25$3.75$-$-$-$-$-$-$3.75$75.20$ 32.70$ 58.06$165.95$0.92$ 11.98$ 11.08$4.63$28.61$0.11$194.68$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Electronic-Electrical, Page: 40 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100160Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs202 Engine Management Systems, Engine Electronic Systems303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Boltings885 Sealing Elements990 Bearing Elements1095 Tools1199 Miscellaneous1200 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D4.00$0.80$3.20$8.00$0.04$0.52$0.48$0.20$1.24$-$9.24$-$-$-$-$-$-$-$-$-$-$-$38.39$20.61$37.88$96.88$0.46$6.77$5.62$2.07$14.92$0.15$111.95$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.10$2.41$0.83$3.34$-$-$-$-$-$-$3.34$42.49$ 23.81$ 41.91$108.22$0.50$ 7.29$ 6.10$ 2.27$16.16$0.15$124.52$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Electronic-Electrical, Page: 41 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100160Engine Management, Engine Electronic, and Electrical Subsystems101 Spark Plugs, Glow Plugs202 Engine Management Systems, Engine Electronic Systems303Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)465 Adapters570 Pipes, Hoses, Ducting675 Brackets780 Boltings885 Sealing Elements990 Bearing Elements1095 Tools1199 Miscellaneous1200 Engine and Vehicle AssemblySUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0-$-$ 0.04$0.11$0.01$0.10$0.10$0.04$0.25$-$0.36$0-$-$ 19.27$48.18$0.42$4.20$4.80$2.40$11.82$-$60.00$0-$-$(3.58)$9.03$0.00$0.39$0.08$(0.09)$0.39$(0.04)$9.38$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$-$-$-$-$-$-$-$-$-$0-$-$ 0.42$0.42$-$-$-$-$-$-$0.42$-$-$ 16.15$57.73$0.43$ 4.69$ 4.98$ 2.35$12.46$(0.04)$70.15$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Electronic-Electrical, Page: 42 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0170 Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors-$-$-$-$-$-$-$-$-$-$-$202 Alternators-$-$-$-$-$-$-$-$-$-$-$303 Power Steering Pumps-$-$-$-$-$-$-$-$-$-$-$404 Vacuum Pumps3.98$2.18$7.34$13.49$0.11$1.62$1.32$0.37$3.41$0.11$17.01$505 Air Conditioning Compressors-$-$-$-$-$-$-$-$-$-$-$606 Hydraulic Pumps-$-$-$-$-$-$-$-$-$-$-$707 Ventilator-$-$-$-$-$-$-$-$-$-$-$810 Other Accessories-$-$-$-$-$-$-$-$-$-$-$965 Adapters-$-$-$-$-$-$-$-$-$-$-$1070 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1175 Brackets-$-$-$-$-$-$-$-$-$-$-$1280 Boltings-$-$-$-$-$-$-$-$-$-$-$1385 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1490 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1595 Tools-$-$-$-$-$-$-$-$-$-$-$1699 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1700 Engine & Vehicle Assembly of Accessory Components0.13$0.74$1.34$2.20$-$-$-$-$-$-$2.20$4.11$ 2.92$ 8.67$15.69$0.11$ 1.62$ 1.32$ 0.37$3.41$0.11$19.22$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DITotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.2 Accessory, Page: 43 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100170Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors202 Alternators303 Power Steering Pumps404 Vacuum Pumps505 Air Conditioning Compressors606 Hydraulic Pumps707 Ventilator810 Other Accessories965 Adapters1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Engine & Vehicle Assembly of Accessory ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Accessory, Page: 44 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0104Printed: 3/26/20100170Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)101 Starter Motors202 Alternators303 Power Steering Pumps404 Vacuum Pumps505 Air Conditioning Compressors606 Hydraulic Pumps707 Ventilator810 Other Accessories965 Adapters1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements1595 Tools1699 Miscellaneous1700 Engine & Vehicle Assembly of Accessory ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:04-Small to Midsize Truck, Passenger + Midsize Towing CapabilityStudy Case#:0104 ( N0104 New Technology Configuration)( B0104 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.98$2.18$7.34$13.49$0.11$1.62$1.32$0.37$3.41$0.11$17.01$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.13$0.74$1.34$2.20$-$-$-$-$-$-$2.20$4.11$ 2.92$ 8.67$15.69$0.11$ 1.62$ 1.32$ 0.37$3.41$0.11$19.22$BASE TECHNOLOGY PACKAGE COST INFORMATION5.4LV8, SOHC, NA, PFIINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION3.5L,V6 DOHC, Turbo DIMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0104, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.2 Accessory, Page: 45 of 45Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0202 Case(s) Subsystem101 Transaxle Case-$-$-$-$-$-$-$-$-$-$-$202 Transaxle Housing-$-$-$-$-$-$-$-$-$-$-$303 Covers-$-$-$-$-$-$-$-$-$-$-$404 OPEN-$-$-$-$-$-$-$-$-$-$-$505 OPEN-$-$-$-$-$-$-$-$-$-$-$610 Plugs-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings-$-$-$-$-$-$-$-$-$-$-$1085 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1399 Transmission Assembly of Case Componments-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.3 Cases, Page: 1 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100202 Case(s) Subsystem101 Transaxle Case202 Transaxle Housing303 Covers404 OPEN505 OPEN610 Plugs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1399 Transmission Assembly of Case ComponmentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0.83$0.53$4.68$6.03$-$-$-$-$-$-$6.03$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.83$ 0.53$ 4.68$6.03$-$ -$ -$ -$-$-$6.03$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Cases, Page: 2 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100202 Case(s) Subsystem101 Transaxle Case202 Transaxle Housing303 Covers404 OPEN505 OPEN610 Plugs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1399 Transmission Assembly of Case ComponmentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(0.83)$(0.53)$(4.68)$(6.03)$-$-$-$-$-$-$(6.03)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.83)$ (0.53)$ (4.68)$(6.03)$-$ -$ -$ -$-$-$(6.03)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Cases, Page: 3 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0203 Geartrain Subsystem101 Sun Gears-$-$-$-$-$-$-$-$-$-$-$202 Planetary Gears-$-$-$-$-$-$-$-$-$-$-$303 Ring Gears-$-$-$-$-$-$-$-$-$-$-$404 Counter Gears-$-$-$-$-$-$-$-$-$-$-$505 Differential Gears-$-$-$-$-$-$-$-$-$-$-$610 Gears Misc-$-$-$-$-$-$-$-$-$-$-$715 Snap Rings-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings (Includes Nuts & Washers)-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290 Bearings Elements Misc-$-$-$-$-$-$-$-$-$-$-$1391 Bearing/Bushings-$-$-$-$-$-$-$-$-$-$-$1492 Roller Bearings-$-$-$-$-$-$-$-$-$-$-$1593 Thrust Bearings/Washers-$-$-$-$-$-$-$-$-$-$-$1694 Thrust Roller/Needle Bearings-$-$-$-$-$-$-$-$-$-$-$1700 Transmission Assembly of Gear Componments-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.3 Geartrain, Page: 4 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100203 Geartrain Subsystem101 Sun Gears202 Planetary Gears303 Ring Gears404 Counter Gears505 Differential Gears610 Gears Misc715 Snap Rings870 Pipes, Hoses, Ducting975 Brackets1080 Boltings (Includes Nuts & Washers)1185 Sealing Elements1290 Bearings Elements Misc1391 Bearing/Bushings1492 Roller Bearings1593 Thrust Bearings/Washers1694 Thrust Roller/Needle Bearings1700 Transmission Assembly of Gear ComponmentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.22$3.95$ 11.79$16.96$0.12$1.19$1.36$0.68$3.34$-$20.30$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.61$0.74$1.89$3.23$0.02$0.26$0.29$0.13$0.71$-$3.94$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$1.83$ 4.69$ 13.67$20.19$0.14$ 1.45$ 1.64$ 0.81$4.05$-$24.24$BASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Geartrain, Page: 5 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100203 Geartrain Subsystem101 Sun Gears202 Planetary Gears303 Ring Gears404 Counter Gears505 Differential Gears610 Gears Misc715 Snap Rings870 Pipes, Hoses, Ducting975 Brackets1080 Boltings (Includes Nuts & Washers)1185 Sealing Elements1290 Bearings Elements Misc1391 Bearing/Bushings1492 Roller Bearings1593 Thrust Bearings/Washers1694 Thrust Roller/Needle Bearings1700 Transmission Assembly of Gear ComponmentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(1.22)$(3.95)$ (11.79)$(16.96)$(0.12)$(1.19)$(1.36)$(0.68)$(3.34)$-$(20.30)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.61)$(0.74)$(1.89)$(3.23)$(0.02)$(0.26)$(0.29)$(0.13)$(0.71)$-$(3.94)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(1.83)$ (4.69)$ (13.67)$(20.19)$(0.14)$ (1.45)$ (1.64)$ (0.81)$(4.05)$-$(24.24)$BASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Geartrain, Page: 6 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0204 Internal Clutches Subsystem101 Sprague/One Way Clutches-$-$-$-$-$-$-$-$-$-$-$202 Clutch Assembly-$-$-$-$-$-$-$-$-$-$-$303 Clutch & Brake Hubs-$-$-$-$-$-$-$-$-$-$-$404 Sleeve & Couplers-$-$-$-$-$-$-$-$-$-$-$505 Disc & Plates-$-$-$-$-$-$-$-$-$-$-$609 Pistons-$-$-$-$-$-$-$-$-$-$-$715 Snap Rings-$-$-$-$-$-$-$-$-$-$-$870 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$975 Brackets-$-$-$-$-$-$-$-$-$-$-$1080 Boltings-$-$-$-$-$-$-$-$-$-$-$1185 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1290 Bearing Elements Misc-$-$-$-$-$-$-$-$-$-$-$1391 Bearing/Bushings-$-$-$-$-$-$-$-$-$-$-$1492 Roller Bearings-$-$-$-$-$-$-$-$-$-$-$1593 Thrust Bearings/Washers-$-$-$-$-$-$-$-$-$-$-$1694 Thrust Roller/Needle Bearings-$-$-$-$-$-$-$-$-$-$-$1700 Transmission Assembly of Internal Clutches-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.3 Internal Clutches, Page: 7 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100204 Internal Clutches Subsystem101 Sprague/One Way Clutches202 Clutch Assembly303 Clutch & Brake Hubs404 Sleeve & Couplers505 Disc & Plates609 Pistons715 Snap Rings870 Pipes, Hoses, Ducting975 Brackets1080 Boltings1185 Sealing Elements1290 Bearing Elements Misc1391 Bearing/Bushings1492 Roller Bearings1593 Thrust Bearings/Washers1694 Thrust Roller/Needle Bearings1700 Transmission Assembly of Internal ClutchesSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D1.61$2.74$ 12.12$16.47$0.12$1.15$1.32$0.66$3.24$0.05$19.77$2.03$1.74$5.73$9.50$0.07$0.67$0.76$0.38$1.87$-$11.38$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$13.03$1.57$ 11.70$26.29$0.13$1.71$1.58$0.66$4.08$0.10$30.46$2.19$0.97$4.44$7.60$0.15$0.74$0.63$0.20$1.72$0.11$9.44$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.61$1.85$0.47$2.93$-$-$-$-$-$-$2.93$19.46$8.87$ 34.46$62.80$0.47$ 4.27$ 4.28$ 1.90$10.91$0.26$73.98$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Internal Clutches, Page: 8 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100204 Internal Clutches Subsystem101 Sprague/One Way Clutches202 Clutch Assembly303 Clutch & Brake Hubs404 Sleeve & Couplers505 Disc & Plates609 Pistons715 Snap Rings870 Pipes, Hoses, Ducting975 Brackets1080 Boltings1185 Sealing Elements1290 Bearing Elements Misc1391 Bearing/Bushings1492 Roller Bearings1593 Thrust Bearings/Washers1694 Thrust Roller/Needle Bearings1700 Transmission Assembly of Internal ClutchesSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(1.61)$(2.74)$ (12.12)$(16.47)$(0.12)$(1.15)$(1.32)$(0.66)$(3.24)$(0.05)$(19.77)$(2.03)$(1.74)$(5.73)$(9.50)$(0.07)$(0.67)$(0.76)$(0.38)$(1.87)$-$(11.38)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(13.03)$(1.57)$ (11.70)$(26.29)$(0.13)$(1.71)$(1.58)$(0.66)$(4.08)$(0.10)$(30.46)$(2.19)$(0.97)$(4.44)$(7.60)$(0.15)$(0.74)$(0.63)$(0.20)$(1.72)$(0.11)$(9.44)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.61)$(1.85)$(0.47)$(2.93)$-$-$-$-$-$-$(2.93)$(19.46)$(8.87)$ (34.46)$(62.80)$(0.47)$ (4.27)$ (4.28)$ (1.90)$(10.91)$(0.26)$(73.98)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Internal Clutches, Page: 9 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0207 Mechanical Controls Subsystem101 Valve Body Assembly-$-$-$-$-$-$-$-$-$-$-$202 Valve Body-$-$-$-$-$-$-$-$-$-$-$303 Valves - Mechanical (Spool)-$-$-$-$-$-$-$-$-$-$-$404 Valves - Electro-Mechanical (Solenoids)-$-$-$-$-$-$-$-$-$-$-$507 Plugs and Cups-$-$-$-$-$-$-$-$-$-$-$609 Piston-$-$-$-$-$-$-$-$-$-$-$710 Accumulator Assemblies-$-$-$-$-$-$-$-$-$-$-$815 Shafts/Rods/Pins-$-$-$-$-$-$-$-$-$-$-$920 Springs-$-$-$-$-$-$-$-$-$-$-$1025 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)-$-$-$-$-$-$-$-$-$-$-$1170 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1275 Brackets-$-$-$-$-$-$-$-$-$-$-$1380 Boltings (Includes Nuts, Washers, etc)-$-$-$-$-$-$-$-$-$-$-$1485 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1590 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1699 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1700 Transmission Assembly of Mechanical Control Components-$-$-$-$-$-$-$-$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.3 Mech. Controls, Page: 10 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100207 Mechanical Controls Subsystem101 Valve Body Assembly202 Valve Body303 Valves - Mechanical (Spool)404 Valves - Electro-Mechanical (Solenoids)507 Plugs and Cups609 Piston710 Accumulator Assemblies815 Shafts/Rods/Pins920 Springs1025 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1170 Pipes, Hoses, Ducting1275 Brackets1380 Boltings (Includes Nuts, Washers, etc)1485 Sealing Elements1590 Bearing Elements1699 Miscellaneous1700 Transmission Assembly of Mechanical Control ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.12$0.10$0.43$0.65$0.00$0.04$0.03$0.01$0.07$0.02$0.74$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.05$0.42$0.08$0.54$-$-$-$-$-$-$0.54$0.17$ 0.52$ 0.50$1.19$0.00$ 0.04$ 0.03$ 0.01$0.07$0.02$1.28$BASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Mech. Controls, Page: 11 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0802Printed: 3/26/20100207 Mechanical Controls Subsystem101 Valve Body Assembly202 Valve Body303 Valves - Mechanical (Spool)404 Valves - Electro-Mechanical (Solenoids)507 Plugs and Cups609 Piston710 Accumulator Assemblies815 Shafts/Rods/Pins920 Springs1025 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1170 Pipes, Hoses, Ducting1275 Brackets1380 Boltings (Includes Nuts, Washers, etc)1485 Sealing Elements1590 Bearing Elements1699 Miscellaneous1700 Transmission Assembly of Mechanical Control ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:08 - 6 Speed Automatic versus 5 Speed Automatic TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0802 ( N0802 New Technology Configuration)( B0802 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.12)$(0.10)$(0.43)$(0.65)$(0.00)$(0.04)$(0.03)$(0.01)$(0.07)$(0.02)$(0.74)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.05)$(0.42)$(0.08)$(0.54)$-$-$-$-$-$-$(0.54)$(0.17)$ (0.52)$ (0.50)$(1.19)$ (0.00)$ (0.04)$ (0.03)$ (0.01)$(0.07)$(0.02)$(1.28)$BASE TECHNOLOGY PACKAGE COST INFORMATION5 Speed Automatic Transmission: 2004-2006 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0802, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.3 Mech. Controls, Page: 12 of 12Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0202 Case(s) Subsystem101 Transaxle Case33.84$2.90$4.81$41.54$2.12$2.75$2.54$0.42$7.83$0.47$49.84$202 Transaxle Housing29.57$3.49$5.46$38.52$1.93$2.50$2.31$0.39$7.13$0.47$46.12$303 Covers-$-$-$-$-$-$-$-$-$-$-$404 Actuators-$-$-$-$-$-$-$-$-$-$-$505 TBD-$-$-$-$-$-$-$-$-$-$-$610 Plugs-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings-$-$-$-$-$-$-$-$-$-$-$1085 Sealing Elements0.04$0.21$0.39$0.63$0.00$0.04$0.04$0.01$0.09$0.00$0.72$1190 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Transmission Assembly of Case Components1.41$0.69$2.43$4.53$-$-$-$-$-$-$4.53$64.85$7.28$ 13.09$85.22$4.05$ 5.30$ 4.89$ 0.81$15.05$0.95$101.21$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Cases, Page: 1 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100202 Case(s) Subsystem101 Transaxle Case202Transaxle Housing303 Covers404 Actuators505 TBD610 Plugs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1300 Transmission Assembly of Case ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D28.33$1.88$ 12.85$43.06$0.22$2.80$2.58$1.08$6.67$0.22$49.96$21.00$6.02$ 26.78$53.81$0.27$3.50$3.23$1.35$8.34$0.22$62.37$7.03$1.16$5.13$13.33$0.07$0.88$0.81$0.33$2.09$0.11$15.53$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$2.67$1.40$1.18$5.26$-$-$-$-$-$-$5.26$59.04$ 10.47$ 45.95$115.46$0.55$ 7.18$ 6.62$ 2.76$17.11$0.56$133.12$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Cases, Page: 2 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100202 Case(s) Subsystem101 Transaxle Case202Transaxle Housing303 Covers404 Actuators505 TBD610 Plugs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1300 Transmission Assembly of Case ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D5.51$1.02$(8.05)$(1.53)$1.90$(0.05)$(0.04)$(0.65)$1.16$0.25$(0.12)$8.56$(2.54)$ (21.32)$(15.29)$1.66$(0.99)$(0.92)$(0.96)$(1.21)$0.25$(16.26)$(7.03)$(1.16)$(5.13)$(13.33)$(0.07)$(0.88)$(0.81)$(0.33)$(2.09)$(0.11)$(15.53)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.04$0.21$0.39$0.63$0.00$0.04$0.04$0.01$0.09$0.00$0.72$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(1.26)$(0.71)$1.25$(0.73)$-$-$-$-$-$-$(0.73)$5.82$(3.19)$ (32.86)$(30.24)$3.49$(1.88)$ (1.73)$ (1.94)$(2.06)$0.39$(31.91)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Cases, Page: 3 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0203 Geartrain Subsystem101 Sun Gears-$-$-$-$-$-$-$-$-$-$-$202 Lepelletier Planetary Set-$-$-$-$-$-$-$-$-$-$-$303 RingGears-$-$-$-$-$-$-$-$-$-$-$404 Counter Gears-$-$-$-$-$-$-$-$-$-$-$505 Differential Gears-$-$-$-$-$-$-$-$-$-$-$606 Carriers-$-$-$-$-$-$-$-$-$-$-$707 Pins/Journals-$-$-$-$-$-$-$-$-$-$-$810 Gears Misc-$-$-$-$-$-$-$-$-$-$-$911 Shafts7.23$4.68$ 14.07$25.99$0.28$2.76$3.15$0.79$6.97$0.37$33.33$1012 Input Shaft Outer6.57$3.20$9.29$19.05$-$-$-$-$-$0.02$19.07$1113 Output Shaft, 1 thru 414.09$5.39$ 21.64$41.12$0.29$2.88$3.29$0.82$7.28$0.46$48.85$1214 Output Shaft, 5,6 & Reverse9.24$4.05$ 15.87$29.16$0.20$2.04$2.33$0.58$5.16$0.44$34.76$1315 SnapRings-$-$-$-$-$-$-$-$-$-$-$1416 Reverse Transfer Shaft4.52$0.90$4.76$10.17$0.07$0.71$0.81$0.20$1.80$0.55$12.53$1517 Drive Adapter-$-$-$-$-$-$-$-$-$-$-$1618 Synchronizers2.32$2.75$6.65$11.72$0.08$0.82$0.94$0.23$2.07$0.55$14.35$1770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1875 Brackets-$-$-$-$-$-$-$-$-$-$-$1980 Boltings (Includes Nuts & Washers)-$-$-$-$-$-$-$-$-$-$-$SYSTEM & SUBSYSTEM DESCRIPTIONNEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 4 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0203 Geartrain SubsystemSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)2085 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$2190 Bearings Elements Misc0.09$0.39$1.01$1.50$0.01$0.10$0.12$0.03$0.26$0.06$1.82$2291 Bearing/Bushings-$-$-$-$-$-$-$-$-$-$-$2392 Roller Bearings-$-$-$-$-$-$-$-$-$-$-$2593 Thrust Bearings/Washers-$-$-$-$-$-$-$-$-$-$-$2694 Thrust Roller/Needle Bearings-$-$-$-$-$-$-$-$-$-$-$2799 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$28100 Transmission Assembly of Gear Components13.26$3.86$2.37$19.49$-$-$-$-$-$-$19.49$57.31$ 25.22$ 75.67$158.20$0.93$ 9.31$ 10.64$2.66$23.55$2.45$184.21$SUB-SUBSYSTEM ROLL-UPFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 5 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100203 Geartrain Subsystem101 Sun Gears202 Lepelletier Planetary Set303 Ring Gears404 Counter Gears505 Differential Gears606 Carriers707 Pins/Journals810 Gears Misc911 Shafts1012 Input Shaft Outer1113 Output Shaft, 1 thru 41214 Output Shaft, 5,6 & Reverse1315 Snap Rings1416 Reverse Transfer Shaft1517 Drive Adapter1618 Synchronizers1770 Pipes, Hoses, Ducting1875 Brackets1980 Boltings (Includes Nuts & Washers)SYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D3.19$5.29$ 14.08$22.57$0.17$2.17$2.00$0.33$4.67$0.20$27.43$13.50$8.61$ 14.25$36.37$2.18$6.36$5.87$0.98$15.40$0.10$51.86$1.03$2.65$5.15$8.84$0.07$0.86$0.79$0.13$1.84$0.07$10.75$-$-$-$-$-$-$-$-$-$-$-$11.76$5.93$ 18.34$36.04$0.20$2.88$2.44$0.31$5.83$0.14$42.01$-$-$-$-$-$-$-$-$-$-$-$1.58$2.46$6.83$10.87$0.05$0.71$0.65$0.11$1.52$0.00$12.40$2.85$7.61$ 17.28$27.74$0.14$1.80$1.66$0.28$3.88$0.03$31.65$0.96$0.71$3.85$5.52$0.03$0.36$0.33$0.06$0.77$0.02$6.32$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.35$0.51$1.67$2.53$0.01$0.16$0.15$0.03$0.35$0.01$2.89$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.15$0.41$1.01$1.57$0.01$0.10$0.09$0.02$0.22$0.02$1.81$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 6 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100203 Geartrain SubsystemSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)2085 Sealing Elements2190 Bearings Elements Misc2291 Bearing/Bushings2392 Roller Bearings2593 Thrust Bearings/Washers2694 Thrust Roller/Needle Bearings2799 Miscellaneous28100 Transmission Assembly of Gear ComponentsSUB-SUBSYSTEM ROLL-UPMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&DBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEM-$-$-$-$-$-$-$-$-$-$-$2.00$1.64$3.37$7.00$0.04$0.46$0.42$0.07$0.98$0.02$8.00$0.77$1.68$3.05$5.50$0.02$0.34$0.25$0.02$0.63$0.03$6.16$-$-$-$-$-$-$-$-$-$-$-$0.07$1.10$1.81$2.99$0.01$0.19$0.18$0.03$0.42$0.01$3.42$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$9.71$4.10$1.23$15.04$-$-$-$-$-$0.04$15.07$47.93$ 42.72$ 91.92$182.57$2.92$ 16.39$ 14.85$2.35$36.51$0.69$219.77$File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 7 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100203 Geartrain Subsystem101 Sun Gears202 Lepelletier Planetary Set303 Ring Gears404 Counter Gears505 Differential Gears606 Carriers707 Pins/Journals810 Gears Misc911 Shafts1012 Input Shaft Outer1113 Output Shaft, 1 thru 41214 Output Shaft, 5,6 & Reverse1315 Snap Rings1416 Reverse Transfer Shaft1517 Drive Adapter1618 Synchronizers1770 Pipes, Hoses, Ducting1875 Brackets1980 Boltings (Includes Nuts & Washers)SYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(3.19)$(5.29)$ (14.08)$(22.57)$(0.17)$(2.17)$(2.00)$(0.33)$(4.67)$(0.20)$(27.43)$(13.50)$(8.61)$ (14.25)$(36.37)$(2.18)$(6.36)$(5.87)$(0.98)$(15.40)$(0.10)$(51.86)$(1.03)$(2.65)$(5.15)$(8.84)$(0.07)$(0.86)$(0.79)$(0.13)$(1.84)$(0.07)$(10.75)$-$-$-$-$-$-$-$-$-$-$-$(11.76)$(5.93)$ (18.34)$(36.04)$(0.20)$(2.88)$(2.44)$(0.31)$(5.83)$(0.14)$(42.01)$-$-$-$-$-$-$-$-$-$-$-$(1.58)$(2.46)$(6.83)$(10.87)$(0.05)$(0.71)$(0.65)$(0.11)$(1.52)$(0.00)$(12.40)$(2.85)$(7.61)$ (17.28)$(27.74)$(0.14)$(1.80)$(1.66)$(0.28)$(3.88)$(0.03)$(31.65)$6.27$3.97$ 10.23$20.47$0.25$2.40$2.82$0.73$6.20$0.35$27.01$6.57$3.20$9.29$19.05$-$-$-$-$-$0.02$19.07$14.09$5.39$ 21.64$41.12$0.29$2.88$3.29$0.82$7.28$0.46$48.85$9.24$4.05$ 15.87$29.16$0.20$2.04$2.33$0.58$5.16$0.44$34.76$(0.35)$(0.51)$(1.67)$(2.53)$(0.01)$(0.16)$(0.15)$(0.03)$(0.35)$(0.01)$(2.89)$4.52$0.90$4.76$10.17$0.07$0.71$0.81$0.20$1.80$0.55$12.53$-$-$-$-$-$-$-$-$-$-$-$2.32$2.75$6.65$11.72$0.08$0.82$0.94$0.23$2.07$0.55$14.35$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.15)$(0.41)$(1.01)$(1.57)$(0.01)$(0.10)$(0.09)$(0.02)$(0.22)$(0.02)$(1.81)$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 8 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100203 Geartrain SubsystemSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)2085 Sealing Elements2190 Bearings Elements Misc2291 Bearing/Bushings2392 Roller Bearings2593 Thrust Bearings/Washers2694 Thrust Roller/Needle Bearings2799 Miscellaneous28100 Transmission Assembly of Gear ComponentsSUB-SUBSYSTEM ROLL-UPMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&DBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)-$-$-$-$-$-$-$-$-$-$-$(1.90)$(1.25)$(2.35)$(5.51)$(0.02)$(0.35)$(0.30)$(0.04)$(0.72)$0.04$(6.19)$(0.77)$(1.68)$(3.05)$(5.50)$(0.02)$(0.34)$(0.25)$(0.02)$(0.63)$(0.03)$(6.16)$-$-$-$-$-$-$-$-$-$-$-$(0.07)$(1.10)$(1.81)$(2.99)$(0.01)$(0.19)$(0.18)$(0.03)$(0.42)$(0.01)$(3.42)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$3.55$(0.24)$1.14$4.46$-$-$-$-$-$(0.04)$4.42$9.38$(17.50)$ (16.25)$(24.37)$(1.99)$(7.08)$ (4.20)$0.31$(12.96)$1.76$(35.57)$File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Geartrain, Page: 9 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0204 Internal Clutches Subsystem101 Sprague/One Way Clutches-$-$-$-$-$-$-$-$-$-$-$202 Clutch Assembly-$-$-$-$-$-$-$-$-$-$-$303 Clutch & Brake Hubs-$-$-$-$-$-$-$-$-$-$-$404 Sleeve & Couplers-$-$-$-$-$-$-$-$-$-$-$505 Disc & Plates-$-$-$-$-$-$-$-$-$-$-$606 TBD-$-$-$-$-$-$-$-$-$-$-$707 Synchronizers10.01$10.75$28.11$48.87$0.26$3.35$3.09$0.51$7.20$0.52$56.59$809 Pistons-$-$-$-$-$-$-$-$-$-$-$915 Snap Rings-$-$-$-$-$-$-$-$-$-$-$1070 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1175 Brackets-$-$-$-$-$-$-$-$-$-$-$1280 Boltings-$-$-$-$-$-$-$-$-$-$-$1385 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1490 Bearing Elements Misc-$-$-$-$-$-$-$-$-$-$-$1591 Bearing/Bushings-$-$-$-$-$-$-$-$-$-$-$1692 Roller Bearings-$-$-$-$-$-$-$-$-$-$-$1793 Thrust Bearings/Washers-$-$-$-$-$-$-$-$-$-$-$1894 Thrust Roller/Needle Bearings-$-$-$-$-$-$-$-$-$-$-$1999 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$2000 Transmission Assembly of Internal Clutches0.80$4.47$1.60$6.87$-$-$-$-$-$0.03$6.90$10.81$ 15.21$ 29.71$55.73$0.26$ 3.35$ 3.09$ 0.51$7.20$0.55$63.48$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Internal Clutches, Page: 10 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100204 Internal Clutches Subsystem101 Sprague/One Way Clutches202Clutch Assembly303 Clutch & Brake Hubs404 Sleeve & Couplers505 Disc & Plates606 TBD707 Synchronizers809 Pistons915 Snap Rings1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements Misc1591 Bearing/Bushings1692 Roller Bearings1793 Thrust Bearings/Washers1894 Thrust Roller/Needle Bearings1999 Miscellaneous2000 Transmission Assembly of Internal ClutchesSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D3.46$4.20$9.43$17.09$0.15$2.09$1.86$0.28$4.39$0.48$21.96$3.15$3.87$5.64$12.65$0.59$5.85$6.69$3.34$16.46$0.05$29.17$2.18$1.93$6.38$10.49$0.05$0.68$0.63$0.10$1.47$0.03$12.00$-$-$-$-$-$-$-$-$-$-$-$26.35$16.92$31.98$75.24$0.41$5.38$4.97$0.74$11.51$1.08$87.83$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$12.18$3.92$ 10.61$26.71$0.34$1.82$1.68$0.28$4.13$0.85$31.69$0.21$0.37$0.62$1.20$0.01$0.08$0.07$0.01$0.17$0.03$1.40$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.12$0.56$1.28$1.95$0.01$0.13$0.12$0.02$0.27$0.18$2.41$1.59$0.32$0.21$2.13$0.01$0.14$0.13$0.02$0.30$0.11$2.53$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$5.63$5.76$1.30$12.69$-$-$-$-$-$-$12.69$54.86$ 37.85$ 67.45$160.16$1.57$ 16.17$ 16.15$4.81$38.70$2.81$201.67$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Internal Clutches, Page: 11 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100204 Internal Clutches Subsystem101 Sprague/One Way Clutches202Clutch Assembly303 Clutch & Brake Hubs404 Sleeve & Couplers505 Disc & Plates606 TBD707 Synchronizers809 Pistons915 Snap Rings1070 Pipes, Hoses, Ducting1175 Brackets1280 Boltings1385 Sealing Elements1490 Bearing Elements Misc1591 Bearing/Bushings1692 Roller Bearings1793 Thrust Bearings/Washers1894 Thrust Roller/Needle Bearings1999 Miscellaneous2000 Transmission Assembly of Internal ClutchesSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(3.46)$(4.20)$(9.43)$(17.09)$(0.15)$(2.09)$(1.86)$(0.28)$(4.39)$(0.48)$(21.96)$(3.15)$(3.87)$(5.64)$(12.65)$(0.59)$(5.85)$(6.69)$(3.34)$(16.46)$(0.05)$(29.17)$(2.18)$(1.93)$(6.38)$(10.49)$(0.05)$(0.68)$(0.63)$(0.10)$(1.47)$(0.03)$(12.00)$-$-$-$-$-$-$-$-$-$-$-$(26.35)$(16.92)$(31.98)$(75.24)$(0.41)$(5.38)$(4.97)$(0.74)$(11.51)$(1.08)$(87.83)$-$-$-$-$-$-$-$-$-$-$-$10.01$10.75$28.11$48.87$0.26$3.35$3.09$0.51$7.20$0.52$56.59$(12.18)$(3.92)$ (10.61)$(26.71)$(0.34)$(1.82)$(1.68)$(0.28)$(4.13)$(0.85)$(31.69)$(0.21)$(0.37)$(0.62)$(1.20)$(0.01)$(0.08)$(0.07)$(0.01)$(0.17)$(0.03)$(1.40)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.12)$(0.56)$(1.28)$(1.95)$(0.01)$(0.13)$(0.12)$(0.02)$(0.27)$(0.18)$(2.41)$(1.59)$(0.32)$(0.21)$(2.13)$(0.01)$(0.14)$(0.13)$(0.02)$(0.30)$(0.11)$(2.53)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(4.83)$(1.30)$0.30$(5.83)$-$-$-$-$-$0.03$(5.79)$(44.06)$ (22.63)$ (37.74)$(104.43)$(1.32)$ (12.82)$ (13.06)$(4.30)$(31.49)$(2.26)$(138.19)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Internal Clutches, Page: 12 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0205 Launch Clutches Subsystem101 Torque Converter Assembly-$-$-$-$-$-$-$-$-$-$-$202 Clutch Assembly C1/C222.97$11.41$40.60$74.97$0.45$5.65$5.37$0.96$12.43$0.35$87.76$303 Fly Wheels/Flex Plates/Starter Rings20.93$11.40$15.35$47.67$0.51$1.96$1.81$0.30$4.59$0.24$52.51$404 TBD-$-$-$-$-$-$-$-$-$-$-$515 Snap Rings and Retainers1.49$0.97$1.91$4.37$0.02$0.28$0.26$0.04$0.61$0.06$5.04$620 Springs-$-$-$-$-$-$-$-$-$-$-$770 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$875 Brackets-$-$-$-$-$-$-$-$-$-$-$980 Boltings-$-$-$-$-$-$-$-$-$-$-$1085 Sealing Elements0.03$0.19$0.13$0.35$0.00$0.02$0.02$0.00$0.05$0.05$0.44$1190 Bearing Elements0.07$0.11$0.10$0.28$0.00$0.02$0.02$0.00$0.04$0.02$0.34$1299 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1300 Transmission Assembly of Launch Clutches1.12$4.44$3.46$9.03$-$-$-$-$-$-$9.03$46.61$ 28.52$ 61.55$136.68$0.99$ 7.94$ 7.48$ 1.31$17.71$0.72$155.11$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Launch Clutches, Page: 13 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100205 Launch Clutches Subsystem101 Torque Converter Assembly202Clutch Assembly C1/C2303 Fly Wheels/Flex Plates/Starter Rings404 TBD515 Snap Rings and Retainers620 Springs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1300 Transmission Assembly of Launch ClutchesSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$89.44$0.46$0.83$90.74$-$-$-$-$-$-$90.74$89.44$0.46$ 0.83$90.74$-$ -$ -$ -$-$-$90.74$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Launch Clutches, Page: 14 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100205 Launch Clutches Subsystem101 Torque Converter Assembly202Clutch Assembly C1/C2303 Fly Wheels/Flex Plates/Starter Rings404 TBD515 Snap Rings and Retainers620 Springs770 Pipes, Hoses, Ducting875 Brackets980 Boltings1085 Sealing Elements1190 Bearing Elements1299 Miscellaneous1300 Transmission Assembly of Launch ClutchesSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$22.97$11.41$40.60$74.97$0.45$5.65$5.37$0.96$12.43$0.35$87.76$20.93$11.40$15.35$47.67$0.51$1.96$1.81$0.30$4.59$0.24$52.51$-$-$-$-$-$-$-$-$-$-$-$1.49$0.97$1.91$4.37$0.02$0.28$0.26$0.04$0.61$0.06$5.04$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.03$0.19$0.13$0.35$0.00$0.02$0.02$0.00$0.05$0.05$0.44$0.07$0.11$0.10$0.28$0.00$0.02$0.02$0.00$0.04$0.02$0.34$-$-$-$-$-$-$-$-$-$-$-$(88.32)$3.98$2.63$(81.71)$-$-$-$-$-$-$(81.71)$(42.83)$28.06$ 60.71$45.94$0.99$ 7.94$ 7.48$ 1.31$17.71$0.72$64.37$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Launch Clutches, Page: 15 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0207 Mechanical Controls Subsystem101 Valve Body Assembly9.93$5.27$ 12.05$27.24$0.69$1.80$1.73$0.32$4.54$0.25$32.02$202 Solenoids-$-$-$-$-$-$-$-$-$-$-$303 Sensors-$-$-$-$-$-$-$-$-$-$-$404 Switches-$-$-$-$-$-$-$-$-$-$-$505 Wiring Harnesses-$-$-$-$-$-$-$-$-$-$-$606 Mechanical Controls7.54$5.08$ 11.47$24.08$0.21$2.79$2.58$0.46$6.05$0.37$30.50$707 Plugs and Cups0.12$0.87$1.28$2.27$0.01$0.15$0.14$0.02$0.32$0.00$2.59$810 Accumulator Assemblies-$-$-$-$-$-$-$-$-$-$-$915 Shafts/Rods/Pins-$-$-$-$-$-$-$-$-$-$-$1020 Springs-$-$-$-$-$-$-$-$-$-$-$1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)0.17$0.71$1.79$2.67$0.01$0.17$0.16$0.03$0.37$0.00$3.04$1270 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1375 Brackets-$-$-$-$-$-$-$-$-$-$-$1480 Boltings-$-$-$-$-$-$-$-$-$-$-$1585 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1690 Bearing Elements0.65$4.05$8.12$12.82$0.04$0.77$0.51$-$1.32$0.01$14.15$1799 Miscellaneous0.03$0.04$0.03$0.10$0.00$0.01$0.00$-$0.01$0.00$0.11$1800 Transmission Assembly of Mechanical Control Components5.42$7.68$7.71$20.82$-$-$-$-$-$-$20.82$19-$-$-$-$-$-$-$-$-$-$-$20-$-$-$-$-$-$-$-$-$-$-$23.85$ 23.71$ 42.44$90.00$0.96$ 5.68$ 5.12$ 0.83$12.61$0.63$103.23$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Mech. Controls, Page: 16 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100207 Mechanical Controls Subsystem101 Valve Body Assembly202Solenoids303 Sensors404 Switches505 Wiring Harnesses606 Mechanical Controls707 Plugs and Cups810 Accumulator Assemblies915 Shafts/Rods/Pins1020 Springs1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1270 Pipes, Hoses, Ducting1375 Brackets1480 Boltings1585 Sealing Elements1690 Bearing Elements1799 Miscellaneous1800 Transmission Assembly of Mechanical Control Components1920SYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D14.13$26.14$34.65$74.92$0.53$6.95$6.42$1.07$14.98$0.19$90.09$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.09$0.10$0.23$0.42$0.00$0.03$0.03$0.00$0.06$0.03$0.50$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.20$2.09$4.80$7.09$0.04$0.53$0.49$0.08$1.14$0.01$8.24$0.43$0.29$0.51$1.24$0.01$0.08$0.07$0.01$0.17$0.01$1.42$0.02$0.06$0.09$0.17$0.00$0.01$0.01$0.00$0.02$0.01$0.20$-$-$-$-$-$-$-$-$-$-$-$0.03$0.31$0.56$0.90$0.00$0.06$0.05$0.01$0.13$0.01$1.04$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.53$2.50$0.40$3.43$-$-$-$-$-$0.00$3.43$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$15.44$ 31.49$ 41.23$88.16$0.59$ 7.66$ 7.07$ 1.18$16.50$0.26$104.92$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Mech. Controls, Page: 17 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100207 Mechanical Controls Subsystem101 Valve Body Assembly202Solenoids303 Sensors404 Switches505 Wiring Harnesses606 Mechanical Controls707 Plugs and Cups810 Accumulator Assemblies915 Shafts/Rods/Pins1020 Springs1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1270 Pipes, Hoses, Ducting1375 Brackets1480 Boltings1585 Sealing Elements1690 Bearing Elements1799 Miscellaneous1800 Transmission Assembly of Mechanical Control Components1920SYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(4.21)$ (20.88)$(22.60)$(47.68)$0.15$(5.16)$(4.69)$(0.75)$(10.44)$0.06$(58.07)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$7.54$5.08$ 11.47$24.08$0.21$2.79$2.58$0.46$6.05$0.37$30.50$0.12$0.87$1.28$2.27$0.01$0.15$0.14$0.02$0.32$0.00$2.59$(0.09)$(0.10)$(0.23)$(0.42)$(0.00)$(0.03)$(0.03)$(0.00)$(0.06)$(0.03)$(0.50)$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.04)$(1.38)$(3.01)$(4.42)$(0.03)$(0.36)$(0.33)$(0.05)$(0.77)$(0.00)$(5.20)$(0.43)$(0.29)$(0.51)$(1.24)$(0.01)$(0.08)$(0.07)$(0.01)$(0.17)$(0.01)$(1.42)$(0.02)$(0.06)$(0.09)$(0.17)$(0.00)$(0.01)$(0.01)$(0.00)$(0.02)$(0.01)$(0.20)$-$-$-$-$-$-$-$-$-$-$-$(0.03)$(0.31)$(0.56)$(0.90)$(0.00)$(0.06)$(0.05)$(0.01)$(0.13)$(0.01)$(1.04)$0.65$4.05$8.12$12.82$0.04$0.77$0.51$-$1.32$0.01$14.15$0.03$0.04$0.03$0.10$0.00$0.01$0.00$-$0.01$0.00$0.11$4.89$5.18$7.31$17.39$-$-$-$-$-$(0.00)$17.39$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$8.41$(7.79)$1.21$1.83$0.37$(1.98)$ (1.95)$ (0.34)$(3.89)$0.37$(1.69)$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Mech. Controls, Page: 18 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0208 Electrical Controls Subsystem101 Controller-$-$-$-$-$-$-$-$-$-$-$202 Solenoids-$-$-$-$-$-$-$-$-$-$-$303 Sensors-$-$-$-$-$-$-$-$-$-$-$404 Switches-$-$-$-$-$-$-$-$-$-$-$505 Wiring Harness-$-$-$-$-$-$-$-$-$-$-$606 Valves-$-$-$-$-$-$-$-$-$-$-$709 Pistons-$-$-$-$-$-$-$-$-$-$-$810 TBD-$-$-$-$-$-$-$-$-$-$-$915 TBD-$-$-$-$-$-$-$-$-$-$-$1020 Springs-$-$-$-$-$-$-$-$-$-$-$1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)-$-$-$-$-$-$-$-$-$-$-$1270 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$1375 Brackets0.13$0.19$0.60$0.92$0.00$0.06$0.06$0.01$0.13$0.01$1.06$1480 Boltings-$-$-$-$-$-$-$-$-$-$-$1585 Sealing Elements0.03$0.24$0.44$0.71$0.00$0.05$0.04$0.01$0.10$0.00$0.82$1690 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1799 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1800 Transmission Assembly of Electrical Control Components95.59$5.95$7.91$109.45$-$-$-$-$-$-$109.45$95.75$6.38$ 8.95$111.09$0.01$ 0.11$ 0.10$ 0.02$0.23$0.01$111.33$SUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Elec. Controls, Page: 19 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100208 Electrical Controls Subsystem101 Controller202Solenoids303 Sensors404 Switches505 Wiring Harness606 Valves709 Pistons810 TBD915 TBD1020 Springs1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1270 Pipes, Hoses, Ducting1375 Brackets1480 Boltings1585 Sealing Elements1690 Bearing Elements1799 Miscellaneous1800 Transmission Assembly of Electrical Control ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.46$0.57$1.74$2.77$0.02$0.24$0.22$0.04$0.51$0.01$3.29$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$104.40$3.37$4.28$112.05$-$-$-$-$-$-$112.05$104.86$3.94$ 6.01$114.82$0.02$ 0.24$ 0.22$ 0.04$0.51$0.01$115.34$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Elec. Controls, Page: 20 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100208 Electrical Controls Subsystem101 Controller202Solenoids303 Sensors404 Switches505 Wiring Harness606 Valves709 Pistons810 TBD915 TBD1020 Springs1125 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)1270 Pipes, Hoses, Ducting1375 Brackets1480 Boltings1585 Sealing Elements1690 Bearing Elements1799 Miscellaneous1800 Transmission Assembly of Electrical Control ComponentsSUB-SUBSYSTEM ROLL-UP

Item Sub-SubsystemSub-Subsystem DescriptionSYSTEM & SUBSYSTEM DESCRIPTIONTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.33)$(0.37)$(1.14)$(1.85)$(0.01)$(0.18)$(0.16)$(0.03)$(0.38)$(0.00)$(2.23)$-$-$-$-$-$-$-$-$-$-$-$0.03$0.24$0.44$0.71$0.00$0.05$0.04$0.01$0.10$0.00$0.82$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(8.81)$2.57$3.64$(2.60)$-$-$-$-$-$-$(2.60)$(9.12)$2.44$ 2.94$(3.73)$ (0.01)$ (0.13)$ (0.12)$ (0.02)$(0.28)$0.00$(4.01)$Total MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupBASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Elec. Controls, Page: 21 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/2010Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D0209 Park Mechanism Subsystem101 Rods/Shafts/Pins-$-$-$-$-$-$-$-$-$-$-$202 Springs-$-$-$-$-$-$-$-$-$-$-$303 Pawls-$-$-$-$-$-$-$-$-$-$-$404 TBD-$-$-$-$-$-$-$-$-$-$-$525 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)-$-$-$-$-$-$-$-$-$-$-$670 Pipes, Hoses, Ducting-$-$-$-$-$-$-$-$-$-$-$775 Brackets (& Levers)-$-$-$-$-$-$-$-$-$-$-$880 Boltings (Includes Nuts, Clips, Retainers, etc)-$-$-$-$-$-$-$-$-$-$-$985 Sealing Elements-$-$-$-$-$-$-$-$-$-$-$1090 Bearing Elements-$-$-$-$-$-$-$-$-$-$-$1199 Miscellaneous-$-$-$-$-$-$-$-$-$-$-$1200 Transmission Assembly of Park Brake Control Components0.10$0.85$0.76$1.71$0.01$0.11$0.13$0.10$0.35$-$2.06$0.10$ 0.85$ 0.76$1.71$0.01$ 0.11$ 0.13$ 0.10$0.35$-$2.06$SYSTEM & SUBSYSTEM DESCRIPTIONNEWTECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenTotalPackagingCost(Component/Assembly)

Item Sub-SubsystemSub-Subsystem DescriptionManufacturingSUB-SUBSYSTEM ROLL-UPNetComponent/Assembly CostImpact to OEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)Technology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPAContract:EP-C-07-069 WA1-3Apdx. C.4 Park Mechanism, Page: 22 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100209 Park Mechanism Subsystem101 Rods/Shafts/Pins202Springs303 Pawls404 TBD525 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)670 Pipes, Hoses, Ducting775 Brackets (& Levers)880 Boltings (Includes Nuts, Clips, Retainers, etc)985 Sealing Elements1090 Bearing Elements1199 Miscellaneous1200 Transmission Assembly of Park Brake Control ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$0.30$1.02$0.72$2.03$0.01$0.12$0.14$0.10$0.38$-$2.41$0.30$ 1.02$ 0.72$2.03$0.01$ 0.12$ 0.14$ 0.10$0.38$-$2.41$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMFile: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Park Mechanism, Page: 23 of 24Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATECASE STUDY #0902Printed: 3/26/20100209 Park Mechanism Subsystem101 Rods/Shafts/Pins202Springs303 Pawls404 TBD525 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)670 Pipes, Hoses, Ducting775 Brackets (& Levers)880 Boltings (Includes Nuts, Clips, Retainers, etc)985 Sealing Elements1090 Bearing Elements1199 Miscellaneous1200 Transmission Assembly of Park Brake Control ComponentsSYSTEM & SUBSYSTEM DESCRIPTION

Item Sub-SubsystemSub-Subsystem DescriptionSUB-SUBSYSTEM ROLL-UPTechnology Level:09 - 6 Speed Automatic versus 6 Speed Direct Shift TransmissionVehicle Class:02 - Mid to Large Size Passenger Vehicle, 4-6 PassengersStudy Case#:0902 ( N0902 New Technology Configuration)( B0902 Baseline Technology Configuration)Material Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$-$(0.20)$(0.16)$0.04$(0.32)$(0.00)$(0.01)$(0.01)$(0.01)$(0.03)$-$(0.34)$(0.20)$ (0.16)$0.04$(0.32)$ (0.00)$ (0.01)$ (0.01)$ (0.01)$(0.03)$-$(0.34)$BASE TECHNOLOGY PACKAGE COST INFORMATION6 Speed Automatic Transmission: 2007-2009 Toyota CamryINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE COST INFORMATION6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagenMarkupTotalMarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/Assembly CostImpact to OEMManufacturingTotalManufacturingCost(Component/Assembly)File: Subsystem CMAT, CS0902, RPT2-032510.xlsEPA Contract:EP-C-07-069 WA1-3Apdx. C.4 Park Mechanism, Page: 24 of 24Author: G. Kolwich(248)373-6000 Ext. 2411