Paired with turbocharging, direct injection gives the new 3.5-liter EcoBoost engine in the Lincoln MKS the power and torque of a 4.6-liter V-8 with the fuel economy of a V-6. The direct injection technology helps Ford’s EcoBoost deliver advancements of up to 20 percent better fuel economy.

As well, EcoBoost is more Earth-friendly, as it helps reduce CO2 emissions. Direct injection uses high-pressure fuel injectors to spray a fine mist of fuel directly into each cylinder. This precisely controlled fuel delivery improves the engine’s transient response and enables improved emissions, particularly at cold start. The EcoBoost engine cuts CO2 emissions by 15 percent.

Unlike port-fuel-injection (PFI) engines that spray fuel in the intake system, the direct injection system puts the fuel exactly where it needs to be for combustion, making it easier to ignite and burn completely, allowing for improved fuel efficiency. Much like a fine-mist atomizer bottle one might use to keep cool in the summer, the mist generated by the direct injection uses its cool to chill engine intake air, which, in addition to improving fuel economy, also reduces the potential for engine knock.

Quotes

“Direct injection is a significant player in Ford’s strategy to replace larger engines with smaller EcoBoost engines, improving fuel economy by up to 20 percent without sacrificing performance. We’re going to be deploying direct injection to bring a wave of EcoBoost engines into Ford Motor Company products. It starts with the Lincoln MKS and by 2013 more than 90 percent of our North American lineup will offer EcoBoost technology.”
- Brett Hinds, EcoBoost Design Manager

“Cool air is good for an engine because it minimizes the engine knocking phenomenon. Anything you can use to cool the air is good. Injecting the fuel into the cylinder, you cool it on the spot, where you’re going to burn it. Fuel vaporization during the intake stroke cools the air, improving the volumetric efficiency, the breathing of the engine and the knocking tendency.”
- Corey Weaver, EcoBoost Project Leader

Under Ford’s global initiative to provide powertrains that deliver fuel efficiency while meeting the power and performance needs customers demand, the first wave of new EcoBoost™ engines make their debut in the Lincoln MKS, MKT and Ford Flex later this year. Here are some key highlights on Ford’s new EcoBoost technology:

Power and fuel economy – The twin-turbocharged 3.5-liter Duratec V-6 EcoBoost engine produces 355 horsepower at 5,700 rpm and 350 ft.-lb. of torque at 3,500 rpm. A 10-15 percent fuel-economy benefit is expected versus normally aspirated 4.6-liter V-8 engines in the same competitive class.

Engine – The proven Duratec 3.5-liter V-6 comprises the base engine architecture. To handle the increased torque that EcoBoost delivers, some upgrades were made to some of the components, such as the cylinder block, crankshaft, connecting rods pistons and exhaust valves to ensure the EcoBoost V-6 engine is as robust as possible.

Turbochargers – Two Honeywell GT15 turbochargers with water-cooled bearings and operate in parallel, spinning at approximately 170,000 rpm up to 12 PSI. They are rated for a 150,000-mile, 10-year life.

Direct fuel injection – A cam-driven high-pressure fuel pump feeds the fuel injectors at pressures ranging from 200 to 2,175 PSI (pounds per square inch) depending on customer driving. A typical port fuel injection system operates at pressures of around 60 PSI. Six sprayers in each injector target fuel into the cylinder, resulting in a cleaner and more-efficient fuel burn and better cold-start emissions.

Quotes

“The Duratec 3.5 family is a good example of Ford’s forward planning in terms of powertrain technologies. The engine architecture itself was well protected for high-boost applications, so it didn’t require an extensive durability program. It was in good shape to start with.”
- Brett Hinds, EcoBoost Design Manager

The first gasoline direct-injection twin-turbocharged engine produced in North America, the 2010 EcoBoost Flex boasts segment-leading fuel economy among full-size performance crossover vehicles with 22 mpg highway and 18 mpg combined. In fact, the all-new engine gives Flex V-8 power and performance feel with the fuel economy of a V-6, saving customers money. Due to Ford’s significant technological advancements, customers can benefit from fuel efficiency with the seamless power delivery they expect from Flex.

Here are some key facts about Ford Flex and EcoBoost

• The 3.5-liter EcoBoost engine delivers an impressive 355 horsepower and a responsive 350 lb.-ft. of torque across a broad rpm range, simultaneously giving Ford Flex the power of a normally aspirated 4.6-liter V-8 while enjoying V-6 fuel efficiency.
• The twin-turbocharged 3.5-liter EcoBoost V-6 engine requires all-wheel drive and will be available on well-equipped SEL and Limited models of the 2010 Flex, packaged with several high-demand customer features.
• The 3.5-liter EcoBoost V-6 is the first in a wave of EcoBoost engines coming from Ford as part of a strategy to bring major fuel-efficiency improvements to millions.
• The key to the EcoBoost system is the harmony between the twin turbochargers and the direct injection fuel system. The turbochargers recover energy from the exhaust that otherwise would’ve been wasted and put it back in the engine to gain efficiency.
• By 2013, more than 90 percent of Ford’s North American lineup will be available with EcoBoost.

Quotes

“We are committed to delivering fuel economy leadership in every new vehicle. We do this with affordable technology that can be applied to the widest number of vehicles. EcoBoost is an important component of that goal. The beauty of EcoBoost is that it enables us to downsize for fuel efficiency, yet boost for power. We’re able to decrease the size of the available engine – such as installing a V-6 versus a V-8 – yet boost the power using turbocharging to deliver similar power and torque of that larger engine.”
- Derrick Kuzak, Ford’s Group President of Global Product Development

“We know that there are customers who are looking for the power and performance of a traditional V-8 but are not willing to sacrifice this for fuel economy. No one else in this segment offers this level of performance and versatility, and when you wrap it up in Flex’s unique package, we believe that it will offer a compelling buy in the crossover segment.”
- Kate Pearce, Flex Marketing Manager

Because turbochargers operate at high speed – up to 170,000 rpm – and under intense temperatures of up to 950 degrees Celsius (1,740 degrees Fahrenheit), Ford’s advanced engine engineers specified the use of two Honeywell GT15 water-cooled turbos to combat this problem.

To validate their water-cooled design choice, the EcoBoost V-6 engine was put through intense testing, well beyond normal test protocols. In an engine dynamometer ‘torture chamber’, Ford engineers ran EcoBoost at maximum boost flat out for a 10-minute period. This meant the turbos went beyond red-hot, to the more extreme orange-hot.

Then the engine and all cooling were abruptly shut down and the turbo was left to “bake” after this high-speed operation. Test engineers repeated this cycle 1,500 times without an oil change. The turbos were cut open for detailed technical inspections and passed the severe tests with flying colors.

Then onto durability testing. Back in the dynamometer lab, the 3.5-liter EcoBoost V-6 went back up to full revs – and maximum turbo boost – for a real endurance test. This time the duration was a bit longer – 362 hours at full throttle. That’s the equivalent of running the 24 Hours of Daytona for more than 15 days straight.

EcoBoost makes its production debut in the 2010 Ford Flex, 2010 Lincoln MKT and MKS, and uses the same grade of 5W20 engine oil specified by Ford for gasoline engines. Oil changes are scheduled at the same 7,500-mile intervals, too.

Quotes

“We put the EcoBoost V-6 through the same extensive durability signoff testing as any Ford gasoline engines, and we went beyond it to validate the EcoBoost water-cooled turbocharger design and air-to-air intercooling strategy. The idea is to run the engine through a very difficult testing regimen at its maximum-rated operating performance. That’s when things get hot.”
- Michael Shelby, EcoBoost Engine Development Leader

“During normal turbo operation, the turbo receives most of its bearing cooling through oil. After shut down, the problems with turbos in the past were you would get coking in the center bearing. Oil would collect in the bearings, the heat soaks in and the oil would start to coke on the side and foul the bearing. Water cooling – used in the EcoBoost engine – eliminates that worry.”
- Keith Plagens, Turbo System Engineer