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New Ford EcoBlue turbodiesel engine debuts amid diesel woes


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https://media.ford.com/content/fordmedia/feu/en/news/2016/04/26/all-new-ford-ecoblue-engine-is-diesel-game-changer--cleaner--mor.html

 

 

26-Apr-2016 | BIRMINGHAM, U.K. All-New Ford EcoBlue Engine is Diesel Game Changer – Cleaner, More Fuel Efficient, More Power, More Torque
  • Ford reveals all-new 2.0-litre Ford EcoBlue engine; first in a new range of advanced Ford diesel engines delivers unrivalled package of fuel efficiency, performance and refinement
  • Clean-sheet design reduces friction with innovations including an off-set crank, belt-in-oil and Ford’s first use of modular camshafts for a 13 per cent fuel efficiency improvement
  • Ford’s first mirror-image inlet manifold and a low-inertia turbocharger with rocket engine materials help deliver more than 20 per cent more low-end torque; enhanced drivability helps commercial vehicle drivers effortlessly tackle challenging everyday driving scenarios
  • Standard selective catalytic reduction emissions after-treatment contributes to improved NOX reduction. Optimised engine structure reduces radiated noise by 4 decibels at idle

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BIRMINGHAM, U.K., April 26, 2016 – Ford today revealed the first new Ford EcoBlue advanced diesel engine that will offer optimised fuel efficiency and reduced CO2 and NOX emissions* for customers, using sophisticated technologies and innovative design.

Building on the industry-leading performance and technology of Ford’s award-winning EcoBoost petrol engines, Ford’s range of EcoBlue diesel engines will power the company’s future passenger cars and commercial vehicles with power outputs ranging from 100 PS to 240 PS.

The four-cylinder 2.0-litre Ford EcoBlue debuts in the new Transit and Transit Custom commercial vehicles, delivering an unrivalled package of fuel efficiency, performance and refinement.

Drivability is enhanced with 20 per cent more torque at 1,250 rpm compared with the outgoing equivalent power 2.2-litre TDCi diesel engine, helping commercial vehicle drivers effortlessly tackle challenging everyday driving scenarios such as creeping in traffic, or overtaking slower-moving vehicles. The new engine also delivers passenger car refinement to the commercial segment, reducing radiated noise by 4 decibels at idle.

“Ford’s EcoBoost created a new standard for petrol engines – smaller, more efficient with surprising performance. That same obsession to innovate for the customer is behind our new Ford EcoBlue diesel engine range,” said Jim Farley, chairman and CEO of Ford of Europe. “This new engine lifts fuel efficiency and reduces CO2 by over 10 per cent in Transit, part of Europe’s best-selling commercial vehicle line-up, lowering costs for our customers.”

An all-new engine architecture delivers reduced friction and a clean-burning combustion system. Sophisticated after-treatment processes for exhaust gasses enable ultra-low emissions in line with stringent Euro Stage VI standards that will be introduced in September 2016, requiring a 55 per cent reduction in NOx emissions compared to Euro Stage V standards.

Advanced technologies include an integrated intake system with Ford’s first application of mirror-image porting for optimised engine breathing; a low-inertia turbocharger featuring rocket engine materials designed for high temperature applications; and an all-new high-pressure fuel injection system that is more responsive, quieter and offers more precise fuel delivery.

Developed by Ford engineering teams in the U.K. and Germany, the versatile all-new 2.0-litre Ford EcoBlue engine initially will be offered with 105 PS, 130 PS and 170 PS in commercial vehicle applications. Capable of delivering more than 200 PS, the engine will later feature in Ford passenger cars alongside further new EcoBlue engines – including a 1.5‑litre variant.

Low friction, sophisticated combustion
The all-new 2.0-litre Ford EcoBlue engine’s clean-sheet design features multiple innovations that reduce friction, contributing to a 13 per cent improvement in fuel efficiency, including:

  • A 10 mm offset crank design that minimises piston side-load, reducing rubbing forces against the cylinder walls of the downsized four-cylinder iron block
  • Minimised crankshaft bearing diameters
  • A belt-in-oil design for the camshaft and oil pump drive belts
  • An optimised valve-train and an all-new single-piece camshaft module

Ford is for the first time using a new mirror-image porting design for the integrated inlet manifold that precisely controls the flow of air into the cylinders – with the clockwise airflow for cylinder numbers one and two, reversed for cylinder numbers three and four.

This symmetrical arrangement ensures uniform mixing of fuel and air in the combustion chambers of all four cylinders, helping engineers more closely control the way the engine burns fuel. When fine-tuning the combustion process, computer experiments used measurements from more than 1,400 factors that affect performance of the valve lift and timing alone.

“Our first ever mirror-image inlet design in combination with an optimised combustion chamber layout helps us turn fuel into energy more effectively than any diesel engine we’ve ever produced,” Dr. Werner Willems, Ford technical specialist, Combustion Systems.

New fuel injectors are capable of delivering up to six injections per combustion event, with each injection taking as little as 250 microseconds (0.00025 seconds) and delivering 0.8 mg of diesel – equivalent to a grain of sugar. This tiny volume of fuel is injected through eight conical holes each 120 microns in diameter – about the width of a human hair.

Piezoelectric technology that uses electrically-responsive crystals to closely control fuel delivery – typically found in premium passenger-car engines – is incorporated into the body of the injector unit. The new injectors deliver reduced noise levels; minimal energy wastage from the fuel pump; more responsive and less intrusive Auto-Start-Stop performance; and real-time calibration correction for maximum fuel efficiency.

Advanced turbocharging
The all-new compact turbocharger has been specifically designed to deliver more air at lower engine rpm compared with the outgoing 2.2-litre TDCi engine, for a light and urgent feel across the rev-range and up to 340 Nm of torque at 1,250 rpm.

An aerodynamically advanced turbine wheel – made from Inconel, an alloy used in extreme temperature environments such as rocket engines – is reduced in diameter by almost 10 per cent. The aerospace aluminium grade compressor wheel is reduced in diameter by 15 per cent. The reductions decrease inertia and enable faster boost performance with wheel speeds up to 240,000 rpm, contributing to improved low-end torque.

“One important factor we noticed through customer feedback is a growing tendency for drivers to ‘creep’ their diesel powered vehicles by engaging the clutch while the engine is at idle – making low-down torque even more essential,” said Paul Turner, base engine technical leader, Ford of Europe.

Compressor wheels are milled from solid, rather than cast, improving tolerances to within two or three microns – around the size of a single bacterium – increasing durability and reducing noise and vibration. A new turbocharger actuator replaces a worm drive with a geared design that halves response times to 110 milliseconds – or the blink of an eye.

The new engine will comfortably meet future European emissions requirements supported by Ford’s first standardised selective catalytic reduction system. The system is close-coupled to the rear of the engine for maximum efficiency and excellent cold-driving performance. A short-loop exhaust gas recirculation channel is incorporated into the cylinder head, contributing to a more compact engine design and helping optimise cooling of gasses.

Enhanced refinement
The 2.0-litre Ford EcoBlue engine will be the first diesel commercial vehicle powertrain from Ford to achieve passenger car noise, vibration and harshness criteria, contributing to enhanced driving appeal.

The new engine radiates half as much sound energy at idle as the 2.2-litre TDCi diesel engine. A noise-optimised a cylinder-head, block, stiffening ladder-frame and oil pan are specifically developed to be desensitised to activity inside the engine, and non-flat mating surfaces are carefully designed to offer tight seals that trap noise within the engine.

“The basic structure of an engine can act as a soundboard for the movements happening inside it, just like a bell. So we try to develop a bell that does not ring very well,” said Dominic Evans, NVH specialist, Ford of Europe. “We’ve engineered every significant noise-influencing component of this engine to be quieter and smoother operating – resulting in the most refined diesel commercial vehicles Ford has ever built.”

A moulded acoustic cover that provides foam encapsulation of the cylinder head, and a front cover made from sound deadened steel, further prevent engine noise being transmitted to the cabin for a quieter driving environment. Additional measures taken to enhance NVH include:

  • Micro-geometry analysis of gear teeth down to a micron level (0.001 mm) to achieve perfect meshing for smoother operation and less high-frequency whine
  • An optimised oil pump featuring unevenly spaced vanes that break up the pump’s noise frequency to make it less perceptible to the listener
  • Advanced fuel injectors featuring integrated piezo-stacks, noise softening software and optimised pilot injection

 

Commercial vehicle durability
The new 2.0-litre Ford EcoBlue engine meets Ford's demanding global commercial vehicle durability standards for extreme usage in markets as diverse as Europe, the U.S. and China.
The engine's performance has been trialled through the equivalent of 5.5 million km (3.4 million miles) of durability testing including 400,000 km (250,000 miles) at the hands of real-world customers, comprehensive analysis in laboratories and at Ford vehicle proving grounds, and CAE evaluations at every stage of development.

The oil system – including the oil specification, oil pan and filter dimensions, bore distortion tolerances and piston ring specifications – has been engineered to extend oil life, and maintenance-free components include the camshaft belt, camshaft module, and water pump.

“We developed the 2.0-litre Ford EcoBlue engine using feedback from customers around the world,” Turner said. “The versatile design even allows the same block to be used for front-wheel drive and rear-wheel drive applications, and the sophisticated design and technologies deliver future-proofed fuel efficiency and emissions.”

# # #

* The declared Fuel/Energy Consumptions, CO2 emissions and electric range are measured according to the technical requirements and specifications of the European Regulations (EC) 715/2007 and (EC) 692/2008 as last amended. Fuel consumption and CO2 emissions are specified for a vehicle variant and not for a single car. The applied standard test procedure enables comparison between different vehicle types and different manufacturers. In addition to the fuel efficiency of a car, driving behaviour as well as other non-technical factors play a role in determining a car's fuel/energy consumption, CO2 emissions and electric range. CO2 is the main greenhouse gas responsible for global warming.

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http://europe.autonews.com/article/20150507/ANE/150509946?template=mobile02

 

Looks like this is a Ford design and the smaller will be PSA.

 

That's why I was a bit confused... the article you linked (and I remember reading about it) from a year ago said Ford and PSA will renew partnership for smaller diesels that will replace 1.4 and 1.6 liter units (while Ford will go it alone on 2.0 and above).

 

But in the OP article (and Ford PR), it said there will be a 1.5 liter version of this new 2.0 EcoBlue diesel. Where does that leave the "small displacement" Ford-PSA diesel?

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Is the block made of CGI?

 

What does Ford mean with "Compact high-strength cast iron block"

 

and lighter.

 

http://www.autocar.co.uk/car-news/new-cars/new-ford-ecoboost-diesel-engine-launched

Ford claims the new engine weighs 10-15kg less than the TDCi engine. These developments also allow the EcoBlue motor to take up less space.

A physically smaller engine family with lighter Cast Iron blocks than the ones used in the current 2.2.

 

As I suspected, Ford will continue with Cast Iron for its intermediate diesels so it can reuse existing machinery and tooling.

You don't need an ultra light CGI block in a Transit or Ranger, just being a lot lighter than the current engines is probably enough.

 

Let's not forget Ford has several Transit and Ranger diesel plants, Dagenham, Thailand and South Africa

so changing all of them over to CGI while continuing 3.2 I-5 for now may have been too hard...

Edited by jpd80
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A physically smaller engine family with lighter Cast Iron blocks than the ones used in the current 2.2.

 

As I suspected, Ford will continue with Cast Iron for its intermediate diesels so it can reuse existing machinery and tooling.

You don't need an ultra light CGI block in a Transit or Ranger, just being a lot lighter than the current engines is probably enough.

 

Let's not forget Ford has several Transit and Ranger diesel plants, Dagenham, Thailand and South Africa

so changing all of them over to CGI while continuing 3.2 I-5 for now may have been too hard...

 

I believe Ford will develop The replacements For the Lion V6 and V8 using this design, i'd expect the V6 and V8 to use CGI blocks instead of grey iron.

 

a 250hp/375ft/lbs V6 would be great in the Transit and F150.

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I believe Ford will develop The replacements For the Lion V6 and V8 using this design, i'd expect the V6 and V8 to use CGI blocks instead of grey iron.

 

a 250hp/375ft/lbs V6 would be great in the Transit and F150.

As you know, the Lion V6 and V8 already use CGI blocks, it's not hard to imagine that engine series getting a heavy makeover

to address now out of date technology. Keep in mind how advanced those designs were when delivered years before

VM Motori had their V6 diesel. The areas for upgrade may be restricted to add ons like injectors and turbo chargers.

 

 

According to the Ford release the new 2.0 diesel replaces the 2.2 Puma in Transit and ranger as well as the 2.2 PSA diesel in cars

so this is a win-win for scales of economy. The smaller sub 2.0 capacty is important in ROW as it's linked to taxes applied to

capacity and CO2 levels. Ultimately, I'd expect a new larger sub 3.0 diesel for ranger and Transit that gives even better fuel economy.

 

Ford does mention this as an engine series so perhaps we see 2.0, 2.4 and a 3.0 diesel as a slight refinement of the

capacities currently supplied by the Puma and PSA engines. Lots of possible permutations.

Edited by jpd80
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Notice the engine uses SCR. I don't think they will have any issues. The problems seem to arise when auto manufacturers try to meet NOX regulations without SCR.

Yes, VW tried to save money by using with NOX traps that were purged by running the engine rich for about 10 seconds.

The other area is when manufacturers try to skimp on the amount of AdBlue used to make refills less frequent.

 

Ford has probably nailed current and foreseeable future requirements regarding NOX and particle emissions in particular.

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As you know, the Lion V6 and V8 already use CGI blocks, it's not hard to imagine that engine series getting a heavy makeover

to address now out of date technology. Keep in mind how advanced those designs were when delivered years before

VM Motori had their V6 diesel. The areas for upgrade may be restricted to add ons like injectors and turbo chargers.

 

 

According to the Ford release the new 2.0 diesel replaces the 2.2 Puma in Transit and ranger as well as the 2.2 PSA diesel in cars

so this is a win-win for scales of economy. The smaller sub 2.0 capacty is important in ROW as it's linked to taxes applied to

capacity and CO2 levels. Ultimately, I'd expect a new larger sub 3.0 diesel for ranger and Transit that gives even better fuel economy.

 

Ford does mention this as an engine series so perhaps we see 2.0, 2.4 and a 3.0 diesel as a slight refinement of the

capacities currently supplied by the Puma and PSA engines. Lots of possible permutations.

 

I think the opportunity to Clean Sheet the design of those engine using Cylinder design optimization, parts and tooling from the new 2.0 would outweigh the benefits of redesigning the current Lion engines, which were released in 2004.

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I think the opportunity to Clean Sheet the design of those engine using Cylinder design optimization, parts and tooling from the new 2.0 would outweigh the benefits of redesigning the current Lion engines, which were released in 2004.

I never said redesigning the Puma, you simply read what you wanted to see...

 

I said a refinement of the capacities currently supplied by Puma and PSA engines.

In as much as reworking 2.2 to be a 2.0 and the 3.2 to be a 3.0 to get under capacity taxes....

 

Th release calls it an engine series and that ultimately implies more than one capacity.......

Before Ford announced it as EcoBlue, the project was called Panther...

Edited by jpd80
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I never said redesigning the Puma, you simply read what you wanted to see...

 

I said a refinement of the capacities currently supplied by Puma and PSA engines.

In as much as reworking 2.2 to be a 2.0 and the 3.2 to be a 3.0 to get under capacity taxes....

 

Th release calls it an engine series and that ultimately implies more than one capacity.......

Before Ford announced it as EcoBlue, the project was called Panther...

 

If you re read my post I was only referring to the Lion family of V6 and V8 engines not to the puma class which is dead AFAIK

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If you re read my post I was only referring to the Lion family of V6 and V8 engines not to the puma class which is dead AFAIK

It's not dead until Ford switches over three engine plants, it still needs lots of 2.2, 2.4 (Transit) and 3,2 engines elsewhere in the world.

If Ford is going to change all of those plants engine , then it's pretty clear that all the machining processes will stay the same but some

measurements will differ. Yes, a lot of the change is in the castings and fine tuning the design of blocks and heads to allow

modern advances in design and technology.

 

Unless Ford has a heavy contract coming for Lion 3.0V6 and 4,4V8, there is no financial justification for anything more than a good makeover

the contract with J/LR was reported as being 10 years, so unless J/LR tips in more money, then those engines remain as they are.

Edited by jpd80
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It's not dead until Ford switches over three engine plants, it still needs lots of 2.2, 2.4 (Transit) and 3,2 engines elsewhere in the world.

If Ford is going to change all of those plants engine , then it's pretty clear that all the machining processes will stay the same but some

measurements will differ. Yes, a lot of the change is in the castings and fine tuning the design of blocks and heads to allow

modern advances in design and technology.

 

Unless Ford has a heavy contract coming for Lion 3.0V6 and 4,4V8, there is no financial justification for anything more than a good makeover

the contract with J/LR was reported as being 10 years, so unless J/LR tips in more money, then those engines remain as they are.

 

I see,

 

I think ford knows the market for Diesels in passenger cars is shrinking, which is why it is no longer affordable to to maintain parallel programs.

If ford is consolidating commercial and consumer Diesels and has to meet new emission standards why duplicate efforts, with two engine families espcailly with the large displacement Lion and puma engines?

 

If the largest engineering expense in modern engines is cylinder modeling why not develop an entire engine family based upon the EURO VI/ EPA tier III compliant 2.0 engine?

 

If ford Touts this motor as Game-Changing why not expand it to other configurations?

 

in 2012

 

Ford, PSA end tie-up on large diesel engines

http://www.autonews.com/article/20120405/COPY01/304059787/ford-psa-end-tie-up-on-large-diesel-engines

 

April 5, 2012 @ 11:06 am

TURIN -- Ford Motor Co. and PSA/Peugeot Citroen said they will end their partnership for joint development of large diesel engines.

Both companies said the move was not related to PSA's new alliance with General Motors Co.

The decision to develop larger diesel engines separately "was being discussed with PSA well before the GM-PSA announcement," a Ford spokesman told Automotive News Europe today. A PSA spokesman also said the decision "was not due to our alliance with GM."

A joint Ford-PSA statement said the two companies "have decided to independently develop and manufacture their larger diesel engines (2.0-liter and above) to meet their future needs as well as new regulations."

 

if this engine represents the Ford's first Post PSA effort why couldn't be the basis for replacing the PSA Lion V6 and V8 engines, Especially if the new engines can meet Euro 6.x standards at less cost than the Lion or Puma engines?

Edited by Biker16
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I see,

 

I think ford knows the market for Diesels in passenger cars is shrinking, which is why it is no longer affordable to to maintain parallel programs.

If ford is consolidating commercial and consumer Diesels and has to meet new emission standards why duplicate efforts, with two engine families espcailly with the large displacement Lion and puma engines?

 

If the largest engineering expense in modern engines is cylinder modeling why not develop an entire engine family based upon the EURO VI/ EPA tier III compliant 2.0 engine?

 

If ford Touts this motor as Game-Changing why not expand it to other configurations?

That is the plan, the 2.0 is part of a new engine family, you can bet that there will be at least one other capacity, maybe two

 

if this engine represents the Ford's first Post PSA effort why couldn't be the basis for replacing the PSA Lion V6 and V8 engines, Especially if the new engines can meet Euro 6.x standards at less cost than the Lion or Puma engines?

Now that J/LR has paid for US EPA compliant V6 TD, I'm betting that Ford will back end it for use in F150 as it now stands.

 

After 10 year engine supply deal with J/LR ends in 2018, it's anyone's guess what Ford will do.

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http://europe.autonews.com/article/20160506/ANE/160509947/-ford-cleans-up-its-diesels-in-europe?cciid=email-ane-daily

 

 

 

Ford cleans up its diesels in Europe Nick Gibbs
Automotive News Europe | May 6, 2016 06:01 CET

Ford Motor has joined Volkswagen Group and PSA/Peugeot-Citroen in switching to a technology said to be more effective in cleaning harmful emissions from diesel engines.

Tougher rules

Ford currently uses lean NOx traps (LNT) to reduce toxic output from its diesels.

It said the new EcoBlue 2.0-liter engine will replace its current 2.0-liter TDCI diesel unit in its car range but did not specify in which models. The automaker also plans to introduce a 1.5-liter EcoBlue diesel cars starting next year that can be configured to use both LNT and SCR.

The 2.0-liter EcoBlue also reduces CO2 emissions by up to 13 percent thanks to reduced friction losses, Ford said. It’s also quieter and in passenger car applications can deliver more than 200hp.


Ford will likely continue to use LNT in its smaller diesels even as EU regulators continue to tighten emissions rules in the wake of the VW scandal.

Ford of Europe’s head of product development, Joe Bakaj said the EU’s move to stricter testing of vehicle emissions does not necessarily mean that all diesel cars will need SCR technology. "It will still depend on vehicle weight and load," he toldAutomotive News Europe on the sidelines of

Edited by Biker16
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Jeez Biker, again copying the whole text......

 

 

This is interesting:

Ford currently uses lean NOx traps (LNT) to reduce toxic output from its diesels.

It said the new EcoBlue 2.0-liter engine will replace its current 2.0-liter TDCI diesel unit in its car range but did not specify in which models. The automaker also plans to introduce a 1.5-liter EcoBlue diesel cars starting next year that can be configured to use both LNT and SCR.

Euro NOX levels are significantly higher than those permitted by EPA

so it appears that the current 1.5-2.0 may still pass Euro 6 with NOX traps,

something carried over from previous Euro 4 and Euro 5 compliance levels.

 

Now, it looks like those old systems are right on the limits of compliance as

Ford moves to proper SCR exkaust aftertreatment with AdBlue. I wonder

how much increase in cost will be associated with this change and yeah,

I know that diesel is still preferred for fule economy there regardless of

the VW cheating fall out.

Edited by jpd80
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