Improved Performance, Fuel Efficiency - FPV Range
IMPROVED PERFORMANCE AND FUEL EFFICIENCY FOR NEW FPV RANGE
AUCKLAND, New Zealand, 28th May, 2008
Ford Performance Vehicles (FPV) has spent more than two years and 29,000 engineering hours designing, validating and releasing its new generation F6 and V8 engines - the 310kW F6 and the Boss 315 V8.
"For the first time in the history of our company the turbo six and V8 engines were designed in parallel” Ford Performance Vehicles General Manager Rod Barrett said.
“Our latest generation of engines deliver the ideal combination of real world performance, driveability and fuel efficiency.
"Power and torque have increased across both engines, while improvements to engine refinement and fuel efficiency are also key components of the new FG range."
4.0-litre turbo charged DOHC 24 valve in-line 6 engine
FPV has developed its 310kW F6 engine to deliver more power, more torque and improved engine efficiency.
Featuring a new strengthened piston and conrod assembly and a complete re-calibration, the new F6 310 is Ford Performance Vehicles’ best in-line turbo six-cylinder package yet.
Maximum power has increased by a massive 40kW to 310kW at 5500 rpm and is matched by a peak torque of 565Nm at 1950-5200 rpm, (up 15Nm from the previous F6 270 engine).
To obtain this significant increase in performance, the inlet and exhaust systems have been re-designed and the camshaft timing revised.
Increased turbocharger boost pressure and a new, bigger intercooler also play a key role in delivering more power, more torque and improved performance feel.
The compression ratio has been reduced from 8.7:1 to 8.47:1 to allow optimum compromise between turbo boost and spark timing, resulting in improved overall engine efficiency and driveability.
A new, higher efficiency Garrett turbocharger – developed specifically by FPV – features a larger compressor wheel, different compressor housing and an upgraded wastegate specification.
Maximum turbocharger boost pressure has increased to 0.91 bar, or 13.3 psi.
The new larger intercooler reduces unnecessary losses in the intake and allows for a higher air intake pressure. Additionally, an improvement in heat rejection allows lower intake manifold air temperatures in all conditions.
Both improvements to the intercooler maintain engine efficiency and deliver substantial gains by way of:
• a 22 percent increase in intercooler core volume
• a 45 percent improvement in heat rejection
• a 34 percent reduction in pressure drop
“The intercooler remains in the existing position; it is chassis mounted in front of the radiator, however it has better airflow because we have removed the grill in front of it.” FPV’s Head of Powertrain Engineering Bernie Quinn said.
“We have re-tuned the wastegate to allow us to reliably achieve 310kW without any unwanted surges due to variation in boost pressure. The improvements made to the intake system, particularly the intercooler, have allowed us to maintain high levels of performance even in high ambient conditions.”
An all new intake manifold contributes to the improved torque delivery and engine responsiveness through the entire operating range.
An all-new exhaust manifold has been tuned to minimise exhaust gas flow restriction into the turbocharger and optimise the flow balance from cylinder to cylinder.
Engineers focused on volumetric thermal efficiency to ensure that losses were kept to an absolute minimum. A new “low loss” short path Air Intake System was developed to reduce losses and improve throttle response.
“With 100 percent of the peak torque available all the way from 1950 rpm to 5200 rpm, the new F6 310 engine transforms the performance feel of our F6 range, delivering seamless power and fantastic responsiveness across all driving conditions," Quinn said.
The Boss 315 engine features a number of unique FPV engine upgrades and components:
• New camshaft timing and a new camshaft profile that gives higher lift and extended duration.
• The compression ratio has been increased from 10.5:1 to 11:1 for a major improvement in engine response and overall engine efficiency.
• Twin Plate Throttle Body improves volumetric efficiency and reduces pressure loss through the induction system.
• New upper intake manifold plenum chamber for optimised air flow.
• A new high flow “straight-through” twin exhaust system and new stainless steel exhaust manifolds which maximise powertrain sound quality and minimise back pressure.
• An increase in engine speed range, from 6000 rpm to 6500 rpm.
• New windage tray which reduces crankshaft windage engine parasitic losses.
The Boss 315 engine has also been equipped with a new oil pan, which has been designed to suit the new front structure design in the FG Falcon, along with new exhaust manifolds to suit the new body structure.
It also employs cylinder cut on gearshifts in automatic transmission vehicles, for improved shift timing and overall shift refinement.
Significant work was conducted to control and eliminate torsional vibration of the crankshaft, in order to achieve a higher rev range. This, combined with improvements to piston assembly strength and increases in engine volumetric efficiency, has allowed an increase of maximum revs from 6000 rpm to 6500 rpm.
FPV invested heavily in improving fuel efficiency and the Boss 315 provides a seven percent improvement in fuel consumption with 14L/100km for the automatic transmission, down from 15.1L/100km in the BF MkII.
“It was always part of our brief to increase power and improve fuel efficiency, and by reducing losses and freeing the engine up we have increased the engine speed range. This means we’re able to get more air into the engine and that’s where we gain the extra power,” Quinn said.
FPV engineers conducted a substantial amount of durability testing, with a total of over 1800 hours of high speed load engine durability on the dyno, followed by thousands of kilometres of powertrain durability tests and a series of manifold shock testing.
FPV also conducted 18 months of solid calibration testing, particularly in the areas of knock control, base engine emissions and fuel economy.
“During our mechanical development, we created our designs then went chasing those designs and ideas with specific testing. We did a significant amount of development to optimise cam timing and valve lift, throttle body design and air cleaner filter selection,” Quinn said.
“We’ve broadened the torque curve so that it picks up better at a lower rev range and gives the driver easier access to torque, so you get that drive all across the rev range. By increasing the torque in the useable, mid-speed engine range we’ve also given the driver more flexibility in overtaking manoeuvres.
“As a result, the car accelerates fasters, while also feeling lighter and more powerful.”
New six-speed manual
A new six-speed manual transmission has been introduced with the FG FPV range, the new Tremec TR6060.
The Tremec TR6060 is now fitted to all manual transmission variants in the FG FPV range – replacing the T56 six-speed manual on previous F6 and GT sedan and ute models.
"Revised fifth and sixth gear ratios on all manual transmissions has improved NVH and highway-cruise efficiency via the reduced engine speed for a given road speed in those gears.
"Also included in the range of developments on the new manual transmission is a new synchroniser package, which provides improved shift precision and shift feel, and reduced shift effort and travel."
The new synchroniser package features triple synchromesh on first and second gears, and double synchromesh on all other gears, including reverse, which has significantly reduced gear shift efforts and shift travel.
The reduced shift travel provided by the synchroniser package has also allowed increased space for the use of larger gears, which are stronger to deliver improved torque capacity and gearbox durability.
A new single-piece countershaft also contributes to the greater torque capacity and durability advancements.
Ford Motor Company, a global automotive industry leader based in Dearborn, Mich., manufactures or distributes automobiles in 200 markets across six continents. With about 245,000 employees and about 100 plants worldwide, the company’s core and affiliated automotive brands include Ford, Jaguar, Land Rover, Lincoln, Mercury, Volvo and Mazda. For more information regarding Ford’s products, please visit www.fordvehicles.com.