| Ford EcoBoost engine | |
| Manufacturer: | Ford |
| Aka: | TwinForce (obsolete) EcoBoost SCTi GTDi |
| Production: | 2009–present |
| Configuration: | I3, I4 and 60° V6 |
| Displacement: | V6 3.5: 3496 cc (213 CID) V6 3.0: 2967 cc (181 CID) V6 2.7: 2694 cc (164 CID) I4 2.3: 2261 cc (138 CID) I4 2.0: 1999 cc (122 CID) I4 1.6: 1596 cc (97 CID) I4 1.5: 1500 cc (92 CID) I3 1.5: 1497 cc (91 CID) I3 1.0: 995 cc (60.44 CID) |
| Bore: | V6 3.5: 3.64 in (92.5 mm) V6 3.0: 3.36 in (85.3 mm) V6 2.7: 3.30 in (83 mm) I4 2.3: 3.45 in (87.55 mm)[1] 3.30 in (84 mm)[2] I4 2.0: 3.4 in (87.5 mm)http://thenewmondeo.fordmedia.eu/ I4 1.6: 3.1 in (79.0 mm)[3] I3 1.5: 3.31 in (84 mm) I3 1.0: 2.83 in (71.9 mm) |
| Stroke: | V6 3.5: 3.41 in (86.7 mm) V6 3.0: 3.39 in (86 mm) V6 2.7: 3.30 in (83 mm) I4 2.3: 3.7 in (94.0 mm) 4.0 in (102 mm) I4 2.0: 3.27 in (83.1 mm) I4 1.6: 3.2 in (81.4 mm) I3 1.5: 3.54 in (90 mm) I3 1.0: 3.2 in (82 mm) |
| Weight: | V6 3.5: 449 lbs (203 kg) V6 3.0: 445 lbs (202 kg) V6 2.7: 440 lbs (200 kg) I4 2.0: 328 lbs(149 kg) I4 1.6: 251 lbs (114 kg) I3 1.0: 213 lbs (97 kg)[4] |
| Block: | V6 2.7: Compacted graphite iron I3 1.0: Cast iron All others: Aluminum |
| Head: | Aluminum |
| Valvetrain: | DOHC with Direct Acting Mechanical Buckets (DAMB) Variable camshaft timing |
| Turbocharger: | V6: Dual Borg Warner K03 low inertia integrated turbo system I4 2.3: Honeywell Garrett Twin scroll MGT2260SZ (Mustang Ecoboost) I4 2.0: Borg Warner K03 low inertia integrated turbo system I4 1.6: Borg Warner KP39 low inertia turbo I3 1.5: Continental RAAX low-inertia turbocharger |
| Fuelsystem: | Gasoline direct injection or dual injection |
| Management: | V6: Bosch [5] I4 2.0: Bosch MED17 with CAN-Bus and individual cylinder knock control I4 1.6: Bosch MED17 with CAN-Bus and individual cylinder knock control I3 1.5: Bosch MG1CS016 with CAN-Bus and individual cylinder knock control. FGEC software |
| Fueltype: | Gasoline |
| Oilsystem: | Wet sump |
| Coolingsystem: | Water-cooled |
| Compression: | V6 3.5: 10.0:1(10.5:1 MY2017) V6 3.0: 9.5:1 V6 2.7: 10.3:1 I4 2.3: 9.5:1, 10.6:1 I4 2.0: 10.0:1 I4 1.6: 10.0:1 I3 1.5: 9.7:1 |
EcoBoost is a series of turbocharged, direct-injection gasoline engines produced by Ford and originally co-developed by FEV Inc. (now FEV North America Inc.).[6] EcoBoost engines are designed to deliver power and torque consistent with those of larger-displacement (cylinder volume) naturally aspirated engines, while achieving up to 20% better fuel efficiency and 15% fewer greenhouse emissions, according to Ford.[7] The manufacturer sees the EcoBoost technology as less costly and more versatile than further developing or expanding the use of hybrid and diesel engine technologies. EcoBoost engines are broadly available across the Ford vehicle lineup.[8]
EcoBoost gasoline direct-injection turbocharged engine technology adds 128 patents and patent applications to Ford's 4,618 active and thousands of pending US patents.[9] Some of the costs of US development and production were assisted by the $5.9 billion Advanced Technology Vehicles Manufacturing Loan Program of the Department of Energy.[10]
The V6 EcoBoost engines are being assembled at Cleveland Engine Plant No. 1 in Brook Park, Ohio.[11] The 2.0-liter I4 EcoBoost engines were produced at the Ford Valencia Plant in Spain in 2009.[12] The 1.6-liter I4 EcoBoost engines are assembled at the Ford Bridgend Engine Plant in the United Kingdom.[13] The smaller 1000cc-displacement 3 cylinder EcoBoost engine is produced both at Ford Germany in Cologne and at Ford Romania in Craiova.
By 2012, the company planned to produce 750,000 EcoBoost units annually in the US and 1.3 million globally in the world market. Ford expected over 90% of its global vehicle lineup (includes North America) to offer EcoBoost engine technology by 2013.[12] [14] From the engine's beginning to November 2012, 500,000 Ford EcoBoost vehicles have been sold.[15]
During Ford's ownership of Volvo (until 2010), it used the term PTDi (petrol turbocharged direct injection) for the 1.6 L I4 engine when introducing Volvo S60 concept[16] and for the 2.0 L I4 engine when introducing Volvo XC60.[17]
Ford has had to refund hundreds of customers worldwide because Ford EcoBoost engines in their vehicles have overheated and, in some cases, caused engine fires.[18] In 2015, a South African man died after becoming trapped in his Ford Kuga after its 1.6-litre EcoBoost engine burst into flames.[19] In 2017, Ford South Africa recalled all Kugas in the country for engine checks.[20]
| Name | Family | Displacement | Year | Features |
|---|---|---|---|---|
| EcoBoost 1.0 | Fox | 999cc | 2012–present | DOHC I3 |
| Ti-VCT 1.1 | Fox | 1084cc | 2017–present | DOHC I3 |
| EcoBoost 1.5 | Ford Sigma engine | 1500cc | 2014–present | DOHC I4 |
| EcoBoost 1.5 | Dragon | 1497cc | 2017–present | DOHC I3 |
| EcoBoost 1.6 | Ford Sigma engine | 1596cc | 2010–present | DOHC I4 |
| EcoBoost 2.0 | Mazda L engine | 1999cc | 2010–2014 | DOHC I4 |
| EcoBoost 2.0 twin scroll | Clean-sheet engine block[21] | 1999cc | 2015–present | DOHC I4 |
| EcoBoost 2.3 | Mazda L engine | 2261cc | 2015–2024 | DOHC I4 |
| EcoBoost 2.7 | Nano | 2694cc | 2015–present | DOHC V6 |
| EcoBoost 3.0 | Nano | 2967cc | 2016–present | DOHC V6 |
| EcoBoost 3.5 | Cyclone | 3496cc | 2010–present | DOHC V6 |
Ford produces a 1.0 L turbocharged in-line three-cylinder engine for the EcoBoost family developed at Ford's Dunton Technical Centre in the UK. Production started in April 2012. The 1.0 is built initially in two versions: 74kW and 88to.
Both versions deliver a maximum of 170Nm from 1,400 to 4,500 rpm, whereas higher performing versions can provide up to 200Nm on overboost for 30 seconds, which makes for a broad torque curve when compared to a naturally aspirated gasoline engine. A 140PS version has also been released in the Fiesta Red Edition and Black Edition (some markets), as well as the Focus ST-Line, with 155lb.ft of torque. The engine block is cast iron, which offers, in addition to the required strength, up to 50% faster warm-up than aluminum, at the expense of additional weight.[22] [23]
To quell the natural vibrations of a three-cylinder design, unspecified efforts have been made in the flywheel design to ensure satisfactorily smooth running without the use of energy sapping balance shafts. The 1.0L EcoBoost GTDI engine uses an oil-bathed timing belt.[24]
The engine is packaged in an engine block with a footprint the size of an A4 sheet of paper.[25] With the introduction of the face-lifted 2013 Ford Fiesta, Ford introduced a naturally aspirated version of 1.0 Fox engine. The two versions produce 65 hp and 80 hp, and both engines use direct injection and Ti-VCT like the turbocharged versions. Start-stop technology is also available.
The engines are produced in Cologne (Germany), Craiova (Romania) and Chongqing (China). Production is expected to be 700,000–1,500,000 units per year.
The 1.0 L EcoBoost engine was introduced to the American market with the 2014 Ford Fiesta sedan and hatchback, although cars with this engine did not sell particularly well. It was announced at the 2012 Los Angeles Auto Show, when the Fiesta was introduced. The 123-hp version debuted in the North American market Focus in the 2015 model year. The engine accounted for less than 5 percent of Fiesta and Focus sales in the U.S., according to a 2017 report.[26] The 1.0 L engine was awarded the International Engine of Year Award 2016, making it the Best Engine Under 1.0 L for the fifth time in a row.[27] After the discontinuation of the Focus and Fiesta in North America, the 1.0 L is only available there in the EcoSport.
In 2017 Ford was again awarded International Engine of Year (for Engines Under 1.0 L) with a largely reconfigured version of the Ecoboost 1.0. Although thermodynamically similar to the old Ecoboost 1.0, the new engine features cylinder deactivation under low-load conditions. A new dual-mass flywheel and a vibration-damping clutch disc (in manual-transmission vehicles) help neutralise engine oscillations when running on two cylinders.[28] Production started in 2018.
In 2019, Ford launched an mHEV version of the 1.0 EcoBoost engine first fitted to the Puma SUV, which uses a belt-driven integrated starter/generator-motor (BiSG); which is in essence a starter motor, alternator, and propulsion motor in one. Fundamentally, the engine is identical to the 2018–present 1.0 EcoBoost, but features the electric starter/generator and its battery system. The motor itself is not used to propel the vehicle on its own, and is mainly used to increase efficiency by reducing engine load, provide extra power during acceleration, and to reduce the perceived ‘turbo-lag’ at certain engine speeds while accelerating. The starter/generator makes use of a 48-volt battery system in the car, although vehicles fitted with these engines are not plug-in hybrids or full hybrids. Further developments introduced include a more comprehensive ‘start-stop’ functionality, which was previously available but did not cut the engine off until the vehicle was completely stopped. The new engines can turn off while the car decelerates, at a maximum speed of about 15 mph. The new, electrified engines are available with a manual- or Ford's new seven-speed dual-clutch PowerShift automatic transmission, and are available in either 125 bhp or 154 bhp outputs.
In 2024, 139,730 US-market Fox engines are subject to a safety recall. The oil pump belt tensioner may fail and/or the belt may fail resulting in a loss of oil pressure causing severe engine damage and/or lockup and loss of power braking assist. Before the recall there were 2,099 allegedly-related warranty claims.[29]
85PS
100PS
125PS
140PS
155PS (EcoBoost Hybrid (MHEV)) & 125 PS (92 kW; 123 hp) (EcoBoost Hybrid (MHEV))
70PS
85PS
On 24 February 2017, as part of the unveiling of the seventh generation (Mk8 - UK) derived Fiesta ST, Ford announced an all-new aluminum inline 3-cylinder 1.5 L EcoBoost engine with cylinder deactivation technology.[30] The version of this engine announced for the Fiesta ST produces 200PS at 6,000 rpm and delivers 290Nm of torque from 1,600 to 4,000 rpm.[31]
The engine is based on an expansion of the 1.0 EcoBoost, taking the capacity per cylinder up to 500cc which Ford consider is likely to be the maximum for optimum thermal efficiency.[32] The engine is an all-aluminum design with integrated exhaust manifold, low inertia mixed flow turbocharger and combines both port fuel injection and direct fuel injection.
The engine will be available with cylinder deactivation technology, implemented by stopping fuel delivery and valve operation for one of the engine's cylinders in conditions where full capacity is not needed.
150PS
182PS
200PS
Four versions of EcoBoost I4 engines are in production. A 1.5 L downsized version of the 1.6 L, the 1.6 L which replaces larger-displacement, naturally aspirated I4 engines in Ford vehicles, a 2.0 L which replaces small-displacement, naturally aspirated V6 engines, and a 2.3 L used in high-performance applications. All four engines are turbocharged and direct injected. The production engine family was officially announced at the 2009 Frankfurt Motor Show.[33]
A 1.5 L version of the EcoBoost engine family was first unveiled in the 2014 Ford Fusion as a downsized version of the 1.6 L EcoBoost engine.[34] The downsized displacement is a result of Chinese vehicle tax regulations which tax vehicles with engine displacements of 1.5 L or less at lower rates. The 1.5 L EcoBoost adds new technology compared to the 1.6 L on which it is based, including an integrated exhaust manifold and a computer-controlled water pump clutch to decrease warm up time. In the 2015 Fusion, the engine produces 1810NaN0 and 185 lb ft .
1840NaN0
1810NaN0
1620NaN0
1600NaN0
1500NaN0
The European market version of the 1.6 L provides 1500NaN0, although a 160hp version is used in the Ford Mondeo.
The 1.6 L EcoBoost engine is raced in the British Formula Ford Championship. The units have replaced the original N/A 1.6 L Duratec units, which in turn replaced the 1.8 L Zetec-engined cars. The engine has also been used for the past few seasons in the WRC in the Ford Fiesta.
The 1.6 L EcoBoost engine is also produced at the Ford Bridgend Engine Plant in Bridgend, Wales.
In 2013, Ford has recalled certain Ford Escapes equipped with this engine due to the potential for them to catch fire after overheating.[36]
In 2017, Ford recalled over 360,000 Ford Escape, Ford Fiesta ST, Ford Fusion, Ford Transit Connect, Ford Focus and C-Max hybrid with 1.6 ecoboost engines because of a risk of engine fires caused by a "lack of coolant circulation". There were 29 fires in the U.S. and Canada reported to Ford. The recall partly contributed to a charge of US$300 million by Ford.[37] [38]
Type-turbocharged, direct gasoline-injected inline four-cylinder engine with twin independent variable-camshaft timing
Displacement-1,596 cc (1.6 L; 97 cu in)
1200NaN0
1500NaN0
1600NaN0
1800NaN0
1850NaN0
2000NaN0
It is the first EcoBoost engine to include twin independent variable cam timing (Ti-VCT), with advertised 10–20% better fuel economy while maintaining the performance of 3.0 L V6s.[40] [41]
This engine is derived from the 2.0 L Mazda L engine block used by Ford in the North American Focus MK3, but equipped with unique heads, fuel injection system, and Ford's Ti-VCT. It should not be confused with the Mazda 2.3 DISI Turbo, which also features direct injection along with turbocharging, but shares little else aside from the same engine block.
The 2.0 L EcoBoost engine used in North American vehicles is now produced at the Cleveland Engine Plant in Brook Park, Ohio.
Type- turbocharged, direct gasoline-injected inline four-cylinder engine with Ti-VCT
Displacement-19990NaN0
Although not listed some 2.0 EcoBoost engines have a different block design including alternate weaker deck design and cooling ports missing. When installed in Volvos, these engines are called B4204T6 and T7.
It should also be noted that North American-spec and European-spec engines have different cylinder heads: North American market vehicles use a cylinder head with an integrated exhaust manifold, while European-spec vehicles use a cylinder head with individual exhaust ports and a conventional exhaust manifold.
A redesigned 2.0 L EcoBoost four-cylinder was introduced with the second-generation Ford Edge, followed by the 2017 Ford Escape in spring 2016.[53] It features a higher compression ratio than its predecessor (10.1:1 vs 9.3:1), with the exception of the Maverick,[54] along with a twin-scroll turbocharger and fuel and oil systems upgrades, as well as a redesigned block and cylinder head.[55] This new engine will deliver more low-end torque than its predecessor. It is expected to tow in the redesigned Edge and 2017+ Escape.
The 2.3L version of the EcoBoost engine debuted in the 2015 Ford Mustang and also the Lincoln MKC crossover and has been implemented in many Ford and Lincoln vehicles with various outputs.
The 2.3 L EcoBoost engine is produced with the 2.0 L EcoBoost at the Valencia Engine Plant in Valencia, Spain. In March 2015 Ford announced the official production start of the all-new twin-scroll 2.0-liter and 2.3-liter EcoBoost engines for North America at its Cleveland Engine Plant in Ohio.[59]
Introduced with the 2015 Ford F-150 is a twin-turbo 2.7 L V6 EcoBoost engine. It delivers about 3250NaN0 and 3750NaN0.[71] The engine is built at the Lima Ford Engine Plant.[72] Ford has invested US$500 million in the Lima plant for the new engine. Ford also states that the new engine will bring 300 jobs to Allen County, Ohio,[73] but transfers from other plants make the actual number hard to pin down. A 335-hp version is to be an option on the 2017 Lincoln Continental. Being a next-generation design, it uses a two piece block design. Compacted graphite iron, a material Ford uses in its 6.7 L PowerStroke diesel engine, is used for the upper cylinder section with aluminum used for the lower stiffening section of the block.[74]
The second generation 2.7L EcoBoost V6 was introduced with the 2018 Ford F-150 and is mated to a 10-speed transmission that debuted the year prior. It produces an additional 250NaN0 of torque over the first generation. The engine uses a compacted-graphite iron (CGI) block, which is both high strength and lightweight.
It boasts a number of changes from the first generation, with many carrying over from the second generation 3.5L EcoBoost engine that arrived a year earlier in the F-150. The most prominent change being the addition of port fuel injection, while keeping the direct injection system. It also has reduced internal friction to improve power and fuel economy, and new exhaust gas recirculation system.[77] The specific output of the engine is now 121 hp/L, versus the 395-hp Ford Coyote 5.0L naturally aspirated V-8 which has a specific output of only 78 hp/L. The peak torque matches the 5.0L V-8, albeit at a lower 2,750 rpm vs. 4,500 rpm for the V-8.
Additional changes include a new lightweight cam to save weight, dual-chain cam drive system that is stronger and reduces parasitic friction loss, a new electrically actuated wastegate that provides more accurate turbo boost control, a high-pressure exhaust gas recirculation system, and a variable-displacement belt-driven oil pump that is electronically controlled to modulate oil flow to further reduce parasitic losses.[78]
A 3.0L V6 twin-turbocharged gasoline direct-injection engine, derived from the 2.7 L EcoBoost, was released in 2016 that produces between 350 and 400 horsepower. The 3.0 L is gradually replacing the 3.7 L Ti-VCT Cyclone V6 engine in various vehicles, including the MKZ, Continental, Aviator, Ford Explorer and the 2022 Ford Bronco Raptor. The 3.0-liter version of the engine was created by increasing the 2.7-liter's cylinder bore in the CGI-block from 83.0 millimeters to 85.3, and by lengthening piston stroke by 3.0 millimeters (to 86.0).[80]
The first Ford vehicle to feature this engine was the 2007 Lincoln MKR concept vehicle under the name TwinForce.[81] The engine was designed to deliver power and torque output equivalent to a typical 6.0 L or larger-displacement V8 while achieving at least 15% better fuel efficiency and reduced greenhouse emissions. In the MKR, the concept TwinForce engine was rated at 4150NaN0 and 4000NaN0 of torque, as well as run on E85 fuel.[82] When the same prototype engine reappeared in the Lincoln MKT concept in 2008 North American International Auto Show, the name was changed to EcoBoost. Official EcoBoost production began on May 19, 2009 at Cleveland Engine Plant No. 1.
The production engines use the Duratec 35 V6 engine block. The fuel charging and delivery systems can attain high fuel pressures up to 2150psi, necessary for efficient operation of the direct fuel injection system. The F-series EcoBoost 3.5L V6 uses two BorgWarner K03 turbochargers which can spin up to 170,000 rpm and provide up to 15disp=flipNaNdisp=flip of boost. The transverse EcoBoost 3.5L V6 uses two Garrett GT1549L turbochargers and provides up to 11psi of boost. The turbos are set up in a twin-turbo configuration. The engine can consume up to 25% more air over the naturally aspirated counterpart. Through the use of direct injection, the engine needs only regular-grade gasoline to run. The EcoBoost V6 was first available as an engine option for 2010 Lincoln MKS, followed by 2010 Ford Flex, 2010 Ford Taurus SHO, and 2010 Lincoln MKT.[83] The fuel-charging and -delivery systems were co-developed with Robert Bosch GmbH.[84]
In 2009, Ford modified an experimental 3.5 L V6 EcoBoost engine with both E85 direct injection and gasoline indirect fuel injection, which achieved a brake mean effective pressure of 395disp=flipNaNdisp=flip (27 bar), which translates to roughly 553lbft of torque and at 3000 rpm (flat torque curve from 1500–3000 rpm).[85]
The second generation 3.5L EcoBoost V6 (codename D35) was introduced for the 2017 Ford GT, revealed at the 2015 Detroit Auto Show in January, as well as the 2017 F-150, 2018 Expedition and 2018 Navigator.[94] It produces up to 6470NaN0 [95] paired with a seven-speed semiautomatic transmission. This engine replaces the 5.4 L supercharged modular V8 from the last generation Ford GT. The GT was on an 11-year hiatus and returned in 2016 for the 2017 model year.
Also announced at the 2015 Detroit Auto Show was the 2017 Ford F-150 SVT Raptor, which is powered by an all-new 3.5 L twin-turbocharged EcoBoost V6.[96] This new engine will produce 450 horsepower in the Raptor, up from the previous 6.2-L V8's 411.
The same second-generation 3.5L V6 is replacing the first-generation engine in the 2017 F-150 line-up. It will be standard on the F-150 Limited and remain an optional upgrade for other trim levels. Paired with the second-generation 3.5L EcoBoost V6 is the new 10R80 10-speed automatic transmission that was designed in partnership with GM, Ford leading the development team.[97] This new transmission will be outfitted on all second-generation 3.5L V6 EcoBoost F-150s. The 10-speed will be exclusive to the 3.5L EcoBoost engine in F-150s for the 2017 model year.The most prominent change is the addition of port fuel injection, while keeping the direct injectors. The port fuel injection was partly added due to the fuel output needs on the 3.5L HO Raptor engine, but also has several benefits for the 3.5L EcoBoost. It will prevent buildup on the intake valves and keep them clean due to fuel passing over the valves. Under certain engine conditions such as low rpm and low loads the high-pressure fuel pump and direct injection system will turn off and the engine will only use the port fuel injection, reducing efficiency losses due to the HPFP. Both systems will operate at cold start, which will reduce emissions that direct injection suffers due to cold cylinder walls and lower fuel atomization.
Turbocharger changes include electronically actuated wastegates, turbine wheels now made with lighter Mar-M-247 super-alloy increasing responsiveness, and the same 51 mm turbine wheels but with sharper vane angles allowing between 2.5psi and 16psi higher boost. The turbochargers continue to be supplied by Borg Warner.
The cam drive system changed from a single primary chain to a stronger two primary chain system with separate chains driving each cylinder bank. In addition to dual primary chains, the side plates on the chains were also thickened. The cam chain drive sprocket on the crankshaft is a double gear arrangement to drive the two primary chains. These two changes were done to improve the harmonics, and are also stronger to help minimize the chain stretch that can occur over time on the 1st generation 3.5L EcoBoost.
The camshafts were made hollow for weight savings, along with the addition of a roller-finger follower valvetrain. The compression ratio was increased from 10.0:1 to 10.5:1 (except on the 3.5L EcoBoost HO for the Raptor, which remains at 10.0:1).
The camshaft VCT (phaser) design was also changed to improve reliability and reduce the development of an engine start-up tapping/rattling noise over time. However, the VCT units are found to be failing around 40-80k miles, requiring a replacement to resolve.
Ford has issued multiple service bulletins, with the most recent being Customer Satisfaction Program 21N03 – Supplement #4.[98] This program extended warranty coverage under certain conditions for a VCT replacement due to tapping phasers.The latest VCT part number (ML3Z prefix) is a significant redesign and so far has been durable and not shown the rattling/tapping issue develop.
Ford uses a single piston cooling jet per cylinder, but the oil volume was increased. The underside of the pistons were also redesigned to better transfer heat into the oil.
The engine also features auto start/stop, which decreases emissions during city driving by shutting the engine off in extended idling periods.
The engines are also 4lbs lighter than the previous 3.5L EcoBoost.[99]