Ford’s “Beat to Hell and Back” 3.5L EcoBoost – Tear down for the Crowds

Discussion in 'Ford' started by xcel, Jan 26, 2011.

  1. xcel

    xcel PZEV, there's nothing like it :) Staff Member

    [​IMG] In a very public reveal, Ford’s F-150 EcoBoost ‘Hero’ engine #448AA after over 165,000 miles of grueling torture testing is laid bare in front of live audience with spectacular results!

    Wayne Gerdes - CleanMPG - Jan. 26, 2011

    Ford’s F-150 w/ the 3.5L EcoBoost Hero Engine Teardown.

    In a release earlier this afternoon, Ford posted the “hero” engine tear down video with the following results: The block, pistons, turbos, crankshaft, valves and other internal parts of the 3.5-liter F-150 EcoBoost “hero” engine were all found to be well within the rigid Fords factory specifications after enduring testing that simulated 10 years of wear and over 165,000 miles of absolute torture testing.

    In an unprecedented public reveal, Ford engineers disassembled the engine in just 35-minutes for the first time in front of a live audience of nearly 1,000 at the North American International Auto Show (NAIAS) in Detroit.

    Over the past three months, EcoBoost engine No. 448AA engine hauled 55 tons of lumber, ran at full throttle for 24 straight hours towing 11,300 pounds, beat competitors’ larger V8 engines in an uphill towing competition and completed the world’s toughest desert endurance race, the SCORE Tecate Baja 1000, in Mexico.

    Gary Heinz, coordinator of the Automotive Student Service Education Training program at Henry Ford Community College in Dearborn:
    Heinz credited the engine design, the high-quality manufacturing process and the precise tolerances between the moving parts with the low wear found on the components.

    Said one spectator:
    Ford powertrain technician Chris Rahill has torn down nearly 2,000 engines in his 20-year career at Ford Motor Company. He said the engine he disassembled is not even close to being near the end of its life.
    Back to the dyno lab

    After completing the SCORE Tecate Baja 1000 in just over 38 hours, the engine was pulled from its race truck and sent to Dearborn for analysis. There it reproduced best-in-class 420 lb.-ft. of torque and 364 horsepower – one horsepower less than its original number!

    Phil Fabien, Powertrain Operations:
    Key findings related to the durability of the 3.5-liter EcoBoost truck engine discovered at the teardown include:
    • Turbochargers: No visual issues with the compressor or turbine, which rotated freely.

    • Pistons: Rings spun freely and pistons showed no obvious signs of wear.

    • Carbon deposits: Nominal. Carbon deposits can vary based on quality of fuel used and when in the cycle the engine was stopped.

    • Cylinder leakdown test: The engine’s cylinders are pressurized with 100 pounds of air to measure the sealing performance of the rings and valves. The cylinder leakdown test results ranged from 6 percent to 13 percent. That's well within manufacturing tolerances, and as demonstrated by the dyno test, had no affect on the engine's performance.
    Why the EcoBoost engine was so clean

    The comparative lack of engine sludge/grime indicates that the engine’s PCV (positive crankcase ventilation) system and the recommended Motorcraft 5W-30 synthetic blend motor oil – available off the shelf – worked in harmony to contribute to clean engine operation.

    The PCV system essentially “recycles” crankcase gases back into the intake for reburning, which contributes to improved fuel economy and lower emissions.

    In terms of oil consumption, the 2011 F-150 EcoBoost has a 10,000-mile oil change interval and includes an intelligent oil life monitor (IOLM). The IOLM uses actual engine and vehicle operating conditions to more precisely calculate anticipated service intervals, depending on vehicle operating conditions, as follows:
    • Up to 10,000 miles: normal commuting with highway driving
    • 5,000 to 7,500 miles: trailer tow/high-load driving
    • 3,000 to 5,000 miles: short-trip usage, extreme temperatures
    Instead of using a predetermined interval schedule (either by time or mileage), the IOLM tells customers, based on their driving habits and engine operating conditions, when to change the oil through simple communications in the message center.

    Intense testing key to durability

    The F-150 EcoBoost engine saw its first action on the dyno in July. Engineers punished it in temperature and load extremes simulating a regimen tougher than any customer’s.

    After the dyno testing, most engines would be ready to be rebuilt or retired, but the EcoBoost torture test was just beginning.

    2011 Ford F-150’s stock 3.5L EcoBoost Engine #448AA in the Baja 1000 Desert Racing Truck

    [​IMG]

    Another day in the life of the 3.5L EcoBoost engine # 448AA


    First the Dyno


    Then the Logs…


    Towing on the track at serious speeds with a serious load...


    And then Drag Towing :D

    [flash]http://www.youtube.com/v/fLsbWkrN6BM?fs=[/flash]
    And finally racing in the Baja 1000​

    Yeah, it has been dyno’ed, log hauled, raced while towing, drag towed, raced across the Baja and when torn down, found that it could easily take another 150,000 miles!

    Jim Mazuchowski, Ford’s Program Manager for V6 engines:
    Engine #448AA – 164,706 miles of “Hell on Earth” and it is still capable of “Kicking @$$ and Taking Names”.
    Mike Rowe:
    Not only has the 6.7L Power Stroke Diesel won us over in the Super Duty, the 3.5L EcoBoost workhorse has proven the same for the light duty F-Series segment.

    And while this may be the end of the #448AA saga, trust me as the 2011 Ford F-150 with the 3.5L EcoBoost story still has a long way to go before its history making adventures are complete ;)
     
  2. moneysaver

    moneysaver Well-Known Member

    what a fantastic engine. The part the kinda surprised me was that after all the grueling torture, the engine was producing almost exactly the same power as it left the factory floor with.
     
  3. wokwithm

    wokwithm Well-Known Member

    American Ingenuity at it's best. Hopefully Ford can follow with good Quality Control.
     
  4. beatr911

    beatr911 Tightwad

    I hope this could be a reapeatable test by Joe Sixpac.
    Getting this kind of power out of a gas engine is not a big deal. Making a boosted 3.5L engine running on 87 octane live this long at these power levels is quite an accomplishment.

    No doubt this is a watershed moment in automotive history. The confluence of excellent lubricants, stable metallurgy, high powered engine management systems and precision manufacturing practices in this case is being well used to great advantage. Good on 'em.
     
  5. msirach

    msirach Well-Known Member

    If you look at the details of the 3.5 EcoBoost, 6 bolt main bearing caps is a detail that ensures durability in this engine to hold up under torque output of V8 numbers. It wasn't a thrown together design like GM did with their gas to diesel conversion of a V8 in the 80's.
     

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