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Old 01-06-2011, 05:54 PM
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Next-Generation Ford Engines Combine Outstanding Performance And Economy

MELBOURNE, Australia, 01 June, 2011

All-new Ford Focus available with a new 2.0-litre GDi Ti-VCT engine

Next-generation petrol engine combines fun-to-drive performance with excellent fuel economy and CO<sub>2</sub> emissions

Advanced engine technologies raise efficiency to new levels

New Focus fuel efficiency improved by employing an advanced six-speed dual dry-clutch PowerShift automatic transmission


The petrol engine range in the all-new Focus is led by a new 2.0-litre GDi direct injection four-cylinder power-plant, which is the most powerful and the most fuel efficient normally aspirated 2.0-litre petrol engine in the small car class.
The new 2.0-litre GDi engine is one of the first on the market to combine the technology of gasoline direct injection (GDi) with twin independent variable camshaft timing (Ti-VCT).

The combination of these technologies helps make the dual overhead camshaft (DOHC) Focus four-cylinder one of the most powerful, fuel-efficient and refined engines in its class and one of the most advanced non-turbocharged four-cylinder engines Ford has ever offered.

It produces 125 kW of power at 6600 rpm and 202 Nm of peak torque at 4450 rpm, up from 107 kW and 185 Nm in the previous-generation Focus, which represents a 17 per cent increase in maximum power and a nine per cent increase in peak torque.
Direct injection improves fuel economy and performance by delivering the precise amount of fuel right into the combustion chamber.

The advanced fuel injection system works in concert with Ti-VCT, which adjusts the valve timing for optimum performance, helping the 2.0-litre GDi engine deliver a best ADR 81/02 combined cycle fuel consumption result of just 6.6 L/100km on PowerShift automatic transmission-equipped Trend and Sport models.
The direct injection 2.0-litre GDi engine serves as another example of Ford delivering significant fuel economy improvements through the use of advanced technologies, while still producing surprising power from minimal displacement.
The engine can deliver outstanding fuel economy and emissions, along with the throttle response, performance and flexibility expected from a world-class engine.

“By combining direct injection and Ti-VCT, we’ve been able to make a quantum leap in fuel economy and performance,” said Derrick Kuzak, Group Vice President, Global Product Development. “We’re meeting the goals of our global power-train strategy, and we now have another key engine in our line-up.”
The 2.0-litre GDi engine is manufactured in Michigan, at Ford’s Dearborn Engine Plant.

Core engine technologies
As a DOHC design, the 2.0-litre GDi engine uses two camshafts – one to open the intake valves and one to open the exhaust valves.
Traditionally, camshafts have only been able to open the valves at a fixed point, defined during engine design and manufacture. Now, with modern variable cam timing (VCT) systems, the camshafts can be rotated slightly relative to their initial position, allowing the cam timing to be advanced or retarded.

Ti-VCT takes this technology and applies it to both the intake and exhaust camshafts of its DOHC design, using electronic solenoid valves that direct high-pressure oil to control vanes in each of the camshaft sprocket housings.
By using one oil control solenoid per camshaft, controlled by the electronic control module, each intake and exhaust camshaft can be advanced or retarded independently from the other as engine operating conditions change, providing an exceptional degree of valve timing control.

“The overlap control via Ti-VCT helps us eliminate compromises in the induction and exhaust systems,” said Jamie Hanshaw, VCT Technical Specialist. “Drivers will notice improved low-end power and better fuel economy. And there are benefits they won’t notice too, like reduced emissions overall, especially at part-throttle.”

Fuel metering duties on the 2.0-litre engine are handled by an injection system that precisely delivers a fine mist of fuel directly into each cylinder for optimal performance, economy and emissions. Unlike port fuel-injection (PFI) engines that spray fuel into the intake system, the direct injection system puts the fuel in the combustion chamber, exactly where it needs to be for combustion.
With gasoline direct injection the engine can safely operate at a high 12:1 compression ratio, further enhancing power and efficiency.
The high-pressure fuel injectors are positioned to the side of each cylinder, aiming the fuel directly into the cylinder adjacent to a high-intensity spark plug and alongside the intake and exhaust valves. Fuel is sprayed into the cylinders at pressures of up to 2150 psi, which is about 35 times more intense than PFI injection.
“The GDi system creates an incredibly fine spray of fuel that’s injected directly into the combustion chamber at the precise moment it’s needed, eliminating a lot of the compromises of traditional fuel systems,” explains Scott Makowski, four-cylinder engine manager.
“It sounds simple, but months of testing and computer simulation went into finding the exact injector spray pattern, where to aim the spray and even the piston dome design.”

The Denso high-pressure fuel injectors use internal solenoids to precisely switch the flow of fuel on and off. Fuel flows through six tiny outlets – like pinholes – in each injector, and each spray is positioned to provide benefits in fuel economy and emissions.
A sophisticated electronic control system varies the timing and intensity of the fuel delivery according to engine operating conditions.

Attention to detail yields fuel economy improvements
Complementing the efficiencies introduced by Ti-VCT and GDi, every aspect of the proven 2.0-litre I4 engine was examined to identify ways fuel economy could be improved. Key strategies focused on reducing internal engine friction and overall weight.

Computer modelling indicated areas where friction reduction strategies would be most beneficial. The valvetrain received a fine surface treatment to present the smoothest surface possible. Piston skirts are treated with a special low-friction coating, and the oil pump and its drive ratio are sized for the exact capacity requirements of the new 2.0-litre engine.

Accessory drive friction was also reduced through a series of actions. Electric power-assisted steering (EPAS) eliminates the drag of an engine-driven power steering pump, while the use of “stretchy belt” technology removes friction from the belt tensioner on the air conditioning compressor drive system.

Additionally, an overriding alternator de-coupler – essentially a special pulley that reduces certain types of vibrations – allows the alternator and water pump drive belt to operate at a much lower tension than is typically used, further reducing frictional losses.
To keep overall power-train weight as low as possible, the block, cylinder head and oil pan – traditionally the heaviest engine components – are aluminium castings. To increase rigidity, these elements are ribbed for additional strength and durability.
Pistons are cast aluminium as well, with the light weight helping to reduce reciprocating mass.

Composite material is employed to keep intake manifold weight to an absolute minimum, while allowing for induction routing to increase thermal efficiency and improve low-end torque characteristics.

Advanced six-speed PowerShift automatic transmission
Fuel economy on the 2.0-litre GDi engine is enhanced by the availability of a new, high efficiency six-speed dual dry-clutch PowerShift automatic transmission, which is one of Ford's most advanced transmission units.

Focus customers have the option of specifying the PowerShift automatic on Trend and Sport models with the 2.0-litre GDi engine, while it is fitted as standard equipment on the high-series Titanium model.

The DPS6 PowerShift unit is also the automatic transmission option on Ambiente models powered by the 1.6-litre Duratec engine.
This advanced transmission combines the efficiency, optimised gear ratios and responsive performance of a traditional manual transmission with the smoothness, convenience and ease-of-use of a conventional automatic.

Low-friction dry clutches are employed, combined with six well-spaced gears to provide responsive acceleration from rest, smooth transitions between gears and optimised fuel economy when cruising.
This transmission is significantly more efficient than traditional torque converter automatics, resulting in fuel economy and CO<sub>2</sub> emission levels which are very close to, and in some cases even exceed, those achieved with a manual transmission.

High Efficiency Powertrains Cut Fuel Bills And Minimise CO<sub>2</sub> Emissions

All-new Ford Focus delivers significant reductions in fuel consumption and CO<sub>2</sub> emissions, with CO<sub>2</sub> emissions starting at just 144 g/km.

High-efficiency petrol and diesel engines that reinforce Ford's powertrain strategy to deliver outstanding fuel economy without sacrificing performance and driving fun.

State-of-the-art transmissions including Ford PowerShift dual-clutch automatic.

Customers of the all-new Ford Focus benefit from an impressive range of advanced new power-train technologies that enhance performance and sustainability while lowering cost of ownership.
In addition to the new 2.0-litre GDi Ti-VCT petrol engine, new Focus will also be available with an upgraded version of Ford’s highly acclaimed 2.0-litre Duratorq TDCi diesel engine, along with a new 1.6-litre Duratec Ti-VCT four-cylinder power plant.

These state-of-the-art engines are complemented by a range of advanced transmissions, including the smooth and efficient Ford PowerShift six-speed dual-clutch automatic.
“Optimising efficiency, and reducing fuel costs for our customers, has been an absolute priority during the development of the all-new Focus,” said Graham Hoare, Executive Director Power-train Development, Ford of Europe.

Impressive CO<sub>2</sub> emissions and fuel economy
Each of the powertrain options on the new Ford Focus will provide its owner with impressive fuel consumption and reduced CO<sub>2</sub> emissions. With sustainability enhanced by the introduction of a host of high-efficiency engine technologies, the line-up achieves impressive results:

1.6-litre Duratec Ti-VCT engine with manual transmission – ADR 81/02 combined cycle average fuel consumption of 6.2 litres/100 km and CO<sub>2</sub> emissions of 144 g/km

2.0-litre GDi Ti-VCT engine with PowerShift automatic – ADR 81/02 combined cycle average fuel consumption of 6.6 litres/100 km and CO<sub>2</sub> emissions of 154 g/km

2.0-litre Duratorq TDCi engine with PowerShift automatic – ADR 81/02 combined cycle average fuel consumption of 5.5 litres/100 km and CO<sub>2</sub> emissions of 144 g/km

High-efficiency engine technology
The 2.0-litre Duratorq TDCi diesel engine has been completely updated to deliver improved performance, fuel economy and refinement. The latest TDCi engine benefits from a comprehensive set of changes including a next-generation combustion system design, higher-pressure common-rail fuel injection system and a smaller, low-inertia variable-geometry turbocharger.

The more efficient combustion system delivers reduced fuel consumption and CO<sub>2</sub> emissions, plus increased performance. Driveability is also significantly improved, with increased responsiveness and more pulling power at low engine speeds.

The petrol engine line-up in the all-new Focus features an all-new 2.0-litre GDi direct injection Ti-VCT engine, one of a new generation of high-efficiency, low-CO<sub>2</sub> petrol engines from Ford. The 2.0-litre GDi engine brings new levels of performance and fuel efficiency to the Focus range.

This new engine is joined by an updated version of Ford’s proven 1.6-litre Duratec Ti-VCT unit. The responsive and economical all-aluminium DOHC 16-valve four-cylinder engine has been further optimised and tuned, with reduced internal friction and improved breathing in the exhaust system, to deliver improved fuel consumption and enhanced torque output.

Fuel-Saving Technologies Help All-New Ford Focus Deliver Cleaner, More Sustainable Performance

Innovative technologies such as Eco Mode and Shift Indicator to assist the driver of the all-new Focus to be more environmentally conscious and achieve lower fuel consumption

Other Ford technologies including EPAS, aggressive deceleration fuel shut-off and smart battery management, help to improve fuel economy

Additional technologies to enhance efficiency include gasoline direct injection (GDi) and twin independent variable camshaft timing (Ti-VCT)

To deliver more sustainable performance, the all-new Focus range incorporates a wide range of features and advanced vehicle and power-train technologies that have been designed to minimise overall emissions and improve fuel economy. “The steps we have taken to increase fuel economy represent significant steps forward in reducing the environmental impact of our products and enabling our customers to make a more sustainable vehicle choice,” said Gunnar Herrmann, Ford’s Global C-Car Vehicle Line Director.

Ford Eco Mode and Shift Indicator help improve driving style
Ford Eco Mode is a new driver information system, first introduced on the previous generation Focus ECOnetic model, which helps motorists to change their habits and adopt a more economical driving style.

The driver has a huge impact on fuel economy, and many motorists could cut their fuel bills by around 10 per cent, or more, by adopting a more environmentally responsible driving style.
Sophisticated software – developed with the help of specialist "eco" driving tutors – monitors driving behaviour and provides the driver with clear feedback about their eco-driving performance, along with simple tips about how to save more fuel.

A simple flower graphic in the instrument cluster display allows drivers to track their progress in the three key areas of gear shifting, anticipation and speed. The system also monitors the number of inefficient short trips made with a cold engine and gives credit for cutting the proportion of shorter journeys.

The Shift Indicator can also be a major support in manual-transmission Focus models for drivers prioritising economy. An indicator light, which is displayed in the instrument cluster, alerts drivers when they could reduce fuel consumption by shifting into a higher gear.

Ford technologies optimise efficiency
Other Ford fuel-saving technologies available in the all-new Focus include:
** Smart regenerative charging battery management
** Twin independent variable camshaft timing (Ti-VCT)
** PowerShift six-speed dual dry-clutch automatic transmission
** Aggressive deceleration fuel shut-off
** Low-friction engine and transmission oils
** Low tension Front End Accessory Drive (FEAD) belt
** Thermal management systems to optimise warm-up
** Low rolling resistance tyres

Most new Focus models also features Electric Power Assisted Steering (EPAS) as standard, which reduces CO<sub>2</sub> emissions by approximately three per cent compared to a traditional hydraulic steering system.

[COLOR=Magenta]Eco Mode only available on Sport and Titanium models/COLOR]

New Focus Delivers Improved Aerodynamic Performance For Fuel Economy And Lower CO<sub>2</sub>

** Improved Focus aerodynamics helps to reduce drag, cutting fuel consumption and CO<sub>2</sub> emissions

** Streamlined new shape reduces drag coefficient by up to 10 per cent, compared to previous Focus models

** Optimised aerodynamic details have significantly enhanced overall aerodynamic performance, with a low drag coefficient on sedan of CD = 0.274

The all-new Ford Focus achieves significantly improved aerodynamic performance, cutting drag by up to 10 per cent to help reduce fuel consumption and CO<sub>2</sub> emissions. After spending nearly 1000 hours in the wind tunnel, the new Focus has an impressively streamlined shape, and is one of the most aerodynamic vehicles Ford has ever produced. The reduction in drag was achieved through detailed optimisation of every aspect of the vehicle design to enhance its aerodynamic performance.

Streamlined shape reduces drag
With its lower roof line and sleek, dynamic profile, the all-new Focus has an inherently streamlined shape. Compared to the outgoing model, it also has a notably ‘faster’ windscreen angle, which adds to its aerodynamic advantage.With careful optimisation of aerodynamic details, it was possible to achieve a significant reduction in drag compared to the previous Focus:

Four-door sedan – CD = 0.274 (was 0.304), reduced by 10 per cent
Five-door hatch – CD = 0.295 (was 0.318), reduced by 7 per cent

The optimisation work was carried out by a combination of wind tunnel testing and analysis using extremely powerful Computational Fluid Dynamics (CFD) simulation tools. “Improving aerodynamics is a key way to help reduce vehicle CO<sub>2</sub> emissions,” said Helmut Reder, Focus Chief Programme Engineer. “Extensive analysis and optimization has enabled us to achieve a major cut in drag on the all-new Focus.”

Detailed features enhance aerodynamics and stability
Aerodynamic performance was enhanced by detailed optimisation in all areas of the vehicle. To prevent unwanted drag, the front end is completely sealed using a hood seal and shielding beneath the engine, so that air is ducted efficiently via the grille to the cooling pack.
Airflow beneath the car is managed by tailored panels on the under-body, with a lower front deflector and speed lip, engine under-shield and optimised front wheel deflectors.

On the sides of the vehicle, an optimised mirror design reduces drag, while also minimising wind noise and managing the flow of rainwater along the side glass. The shape of the A-pillar was carefully optimised, and incorporates a special moulding to further reduce drag and minimise wind noise.

At the rear, airflow under the vehicle is managed by a diffuser integrated with the bumper moulding, while an additional undershield contributes further drag reduction. Integrated rear spoilers help to minimise drag and enhance stability, while subtle features added to the sides of the rear lamp mouldings provide a sharp edge that allows the airflow to separate from the body sides in exactly the right place.

All-New Ford Focus Is Designed For Sustainability

** Comprehensive approach to ensure the all-new Focus represents an improvement in environmental performance

** Ford’s ground-breaking Product Sustainability Index used by engineers to measure progress in improving environmental performance

** Key sustainability initiatives on all-new Focus include expanded use of renewable and recycled materials, and elimination of potential allergens

Maximising sustainability was a primary goal for the all-new Ford Focus, with a comprehensive approach to improving the vehicle’s environmental performance. In addition to the major efforts in minimising CO<sub>2</sub> emissions through high-efficiency powertrains, weight saving and improved aerodynamics, a wide variety of other factors were considered to ensure that the all-new Focus represents a more sustainable vehicle choice.
This holistic approach addressed the entire vehicle life cycle and included measures that ranged from maximising the use of recycled and renewable materials, to avoiding any potential allergenic substances from the cabin.

Design for sustainability
The progress in improving sustainability for the all-new Focus was monitored using Ford's ground-breaking Product Sustainability Index (PSI). This index represents the automotive industry's most comprehensive approach yet in assessing the environmental, societal and economic impact of vehicles, and demonstrates Ford's commitment to taking a leading role in addressing these issues.

“The Product Sustainability Index gives us a very clear view of the sustainability of our vehicles,” said Gunnar Herrmann, Ford’s Global C-Car Vehicle Line Director. “As we develop a new model, we can use the index to ensure that every aspect of the product is as sustainable as possible.”
Ford's PSI tracks eight product attributes identified as key sustainability elements of a vehicle:

** Life cycle global warming potential (mainly CO<sub>2</sub> emissions)
** Life cycle air quality potential (other air emissions)
** The use of sustainable materials (recycled and renewable materials)
** Substance management (including elimination of potential allergens)
** Exterior noise impact (drive-by noise)
** Safety (for occupants and pedestrians)
** Mobility capability (seat and luggage capacity relative to vehicle size)
** Life cycle ownership costs (full costs for the customer over the first three years)

These metrics reflect the multi-dimensional nature of sustainability and illustrate the breadth of Ford’s holistic approach. During product development, the index allows new models to be compared to their predecessors, to confirm that sustainability performance is improved. This approach has helped to ensure the all-new Focus provides a more sustainable choice than previous models.

Eliminating potentially harmful materials
For more than 20 years, Ford's Restricted Substance Management Standard has defined what materials to avoid or eliminate in Ford products, and in the parts and materials provided by suppliers.
To manage materials across the vehicle life cycle, Ford has developed a Global Materials Management process. This helps Ford communicate materials requirements to suppliers, as well as track the materials used in the parts they produce.

Use of recycled and renewable materials
As a key part of the sustainability program, Ford has implemented stringent internal requirements to increase the use of recycled and renewable materials within its products. Ford’s material engineers have developed components from recycled material while ensuring no compromise to quality, durability or performance, and Ford expects its global suppliers to use sustainable materials whenever feasible, provided these materials are environmentally favourable in the specific application.

The all-new Focus features a range of parts produced using recycled content. These include sound insulation material manufactured from recycled denim jeans and cotton fibres, as well as carpets featuring recycled plastic content – plus a number of plastic components produced from a variety of consumer and industrial waste materials, including the battery housing, cover and baseplate, wheel arch liners, and heating/ventilation unit.

 


Last edited by russellw; 28-12-2012 at 12:49 PM..
 

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