Direct Injection

FORD EcoBoost Technology for the 2010 Flex

Ford Flex

Ford has added an new engine/drive-train option to their 2010 Flex that it calls ECO Boost. The company claims that the new system maximizes the effect of a twin turbo charger by using direct fuel injection, giving the vehicle a considerable improvement over a standard base V6. The EcoBoost V-6 engine produces 355 horsepower, 35 percent more horsepower than the base V-6 engine in the Ford Flex, and 350 ft.-lb. of torque, an increase of 41 percent.

In addion the all-wheel-drive Flex with EcoBoost delivers 16 mpg city, 22 mpg highway – 20 percent better fuel efficiency than competitor premium V-8 engines and the same fuel efficiency as the base AWD Flex

According to Ford;

The key to the EcoBoost system is the harmony between the twin turbochargers and direct-injection fuel system. The turbochargers recover energy from the exhaust that otherwise would have been wasted and put it back in the engine to gain efficiency. Simply, the turbocharging systemputs more air into the engine for more power. A compressor increases or “boosts” the pressure of the air entering the engine. An intercooler reduces the air temperature before it enters the engine.

How EcoBoost delivers the power

The twin parallel turbochargers, which are water cooled and operate simultaneously, combine with a direct-injection fuel system to produce power when the driver pushes down on the gas pedal. The high-pressure fuel pump operates up to 2,175 psi – more than 35 times the pressure seen in a conventional V-6 engine. The high-pressure pump is a cam-driven mechanical pump with a single piston and an electronic valve that controls fuel-rail output to the injectors.

As demands on the twin-turbocharged 3.5-liter EcoBoost V-6 engine increase, the control system responds to maintain optimal combustion, timing and injection duration. On each stroke, six individual jets spray fuel directly into the combustion chamber, mixing with the incoming air. The fuel injectors are located on the side of the combustion chamber. When the fuel is injected into the cylinder, it evaporates and cools the air that has been inducted into the cylinder, improving engine breathing and minimizing knock.

The direct injection of fuel into the cylinder also helps provide a well-mixed air-fuel charge, increasing engine efficiency. Direct injection provides several benefits in terms of fuel burn and lower emissions.

Turbo lag eliminated

Turbo lag – a main reason turbocharger technology was not previously more widely used – is eliminated through the use of EcoBoost’s simultaneous turbocharger operation paired with the direct-injection system. The company claims that the dual-turbocharger setup has several advantages over previous turbocharging systems, including:

•The turbochargers are smaller and spool up more quickly, allowing the 3.5-liter EcoBoost V-6 engine to reach peak torque faster. The turbochargers can spin in excess of 170,000 rpm. By comparison, the redline for the engine is approximately 6,200 rpm

•Turbochargers are packaged adjacent to the cylinder block and have improved mounting, which provides NVH (noise, vibration, harshness) improvements

The two turbochargers both operate identically over the speed range of the engine – one gets its energy from the left bank and the other gets its energy from the right bank, with both feeding together into the engine. Both spin immediately and produce boost, even at low engine speeds.

Trailer Sway Control AnimationNew, dedicated transmission and SelectShift complement EcoBoost

Mated to the 3.5-liter EcoBoost V-6 engine is the six-speed 6F-55 SelectShift Automatic™ transmission, which is dedicated to the twin-turbocharger engine. The 6F-55 transmission was developed to specifically respond to the increased torque demands of the EcoBoost V-6 engine. Upgrades were made to the transmission’s friction material in response to the higher shift energies, and a new torque converter has been optimized for performance and fuel economy.

The 2010 Flex with EcoBoost driveline combines the high-capacity 6F-55 SelectShift Automatic transmission with a sophisticated torque-sensing All-Wheel Drive (AWD) system. These components work in harmony to deliver ample traction when putting EcoBoost power on the road. The six-speed transmission offers a wide array of gears to enable spirited acceleration, yet comfortable high-speed cruising.

SelectShift provides conventional automatic operation or a manual shift mode that gives the driver complete control over gear selection. For performance-minded drivers, paddle controls allow “match-rev” downshifts and will hold manually selected gears for precise control. Intuitively operated, a squeeze on either paddle will deliver an economical upshift under acceleration, while a gentle push forward brings a smooth downshift, synchronizing the engine and transmission speeds for responsive and positive engagement