3.5 V-6 DOHC Duratec

Announced: 2005.11.09
Early Preview: 2003.07.15
Production: MY2007

Press Introduction

The new 3.5 liter DOHC Duratec was introduced to the press in July 2003. Note that this is a clean sheet design - it is not related to the existing Duratec (2.0/2.5/3.0) engines. It is believed that this will be the first example of a family of engines. It's taken over two years to get to the full press introduction, and will have taken almost three to get to production usage in the summer of 2006.

Technical Specs

Duratec 35 - Base engine & new 6-sp transmission as in Ford Edge/Lincoln Aviator & Lincoln MKZ

Type

3.5L DOHC 24-valve V-6

Manufacturing Location

Lima Engine Plant, Ohio

Configuration

60-degree V-6, aluminum block and heads

Intake Manifold

Composite, split plenum

Exhaust Manifold

Cast iron

Crankshaft

Forged steel

Redline

6700 rpm

Throttle Body

65mm, electronic

Valvetrain

DAMB, 4 valves per cylinder, intake variable camshaft timing

Valve Diameter

Intake: 37mm Exhaust: 31 mm

Pistons

High temperature cast aluminum alloy with low-friction coated skirts, low-tension rings

Connecting Rods

Cracked-powder metal

Ignition

Pencil coil

Bore x Stroke

3.6 x 3.4 in/92.5 x 86.7 mm

Displacement

213 cu in/3.496 cc

Compression Ratio

10.3:1

Horsepower

Ford Edge & Lincoln MKX

265 @ 6250 rpm

Lincoln MKZ

263 @ 6250 rpm

Horsepower per Liter

75.7

75.1

Torque

250 lb-ft @ 4500 rpm

249 lb-ft @ 4500 rpm

Recommended Fuel

87 Octane

Fuel Injection

Sequential multiport fuel injection

Oil Capacity

5.5 quarts, with filter

Recommended Oil

GF4, 5W-20

 

Images

High Res Images

Right-vs-Left Sides: medium res

Comparison: Duratec 3.5 version Duratec 3.0

Cross-Reference to prior Duratec design

 

Press

Ford Press

 2005.11.09:  INNOVATION IN OVERDRIVE: FORD DEVELOPS FUEL-EFFICIENT NEW ENGINE, 6-SPEEDS, HYBRIDS

DEARBORN, Mich. Nov. 9, 2005 Building on its promise to make innovation the compass that sets the company's future direction, Ford today unveiled a new engine, new 6-speed automatic transaxle and more hybrid plans that bring fuel economy and performance to the next generation of vehicles

  • New 3.5-liter V-6 engine to power one in five Ford vehicles by the end of the decade including the new Ford Edge and Lincoln Aviator crossover utility vehicles next year
  • Ford leads the way with a new 6-speed automatic transaxle that saves fuel up to 7 percent in highway driving and nearly two tanks of gas a year compared with typical 4-speed automatics
  • Work begins on Ford third-generation hybrid technology for future I-4 and V-6 engines
  • Ford hybrid leadership continues with the debut of Escape Hybrid taxis in New York City

As Bill Ford has promised, Ford plans to be first in delivering innovative products to our customers – products that are stylish in design, safer for families, first in technology with new fuels and better efficiency, and first in offering new services to consumers,” says Derrick Kuzak, Ford group vice president, Product Development. “That commitment includes innovation in the powertrain lineup that we’ll be offering beginning next year.”

New 3.5-Liter V-6
Ford next year will introduce two new breakthrough crossover utility vehicles (CUVs) – the Ford Edge and Lincoln Aviator – equipped with an all-new 3.5-liter V-6 engine and new 6-speed transaxle. The new V-6 engine will be a powertrain cornerstone for Ford Motor Company, eventually powering one in every five Ford Motor Company vehicles on the road by the end of the decade.

The new 3.5-liter V-6 was designed to deliver the best combination of fuel economy, refinement and performance for the customer and be compact enough to fit into a variety of vehicles. The height and width of the engine is the same as the smaller displacement Duratec 30 V-6.

The engine produces 250 horsepower and 240 pound-feet of torque in its CUV applications. It uses a dual-overhead cam valvetrain for peak power capability and smooth operation at high RPM. It incorporates intake variable cam timing to optimize fuel economy by adjusting valve timing for a smooth idle, optimal part-load driving and an impressively broad torque curve with good power.

In anticipation of future needs, the new V-6 has been designed to accommodate advanced technologies, including gasoline direct injection and turbo charging.

The engine will be built in the fall of 2006 at Ford’s Lima (Ohio) Engine Plant.

6F 6-Speed Transaxle
Ford also underscored its leadership in fuel-saving transmissions with the reveal of a new 6-speed for the new Ford Edge and Lincoln Aviator. Ford is an industry leader in 6-speed transmissions with 24 nameplates already offered with the highly efficient technology.

Six-speed automatic transaxles improve performance and fuel economy. It is estimated that, for every 500,000 6-speeds – rather than traditional 4-speeds – fitted to vehicles, 12 million gallons of fuel can be saved annually (based on 25 mpg combined fuel economy for 15,000 miles).

The enhanced performance and fuel economy of the new 6F comes from a wide span of 6.04 between the transaxle’s lowest and highest gear ratio. The high ratio span helps deliver improved fuel economy of up to 7 percent and improved sustained acceleration compared with a typical 4-speed automatic.

The new 6F will be fitted to the 3.5-liter V-6 in the Ford Edge and Lincoln Aviator. The combination delivers optimal fuel economy and powerful performance combined with smooth, refined and quiet shifts.

The new Ford 6F will be built at Ford’s Van Dyke (Mich.) Transmission Plant.

More News on Hybrids
Ford also took another step toward delivering on its commitment of putting 250,000 hybrid vehicles a year on the road by 2010 with the announcement that engineering work already is under way on a third-generation hybrid transaxle – one developed using Ford’s in-house hybrid expertise.

Engineered in Dearborn, the new hybrid transaxle will be capable of handling both 4-cylinder and 6-cylinder engines for future vehicles.

In addition, Ford announced that the Ford Escape Hybrid would debut this week as the first hybrid taxi carrying passengers throughout the five boroughs of New York City. Ford, the New York City Taxi & Limousine Commission and the Coalition for Smart Transportation will mark the milestone on Thursday.

 

2003.07.15  Fords Lima (Ohio) Engine Plant to Build New Duratec 35 V-6

  • All-new, all-aluminum dual-overhead-cam 3.5-liter V-6 engine named the Duratec 35

  • Investment of $335 million at Lima plant in tooling and equipment to build new engine

  • Ford continues rollout of new flexible manufacturing system; to be installed at Lima plant

LIMA, Ohio, July 15, 2003 Ford Motor Company today announced it is investing $335 million in its Lima (Ohio) Engine Plant to build an all-new, modern fuel-efficient 3.5-liter V-6 engine.

The sophisticated, all-aluminum dual-overhead-cam (DOHC) 24-valve Duratec 35 V-6 engine will power a variety of future Ford, Lincoln and Mercury vehicles, including passenger cars and crossover vehicles. Annual production capacity is projected to be up to 325,000 engines a year. Production of the new engine will begin at the Lima plant by the end of 2005.

This new V-6 will be cutting edge, truly world-class, said Dave Szczupak, vice president, Powertrain Operations, Ford Motor Company. Our engineers started with a clean sheet of paper to develop this new engine. It will power a variety of vehicles and includes advanced technologies such as variable-valve timing, a feature we are adding to a significant number of all our engines.

A feature favored by many environmentalists, variable-valve timing helps to reduce emissions, improve fuel efficiency as well as idle smoothness, while at the same time maximizing performance. The variable-valve mechanism works by precisely controlling the engines camshaft position at any given millisecond based on engine speed and load. The investment at the Lima Engine Plant continues Fords move to a new cost-effective and quality-enhancing global flexible manufacturing system to build powertrains. At Lima, Ford will install a new engine assembly line, a new cylinder-block machining line, a new cylinder-head machining line as well as a new crankshaft line.

As part of the new cylinder-head machining area, Ford will install a series of flexible computer-numerically controlled (CNC) machines to manufacture the engines cylinder head. Ford also will convert its existing flexible manufacturing equipment at Lima to build crankshafts for the new V-6 engine.

We are building a network of lean and flexible powertrain plants around the world that can respond quickly to changing market needs, while improving quality and manufacturing efficiency, said Roman Krygier, group vice president, Global Manufacturing and Quality, Ford Motor Company. The launch of this new V-6 will further our push into flexible manufacturing, helps us reduce costs and ensures a bright future for the Lima Engine Plant.

Krygier said that the Lima, Ohio plant was chosen to produce the new V-6 engine because of its strong workforce and reputation for building high-quality engines. The plant has received numerous quality awards from Ford management.

We truly have a world-class workforce here in Lima, dedicated to building high-quality engines, said Jan Allman, plant manager of Lima Engine. This new V-6 engine ensures we have a strong future here and a strong future for our workforce. We are also proud that later this year we will build our 36-millionth engine, our 10-millionth 3.0-liter V-6 and our 200,000th 3.9-liter V-8.

Brett Fox, chairman, UAW Local 1219 added: We are extremely proud to be chosen to build this all-new V-6. This is a big day for Lima, UAW Local 1219 and our employees. This program is not only important to Ford Motor Company, but it is important to the families of our workers. We look forward to a bright future of providing our customers with this great new V-6 engine.

Fords New Flexible Manufacturing System
Ford currently is in the middle of a comprehensive global rollout of its new flexible manufacturing system to build cars and trucks as well as engines and transmissions.

The Lima Engine Plant was Fords first engine plant in North America to receive its new flexible manufacturing equipment with the installation of a flexible crankshaft machining line in 2001. The line builds cast-iron and steel crankshafts for Fords Duratec V-6 built in Cleveland and will be converted to also build crankshafts for Fords all-new 3.5-liter V-6.

Three main elements are at the core of Fords flexible manufacturing strategy for powertrains:

  • Common engine architectures;

  • Commonized manufacturing facilities, and;

  • Modern, flexible, numerically controlled machine tools (CNC machines) that can be easily retooled and reprogrammed to perform new tasks with minimal disruption to production.

The new flexible CNC machines help Ford to react quickly to changing production needs and have a total cost less than Fords outgoing transfer-line system.

The new CNC machines were installed last year at Fords Windsor (Ontario) Engine Plant to manufacture its new 3-valve cylinder head for the all-new 2004 Ford F-150 pickup. The same type of flexible CNC machines are being installed at the Lima plant to manufacture the new V-6 as well as at Fords Cleveland Engine Plant No. 1 (2004) and Fords Romeo Engine Plant (2005). The new flexible system also is being installed at Fords Dagenham and Bridgend engine plants in the UK later this year.

Rather than requiring a complicated process of removing old-style dedicated milling or boring machines and installing new ones which can interrupt production for months the new machines can be retooled and reprogrammed internally, with little or no interruption in production. In many cases, this reprogramming can be accomplished over a weekend.

New Database Improves Engine Quality
During production, each engine built at Lima, Romeo, Cleveland, Dagenham and Bridgend will develop a sophisticated engine birth history that allows plant engineers to track every stage of production starting even before major components such as cylinder heads arrive at the engine plant.

Fords engine birth history technology is currently used at Ford plants building its new global I-4 engine Dearborn, Mich., Chihuahua, Mexico, Valencia, Spain and Mazdas plant in Hiroshima, Japan as well as at Fords Windsor and Essex (Canada) engine plants.

Each engines birth history is recorded on a microchip that travels with the engine, or data is maintained in a database related to a bar code. Such data include hundreds of metrics, including torque levels for specific bolts; crank journal clearances; pressure test results; and the amount of torque it takes to turn the crankshaft after all parts are bolted together.

The birth history allows engineers to trace the precise path taken by any part, so any quality control issue can be traced back to its source, and affected parts taken out of production. This has potential to save thousands of unnecessary replacements, and spare customers considerable inconvenience, said Allman.

The new V-6 engine, Fords global rollout of its new flexible manufacturing system, and its quality initiatives, are all key components of Fords product-led Revitalization strategy, according to Szczupak:

This is the most dramatic change in manufacturing since the introduction of the assembly line by Henry Ford, Szczupak said. When you think about any great vehicle, it always has a great powertrain. Its the heart of the vehicle. What were doing now with our engine manufacturing strategy is to deliver more great new powertrains to our customers more quickly, at the highest quality levels, and at the same time, at the lowest cost.

Standardization Leads to Efficiencies
Limas new cylinder-head line will feature a series of CNC machines arranged in cells of up to eight machines. Cell operators will be able to monitor production at a computer workstation. Another benefit of this standardization is that each operator knows how to run all of the machines theyre all the same and not only can step in to other roles, but can trade information, concerns and best practices with coworkers.

These identical CNC machines can perform any of a number of functions, depending on need. That means diesel engine cylinder heads could be manufactured at the same time as two-valve or multi-valve gasoline engine heads, and each type would route itself to the machine that was equipped with the proper tooling and programs.

Since the machines are identical, Ford is able to dramatically reduce the number of spare parts kept on hand. The new plants typically have one set of shared common spares for each system, rather than each machine, which results in a huge inventory cost savings.

Every new or reworked cutting tool is measured before it is put into service, and that measurement is recorded in its memory chip. The computer-controlled machine reads this data as it loads the tool, and automatically compensates for any minor variation in tool sizes. A laser in each CNC verifies tool length every time the tool is used in production. This assures that if the tool breaks or goes out of adjustment, the machine doesnt continue to produce parts.

The degree of quality control that were getting with this new system is second-to-none, Szczupak said. We are verifying the quality of build throughout the process. Faults cant pass down the line. With this degree of integrity, we can target 100-percent right, first time.

Lima Engine Plant Background
The Lima Engine Plant, which was originally built in 1957 to manufacture V-8 engines for the Edsel, today measures 2.4 million square feet and employs more than 1,600 people.

In recent years, the Lima plant has received numerous awards from Ford management for its outstanding quality. In addition, the plant also received two awards in 2002 for its safety record from the West Central Ohio Safety Council.

The workforce of the Lima plant is involved in numerous charitable and community events in the Lima area, such as donating funds to the United Way and Juvenile Diabetes Research Foundation.

In October 2001, the plant sponsored Limas Families for Families A Celebration of America, which was attended by more than 6,000 area residents with six New York Firefighters in attendance. Through this event, the plant and local community raised more than $100,000 for the New York and Washington, D.C. families involved in Sept. 11, 2001.

The investment at Lima was made possible due in part to state and local tax incentive commitments.

 

 

 

 
2003.07.15 FACT SHEET: LIMA ENGINE PLANT BACKGROUND

Located in Lima, Ohio, Fords Lima Engine Plant was originally built in 1957 to manufacture V-8 engines for the Edsel. Lima builds Fords Vulcan V-6 engine and 3.9-liter V-8 for the Ford Thunderbird and Lincoln LS as well as cLocated in Lima, Ohio, Fords Lima Engine Plant was originally built in 1957 to manufacture V-8 engines for the Edsel. Lima builds Fords Vulcan V-6 engine and 3.9-liter V-8 for the Ford Thunderbird and Lincoln LS as well as crankshafts for Fords 3.0-liter Duratec V-6, which is built in northeast Ohio at Clevelands Engine Plant No. 2.rankshafts for Fords 3.0-liter Duratec V-6, which is built in northeast Ohio at Clevelands Engine Plant No. 2.
  • The Lima plant employs more than 1,600 men and women.
  • The plant sits on 326 acres and the plant itself totals 2.4 million square feet.
  • In 2002, LEP produced more than 500,000 engines, an average of 2,500 per day, and it has produced nearly 36 million engines since engine production began in 1957. Lima supplies Ford plants in Atlanta, Chicago, Cleveland, Edison, N.J. and Wixom, Mich.
  • In recent years, the Lima plant has received numerous awards from Ford management for its outstanding quality. In addition, the plant also received two awards in 2002 for its safety record from the West Central Ohio Safety Council.
  • The workforce of the Lima plant is involved in numerous charitable and community events in the Lima area. In October 2001, the plant sponsored Limas "Families for Families A Celebration of America," which was attended by more than 6,000 area residents with six New York Firefighters in attendance. Through this event, the plant and local community raised more than $100,000 for the families involved in Sept. 11, 2001.