Ford Begins Production of the Most Powerful Diesel Engine

The best-selling 2011 Ford F-Series Super Duty Diesel boosts power, capability, fuel economy and value.

Ford Motor company will begin production this week of the most powerful diesel engine ever installed in a heavy-duty pickup.  The 6.7-liter Power Stroke V8 turbocharged diesel that was in introduced in April 2010, will be upgraded to best-in-class 800 lb.-ft. of torque and 400 horsepower. If you are already a current 2011 Ford F-Series Super Duty diesel owner you can get the increased performance through a free-dealer-installed software upgrade to the truck’s powertrain control module.  Customers will receive letters explaining the procedure.  The upgrade programs will begin by August 31st, 2010 and continue for the next 12 months. 

The higher torque means that fleet operators can plow through deep swamps faster and more condidently and oil and gas crews can tow up an 8,000-foot grade maintaining a steady speed and using less fuel.  A rigorous testing protocol that included computer, laboratory and on-road validation ensured 250,000-mile durability in the new Power Stroke’s components and systems.  This strict testing opened the door for the 2011 Super Duty’s increased capability.

Benefits of the new 6.7-liter Power Stroke V8 turbocharged diesel engine include:

• First use of a compacted graphite iron (CGI) engine block in a Super duty-class vehicle in North America; stronger than cast iron, Ford has successfully used CGI in engine blocks in products around the world.  The block structure was optimized for reduced weight and maximum strength to meet the demands of higher torque and horsepower.
• Unique inboard exhaust and outboard intake architecture, an automotive-industry first for a modern production diesel engine, reduces overall exhaust system volume, which leads to better throttle response for the customer
• The new engine architecture enables easier service work for all major engine components, potentially reducing downtime.  On turbocharger service, for example, the body/cab no longer has to be removed from the frame to access the turbo.
• The turbocharger features an industry-first dual-sided compressor wheel that works in a single housing.  The unit is uniquely center-mounted on a pedestal low in the back of the valley for improved noise, vibration and harshness.  This turbocharger design allows the single unit to deliver the benefits of a twin-turbocharger system in a smaller, more efficient package, combining the advantages of a small turbocharger (faster response) and a large turbocharger (ability to compress and force more air into the engine for more power) in one unit.
• The high-pressure fuel system injects fuel at more than 29,000 psi.  The system delivers up to five injection events per cylinder per cycle using eight-hole piezo injectors to spray fuel into the piston bowl. 
• Aluminum cylinder heads for reduced weight; the mid-deck construction with dual water jackets provides increased strength and optimal cooling; also, six head bolts, instead of four as found on other engines, help improve sealing and maintain cylinder integrity.
• Compatible up to B20 fuel, allowing greener fueling options of up to 20 percent biodiesel and 80 percent petroleum diesel. 

Fuel economy is expected to improve at least another 2 percent, making the 2011 F-Series Super Duty 6.7-liter Power Stroke diesel a full 20 percent more fuel efficient than the 2010 model.  The improved torque and horsepower, for example, means a customer can get to a higher gear faster and stay in it longer, both of which aid fuel economy.  Increased performance will be evident in situations such as improved passing capability on the highway or when towing a heavy load up a steep grade.

Going forward, the F-350 dual-rear-wheel (DRW) model will add vehicle upgrades to bring maximum payload and maximum fifth-wheel towing to best-in-class levels.  Higher-strength steel in the frams will boost the payload and towing ratings as follows

• F-350 DRW max payload to 7,070 pounds, from 6,520
• F-350 DRW fifth-wheel towing to 22,600 pounds, from 21,600 pounds

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Diesel Exhaust Fluid Explained Simply

The all-new Ford 6.7L Power Stroke V8 Turbo Diesel uses Selective Catalytic Reduction and Diesel Exhaust Fluid to meet stricter government diesel emissions requirements while helping deliver improvements to horsepower, torque, towing, hauling, reliability and fuel efficiency.

What is Diesel Exhaust Fluid(DEF)?  A non-hazardous clear fluid (67% deionized water and 33% chemically pure urea) that is injected into the diesel exhaust system to greatly reduce NOx emissions.

Where is the DEF fill nozzle and tank?  On pickups, they are located together with the fuel tank and fill nozzle on the driver’s side.  This location may vary on Chassis Cabs.

How large is the DEF tank?  Pickups have a 5.1-gallon tank, Chassis Cabs have a 6.1-gallon tank.

Where do I get a DEF?  Available from dealerships, major auto parts chains and gas stations.  Customers can purchase Motocraft DEF in 1-and 2.5-gallon jugs.

How much does DEF cost?  Suggested list price of Motorcraft DEF is $5-$10 a gallon, depending on quantity purchased.  Refilling is typically only required at oil change intervals, depending upon vehicle usage, and the fuel economy savings greatly outweigh this cost.

How do I know when to refill DEF?  Adding DEF is as simple as adding washer fluid, and Super Duty provides numerous warnings that the tank is getting low starting at 800 miles to empty.

What happens if I run out of DEF?  Drivers will have plenty of warning long before entering the required speed-limited modes that occur once the tank is empty.  This eventually progresses to an idle-only mode.

Can I use water or anything other than DEF?  No. The system will sense that the DEF has been contaminated and enter a speed-limited mode until it is remedied.

What if the DEF freezes in the tank?  The tank and supply lines are heated and allow for expansion.  You can start the engine and drive while the DEF thaws.

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Testing And Durability of the 2011 Super Duty

Super Duty may be all new, but it is already tested and proven to be Built Ford Tough.  The F-Series Super Duty trucks are pushed to, and sometimes beyond, their limits with some of the most rigorous durability testing.

The all-new Super Duty has been durability tested for a minimum 250,000-mile service life and is currently being put to the test by real customers.  Test engines spend 1200 hours (50 Days!) running at peak torque to test the strength of the engine’s internal rotating parts.

Deep thermal shock test stresses the cylinder head gaskets, engine sealing and cooling system connections.  Engines are idled, run at peak power until components are red hot, thens shut off and allowed to soak while 16-degrees-below-zero Fahrenheit coolant is pumped through the engine.  This process is repeated for 150 hours.

Structural testing verifies the design parameters are being met, including the assessment of tolerances designed into the components.  Engineers build engines with intentionally defective parts to simulate and solve potential quality issues before they happen to the customer.

Watch the Field Work videos at fordvehicles.com/2011SuperDuty for more details.

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2011 Ford Super Duty Questions and Answers

The NEW 2011 F-Series Super Duty pickup arrives at Beechmont Ford in April offering customers an all-new diesel engine. With 735 ft.-lbs. of torque and 390 horsepower in the Ford-built 6.7-liter Power Stroke® diesel, the new Super Duty F-250 and F-350 lead the heavy duty pickup segment in towing, hauling and fuel efficiency.  In addition, the new F-450 and F-550 tow and haul even more weight.

Q: How is bringing the Power Stroke diesel in-house going to improve customer satisfaction with the engine?
A: Power Stroke is an established brand with approximately 3 million Power Stroke diesel trucks sold since its launch in 1998. The new 6.7-liter Power Stroke was designed, engineered and built by a dedicated Ford team that put the engine and its components through a severe testing regimen, both in the lab and on the road. These tests replicate the way our Super Duty customers drive and use their trucks. Customer satisfaction and third-party accolades for current Ford powertrains, including the company’s new EcoBoost and hybrid technology, provide added confidence in the new, Ford designed and built Power Stroke diesel.

Q: How stringent were the tests in the development of this new diesel engine?
A: The severe testing regimen includes 10.3 million miles of testing in the laboratory and on the road; extensive CAD and CAE testing prior to hardware tooling; thousands of hours in over-boosted, over-pressurized and overloaded conditions; 30 days running at maximum speed and boost; 2,600 engine starts at sub-zero temperatures; thermal shocking with alternating hot and frigid fluids; simulated 10-year use in arctic conditions; and field testing on torturous roads and courses. We also used data-driven analysis that incorporated warranty information, customer driving styles and road conditions.

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