A quick overview about the technical features of the new 1l EcoBoost engine.

1. 1
WELCOME
FORD POWER DRIVE :
NICE TO GENEVA
#fordpowerdrive

2. 2
Why are we here?
The Ford Focus The 1.0-litre EcoBoost Engine
An amazing new engine in a great, technologically advanced
family car
Fuel efficiency without compromise on power
Driving is believing – and fun!

3. 3
The Route
3. LAUSANNE
Hotel Alpha-
Palmiers
2. LUNCH
La Maison
de Bonthoux
1. START
Hotel Le Mas
de Pierre

4. 4
New 1.0 litre Ecoboost Powertrain
Andrew D.J. Fraser
Manager, Gasoline PT Development
March 4th 2012

5. 5
Introduction
• Ecoboost is a new generation of Ford petrol engines, which deliver
outstanding fuel economy, together with great fun to drive and refinement in
line with the Ford brand DNA.
• Ecoboost offers customers a genuine alternative between conventional
naturally aspirated petrol engines, and very efficient, but increasingly
complex and expensive Diesels.
• The new 1.0l engine is the fourth in the Ecoboost series, which started with
the 3.5 V6, launched in North America in 2009, continued with the 2.0 and
1.6 in 2010, and extends further with the 1.0 launch in 2012.

6. 6
Ecoboost Engine Families
600
3.5 V6
500
400
Torque [Nm]
2.0 I4
300 1.6 I4
200
1.0 I3
100
0
0 50 100 150 200 250 300
Power [kW]

7. 7
Ecoboost Family Philosophy
• All Ecoboost engines feature significant downsizing vs. naturally aspirated
derivatives, as a means to enhance fuel economy. Downsizing offers
numerous advantages:
• Lower mass: better performance, reduced real world consumption,
improved dynamics, smaller tyres, less energy consumed by PAS.
• Less cylinders: lower cost, keeps technology accessible for consumer
• Reduced friction: fewer cylinders, bearings, less lubrication
• Significantly better warmup for both good fuel economy and rapid
cabin heating.
• Key engineering challenge is to maintain, or enhance, performance and
refinement, while delivering the fuel economy advantages of downsizing, as
customers have shown that they are reluctant to compromise.

8. 8
European Diesel share vs. performance.
• Diesel sales growth driven by performance gains, not FE advantage.
60 380
50 330
Peak Torque [Nm]
Diesel Share [%]
40 280
30 230
20 180
10 130
Diesel share (%)
Peak Torque [Nm]
0 80
88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04
Year

9. 9
Customer Performance Expectations
• Traditional petrol engine customers enjoy smooth, free-revving nature and
peak power figure high in RPM range.
• Diesel customers like high peak torque from low RPM, and relaxed cruising.
• Ecoboost engines offer both of these attributes, and careful matching to the
vehicle by means of gearing, means that Ecoboost engines appeal to wide
variety of customers, driving style and environments.

10. 10
Engine Torque Comparison
Engine Torque Output
300
1.6 T/C Diesel
1.6 Petrol
250
1.0L Ecoboost
Engine Torque [Nm]
200
150
100
50
0
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Engine Speed [rpm]

11. 11
1.0L Ecoboost Performance 6th Gear
Torque at Wheels - Top Gear Flexibility
1.0L Ecoboost has
700
more torque at wheels
than 1.6 Diesel up to
80 KPH600
500
Wheel Torque [Nm]
400
300 1.6 T/C Diesel
1.6 Petrol
200
1.0L Ecoboost
100
0
20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0
Vehicle Speed [kph]

12. 12
Ecoboost Technology
• Ecoboost engines feature three key enabling technologies:
• Turbocharging – allows much greater torque & power from smaller engine
• Direct injection – improves combustion efficiency
• Variable camshaft timing – increases bottom end torque, mid range
efficiency and peak power capability.

13. 13
Ecoboost: Three Key Elements Working as a System
Turbocharging
- 50% engine size reduction for same power
- Proven, reliable, cost effective technology
- Matched for low speed response
Direct Injection Twin VCT
- Charge cooling for improved efficiency - Scavenging for low RPM response
- Higher knock limit/more torque at low RPM - Improved efficiency and stability at part load
- Enables scavenging action - Higher peak output

14. 14
Ecoboost Technology - Turbocharging
• Ecoboost focus is on responsiveness and low speed torque rather than very
high peak power figures.
• Torque at 1500 RPM, and time for torque to increase to maximum output are
key metrics.
• Achieved by utilising very small, low inertia turbochargers, capable of
running at very high speeds, up to 248,000 RPM on 1.0L
• Low inertia turbos greatly reduce “lag” in response when throttle is opened
from low RPM, a traditional problem with turbocharged engines

15. 15
Ecoboost Technology – Direct Injection
• Fuel is injected directly into combustion chamber via high pressure solenoid
injectors, with 6 holes giving precise fuel targeting and mixing.
• High injection pressures (up to 150 Bar) give excellent atomisation and
mixing.
• Multiple injections per stroke are used at some operating points to optimise
fuel economy, emissions and stability
• Evaporation of fuel in cylinder cools mixture before combustion, reducing
tendency to “knock”.
• Allows higher Compression Ratio than normal for turbo engines, improving
part-load fuel efficiency.
• Eliminates transfer of fuel mixture from inlet to exhaust during valve overlap,
improving fuel consumption and reducing exhaust emissions.

16. 16
Ecoboost Technology – Variable Cam Timing
• Variable cam timing on both intake and exhaust allows great flexibility to
optimise engine efficiency under all conditions, e.g.
• Moderate overlap at full load to improve breathing and output with
reduced boost level
• Low overlap at idle for stability
• Late exhaust valve opening at part load for fuel efficiency
• Greatest benefit is for low speed torque and responsiveness, where valve
overlap can be increased to allow scavenging effect.

17. 17
Scavenging Effect
• At low speed & high load, • Intake Manifold Pressure > Exhaust Back
during the valve overlap period, Pressure (due to boost)
it is possible for the intake
manifold pressure to exceed the
instantaneous exhaust back
pressure due to turbo-charging.
• Under these circumstances,
“scavenged” air will flow directly
from the intake into the exhaust.
• Scavenging flushes residual
gases from cylinder, increasing
mass of following charge, and
cooling gas to reduce tendency
to knock. It also increases
turbo mass flow, helping spool-
up turbo.

18. 18
Ecoboost – Low RPM Torque Benefit
Scavenging Torque Enhancement 1.0l Ecoboost
180
170 40Nm benefit at 1400RPM
160
30Nm benefit at 1250RPM
150
140
Torque/ Nm
130
Zero scavenging, stoichiometric
120
exhaust AFR
110
Steady state scavenging,
stoichiometric combustion AFR
100
Transient 'turbo spool-up'
90 scavenging, stoichiometric
combustion AFR
80
800 1000 1200 1400 1600 1800 2000
rpm

19. 19
1.0L 3-Cyl Ecoboost Technology Highlights
• Extremely compact block design, enabled by use of cast iron ilo
aluminium, small bore, long stroke geometry (71.9mm x 82.0mm),
and 6mm siamesed bore design. Total block length 286.2mm.
• Aluminium cylinder head with integrated exhaust manifold (IEM). 4V
layout with central injector & compact spark plug. 10.0:1 CR
• Rapid warmup due to small iron block, IEM, and split cooling system
with horizontally split head and controlled block/head circuits.
• ECU controlled variable displacement oil pump and low loss
lubrication system
• New Continental turbocharger with vacuum actuated wastegate,
allowing opening when off boost to reduce backpressure.
• Ultra-low friction design, with offset crank, coated pistons & tappets,
low tension rings, low friction crank seals.
• Cam drive via unique belt-in-oil design, giving full life belt, with
advantages of quietness & lightness vs. chain.

20. 1.0L Ecoboost Balancing Strategy 20
In-line 3 cylinder engines
naturally develop a 1st order
(engine speed) couple resulting Balance shafts are conventional
in a combined pitch and yaw technology to counteract out-of-
RHS engine Mount Velocity
motion balance forces in a I3 engine. 32
However, they increase engine Instead of 28
Baseline
Vehicles are often sensitive to weight and degrade friction thus employing energy- 24 Optimised
this 1st order forcing and this is fuel economy and CO2 draining balance 20
manifested as a booming noise performance shafts, Ford 16
and vibration in the vehicle strategy on the 1.0 12
engine is to 8
intentionally 4
“unbalance” the 0
flywheel and crank Vertical Lateral
pulley in
conjunction with LHS engine Mount Velocity
64
Force P/T mount
56 Baseline
optimisation to Optimised
48
offset the primary
40
engine shaking 32
forces into a less 24
sensitive direction. 16
8
0
Resultant engine Vertical Lateral
motion about
centre of gravity
1st order balance
shaft
• Patents applied for: DE102009047545.1, DE102011078356.3

21. 1.0L Ecoboost Noise and Vibration Refinement 21
120PS (DMF)
Engine mount system refined to decouple
DMF (125PS) and clutch damper
shaking forces and provide best balance
tuning, flywheel inertia
between idle and pullaway vibration
optimisation (100PS) to minimise
performance
torsional excitation – better
vibration characteristics and
rattle avoidance
100PS (SMF)
Modified
driveline to
achieve
optimum
balance between
vibration
transfer path
and
ride/handling
attribute

22. 1.0L Ecoboost Noise & Vibration Refinement 22
Fuel injector
isolators and
fuel pump soft-
landing
strategy to
control high
frequency
noise content
Engine
structure
optimised for
Belt-in-oil primary drive
best radiated
system provides low
noise, stiffness
noise content and
and weight
controls any whine
character
Ford 1.0L 120PS EcoBoost Full Load Radiated Noise Performance
Engine acoustic foam 105
cover to reduce top end
100
noise
95
Sound Pressure Level
90
85
80
Integrated engine
mount bracket and 75 New Ford 1.0 I3 engine has been targeted to
front cover for best achieve exceptional quietness for this power
70
stiffness and weight density and out perform naturally aspirated
65 engines in the class above
60
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
Engine Speed (rpm)

23. 23
1.0L Ecoboost
• Outstanding performance, flexibility & responsiveness for 1.0 l engine
• Benchmark fuel economy
• Class leading refinement

24. 24
What You Need
• TO BE SAFE
• This is not a race, but hopefully an experience we will all enjoy...and all arrive in
one piece
• TO NOT SPEED
• Any speeding tickets will need to be paid for by the driver of the vehicle
• TO ASK QUESTIONS
• We have badges for the toll roads and maps etc but if we forget anything feel free
to ask
• TO ENJOY YOURSELF
Good scenery, good food, good driving and good company
If you need it the hashtag for the drive is #fordpowerdrive

25. 25
In Geneva
• Ford B-MAX– Ford’s ingenious new car with best in class
technologies, powertrains and all new ‘easy-access’ door
system
• Ford Kuga –Rugged SUV provides more load space and
new technologies including hands-free tailgate lift
• Fiesta ST – Global production reveal of Ford’s small
car performance vehicle
• PLUS: Focus BEV, and the Transit Tourneo