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24-05-2011, 06:17 PM
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Chairman & Administrator
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SZ Territory - Power-train
March 5, 2011
NEW FORD TERRITORY – HIGHLY EFFICIENT TURBO-DIESEL POWER JOINS THE RANGE
"With the introduction of new and improved drivetrains, Ford has enhanced all of Territory’s famed hallmarks, such as driving enjoyment, refinement and performance."
- David Mitchell, Powertrain Development Manager, Ford Asia Pacific and Africa
In an Australian first, Ford has introduced high-tech turbo-diesel power in the new Territory. It has enhanced its proven 4.0-litre I6 petrol engine and partnered both of these dynamic power units with smooth-shifting and efficient six-speed automatic transmissions. The results: dynamic driving performance and real-world fuel efficiency.
Several important goals were set - and achieved - when enhancing Territory’s drivetrains for the new SZ model. These objectives had to be achieved while retaining Territory’s famed attributes, such as its performance and drivability. Critical targets in the programme were improvements in fuel economy, refinement, and meeting Euro4 emission standards.
These goals were achieved in both Territory’s petrol I6 and V6 TDCi engines. A cornerstone of this success was the benchmarking process Ford used when developing the new Territory. Not only were internal targets set to a very high level but the company looked to several more expensive competitor products, such as the BMW X5 and Land Rover Discovery, to ensure the new Territory exceeded customer expectations.
“The introduction of turbo-diesel power and enhanced six-cylinder petrol engines is a major advancement for the Territory range,” Powertrain Development Manager, Ford Asia Pacific and Africa, David Mitchell, said.
“Both engines bring enormous benefits to our customers and are among a comprehensive package of technical upgrades driven by the extensive engineering and development work undertaken by Ford.”
The development path undertaken to produce the new Territory was comprehensive and detailed. The new model’s testing schedule was, put mildly, gruelling and involved extensive on-road testing. Locally, this included the Snowy Mountains, the Victorian high country and the punishing Australian outback. Overseas, it involved high-altitude testing up to 2500m in the US and extreme hot-weather testing in areas such as Arizona and California’s notorious Death Valley.
Other development venues included New Zealand, Sweden and Alaska.
Exhaustive trials at Ford’s proving ground in Lara, Victoria contributed to new Territory’s outstanding qualities. In all, the new Territory covered more than 800,000 km of testing both in Australia and overseas.
Ensuring the new Territory remained a tailored vehicle solution for local customers, all calibrations for both engines and transmission shift schedules were performed in Australia by Australian engineers.
"Being directly linked into Ford’s global resources meant we were able to make very good use of these important tools and references, but all engine calibration work was done in Australia,” Mitchell said.
The new SZ Territory engine range comprises two impressive power units: an upgraded 4.0-litre in-line six-cylinder (I6) petrol unit (available only in rear-wheel drive; standard fitment to all new Territory models) and a 2.7-litre V6 turbo-diesel engine (available in both rear- and all-wheel drive; optionally available in all new Territory models). This is summarised in the table below.
Available drive train combinations: new Ford Territory
Note: these drivetrain combinations are available for all new Territory models: TX, TS and Titanium
Each engine available in the new Territory is detailed below.
NEW: 2.7-litre V6 turbo-diesel engine – optional engine
Headlining the 2011 Territory story is the introduction of a turbo-diesel engine. This is the first time highly-efficient turbo-diesel power has appeared in Ford’s popular Territory SUV.
This TDCi (Turbo-charged, Diesel, Common-rail injection) V6 engine was designed by Ford and developed at its Diesel Technology Centre in Dagenham, UK. Having powered a number of European-based luxury SUVs and passenger cars this is the first time this engine has been fitted to a Ford-badged vehicle.
The TDCi-powered Territory uses a CGI (Compacted Graphite Iron) cylinder block which is vital for strength and excellent NVH properties. It employs alloy cylinder heads in a Double Over-Head Camshaft (DOHC) design with four valves per cylinder.
To maximise power, torque, efficiency and fuel economy it employs forced induction in the form of a single VGT (Variable Geometry Turbocharger) turbocharger with intercooler. Fuel delivery is via high-pressure common rail diesel injection using electronically controlled piezo injectors that deliver multiple injections of precisely metered fuel to each cylinder during every combustion cycle. Exhaust emissions are managed using a dual EGR (Exhaust Gas Recirculation) system.
This new Duratorq TDCi V6 also uses smart glow-plug technology to improve combustion efficiency and fuel economy during engine warm-up.
The high-pressure fuel system employs a run-dry protection system in the event a driver operates the vehicle until it entirely runs out of fuel.
Total engine weight is 210.5kg.
David Mitchell: “This is a highly efficient, high-technology engine and its performance speaks for itself.”
Territory’s Duratorq TDCi engine produces its maximum power of 140kW at 4000RPM and an impressive 440Nm of torque at only 1900RPM. In fact, its flat torque curve sees this maximum torque maintained until 2500RPM, making it very fuel-efficient and great for towing. The new Territory’s maximum towing capacity (for all-wheel-drive models) is 2700kg (braked trailer) with a maximum downward towball capacity of 270kg*.
For all petrol and rear-wheel drive models the maximum towing capacity is 2300kg (braked trailer) with a maximum downward towball weight of 230kg*.
The new Territory’s impressive fuel economy is certain to attract the attention of SUV buyers. The highly efficient 2.7-litre TDCi engine returns a low 8.2l/100km in RWD configuration (combined cycle, according to ADR 81/02). TDCi-powered TX and TS all-wheel-drive models consume 8.8l/100km and the range-leading Titanium 9.0l/100km (combined cycle, according to ADR 81/02).
Impressively, rear-wheel-drive TDCi models achieve a low 6.5l/100km in the extra-urban cycle (according to ADR 81/02), giving customers of the new Territory extensive range from its 75-litre fuel tank and excellent fuelling costs.
Packaging the new TDCi V6 engine into the new Territory’s structure, while retaining the SUV’s famed driving and refinement attributes, required attention be paid to specific areas and systems.
The arrival of the new TDCi V6 engine coincides with an all-new front subframe that is 14 kilograms lighter compared to that used in the previous model. This new structural element necessitated a new front crash structure resulting in a completely new crash development programme for the new Territory.
All-wheel-drive models now have a not only a new transfer case but a new front differential mounted in conjunction with the engine's oil sump. Cleverly, this new front differential employs a clutch mechanism to de-couple drive to the front wheels when the vehicle is stationary, optimising Territory’s NVH performance at stand-still.
“The results of all of this work are impressive, especially with regard to driving performance and real-world fuel efficiency,” Mitchell said.
"We went to this amount of effort to ensure the attributes that have made Territory so popular with buyers were not only maximised, but built-upon, something we have certainly achieved.”
The new TDCi Territory achieves excellent performance and fuel economy, details of which are summarised below:
Maximum Engine Outputs: V6 turbo-diesel (RWD and AWD)
Combined-cycle fuel consumption (tested to ADR81/02): V6 turbo-diesel
[I]Urban-cycle fuel consumption (tested to ADR 81/02): V6 turbo-diesel
Extra-urban-cycle fuel consumption (tested to ADR 81/02): V6 turbo-diesel
Combined with a fuel tank capacity of 75 litres, all Duratorq TDCi-powered models have a potential driving range of more than 1000km from one tank of diesel fuel in the extra-urban driving cycle.
“Achieving these fuel economy results was paramount and the customer benefits are sure to cement the TDCi Territory as a favourite among SUV buyers,” Mitchell said.
4.0-litre I6 petrol engine – standard engine
The advanced design features of Ford's naturally aspirated 4.0-litre I6 petrol engine are well established and have been extended with the development of the latest-generation version fitted to the new Territory.
Borrowing technology from the successful current-model FG Falcon, this engine boasts a variety of sophisticated features, such as a redesigned DOHC alloy cylinder head with four valves per cylinder and Dual Independent Variable Camshaft Timing (DIVCT). The performance from the I6 petrol engine is a cornerstone of Territory’s hallmark driving enjoyment and in this new model it delivers more of what customers have requested.
When compared to the outgoing model, the six-cylinder petrol engine used in the new Territory achieves:
• More power;
• More torque;
• Better fuel economy;
• Reduced CO2 exhaust emissions.
Maximum power in the new petrol-powered Territory has increased by 5kW to 195kW at 6000RPM with peak torque now 391Nm at 3250RPM, an increase of 8Nm.
Importantly, fuel economy has also improved in the new-model I6-powered Territory.
“Fuel economy and engine performance are usually competing desires; typically one would improve at the expense at the other,” Mitchell said.
“Our customers made it clear: they wanted improvements in both fuel economy and performance and we set out from the start to deliver both.”
The official ADR81/02 combined-cycle fuel consumption figure in the new RWD I6-powered Territory has reduced by 1.0l/100km to 10.6l/100km. In the extra-urban cycle this figure has fallen to 8.0l/100km (down from 9.1l/100km) and the urban cycle rate has reduced to 15.0/100km (down from 16.0l/100km).
These important gains were the result of numerous FG Falcon-based hardware and calibration changes made to the I6 petrol engine by Ford’s engineers.
The new Territory I6 gains a new “fast-burn” cylinder head. This clever piece of design uses revised intake port profiling and combustion chamber geometry to increase the swirl of the incoming fuel / air charge for a quicker rate of combustion.
Also fitted to the new I6 petrol engine is a new dual-resonance intake manifold.
David Mitchell: “This dual-mode, equal runner-length intake system has been tuned to achieve good low-end torque and strong peak power characteristics.”
This split plenum composite intake uses a new electronic throttle body and fuel rail assembly. The new intake manifold increases maximum engine power compared to the previous version and improves power delivery and drivability by enhancing throttle response.
This new intake manifold’s composite construction delivers a four kilogram weight saving compared to the previous version’s cast aluminium construction. Its more efficient thermal qualities also enhance drivability under heat-soak conditions.
Ford’s knowledge in engine modelling and drive-train design also resulted in a revised engine calibration and contributes measurably to the I6’s improved performance - both on the road and at the petrol pump. Part of this change includes a more aggressive fuel shut-off facility at lower engine speeds that sees less fuel consumed when the vehicle is coasting or decelerating.
“The results are clear: we managed to simultaneously increase maximum power and torque while improving the engine’s rate of fuel consumption, an achievement that will certainly be welcomed by our customers,” Mitchell said.
The following table summarises the key performance and fuel economy figures for the previous-model petrol-powered Territory and the new SZ model:
Maximum Engine Outputs: I6 Petrol RWD
[I]Combined-cycle Fuel Consumption (tested to ADR81/02): I6 Petrol RWD
Urban-cycle Fuel Consumption (tested to ADR81/02): I6 Petrol RWD
Extra-urban-cycle Fuel Consumption (tested to ADR81/02): I6 Petrol RWD
1 SY MkII Territory, TX or TS fitted with five seats
The fuel economy improvements achieved with the petrol I6-powered Territory means a potential driving range of more than 900 kilometres from a single tank of petrol in the extra-urban driving cycle.
Six-speed automatic transmission
All models in the new Territory range come fitted with a six-speed automatic transmission as standard equipment.
New model Territory's powered the I6 petrol engine (rear-wheel drive) come fitted with the ZF 6HP26 six-speed automatic transmission. The optional V6 turbo-diesel (rear- and all-wheel drive) comes fitted with the ZF-based 6R80 six-speed automatic transmission. Both of these smooth-shifting gearboxes use a conventional torque convertor to transmit drive.
For the new Territory, the transmission’s shift schedule has been optimised for fuel economy and performance feel. This has contributed to Territory’s improved real-world fuel economy while meeting customers’ preferences for a performance feel when driving.
What’s more, Ford engineers have optimised accelerator pedal progression to provide drivers with a more progressive and controllable vehicle launch and under-foot response.
When matched with the engine enhancements made to the new petrol-powered RWD Territory, which was previously only available with a four-speed automatic, and the outstanding attributes of the new TDCi V6, the results achieved with this new six-speed transmission are certain to seize the attention of buyers.
“The opportunity to introduce this six-speed automatic transmission to the rear-wheel-driven petrol-powered Territory brings with it a new level of refinement for drivers,” Mitchell said.
“It has contributed to not only its improvements in drivability and fuel economy but helped make it such a compelling offer to our two-wheel-drive customers."
“The six-speed automatic transmissions allow the driver to fully exploit the excellent attributes of both the 195kW petrol I6 motor and the new torque-rich TDCi V6 engine.
"Importantly this ability comes without sacrificing the refinement and smoothness of the overall Territory package.
"These are the things our Territory customers expected from us and we have delivered,” concluded Mitchell.
ZF-based 6R80 six-speed automatic transmission
Active transfer case
The all-wheel drive version of the new Territory uses a permanent all-wheel drive system. All-wheel drive is only available with the new Duratorq TDCi V6 engine.
The introduction of the new turbo-diesel V6 engine to the Territory range saw Ford's engineers make a number of important technical changes to the optional all-wheel drive powertrain. This is one particular area where the Ford team went to great lengths to achieve the product attribute targets set at the start of this new model's development programme.
Two important changes were re-engineering the front differential to be mounted on the engine's oil sump as opposed to mounting it to the chassis - the method used on the outgoing all-wheel-drive model – and the introduction of an active transfer case.
This new diff-on-sump architecture provides a number of excellent attributes, including excellent management of any driveline imbalance-related NVH issues.
To avoid these, the new Territory's drivetrain engineering team developed an active transfer case: a clever clutch-operated control for the front driveline for all-wheel-drive models.
When the driver is stationary in DRIVE and has their foot on the brake while the engine is idling, a clutch mechanism within the active transfer case decouples any driving forces applied to the front drive shafts to cancel out this structure-borne path.
These invisible forces can have a noticeable impact on a vehicle's refinement. Therefore, even when a driver is sitting at a set of traffic lights they will enjoy the best possible ride.
At a glance: New Territory engines and Transmissions
Notes
2 Maximum towing capacity using a Genuine Ford heavy-duty tow pack with load levelling kit. To achieve maximum capacity, occupants and/or luggage may need to be restricted. For further details regarding passenger and luggage requirements please consult an authorised Ford dealer and/or refer to the Territory's owner's manual under "Trailer Towing" for further guidance. Subject to state and territory regulations.
Source: Ford Media
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