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  • The 2011 Super Duty with the all-new Ford 6.2-liter V-8
    engine will deliver significantly improved torque and horsepower as
    well as class-leading fuel economy; it can run on regular-grade
    gasoline, E85 or any blend in between
  • Optimization of the engine’s “breathing” delivers increased horsepower compared with outgoing F-250/F-350 6.8-liter engine
  • Base engine performing flawlessly in Ford F-150 SVT Rapor R off-road racing truck, complementing rigorous testing regimen

DALLAS, Sept. 24, 2009 ““ An all-new 6.2-liter V-8 gasoline engine,
which has its roots in Ford Racing powerplants, joins the lineup for
the 2011 Ford F-Series Super Duty.

“Our all-new 6.2-liter V-8 engine uses reliable components and
proven technology that has been optimized for the high performance and
efficiency that our Super Duty customers demand,” said Mike Harrison,
Ford V-8 engine programs manager. “It delivers not only significantly
better torque and horsepower than the outgoing engine, but also
improved fuel economy.”

Core to the improvements is the adoption of an all-new engine
architecture, with increased bore spacing, that allows better engine
“breathing” in both the intake and exhaust for more power and more
overall efficiency.

A closer look at how the new engine achieves its performance:

  • Large bore, shorter stroke: This
    approach to creating power has its roots in storied Ford racing engines
    from the past. The large bore (102 mm) allows for larger intake and
    exhaust valves for improved engine breathing, and the short stroke (95
    mm) allows higher engine speed for increased horsepower. Still, peak
    horsepower is generated at a relatively modest 5,500 rpm.
  • SOHC valvetrain with roller-rocker shafts:
    The single overhead camshaft (SOHC) per cylinder head design results in
    a stiff valvetrain that allows optimized camshaft lift profiles and
    helps produce great low-speed torque. The roller-rocker shafts allow
    valve angles to be splayed, resulting in optimized intake and exhaust
    port layout for better breathing.
  • Dual-equal variable cam timing: Intake
    and exhaust valve opening and closing events are phased at the same
    time to optimize fuel economy and performance throughout the engine
    speed range and throttle positions.
  • Two spark plugs per cylinder: Because of
    the large bore size, two spark plugs per cylinder are used to more
    efficiently burn the fuel-air mixture in the combustion chamber,
    enabling better fuel economy and increased engine torque. The twin
    plugs also help the engine maintain a smooth, stable idle.
  • Dual knock sensors: A knock sensor on
    each bank of cylinders of the V-8 engine allows the spark timing of
    each of the cylinders to be individually optimized real time,
    throughout the engine speed range. The engine continuously monitors
    engine performance and applies this real-time learning to optimize
    timing via an adaptive algorithm.
  • Better engine crankcase “breathing” and efficiency:
    Significant development work and computer-aided engineering optimized
    the cylinder block for more efficient airflow in the crankcase as the
    pistons move up and down in the bores, resulting in improved torque at
    higher engine speeds. Piston-cooling jets squirt oil on the underside
    of the pistons to keep the piston crowns cool under extreme operating
    conditions. The cooling jets also allow for a higher compression ratio
    for better engine efficiency and faster engine oil warm-up on cold
    starts, also improving fuel economy.

Key features of the new 6.2-liter V-8 gasoline engine include:

  • Cast-iron engine block and four-bolt main bearing caps, with cross bolts, for durability
  • Aluminum cylinder heads, with two valves per cylinder and two spark plugs per cylinder
  • Cast-iron crankshaft, with dual-mode damper
  • Forged steel connecting rods
  • Cast-aluminum pistons, with cooling jets
  • Single overhead camshaft with variable valve timing and roller-rocker shaft valvetrain
  • Magnesium cam covers for lighter weight
  • Stamped-steel oil pan
  • Composite intake manifold
  • Stainless-steel fuel rail; port-fuel-injected; mechanical returnless fuel system
  • 9.8:1 compression ratio
  • E85/flex fuel capable

Performance heritage with proven durability and reliability
The concept of using a large-bore engine to make horsepower is part of
Ford’s DNA, especially its racing heritage ““ the famous Ford Boss 302
and 351 engines, for example, pioneered many of the same concepts.
Several racing projects proved out the performance, durability and
flexibility of the new 6.2-liter V-8 engine architecture.

Among the racing-themed highlights that contributed to the engine’s development:

  • A 7.0-liter version running on E85 fuel produced 800
    horsepower in a winning Mustang drag racing application driven by Don
  • A specially calibrated production-based 6.2-liter
    engine achieved 500 horsepower and ran flawlessly in the Ford F-150 SVT
    Raptor R race truck in the 2008 Baja 1000

Testing on the 6.2-liter V-8 included running multiple engines for
more than 500 hours at peak torque and peak horsepower as well as
customer-correlated 1,000-hour road load tests to ensure dependability
for even the toughest Ford F-Series Super Duty customer.

All told, more than 50 engines were put through the dynamometer lab,
running a variety of durability and development tests, undergoing
extremes far harsher than can be expected ““ or duplicated ““ in the real
world. Testing also included high-speed durability,
crankshaft-torsional evaluation and engine thermal cycling where the
running engine is “shocked” from one coolant temperature extreme to the

“From the first test on the dynamometer, this engine was very
reliable,” said Bob DeBona, supervisor, Engine Performance and
Development. “The precision that went into the engineering and
manufacturing of this engine led to very few tweaks to the block during
development. Components such as the crank, connecting rods, heads and
intake manifold stayed essentially the same throughout our durability
testing, which is a testament to the reliability of this new engine.
It’s able to pound out the torque, hour after hour, week after week,
demonstrating extreme durability.”

The new 6.2-liter V-8 gasoline engine will be built at the Romeo (Michigan) Engine Plant.

Come check out the discussion on the new Super Duty!

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