Join Our Live Chat to Ask a Ford Engineer About the F-150 EcoBoostTorture Test
APR
07

In the fall of 2010, Ford threw everything they could at the new 3.5-liter EcoBoost engine in a series of grueling tests designed to prove its toughness and durability. They started by choosing a random engine off the assembly line and throwing it on the dyno for 150,000 miles of stress testing. They froze it. They fried it. Then they pulled 55 tons of timber up a mountain, ran full throttle pulling maximum load for 24 hours straight at the Homestead Racetrack and finished the legendary Baja 1000 off-road race with it. Ford even took it up to Davis Dam and embarrassed the best that Dodge and Chevy had to offer in a torque sprint up a 6 percent grade while pulling 9,000 pounds trailers. After 165,000 miles of abuse, they completed the engine’s journey with a live teardown in front of 1,000 spectators at the 2011 North American International Auto Show. You can view all of the videos at ford.com . You can also see all the torture Sunday, April 10, 2011, at 4:30 p.m. EDT on NBC.

We had some questions for Jim Mazuchowski, the engineer in charge of this engine program, and we thought you might too. While you can read our questions and Jim’s answers below, you can join also join Jim here on Sunday, April 10, 2011, at 4:30 p.m. EDT.

The first application of the award-winning EcoBoost technology – which combines direct fuel injection and turbocharging – in a rear-wheel-drive truck highlights an all-new class-leading powertrain lineup for the 2011 Ford F-150. This marks the most extensive engine makeover in the 62-year history of Ford F-Series. Animations of key technical features of all four new engines will be available at the site as well.

The new EcoBoost engine’s turbocharging and direct fuel injection are particularly relevant to F-150 customers looking for the power to haul and tow heavy loads. This unique EcoBoost engine delivers impressive low-end torque and maintains it across a broad rpm range, which is key in towing applications. Approximately 90 percent of the EcoBoost engine’s peak torque of 420 lb.-ft. is available from 1,700 rpm to 5,500 rpm. EcoBoost’s 420 lb.-ft. of torque is more than any other competitive half-ton truck.

Here is what was on our mind as we watched the videos, and what Jim had to say:

theFordStory: Did you have any concerns before the Torture Test Program began?

Jim: Yes: The fact that we did all the torture test episodes in-series and on the same engine. This was a first for us. We normally would have stopped after the dyno test (what was captured in the Dyno Stress video) and called that a complete durability test. That was just the beginning!

The Baja 1000 test course & environment also concerned me during episode #5. The fact that it was the last episode and engine 448AA was a stock engine out of Cleveland with no special treatment. The engine had already experienced the equivalent of 150,000 miles of very harsh use, and continued to be tortured in a production truck during the NASCAR episode.  Towing 11,300 pounds around a race track at speeds over 90 mph put a lot of stress on the engine.   Now we were putting engine 448AA into a race truck to compete in one of the most grueling off road races in North America.  It was great to see the engine complete all of the challenges without a single component issue.

Were there any surprises you didn’t anticipate along the way?

That we completed all five episodes with no engine issues – none – during all five torture tests surprised even us. The web following was also surprising as 800-900 people watching the teardown that we did at the 2011 North American International Auto Show. Some from as far away as South Carolina. The following and interest created by the web documentaries was phenomenal.

What Torture Test Episode is your favorite?  Why?

The Baja 1000 desert endurance race was my favorite. The engine was really tested to the limits. Hard accelerations on and off the throttle, high loads, extreme temperature swings. and of course the Baja environment and terrain.

The best testimonial was captured on the webisode when the race team member said, “it’s a game changer, man, we skipped the last pit stop [fuel] with Ecoboost.” That really substantiates our EcoBoost strategy of performance and fuel economy.

Was there a point in any episode that you thought “Will the EcoBoost endure this test?”  What was the end result?

I was worried during the 24 hours on the Homestead Miami Speedway due to the continuous nature of the test: High engine rpm, a heavily loaded trailer and the transient nature of the engine rpm and turbo rpm around the corners.  Also the elevated oil and coolant temps complicated the situation.

The end result was that the engine performed perfectly fine. No issues! No oil was required during the test: Just fuel, tires and a driver change. In fact the engineers drove the vehicle back to the hotel that night after the test was finished.

Overall, how do you feel the EcoBoost engine performed?

The EcoBoost engine performed extremely well. We pulled a stock engine out of the Cleveland assembly plant and had no issues during the torture tests. The engine didn’t require any parts replacement during any of the tests. And we used normal 5W30 Motorcraft oil.

During teardown, the engine looked very good and in-fact was within new-build specification for thrust washer wear and valve lash wear. There was also minimal wear on the rotating components. There were not many carbon deposits or signs of contamination abuse. The engine looks like it could go another 150,000 miles.

Is there a fuel economy advantage with the EcoBoost?

Inherently, when you downsize to a smaller displacement engine, you save fuel. The EcoBoost technologies (direct fuel injection and turbocharging) work together to allow efficient use and operation across a wide customer usage profile.

Direct injection also provides some charge air-cooling which allows the engine to operate at a higher compression ratio, making it more efficient and saving fuel.

Lastly, the EcoBoost torque curve with peak torque at 2,500 rpm and 90 percent of torque available at 1,750 rpm, allows the customer to spec out a lower axle ratio saving fuel and still maintaining excellent performance feel.

Can we expect the same durability and capability from the other F-150 engines offered?

Absolutely. All the engines in the F-150 follow a testing protocol and are required to pass a series of very rigorous tests that demonstrate reliability to at least 150,000 miles. The F-150 engines follow the same engine-development process and the same durability testing. Over 13,000 hours of dynamometer testing and 1.6 million miles of customer usage.

The Computer Aided Design and Computer Aided Engineer analytical tools are all the same as well. Over 1,000,000 hours of computer analysis are performed.

Besides the engines, are there other aspects to the F-150 that add to its durability and capability?

Several vehicle actions complement the EcoBoost in the F-150. Good underhood placement of the charge air-cooler allow for efficient cooling of the “boosted air” and maximize EcoBoost performance. Cooling upgrades to the radiator and water pump were made that keep oil and coolant temperatures under control with EcoBoost. And finally underhood air-flow and component temperatures were mapped out and properly managed which also allow us to take full advantage of the EcoBoost capabilities.

See all the torture Sunday, April 10, 2011, at 4:30 p.m. EST on NBC right after the PBR Built Ford Tough Invitational.

Related Tags
ecoboost
ecoboost truck engine
f-150
f-150 ecoboost
live chat
torture test

0 COMMENTS ON THIS ARTICLE
Loren Dunn Hi Ford Design Department, I was wondering if you guys could please make a new 2012 or 2013 Ford Ranger that is mixed with these designs of the 2011 Ford Ranger and the 2011 Ford F-150. For example, Have the new Ranger mid-size truck have the same Front design as the 2011 Ford F-150..plus have the new Ranger have the same back lights of that of the 2011 Ford F-150/ You guys may need to make the lights smaller because the new ranger is going to be a midsize truck instead of a full size truck. But, please leave the sides, the hood, and the door handles the same as the 2011 Ford Ranger. Also if you do make this..keep in mind for making a new stepside & for keeping the lite metallic gray color as usual. Also try not to make the new 2012 ranger into a futuristic hunk of junk like is shown on the photos on google...which looks alot like the ford ranger that Australia has today. Anyway if my idea sounds good, Please feel free to contact me, Your Friend Always, LJD... Also keep in mind a boxed frame (like F-150) and a crew cab option on this new Ford Ranger...
3 year(s) ago via
John Minerich Please, Please, Please, the 36 gal tank with the EB V6 in a Platinum.... I will order one as soon as it is available.
3 year(s) ago via
Larry Stonesifer Comment on this ARTICLE!
3 year(s) ago via
Jim Mazuchowski No need to idle the vehicle on a hot shutdown because of the Turbos. We run both oil and coolant through the Turbine center housing to keep it cool and well lubricated. On a hot shutdown, we also have a siphoning mechanism which continues to circulate coolant thru the Turbo. Jim Mazuchowski V6 Engine Program Manager
3 year(s) ago via
Jim Mazuchowski The EcoBoost engine in the F-150 has a conventional water pump mounted external to the Front Cover and is FEAD belt driven. Easy access if you need it. Jim Mazuchowski V6 Engine Program Manager
3 year(s) ago via
Jim Mazuchowski Fuel Economy will vary depending on your usage, driving habits, weather, altitude, etc. 25 mpg is possible depending on how you use the truck and what you do with it. You can give yourself the best chance by specing out the lightest weight vehicle configuration for your usage. Jim Mazuchowski V6 Engine Program Manager
3 year(s) ago via
Jim Mazuchowski We set out to select similarly equipped trucks for max trailer towing using high volume configurations from the major players (GM and Ram). The configuration was a crew cab 4x4 with premium engine and max trailer towing package. Given that configuration, the final drive ratio for the trucks were: F150 3.73 Ram 3.92 Silverado 3.42 The 3.42 was the best final drive ratio available in the Silverado with this high volume configuration. Jim Mazuchowski V6 Engine Program Manager
3 year(s) ago via
Billy Conboy i'm an ex truck driver that now sell fords, i have alot of experience pulling heavy equipment around the ozarks that i probably shouldnt have been using a half ton to pull. Now i sell Fords and have used to eco boost to pull and was very impressed. I'm loving it more and more everyday. I truly think this is the truck of the future that everybody is going to be talking about
3 year(s) ago via
Eric Pierunek do the new eco boost engines have like a timer for the oil supply to the turbos for better cooldowns from running the truck and then turn off would it not be better to idle the truck befor turning off but people dont have time to do so and not needed if oil supplied oil to them for a few min after turn off
3 year(s) ago via
Michael Hirst This show rocks
3 year(s) ago via
Brad Kiser What are the limiting factors in getting 25 mpg out of this engine? Could this be done by allowing the driver to switch settings based on truck use? For example commute, towing, offroad, etc.
3 year(s) ago via
Henry Northrop Hi , A couple of years ago Schmoyoda did a similar accelleration test pitting the Tindra against all the others . They were all pulling max weight and the Tindra won . What nobody knew until later was that their " truck " had a lower axel ratio than all the others . So , did the EcoBoost F 150 have the same rear axel ratio as the Chev and Dodge ? Henry and Brenda Northrop Hooper , Ut. ( Mercs still rule )
3 year(s) ago via
Bob Fremont I am still driving a Ford F150 P/U. Bought her in 1999 and she still percolates having over 225,000 miles. I am about ready to try out this new technology. Ford is the Proven One in my book.
3 year(s) ago via
Gary The internet is full of images of the 3.5L Ecoboost engine. Some confusion has developed over whether the water pump is internal and behind the front chain cover, or rather it is conventional and mounted on the outside. Specifically, is the F150 engine an external or internal water pump engine?
3 year(s) ago via
Ed Peaslee I watch the show. NowI have to ask about the comparsion towing of dodge and chevy. was it an apples to apples test. did the have same gear ration in the rear ends?
3 year(s) ago via
Houston Woodruff I jus finished watching the torture test on tv, and lemme start by saying i am 100%, without a doubt a Chevy man, but that engine is the Truth! I am so sold and amazed at the way that thing performs! The drag tests between those trucks were amazing! And how pitiful did the Chevy do? Dissapointing to say the least. Anyhow i dont blog r tweet r anything like that bit after seeing that i feel compelled to speak on the shame i feel for Chevy and the bewilderment Ford has instilled. Great job Ford guys...i hate u all!...in good humor.
3 year(s) ago via
Steve Kendig Just saw that show about the eco- boost makes me want to go out and buy a new ford F150 right now
3 year(s) ago via
Dean Desmarais How during testing can they figure oil changes equaled 28,000 mi for after 50 hrs. of running. That would be 560mph Dean
3 year(s) ago via
Dan Jones Ford is the only U.S. manufacturer who did not take a government bail out. This engine is another example why Ford is the true leader in the automotive industry. Period
3 year(s) ago via
Robert I assume this engine will pull a 23 to 27 ft Travel Trailer in the 6000 to 7300 GVWR range, through mountains, etc.
3 year(s) ago via
John Minerich Why is the 36Gal gas tank not available with EchBoost? This is a deal breaker foir me... Hope Ford makes this combination available in 2012, then I may pick one up....
3 year(s) ago via
Rushville Citizen I got cold chills watching the Ecoboost Torture test on TV. I am definately going to have one of these trucks for myself.
3 year(s) ago via
Gregory M Fantastic and gutsy/risky presentation...awesome results! Winner: FORD
3 year(s) ago via
Kory Will there be an EcoBoost Expedition and Navigator? Or will the 5.0 V8 or 6.2 V8 soon be and option in those SUVs?
3 year(s) ago via
Bb Dug Hello, I am looking to buy my first pick-up truck; I see the F-150, I look at the RAM 1500 and honestly I haven't find anyone yet that can explain why so much difference in price... Really , what do I hae more for the $7000 to $8000 difference? Fuel economy - That a lot of fuel to burn.... It really look to me that I will be paying for the name "Ford" ... Any help will be appreciate
3 year(s) ago via
Imminent truck buyer Talk to me in a year. Did somebodysay, "2012?"
3 year(s) ago via
Tim Wimer judge it all you want, I sell fords and drive them daily. The ecoboost technology is incredible, and by far the second best motor ford currently makes. It falls short only of the 6.7 diesel. But; 23 mpg, 365hp, 420 ft/lbs torque, and can tow 11,300 lbs... what is not to like. The turbos work seamlessly, and at only 1700rpm, they are at 90% of their torque curve. The truck is faster than a chevy v8 and a dodge hemi big horn. I know personally... I raced them in the 1/4 mile and won.
3 year(s) ago via
KEVEN ZIEGELT Dear Barricade, the engine is just an air pump. They beefed up the bottom end, I think I saw a 6 bolt main. Other than that,it is still an air pump. The Dodge Cummins is a 6 cylinder with a turbo and nobody ever worries about it being smaller than the other two V8 diesels.
3 year(s) ago via
Jaya Philip Thanks for the update
3 year(s) ago via Facebook
nn nnnn when is 2012 F150 Eco boost available
3 year(s) ago via
mmp Will EcoBoost make to the SVT Raptor?
3 year(s) ago via
nick the new chevy hd showed that the fords tail gate cracked when had full payload going over ditch simulation. whats up with that?
3 year(s) ago via
Barricade Not trying to sound like a big critic here, but I'm not sold on Ecoboost technology. Every test I've ever seen from a media source (not the manufacturers themselves) seems to show these direct injection turbo 4 and 6 cylinder engines, don't really get that great of gas mileage as they promise. I would bet on the 5.0 or the 6.2 in the F-150 being able to pull the same weighted trailer as the Ecoboost, and getting as good or better mileage than the Ecoboost engine too. Think of it this way: If you took a 300 pound football player and asked him to carry an 80 pound object for a mile, and then asked a 95 pound teenage girl to do the same thing, guess who is going to use more energy in doing the same task? That's how I look at the Ecoboost idea. A good concept, but I'm not convinced it actually works in the real world. I would stick with a 5.0 or the new 6.2
3 year(s) ago via
Dennis Murphy I'm going to bet on two reasons for no plowing - 1. The charge air cooler is right behind where most plows ride at, a snow plow would block air flow to the CAC. 2. EPAS - Electric power steering. This would probably kill the battery under prolonged use, since the alternator wouldn't be spinning at its rated charging speed.
3 year(s) ago via
Eric Nelson Why cant a plow be installed on the new f 150 and is the prob going to be fixed?
3 year(s) ago via Facebook
Mark Halliday Why was the 3.5l v6 selected rather than the 4.4l diesel. I think the diesel would have been better more torque and better mpg?
3 year(s) ago via Facebook
Tom Phillips So far i've enjoyed driving my f-150 with the ecoboost.
3 year(s) ago via Facebook
Christopher Crawford Shall we see a 2013 ecoboost based mustang with great handling? I think/hope so.... :-)
3 year(s) ago via Facebook
Liam Kelly Henry Ford Died today in 1947
3 year(s) ago via Facebook
Brad Shankin And the EGR coolers
3 year(s) ago via Facebook
Joey's Home Improvements Ford does rule, but I would ask him when is Ford gonna recall diesel fuel tanks in 03 to 10 super dutys, the lining is falling apart inside the tank, killing injectors in 6.0's, costing his future customers 4-7 thousand dollars to fix! WTF FORD!
3 year(s) ago via Facebook
Jean-Luc Cassanas Why not! But in french!please!
3 year(s) ago via Facebook
Bret Gundy Ford is #1
3 year(s) ago via Facebook
Denis Perković i agree ....... :))))
3 year(s) ago via Facebook
Mark Conrad FORD RULES
3 year(s) ago via Facebook
Christopher Crawford How about a "svo style" revival with a special ecoboost mustang for the 2013 model year. Lighter weight and descent gas mileage is a must! The 2.0 or 3.5 ecoboost would be fine as long as you keep the weight down. Give it the handling characteristics of the current boss 302 mustang and you will have a winnrer. I love the new 5.0 engine, but your currently missing a huge tuner/greener market for turbo mustangs......
3 year(s) ago via Facebook
Tj Allerdings stephen, two problems with that: 1. those diesel engines wont meet epa standards here 2. the european gallon is larger then the american
3 year(s) ago via Facebook
Butch Atkins We have very high emission regulations and government regulations that hinder the higher mileage here in the states
3 year(s) ago via Facebook
This discussion is missing your voice.

Your comment has been received and will be reviewed.
Thought of something else? Add another comment.
Comments are moderated in accordance with the
Ford Story Rules of Conduct.
Flickr
Josh Mishells  Ford F150 EcoBoost Challenge Event in Denver
2010 Ford F-150 SVT Raptor
2011 Ford F-150 EcoBoost truck 3.5L Engine
Louisville F-150 EcoBoost Challenge
Josh Mishells  Ford F150 EcoBoost Challenge Event in Denver
YouTube
BFT Buzz 2011 F-150 EcoBoost Dyno Torque Challenge
Ford F-150 New 6.2L V8 Engine
Mascot + Port-a-potty
Ford F-150 EcoBoost Torture Test Episode 6: Teardown
Mascot + Hotdog
Ford F-150 EcoBoost Teardown from NAIAS - Part 3
Promo Promo Promo
Register Now
SOCIAL NETWORKS
|
RSS
|
|
EVENTS
|
BLOGS
|
ABOUT