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New F-150 engine plays key role in weight reduction

The new engine, a 2.7-liter twin turbo revealed today with the 2015 F-150, features a uniquely designed cylinder block.

DETROIT -- The weight watchers who developed Ford Motor Co.'s new F-150 truck included the powertrain team.

The 2015 all-aluminum F-150 will be available later this year with a new, smaller V-6 engine, one of the smallest, lightest and most compact engines in its class.

The new engine, a 2.7-liter twin turbo revealed today with the 2015 F-150, features a uniquely designed cylinder block and several design cues from Ford's biggest and smallest engines, the 6.7-liter PowerStroke diesel V-8 and the 1.0-liter three-cylinder.

The 2.7's block is about 18 inches from front to rear, including the front cover and flywheel.

The two-piece block has compact graphite iron on the upper section, while the lower half is made from die-cast aluminum.

"We used iron only where we need the strength, which is in the main bulkhead," said Bob Fascetti Ford's vice president of powertrain engineering. "This whole thing, including the [bearing] caps are cast together," he said.

Fascetti said the 2.7-liter is the first to have main-bearing caps that are fracture-split, a technique that enables extremely precise tolerances and adds strength. The heads also are aluminum.

Ford uses compact graphite iron on the PowerStroke 6.7-liter diesel engine, the Super Duty, while the water cooled exhaust manifolds are used in the 1.0-liter engine.

"This engine has taken the same features from the 6.7-and the European 1.0-liter and technologies under EcoBoost umbrella and has married them all into this new design," said Ed Waszczenko, Ford's engine systems supervisor for the 2.7.

As with other EcoBoost turbo engines, the 2.7 uses direct fuel injection and variable valve timing.

Ford officials would not say how much the engine weighs, nor would they give specific horsepower numbers. But Waszczenko said the output is roughly equal to most other automakers' "midlevel" V-8s, which would put the 2.7's output between 350 and 400 hp.

This is the second extremely compact, lightweight engine Ford has introduced recently. A 1-liter, three-cylinder is so small that the block can fit in an airplane carry-on bag.

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