The Development of New 7400 and 9400 Series Ford ECOTORQ® Heavy-Duty Engines

FORD OTOSAN has developed new 7400 and 9400 Series ECOTORQ engines. The new series has 7.3 L and 9.0 L engines and replaces current 7300 Series Ecotorq engines powering Ford Cargo trucks since 2003.

In this paper, new features of the engines are described. The engines have high peak fire pressure capability achieved by implementation of the new cylinder head gasket concept, and Compacted Graphite Iron (CGI) material for cylinder block and cylinder head. Parent bore power cylinder application together with new fine boring process brings low oil consumption and long engine life. Lateral cooling concept of the cylinder head provides both efficient cooling and higher cylinder head stiffness. Double stage oil pump used is a compact solution for the case where the part has challenging packaging limitations.

The cylinder head gasket concept is described in view of not only its unique features to comply with the stringent technical requirements of a high-end heavy duty engine but also how it supports modular manufacturing concept developed for all engine variants with minimized cost. Durability data with CGI parent bore application is shared and also compared with Gray Cast Iron dry liner power cylinder. Achievements with new fine boring process and double stage oil pump are described. Experimental development to optimize the cooling system on the rig is described and results on running engine are presented. Finally, SCR system and development steps including urea mixer design are discussed.