Ford Mondeo Engine

The Ford Duratec V6, is an aluminum-block, dual overhead cam V6 engine with a 60° bank angle and cast iron cylinder liners — introduced with the 1993 Ford Mondeo and used widely through 2012 in numerous vehicles by Ford's associates brands, including Mercury, Lincoln, Jaguar and Mazda.

Ford's design brief outlined an engine for front-drive, transverse layouts, short enough for an 11-metre turning radius and with class-leading performance, emissions, economy and durability — as well as reduced NVH.

Interviewed at the time of the engine's U.S. launch in the Ford Contour, head of Ford's V6 program Bruce Coventry noted that Ford had turned to Porsche at a time when its engine development resources were stretched thin. Porsche had already completed the engine's early development — which explains its commonality with Porsche's engines of the period. Notably the cylinder head design and use of a main bearing ''ladder'' design both recall Porsche's V8 engine design for its 928.

While primary engineering was thus Porsche-derived, Ford licensed a high-integrity cylinder head manufacturing method from Cosworth, specifically a sand casting process developed by noted scientist John Campbell which used zircon as its casting aggregate, where the mold was preheated and cooled to achieve even temperatures and where the mold was rotated during casting to improve material uniformity and create dimensional accuracy, high strength, and a dense, low- or no-porosity structure — the so-called Cosworth Casting Method.

Inspired by the variable intake system on its 4.6-litre ‘modular’ V8 which used dual intake ports opening and closing so as to vary the effective inlet tract length, with the early 2.5-litre variant of the US-market Contour's Duratec, the torque varied by no more than five per cent from 1500rpm up to 5200rpm. Bruce Coventry said “there won’t be a four-valve V6 that can match our torque curve." At higher speeds, the engine's inlet tract was effectively shortened at higher speeds. The design featured a cam chain vs a belt, an efficient water pump and an over-capacity oil pump.

During its ownership by Ford's Premier Automotive Group, Aston Martin reportedly created a V12 engine by hand-welding two 2.0 Duratec blocks together.

The engine features fracture-split (cracked) forged powder metal connecting rods, and a forged steel crankshaft in two major variants for the 3.0L version: a 232 hp using direct-acting mechanical bucket (DAMB) tappets and a 208 hp variant using roller finger followers (RFF) .

The engines were manufactured at Ford's Cleveland Engine Plant 2, which had undergone a $688M renovation in 1988 when the 3.0L Duratec engine family was under design. Every engine was hot-run on an 85-foot, 34-station carousel that monitored eight critical operational functions for a minimum of four minutes prior to its completion. The plant floor was composed of individually laid cross-cut end-grain wood blocksto eliminate vibration transfer within the assembly area. Approximately 3.5 million 3.0L Duratec engines had been manufactured by late 2005.

2.5 L

The Duratec 25 is a 2.5 L (2544 cc) 60° V6 and was introduced in 1994. It was developed for the Ford Contour and also used in the Ford Mondeo Mk 1 and others. Bore and stroke is .

The Duratec 25 was on the Ward's 10 Best Engines list for 1995 and 1996, and the SVT version made the list for 1998 and 1999.

SVT

An SVT version produced and in 1998. It included a larger throttle body from the Duratec 30, a new cone-shaped air filter, and abrasive flow machining processing on the intake manifold. SVT specific cams, a lighter flywheel and low-restriction exhaust complete the picture. Further improvements (mostly improved intake porting of the heads) were made in 1999 that raised power output to and and were carried over in the 2000 model. The SVT engine was used in the 1998 to 2001 European Ford Mondeo Mk 2, Ford Cougar and called the ST200, it also appeared in the American Ford Contour ''SVT''.

Duratec 2.5 L

The Duratec 2.5 L (aka Mondeo V6) DOHC 24 valve engine had at 6,250 rpm and of torque at 4250 rpm. Used in the Ford Mondeo Mk 3 and last generation Ford/Mercury Cougar (1999-2002). The Displacement of the 2.5 L VE was decreased from 2544 to 2495cc.

Mazda GY

Mazda used the Duratec 25 block and camshafts in their 2000 MPV. However, they reduced the size from to keep under a 2.5 L tax cap in Japan. This was accomplished with a reduction of the bore from to . The engine produced at 6250 rpm and of torque. It was replaced in 2002 with the larger 3.0 L Duratec 30-based Mazda AJ.

3.0 L

Ford's DOHC V6, marketed as the Duratec 30, was introduced in 1996 as a replacement for the 3.8 L Essex engine used in the Ford Taurus and Mercury Sable. With of displacement and produces between and it was essentially a variant of the Duratec 25, bored to . Manufactured at Ford's Cleveland Engine #2 plant, a slightly modified version for the Ford Five Hundred entered production at the Cleveland Engine #1 plant in 2004.

Using an aluminum engine block and aluminum DOHC cylinder heads, the cylinders are lined with cast iron. It uses sequential fuel injection, has 4 valves per cylinder and features fracture-split forged powder metal connecting rods and an assembled cast aluminum intake manifold.

The , V6 used in the Mondeo ''ST220'' is called the Duratec ST. The , V6 in the Mondeo ''Titanium'' is called the Duratec SE.

There are two key versions of the Duratec 30:
* DAMB - The Jaguar AJ30 versions have direct-acting mechanical bucket (DAMB) tappets. Output is at 6750 rpm with of torque at 4500 rpm.
* RFF - The Taurus/Sable/Escape version used roller finger followers (RFF) instead and produced at 5900 rpm with of torque at 4400 rpm.

Applications include the Jaguar S-Type, Lincoln LS, Mazda MPV, Mazda6, Mondeo ST220, Ford Five Hundred, Ford Freestyle — and numerous other Ford vehicles.

Applications:
*
** 1996-2005 Ford Taurus/Mercury Sable
** 2001-2005 Ford Escape/Mercury Mariner/Mazda Tribute
** 2005-2007 Ford Five Hundred, Mercury Montego and Ford Freestyle

VCT

The 2006 Ford Fusion, Mercury Milan, and Lincoln Zephyr feature a version of the Duratec 30 utilizing variable camshaft timing. The VCT is a RFF engine derived from the Mazda MZI and does not have the mechanical buckets as on the Lincoln LS version.

The engine has an output of at 6250 rpm, and of torque at 4800 rpm.

In second generation of the engine, it is updated to run on E85. This version of the engine has an output of at 6550 rpm and at 4300 rpm while running on 87 octane gasoline, and at 6250 rpm and at 4150 rpm whilst running on E85. To achieve this, the engine now includes Cam Torque Actuated Variable Cam Timing developed with BorgWarner. Fuel saving features include adaptive knock control and aggressive deceleration fuel cutoff.

First generation
*2006-2009 Ford Fusion
*2006-2009 Mercury Milan
*2006 Lincoln Zephyr
*2003-2008 Mazda6
Second generation
*2010-2012 Ford Fusion
*2010-2011 Mercury Milan
*2009-2012 Ford Escape

Replacement

The Fusion later received the all new Duratec 35 V6 as an option to remain competitive with the Toyota Camry and Honda Accord. The older Duratec 30 remained as a step up from the base I4 in the Fusion, but the Milan kept the as its sole V6 until it was discontinued for the 2011 model year. Eventually, the Duratec 30 was discontinued in favor of the newer Duratec 35 and its variants.

Other applications

A twin-turbocharged version of this engine is used in the Noble M400, a British sports car. The engine is rebuilt and tuned to a max power of at 6500 rpm, with a torque figure of at 5000 rpm. Noble has used forged pistons, an oil cooler, a larger baffled oil sump and extra cooling ducts to maintain its durability. .

The 2015 Rossion Q1 is also powered by the Duratec V6, developing a maximum power of at 4700 rpm, with a torque figure of at 4700 rpm.(Q1 Specs) It has a weight-to-power ratio of /hp. As with the Noble M400, the Q1 uses a transversely-mounted, rear mid-engine, rear-wheel drive layout, twin-turbocharged engine.

Mazda's MZI version adds variable valve timing, as does Jaguar's AJ30. Note that the MZI name is also used in Europe on Mazda's version of the Ford ''Sigma'' I4. The , V6 used in the Mondeo ''ST220'' is called Duratec ST. V6 in the Mondeo ''Titanium'' is called Duratec SE.

A racing version of this engine exists and is used on mini prototypes like the Juno SS3 V6. It is a naturally aspirated non variable timing engines producing between with a redline of around 8700 rpm. The engine has a 40-hour racing life span before it needs to be rebuilt with rings and bearings, and has proven very reliable and competitive. The engine has a Jaguar badge, and is branded as a Jaguar V6 since it is built and mostly sold in the U.K.

3.4 L SHO V8

Ford's 3.4 L SHO V8 is related to the 2.5 L Duratec V6. Each cylinder uses the same bore and stroke as the 2.5 L, but this engine was never officially referred to with the ''Duratec'' name.

5.9 L V12

Ford's 5.9 L V12 version of its Duratec engine is used in the present Aston Martin lineup. It is best thought of as two Duratec V6s mated end to end, albeit with slightly larger main journals. The engine has also received extensive crankshaft modifications, giving the engine uneven firing intervals. The regular Aston Martin V12 uses roller rockers (RFF), and was designed by Ford and Cosworth.

Cosworth assembled the V12 engines for a year before Aston Martin took over production.
However, Cosworth still casts the heads and blocks.
The variant used in the Aston Martin One-77 uses (DLC coated) DAMB cam followers like the later Duratec engines, and is built by Cosworth.

See also

* Ford Duratec engine
* List of Ford engines

References

{{DEFAULTSORT:Ford Duratec V6 engine
Duratec V6
V6 engines
Gasoline engines by model