The Ford Press Release Thread

[DFB FGXR6]

I have created this thread in support of my image thread, which will house several Ford press releases from the last 20 years.

Despite being professionally written, there are occasional spelling and grammatical mistakes, but I have left them as is.

These press releases are often quite nuanced, offering great insight into what Ford was doing at the time. In particular, I find the powertrain and styling information within these press releases to be a valuable reference.

[DFB FGXR6]

Smart Technology Spearheads Ford Engine Line-up

Wednesday, August 17, 2005

“We’ve taken the most technologically advanced six-cylinder engine we had ever produced and made it even better. It’s now a smarter design in every key area – technology, performance, refinement, fuel economy and emissions.”

- Trevor Worthington, Product and Development Vice President, Ford Australia.

Ford Australia today unveiled a series of upgrades to the engine line-up that will power the BF Falcon and SY Territory due to go on sale at the end of October.

BF ENGINE LINE-UP

Barra 190
4.0-litre DOHC I6

190 kW @ 5250 rpm
383 Nm @ 2500 rpm

Barra 245T
4.0-litre DOHC I6 Turbo

245 kW @ 5250 rpm
480 Nm @ 2000 rpm

Barra E-Gas
4.0-litre DOHC I6

156 kW @ 5000 rpm
374 Nm @ 2750 rpm

Barra 230
5.4-litre SOHC V8

230 kW @ 5350 rpm
500 Nm @ 3500 rpm

Boss 260
5.4-litre DOHC V8

260 kW @ 5250 rpm
500 Nm @ 4000 rpm

“The new Falcon and Territory will boast an engine line-up offering the latest technology providing customer with ……

…..dual knock sensors keep the engine powering the new vehicles at the forefront of automatic technology.

“Customers will notice the gains from the minute they turn the key with greater refinement, extra performance each time they press the accelerator, and most importantly, see improvements in fuel economy for all petrol versions each time they fill up their vehicle.”

Worthington said the engine improvements were driven by feedback from customers looking for an improvement in fuel economy but, importantly, not at the cost to the levels of power and refinement they were used to.

“With the introduction of this new engine programme, Ford Australia is providing customers with the best of both worlds – more usable performance, cleaner emissions and increased economy for all petrol engines.

This strategy has also helped us meet all the requirements of the stringent Euro III emissions legislation which come into force on January 1, 2006.

“Working in combination with our new ZF six speed automatic, revised Ion four speed automatic and the Tremec t56 six speed manual transmission, the BF Falcon and S Territory are truly world-class cars,” Worthington said.

Barra 190

The new Barra 190 spearheads the engine range, building on the strengths of the DOHC inline six first seen in the BA Falcon released in 2002.

The Barra 190 adds to that critically acclaimed engine with a superb combination of power, torque, refinement and fuel economy.

The changes implemented in the program mean the Barra 190 is the best in-line six cylinder engine Ford Australia has produced and one that ranks with the best I6 engines in the world, Engine Design Supervisor Colin Reddington said.

“With the Barra 190, customers will have access to the inherent smoothness only an in-line six can provide with an abundance of torque, the refinement of a state of the art double overhead camshaft design and greatly improved levels of fuel economy.

“The Barra 190 really has everything in terms of technology and features: double overhead cams, 24 valves, increased compression ratio for a more efficient burn, dual independent variable camshaft timing. It’s got all the features you’d want in a top of the line engine,” he said.

Reddington said the engine team was excited by the possibilities brought about by the inclusion of the latest generation dual independent variable camshaft timing.

“We have twin VCT phasers in the BA Falcon, which was an excellent platform for this program. In the Barra 190 each phaser can rotate each camshaft independently to maximize power, torque and fuel economy.”

Dual independent VCT delivers a significant low speed torque enhancement and sustains it throughout the engine speed range.

“In addition to the improved performance across a broad rev range, there is a noticeable decrease in fuel consumption, especially at part throttle.

“At cruise on the highway, where throttle openings are reduced, the system is able to retard the timing by as much as 50 degrees.

“The VCT phasers also retard the camshaft angle at part throttle loads and advance the angle for higher loads, or when under wide open throttle applications.

“This optimizes the cam timing for the range of conditions enabling maximum low speed torque and best high rpm power.

“This cuts fuel consumption as well as providing internal exhaust gas recirculation that helps lower tail pipe emissions,” he said.

At idle, the intake camshaft is retarded by 18 degrees for improved combustion stability providing smoother running.

“Traditionally, four-valve engines demonstrate a strong top end but can suffer from a weak bottom end. Thanks to the dual independent VCT system and a well proven variable intake system the new engine provides purposeful torque from very low revs.”

He said the transition though the advance/retard range was seamless, unlike some less advanced systems where there was a noticeable switch point.

The amount of adjustment is determined by comparing the position of the camshaft with a pre-mapped calibration.

Each camshaft on the I6 engine is fitted with a camshaft phaser that allows up to 60-degrees of variation, depending on the engine load and speed.

“From the pin-lock position we are able to advance 10 degrees and retard up to 50 degrees. The variation is achieved via oil-pressure acting against the phaser,” Reddington said.

An oil control valve directing oil pressure to each cam phaser is located to provide an immediate and reliable response. Both control valves are activated simultaneously by impulses received from the Powertrain Control Module.

Mounting the oil control valve within the cylinder head assembly removes the need for separate oil ways and offers greater durability and reliability, as well as packaging efficiency and weight savings.

To ensure perfect seating of the camshafts, four oil control galley plates are bolted to the top of the cylinder head before the galleys for the camshafts are bored. The front two house oil control valves.

Each of the four galley plates is unique so they cannot be mismatched during in-field service. The galley plates locate on the dowels sunk into the head for perfect positioning every time.

“What it means for the customer is instant power when you need it, combined with a noticeable improvement in fuel economy.”

Compression ratio increase / Dual knock sensors -

Adding a second knock sensor to all I6 engines enabled engineers to deliver fuel economy benefits by taking advantage of an increased compression ratio.

The upgraded I6 engine features an increased compression ratio for improved power and better fuel economy.

“The new pistons feature a revised crown profile, which delivers a compression ratio increase from 9.7:1 to 10.3:1 on the base petrol engine.

“Te pistons are also stiffer and feature a new pin bore which improve refinement, while retaining the high durability levels Ford engineers are renowned for,” Reddington,

“Dual knock sensors provide the foundation for a strategy change which enables the Powertrain Control Module (PCM) to optimize the ignition timing for each individual cylinder.

This has resulted in improved engine performance via more accurate spark control, improvements in fuel economy and improved levels of powertrain refinement.”

Reddington explained four modes of spark control were employed in the engine programme.

Individual / averaged spark correction is a performance mode which uses 50 per cent of the individual cylinder correction and 50 per cent of the engine average spark correction. This gives a more consistent performance for a fast revving engine heavy loads.

“Individual fast only spark correction reacts to detonation noise and retards the spark for the next firing event on the same cylinder. This mode provides optimum fuel efficiency because spark is only retarded when detonation is ‘heard’ by the system.

“Individual slow / fast spark correction is applied in addition to the fast only mode. Slow correction remembers the spark advance used on the previous events and is slowly removed if knock is not detected for a few seconds, adding to the refinement levels for the engine.

“The fourth model is no spark correction, used at low engine loads where detonation is not possible. As a result, no spark correction is applied and the engine runs at the optimum levels for the engine.”

While the engine is calibrated to deliver benefits for all types of petrol users, Reddington said the addition of a second knock sensor meant customers could obtain further performance and economy from using premium unleaded fuel (95 RON)

Ignition system -

All Ford I6 engines in the programme – Barra 190, Barra 245T and Barra E-Gas – include an ignition system featuring adaptive and variable dwell enabling more efficient ignition control across the speed / load range.

“Adaptive dwell takes account of the battery voltage and temperature of the coil windings in the ignition system, ensuring a reliable, repeatable charge.

“The variable dwell delivers maximum coil energy when required voltage is high – under heavy acceleration for example – and minimum coil energy when the engine is cruising, or at idle.”

Reddington said the I6 engine featured the latest in spark plug technology.

“Spark plugs in all I6 engines now have a 0.5mm finewire centre electrode – the smallest available – and platinum pad ground electrodes.

“They have been optimized for idle stability and help prevent misfire at high time in service in every one of the I6 engine line-up.”

Camshafts -

Reddington said every I6 engine in the programme had benefited from revised camshafts.

“The profiles have been specifically selected to work with the dual independent VCT strategy and provide optimum performance for customers.

“We worked closely with powertrain engineers in Ford US, who helped with the advanced CAE techniques to define the optimum cam durations. From this we devised specific profiles for compatibility with our valvetrain.

“Those CAE models also helped us further refine the engine strategy.”

Reddington said exhaust duration on the Barra 190 was 256 degrees (246 at BA) and inlet duration also 256 degrees (251 at BA).

“These new camshaft profiles will benefit the customer in terms of cleaner, smoother power delivery and increased fuel economy.”

Refinement / economy -

Reddington explained two key factors driving the engine upgrades were to improve refinement and fuel economy.

“We have incorporated a number of measures which specifically target those key areas.”

The Barra 190 will use a new lower viscosity engine oil, changing from a 10W30 GF2 to a new 5W30 GF3 for less friction and improved fuel economy, particularly at lower engine operating temperatures.

The I6 air intake system has been significantly revised resulting in lower overall noise levels, as well as a purer engine tone during acceleration.

Power steering pumps have been revised by optimizing fluid flow discharge timing, further improving the refinement levels of the I6 engines.

“We have also incorporated a new ‘smart’ alternator on all I6 engines, which ramps voltage changes smoothly, making a smoother idle easier to control.

“Another new feature is a lighter driveplate, with the ring gear welded to the drivepate – rather than riveted - to further reduce weight and help improve economy.”

BARRA 190 UPGRADES

Dual independent VCT

10.3:1 compression ratio

Revised camshaft profile

Dual knock sensors with individual spark control

Lighter drive plate

Low viscosity oil

Euro III emissions

Transient rpm limit

Improved fuel economy

Improved NVH

190 kW @ 5250
383 Nm @ 2500

Barra E-Gas

The environmentally friendly E-Gas engine has been upgraded for the BF Falcon programme to meet the stringent ADR79/01 (Euro III) emissions requirements.

Reddington said the upgrades included a revised venturi, throttle body, inlet pipe and calibration.

“Communization of the pistons across the I6 programme means the E-Gas engine also shares the revised 10.3:1 compression ratio of the petrol engines.

“However, the E-Gas engine maintains stronger con-rods and harder valves and seats to meet the higher demands placed on the engine by using LPG fuel.

Reddington said the revised venturi provided better air/fuel mixing, while the smooth curve of the new inlet pipe provided better flow so the gas could be withdrawn in a more controlled manner.

Power output on the E-Gas engine remains at 156 kW, while torque has increased slightly from 372 Nm @ 3000 to 374 Nm at a lower 2750 rpm.

BARRA E-GAS UPGRADES

Dual independent VCT

10.3:1 compression ratio

Revised camshaft profile

Dual knock sensors with individual spark control

Revised venturi, throttle body and inlet pipe

Euro III emissions

Transient rpm limit

Improved NVH

156 kW @ 5000
374 Nm @ 2750

BARRA 245T UPGRADES

Dual independent VCT

Revised camshaft profile

Dual knock sensors with individual spark control

Euro III emissions

Transient rpm limit

Improved NVH

245 kW @ 5250
480 Nm @ 2000

“The upgrades take what was an exceptional engine and add further refinement and performance to satisfy our customers.

“XR6 Turbo customers wanting an automatic transmission will receive all the benefits of the new six speed automatic transmission, which is perfectly suited to take full advantage of torque enhancement offered by the Barra 245T,” Reddington said.

Barra 230

The torrent of torque Ford unleashed with the launch of the Barra 220 V8 in 2002 has been further liberated for the BF Falcon programme, with the Barra 230 5.4-litre SOHC 3-valve V8 now boasting 230 kW of power and 500 Nm of torque.

BARRA 230 UPGRADES

Dual knock sensors with individual spark control
(sedan only)

Euro III emissions

Improved fuel economy

230 kW @ 5350 rpm
500 Nm @ 3500 rpm

Produced in Fords Windosr plant in Canada, the Barra 230 V8 boasts VCT variable camshaft timing on each camshaft per bank as well as three valves per cylinder, electronic throttle control, failsafe cooling system and unique, Australian designed inlet and exhaust manifolds.

Reddington said the extra power and torque were by-products of employing additional hardware to improve the knock sensing capability.

“The engine was designed to power the new range of F-Series trucks in the US and always delivered good low-speed torque.

“The addition of two knock sensors allows for a more aggressive ignition calibration with variable camshaft timing and a greater degree of spark advance.

It’s made the Barra 230 a wonderfully smooth engine, with excellent bottom end torque characteristics, making it perfectly suited to the Fairlane G8 and LTD DNA.

“Used in tandem with the new ZF six-speed automatic transmission, it makes the G8 and LTD refined, smooth vehicles around town and the types of car that eat up long distance touring with consummate ease.”

“Multiple valves also enhance the engines ability to ‘breath’ – that is, to move large volumes of air in and out of the cylinders – which is a key to generating maximum power.”

Unique Ute application

Reddington explained two versions of the 3-valve V8 would be offered with the BF Falcon programme, with unique versions for sedan and ute.

“The torque output resultant from the upgrades to the Barra 230 demand the use of a high-torque transmission.

“As a result, sedan buyers opting for the Barra 230 will have their engine matched to the ZF six-speed automatic transmission.

“We conducted a lot of research with our commercial buyers, for whom price sensitivity is a key factor.

“Those customers overwhelmingly reinforced the fact the power and torque of the Barra 220 teamed to the updated four-speed automatic transmission was more than adequate.

“As a result, XL, XLS and RTV ute customers opting for a V8 will have a version of the engine with power and torque remaining at an extremely healthy 220 kW and 470 Nm.

“Ute customers wanting a more performance oriented vehicle have the option of the XR range, with the XR8 and Turbo versions offering the ZF six-speed automatic or Tremec t56 six-speed manual transmission.”

Variable Cam Timing (VCT) -

Fords three-valve cylinder head uses a single overhead camshaft for each bank of cylinders. The cams press down on roller finger followers to open the intake and exhaust valves, which are closed by coil springs.

Conventional camshafts are permanently synchronized with the engines crankshaft so that they operate the valves at a specific point in each combustion cycle.

Variable cm timing allows the valves to be operated at different points in the combustion cycle, to provide performance that is precisely tailored to the engines specific speed and load at that moment. The timing is set to allow the best overall performance across the engines normal operating range.

The result is enhanced efficiency under low-load conditions, such as at idle or highway cruising, and increased power for brisk acceleration or at times of high load.

Electronic Throttle Control

The BF Falcon and SY Territory programme improves on the jet fighter derived fly-by-wire Electronic Throttle Control (ETC) and its numerous customer benefits.

The system debuted on the BA Falcon and was the first locally made car to feature such technology.

“The pedal map has been revised, resulting in improved durability and more linear vehicle performance and we have added a kickdown switch to take full advantage of the upgrades to the automatic transmissions,” Reddington said.

Standard to all Falcon and Territory models, ETC provides precision control of acceleration, helps reduce fuel consumption and emissions, and doubles as the cruise control actuation system, saving weight and improving NVH.

Driver benefits include:

Consistent pedal feel and grater responsiveness to accelerator inputs

Smoother traction control engagement

A more refined engagement of the rev limiter function

More seamless activation and re-activation of the cruise control system

Fine throttle control for low speed maneuvering and optimized pedal response for high speed kickdown

Smooth idle thanks to inputs from the Powertrain Control Module

Electronics are more reliable and durable and do not require regular servicing like mechanical systems.

[DFB FGXR6]

World Class Six-Speed Automatic

Wednesday, August 17, 2005

Ford Australia now has a world class, premium six-speed automatic transmission available in its locally designed and built vehicles. It is a unique transmission courtesy of the hardware software calibrations engineered by our Powertrain team

- Trevor Worthington, Vice President Product Development, Ford Australia.

“Ford Australia today announced it would introduce a world class ZF six-speed automatic transmission on high-series and performance Falcon and AWD Territory models, when the new BF Falcon and SY Territory go on sale at the end of October.

“As the first Australian-manufactured vehicles with a six-speed automatic transmission, Falcon and Territory remain at the forefront of engineering innovation, delivering best-in-class technology to Australian drivers while maintaining the Ford hallmarks of affordability and durability,” Ford Australia Vice President Product Development Trevor Worthington.

“However, the introduction of the ZF 6HP26 six-speed automatic is not just a case of taking an off the shelf transmission and putting it into Falcon and Territory.

“Just as we did with the Tremec T56 six-speed manual transmission at BA MK II, with its double synchros on all forward gears and unique gear sets for both the XR6 Turbo and XR8, we have designed the transmission parameters within the ZF unit to suit our engines and our vehicles.

“We have worked closely with ZF Getriebe GmbH and our Premier Automotive Group (PAG) partners to integrate the transmission into the Falcon platform. A number of hardware changes have been implemented, while a host of dedicated software calibrations make this a unique six-speed automatic for Australian vehicles operating in Australian conditions.”

ZF 6HP26 six-speed automatic

The six-speed automatic is a compact and lightweight, high efficiency, high torque transmission with a low first gear.

The low first gear greatly improves launch feel, while the larger and tighter spread of ratios delivers livelier performance, especially at wide open throttle, along with the added benefits of smoother shift quality and reduced fuel consumption.

1st gear ratio 4.17
2nd gear ratio 2.34
3rd gear ratio 1.52
4th gear ratio 1.14
5th gear ratio 0.87
6th gear ratio 0.69
Reverse 3.40
Final Drive
Barra 190 – Falcon: 2.73
Barra 230: 2.53
Barra 245T/Boss 260: 2.73
Barra 190 – Territory 3.46

“Gear shifts between the top few gears are often imperceptible, while the smaller steps between 3rd, 4th, 5th and 6th also ensure less ‘busyness’ within the transmission as it determines the right gear.

“The end result of the transmission being in the right gear at the right time is both an improvement in vehicle performance and a reduction in fuel consumption.”

Improved transmission cooling capability in the six-speed auto, by virtue of a heat exchanger, ensures rapid warm-up of the transmission fluid and a more stable operating temperature.

As well as contributing to a reduction in fuel consumption, the improved cooling also enables the maximum towing capacity to be utilized without requiring additional transmission coolers.

Gear train

The six speed automatic is based on the Lepelletier gear set, which is constructed by connecting a planetary gear to a Ravigneaux gear – a double planetary gear set commonly used in four speed automatic transmissions.

The sun of the planetary gear is connected to the housing and cannot rotate, while the carrier of the planetary gear is connected by clutches to the large and small sun wheels of the Ravigneaux gear.

The input shaft is always connected to the ring of the planetary gear and can be simultaneously connected to the carrier of the Ravigneaux gear using a separate clutch.

The output, or driven, shaft is connected to the ring of the Ravigneaux gear.

Hardware changes that have been made to the six-speed automatic transmission to suit Falcon and Territory include:

- Unique Transmission case
- Unique torque converter
- New transmission cross member attachment compatible with both ZF six-speed and ION four-speed automatics
- Transfer case compatibility for Territory AWD application
- Unique output/driveshaft flange.

Ford has engineered two versions of the six-speed automatic transmission - a standard version with a torque capacity of 450 Newton meters and a performance version with a torque capacity of 600Nm.

The performance version features upgraded clutches, with extra plates in the clutch packs, to increase the torque capacity for use with higher torque output engines.

Falcon, Fairlane and Territory models using the Barra 190 engine will be fitted with the standard version, while Falcon and Fairlane models using either the Barra 230, Barra 245T or Boss 260 powerplants will be fitted with the higher torque capacity performance version.

Software and calibration

“The ZF transmission is able to tailor its responses to individual driving styles courtesy of a number of software functions and Driver Recognition features, all designed to deliver increased transmission functionality and performance, and a refined shift quality,” Postgate said.

The Sequential Sport Shift feature introduced on BA Falcon continues as a key element of the new six-speed automatic transmission, offering the same style of adaptive and performance automatic modes as well as total manual control through sequential manual shifting.

Torque converter clutch pack lock-up is available in all six forward gears, not just in the top two overdrive gears.

When towing heavy loads at low speeds, such as in city driving or through hilly terrain, converter clutch lock-up in all gears assists with better transmission cooling and reduced fuel consumption.

Electronic control of all gearshifts in the six-speed automatic transmission is via clutches rather than bands, delivering a more direct and refined shift quality.

The internal Transmission Control Module (TCM), which is mounted on the hydraulic control valve assembly, or mechatronics unit, has been matched to the transmission’s valve body.

The TCM and the valve body are an exact matched pair, with the TCM being calibrated to the specific valve body assembly, which ensures accuracy of operation and a more refined shift quality.

Calibration features of the six-speed automatic transmission include:

- Grade Control Logic(Automatic modes)
When driving downhill, with sufficient brake pedal pressure, the transmission will downshift to provide increased engine braking.

Introduced with the four-speed automatic on Territory, Grade Control Logic operates in an even more refined and subtle manner with the six-speed automatic transmission, as the gap between the gear ratios is smaller and the execution of gear changes is smoother.

- Upshift prevention at zero throttle (Automatic modes)

When coasting downhill from rest, this feature inhibits upshifts beyond 2nd gear with zero throttle pedal input, to prevent a ‘running away’ feeling.

- Emergency downshift (Manual mode)

When in manual mode, if the throttle pedal is pushed through the detent to activate the kickdown switch, the transmission will downshift to a lower gear (depending on vehicle speed) to provide acceleration in an emergency situation. The transmission will then revert to full manual control, remaining in the kickdown gear and requiring the driver to input for upshift.

- Transient rpm limit

The transient rpm limit allows the engine to momentarily exceed the prescribed rev limit during upshifting. This enables wide open throttle upshifting of gears to be scheduled at an engine speed closer to the rev limiter than would otherwise be possible. The transient rpm feature allows the engine to exceed 6000 rpm – up to 6250 rpm – while the transmission is completing the gear change, thereby taking full advantage of the high rpm performance of Barra 190 and 245T engine.

Driver Recognition -

A host of advanced features are accessible to the driver as part of the Driver Recognition software with the six-speed automatic transmission.

“Driver Recognition matches transmission performance to the current driving style by considering acceleration and deceleration rates, brake and throttle applications, and cornering speed, to ensure the vehicle is in the right gear at the right time without undesired gear shifts,” Postgate said.

“The transmission ‘learns’ the drivers style and assigns a theoretical count system to certain driving scenarios to determine the activation point of particular features.”

The count system extends from a “base” fuel economy bias (0 counts), through stages such as “sporty” driver (100 counts), up to “enthusiast” (200 counts),

The transmission software recognizes various performance based actions, such as rapid acceleration / pullaways, enthusiastic cornering, pushing the accelerator pedal through the detent and moving the shift lever into performance mode, and increases the number of counts accordingly.

By moving the shift lever across from adaptive to performance mode, the driver recognition function increases by 100 counts instantly, making the advanced features more accessible. If the transmission had already learnt 40 counts in adaptive mode, then the when the shift lever is pushed across into performance mode it would be become 140 counts.

In performance mode, driver recognition can learn from “sporty”, representing 100 counts, up to “enthusiast” (200 counts).

Counts can be gathered quickly as increases occur in blocks, while a more graduated, single point decrease in counts occurs when you return to a less sporty driving style.

Advanced Features

Advanced features through the Driver Recognition software include:

- Brake support downshift (Automatic modes)
Driver Recognition will enable early downshifting during heavy braking, to provide engine braking and to optimize gear selection for tip-in (throttle re-application) response.

- Gear hold around corners (Automatic modes)
This feature will enable the selected gear to he held when the vehicle is cornering enthusiastically, to avoid an unwanted upshift or downshift through the corner. Cornering is detected by differential wheel speed and the ABS sensors on each wheel.

- Gear hold going uphill / downhill (Automatic modes)
If the throttle pedal is released when traveling up or down hills, upshifts are prevented to reduce shift busyness on grades (on tip in when going up hill) and to assist with vehicle speed control (reduce the need for repeated brake application).

- Gear hold, fast off throttle (Automatic modes)
Upshifts are prevented when the throttle position sensor detects the driver has instigated a rapid lift off the throttle pedal (fast off) and maintains the current gear until the driver tips-in (reapplies throttle pressure). It also helps prevent shift busyness in sporty driving and inhibits the ‘running away’ feeling when cresting hills.

“A lower point count and more normalized driving style will deliver significant benefits in terms of refinement and fuel economy, while a greater count will reward sporty driving with sharper responses and a more defined sporty feel.”

All the Driver Recognition features are available on all models fitted with the ZF six-speed transmission, although certain features are more accessible on the sports XR models through a more performance-based calibration.

Enhanced adaptive shift strategy

The refinement of Ford’s adaptive shift programming that occurred on BA Falcon has been further enhanced on BF Falcon and SY Territory.

“The sheer capacity of the ZF transmission to allow for the real time calculation of a variety of parameters has enabled us to further refine the shift strategy, shift schedules and shift pressures to cover the whole gamut of driving scenarios,” Postgate said.

“With corner, grade and load recognition, the transmission is able to adapt its functionality to suit the situation as demanded by the driver.”

Adaptive modes include economy, performance, sports, uphill, downhill and towing.

The transmission software compares wheel speeds to infer lateral acceleration, as well as longitudinal acceleration versus flat road acceleration to infer uphill/downhill operation. It then uses this information to assist the driver by inhibiting upshifts or enabling earlier downshifts.

When towing, the transmission perceives the load as a hill and employs gear hold logic. At highway speeds, it will cruise in the appropriate gear to account for the load being towed, which could be 4th, 5th or 6th gear, depending on the precise situation.

The result is improved vehicle performance and fuel economy, as well as improved engine and transmission efficiency.

Accelerator pedal detent and kickdown switch

An accelerator pedal detent feature has been introduced on all automatic Falcon and Territory models, which provides physical feedback when accessing the kickdown switch.

When the accelerator pedal is pushed through the pedal detent to the floor, the kickdown switch (which is integrated into the accelerator pedal mechanism) activates the kickdown feature.

Depending on vehicle speed and the current gear, the kickdown switch will trigger a single or double downshift. However, to prevent potential damage to engine or gearbox, no downshift will occur if the engine speed is already too high to permit a lower gear from being selected.

Revised accelerator pedal map

The accelerator pedal map has been revised for more refined foot rotation verses engine throttle-plate calibrations, which has improved drivability and resulted in more linear vehicle performance.

Remote transmission oil cooler

The new remote transmission oil cooler fitted to all automatic I6 Falcon and Territory models is a heat exchanger mounted to the engine bloc with a three-way coolant thermostat.

It serves the dual function of using coolant to provide rapid warm-up of the transmission fluid during start-up, as well as improved cooling of the transmission under high load/high temperature operating conditions.

“The rapid warm-up feature delivers a significant reduction in friction losses within the transmission, contributing around 1.5 per cent to the overall improvement in fuel economy within the BF program,” Postgate said.

“The remote oil cooler also delivers further refinement to shift quality, as well as reduced fuel consumption, due to better control of the operating temperature of the transmission.”

New fine-feel shift lever

A uniquely styled shift lever has been developed for all Falcon, Fairlane and Territory models fitted with the six-speed automatic transmission.

The new, fine-feel shift lever features a steel shaft, leather look boot, leather inserts around the selector button and LED illumination.

“The steel shaft delivers a more precise, engineered feel to the transmission lever, with the increased rigidity providing clean, crisp shifts when accessing manual gear selection in the Sequential Sports Shift mode,” Postgate said.

“It also improves the balance of the lever when moving between Drive and the sequential manual shifting positions.”

A new leather-look boot replaces the slider used on the four-speed auto, resulting in reduced noise when changing gears as well as improved feel through the shift lever.

LED’s with daytime and night-time illumination of the ‘PRND’ positions have been integrated with the instrument panel and interior lighting strategies.

The drivers ability to identify shift lever position and gear selection has been improved, even in low lighting conditions or with the headlights off, through the use of LED’s, which are activated as soon as the drivers door is unlocked.

The selector button on the new fine-feel shift lever must be depressed to move the transmission from Drive to Neutral, which prevents inadvertent selection of Neutral when on the move.

Transmission protection for the Neutral to Drive shift is also a feature of the six-speed automatic, limiting torque on engagement if the driver attempts a shift from Neutral to Drive under throttle.

Model range

The ZF six-speed automatic transmission will be available on high series and performance Falcon variants, as well as all Territory AWD models.

The six-speed automatic will be standard on:

Fairmont Ghia
Fairlane Ghia
Fairlane G8
LTD
Territory TX AWD
Territory TS AWD
Territory Ghia AWD

It will also be offered as the automatic transmission option on Falcon XR6 Turbo and XR8 sedans and Utes, while it is specified as mandatory fitment with the optional Barra 230 V8 on Falcon XT and Fairmont.

Falcon XR6 sedan is available with a choice three transmissions: the Tremec T56 six-speed manual (available from January 2006) fitted as standard, with the option of the improved ION four-speed automatic (at no additional cost) or the new ZF six speed automatic.

[DFB FGXR6]

Refined Four-Speed Automatic

Wednesday, August 17, 2005

Significant upgrades to the ION 93-4AT four-speed automatic transmission contributes to improvements in fuel economy achieved the BF Falcon and SY Territory RWD model lines.

“Upgrades to the four-speed auto have improved overall refinement, shift quality and fuel economy, while building on the success of existing features such as Sequential Sports Shift, the adaptive shift strategy and intelligent shift program,” Calibration Supervisor Tim Postgate said.

Upgrades to the four-speed automatic include:

Radial dead-end grove clutch plates
A second ‘Ball Check valve’ in the valve body
Addition of Grade Control Logic on Falcon models
Accelerator pedal detent and kickdown switch
Remote transmission oil cooler
Software and calibration improvements

“By incorporating dead-end groove clutch plates with the addition of a second ‘Ball Check valve’ in the valve body, oil flow between the clutch plates has been improved, which in turn has reduced viscous drag within the transmission,” Postgate said.

“The reduction in the variability of clutch response, in conjunction with some software revisions, have enabled more precise calibration of the Park to Reverse shift, or ‘garage shift’, as well as improving shift refinement throughout the range.”

The optimization of clutch response has also improved upshift duration times, so that they are now more:

Refined – smoother shift due to more controlled engagement between friction elements within the clutch
Consistent – upshift is completed within a shorter time period
Predictable – the transmission upshifts when you expect it to

Grade Control Logic

“Grade control logic, which is already a feature of the four-speed automatic on Teritory has now been introduced to Falcon. As per the Grade Control Logic system in Territory, the transmission ‘reads’ when the vehicle is traveling downhill and increasing speed. If t driver applies sufficient brake pedal pressure the transmission automatically downshifts to provide increased engine braking.

This feature helps prevent the need for the driver to ‘ride’ the brakes when driving down steep grades.

As per Territory, Grade Control Logic is disengaged when the driver switches to manual mode for manual sequential gear shifting.

Accelerator pedal detent and kickdown switch

An accelerator pedal detent has been introduced on all automatic Falcon and Territory models, which provides physical feedback when accessing kickdown switch.

When the accelerator pedal is pushed through the pedal detent to the floor, the kickdown switch (which is integrated into the accelerator pedal mechanism) activates the kickdown feature.

Depending on the vehicle speed and the current gear, the kickdown switch will trigger a single or double downshift. However, to prevent potential damage to engine or gearbox, no downshift will occur if the engine speed is already too high to permit a lower gear from being selected.

Revised accelerator pedal map

The accelerator pedal map as been revised for more refined foot rotation versus engine throttle plate calibrations, which has improved drivability and resulted in more linear vehicle performance.

Remote transmission oil cooler

Te new remote transmission oil cooler fitted to all automatic I6 Falcon and Territory models is a heat exchanger mounted to the engine block with a three way coolant thermostat.

It serves a dual function of using engine coolant to provide rapid warm-up of the transmission fluid during start up, as well as improved cooling of the transmission under high load/high temperature operating conditions.

“Te rapid warm-up features delivers a significant reduction in friction losses within the transmission, contributing around 1.5 per cent to the overall improvement in fuel economy within the development program,” Postgate said.

“The remote oil cooler also delivers further refinement to shift quality, as well as reduced fuel consumption, due to better control of the operating temperature of the transmission.”

Software and calibration

Software and calibration improvements to the four speed automatic have delivered a more refined and consistent shift feel, as well as improved shift schedules.

“We’ve taken our most popular transmission and delivered real world customer benefits through improved fuel economy, enhanced durability, more refined gear shifts and the addition of advanced transmission features like Grade Control Logic,” Postgate said.

[DFB FGXR6]

XR6 Six-Speed Manual

Wednesday, August 17, 2005

The Tremec T56 six speed manual transmission introduced at BA MK II on all XR6 Turbo and XR8 models will now be fitted to the XR6 sedan, from January 2006.

A new variant of the Tremec T56, with unique ratios specific to the XR6, will replace the existing T5 five speed unit.

XR6 T56 six speed manual -

1st gear ratio 3.36
2nd gear ratio 2.07
3rd gear ratio 1.35
4th gear ratio 1.00
5th gear ratio 0.80
6th gear ratio 0.62
Reverse 3.28
Final Drive 3.45

“The Tremec T56 for the XR6 sedan is the same transmission introduced at BA MK II on the XR6 Turbo and XR8 models, but with a new set of ratios, optimized using Computer Aided Engineering to suit the naturally aspirated Barra 190 engine,” Postgate said

“The dedicated ratios provide the optimum balance between performance and economy. The lower 1st gear improves launch feel and performance, while the additional top gear ratio reduces engine rpm at highway speeds, contributing to a reduction in fuel consumption.”

The T56 unit employed in the XR6 delivers improvements in shift quality courtesy of revisions introduced at BA MK II, as it has all the same features and advantages as the T56 transmission used on the XR6 Turbo, including:

Double synchros on all six forward gears
Linear bearings on the shift rail
Direct shifter linkage
Electronic reverse gear lockout (controlled by the PCM)
Reverse gear synchro

[DFB FGXR6]

BF FALCON – A REFINED EVOLUTION

Wednesday, August 17, 2005

As the most refined and sophisticated Falcon range ever built, BF Falcon combines fresh design elements and leading edge technologies with the elegant and powerful appeal of its award winning predecessor.

Refinements to the exterior and interior designs see the introduction of new front and rear graphics, new alloys wheel and wheel cover styles, and array of new fabrics, trims and finishes, which gives BF Falcon a commanding presence on the Australian motoring landscape.

“BF Falcon is a refined evolution of the successful BA range of vehicles,” said Ford Australia Director of Design Simon Butterworth.

“By utilizing Ford’s corporate design DNA, the new BF Falcon range strengthens the Falcon brand by delivering a more dynamic, powerful and exciting front graphic, while still maintaining the elements of sophistication evident throughout the BA range.

“The rear of the car has been endorsed by improved, dynamic tail lamps that mirror the design philosophy of Falcons distinctive and successful front.”

Sports and Luxury

The XR performance range continues to make a bold, powerful statement with the introduction of BF Falcon, building on the very successful BA XR range and drawing further inspiration from the Falcon V8 Supercar.

It also continues to forge strong links wit Fords performance heritage, expressed by the new sports front bumper featuring a deep, wide central opening and GT style fog lights, recessed in a more angular surround with pronounced fluting.

Fairmont Ghia presents its own unique variation of the new design BF front graphic, dominated by chrome details and new fog lights that replace the cornering lamps on BA MK II.

“The new Fairmont Ghia exterior design features chrome highlights across the front and along the side, which give the luxury sports model a level of jewellery and sophistication. Chrome strips in the bumper, a full width chrome strip segments the lower grill opening and fog lamp surrounds.

Fabrics and Finishes

Inside BF Falcon, a host of new trims, fabrics and finishes have been introduced to complement the modern, stylish and sporty design of the exterior, while specification enhancements on Fairmont and Fairmont Ghia build on their established prestige profile.

Falcon, Fairlane and Territory models equipped with the new six speed automatic transmission feature a new shift lever, making it immediately distinguishable from the four speed automatic

“The gearshift on the six speed automatic combines a crisp, accurate throw with a more detailed appearance, while the leather-look gearshift boot reinforces the sporty nature of the new Falcon and Territory models,” Butterworth said.

New door handles with a satin chrome insert and soft feel hand grips are fitted across the board to all Falcon, Falcon Ute and Fairlane models, endowing the cabins with a classy, prestige detail.

All Falcon models also feature new seat fabrics, fabric inserts and door trims in a range of fresh colours and technical patterns.

The Interior Command Console (ICC) and centre console surround is now finished Titanium Stone Metallic on XT, Futura and Fairmont, as well as XL, XLS and RTV Falcon Ute models.

Falcon XR6, XR6 Turbo and XR8 sedans and Utes, as well as Fairmont Ghia, feature a new Liquid Metal finish on the ICC and centre console.

Fairmont and Fairlane Ghia acquire stylish new Ruby Mahogany woodgrain finishes, while Fairmont Ghia and LTD receive Rabbit Rose woodgrain finishes.

Fairmont Ghia now features an eight way power driver’s seat with memory, as fitted to the Fairlane models, while Fairmont gains six way power drivers seat previously fitted to Fairmont Ghia.

The Key

A new ignition key further distinguishes the new Falcon, Fairlane and Territory models form their predecessors.

The new, latest generation key design offers a greater range of security codes combinations for improved vehicle security, while eliminating the complexity of multiple keys for ignition and glovebox locks.

A common key, featuring a two wave external track key design, now provides access to all external and internal vehicle locks – ignition, door and glovebox locks on Falcon based models and ignition, door and under-seat storage box locks on Territory.

Innovative colour palette

Since the introduction of the BA Falcon in September 2002, the Falcon colour palette has blended sophistication and style with innovation and excitement, delivering a unique range that caters to the wide variety of Falcon customers.

Two new exterior colours, Menace and Kashmir, have been introduced in the lead up to the BF Falcon and SY Territory, while another five colours announce the arrival of the new generation models, including the first use of Chromaflair paint by an Australian manufacturer.

Menance - A bold purple with an intense blue highlight, this daring metallic hue is sure to excite the sports enthusiast. Menance is only available on Falcon XR and FPV models

Kashmir - A luxurious mid-tone European grey with golden undertones that radiates timeless elegance. Kashmir is available on the Falcon passenger range, excluding XR models, as well as Fairlane, LTD and Territory.

Toxic - Beyond citrus, this new acidic yellow green is sure to turn heads. Toxic is only available on Falcon XR and FPV models.

Bionic - An explosive and exciting new blue full of energy and life. Bionic is only available on Falcon XR and FPV models.

Wired - A warm, copper metallic, rich with warmth and sophistication. Wired is available on the Falcon passenger range, excluding XR models, as well as Fairlane, LTD and Territory.

DeJaVu - A classic, dark emerald green full of depth." DeJaVu is available on all Falcon passenger models, including Falcon XR and FPV, as well as Falcon Ute, Fairlane, LTD and Territory models.

Fantasy - A vivid chameleon colour full of power, with high chromaticity and dramatic effects, which constantly changes its personality from royal purple to an amazing new blue. Fantasy is only available on Falcon XR and FPV.

Set to become an iconic colour, the release of Fantasy marks the first use of revolutionary ChromaFlair paint technology in volume production within Australia.

Unlike the special-effect pigments of the early 1980’s, which showed a subtle shift in shade, these next-generation colour shifting pigments take on a completely different hue depending on the angle of view or light source projected upon them.

Elegant and strong

New alloy wheel and wheel cover designs have been introduced across the BF Falcon range, delivering a fresh, contemporary finish to the new vehicle lineup.

“The new design alloy wheels and wheel covers are both elegant and strong in their appearance, for a more refined aesthetic that builds on the sophisticated style of the BA range”, Butterworth.

“The XR6 and XR6 Turbo continue the tradition of bold, performance driven five-spoke, 17-inch designs, while the XR8 sedan has a new 18-inch alloy wheel as standard that contributes to its powerful, road hugging stance”.

All Falcon models gain new wheel designs for an enhanced appearance, while Fairlane Ghia and LTD increase wheel size form 16’’ to 17” for a more dynamic driving experience.

Wheel styles

XT – a seven-spoke, 16’’ wheel cover in a twin spoke style that has been designed with new resin technology and Computer Aided Engineering to deliver high strength and stiffness, while also reducing weight.

Futura – a nine-spoke, 16’’ alloy wheel with elegant cues.

XR6 – a five-spoke, 17’’ alloy wheel with a bold ‘Tuning Fork’ design (standard on XR6 and XR6 Turbo sedans and Utes, and XR8 Utes).

XR8 – a five-spoke, 18’’ alloy wheel with an aggressive ‘Boomerang’ spoke design and machined ‘Boomerang’ features on the spokes (standard on XR8 sedans, optional on all XR variants).

Fairmont – a 10-spoke, 16’’ alloy wheel with classic lines.

Fairmont Ghia – a nine-spoke, 17’’ alloy wheel with a machined front face and ‘Ghia’ script on the centre cap.

Fairlane Ghia – a seven-spoke, 17’’ sports luxury alloy wheel with a fully machined front face, chrome finish centre cap and ‘Ghia’ badge (16’’ alloy wheel at BA MK II).

Fairlane G8 – a five-spoke, 17’’ sports alloy wheel with a fully machined front face, chrome finish centre cap and ‘G8’ badge.

LTD - a seven-spoke, 17’’ sports luxury alloy wheel with a fully machined front face, chrome finish centre cap and ‘LTD’ badge (16’’ alloy wheel at BA MK II).

MODEL BY MODEL

Ford BF Falcon

BF XT Sedan and Wagon

• New front Bumper
• New tail lamps on sedan
• New XT wheel cover
• New shifter with optional V8 engine and six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console and rear air vent register.
• New seat fabrics and trim inserts
• New paint colours : Kashmir, Wired and déjà vu.

BF Futura Sedan and Wagon

• New front Bumper
• New tail lamps on sedan
• New XT wheel cover
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console and rear air vent register.
• New seat fabrics and trim inserts
• New paint colours : Kashmir, Wired and déjà vu.

BF XR6 and XR6 Turbo

• New sports front bumper
• New tail lamps
• New 17’’ alloy wheel
• New optional 18’’ alloy wheel
• New shifter with optional six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console and rear air vent register.
• New seat fabrics and trim inserts
• New paint colours : Toxic, Bionic, Fantasy and déjà vu

BF XR8

• New sports front bumper
• New tail lamps
• New 18’’ alloy wheel
• New optional 17’’ alloy wheel
• New shifter with optional six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console and rear air vent register.
• New seat fabrics and trim inserts
• New paint colours : Toxic, Bionic, Fantasy and déjà vu

BF Fairmont

• New front bumper
• New tail lamps
• New 16’’ alloy wheels
• Six way power drivers seat
• New shifter with optional V8 engine and six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console and rear air vent register.
• New Ruby Mahogany woodgrain finishes
• New seat fabrics and trim inserts
• New paint colours : Kashmir, Wired and déjà vu.

BF Fairmont Ghia

• New front bumper
• New tail lamps
• New 17’’ alloy wheels
• Chrome strip in body-side protection moulds
• Fog lights (replace cornering lamps)
• Chrome fog light surrounds
• Chrome strip in lower grill
• Eight-way power driver’s seat with memory
• New shifter with six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console and rear air vent register.
• New Rabbit Rose woodgrain finishes
• New seat fabrics and trim inserts
• New paint colours : Kashmir, Wired and déjà vu.

MODEL BY MODEL

Ford BF Fairlane and LTD

BF Fairlane Ghia

• New tail lamps
• New 17’’ alloy wheels (16’’ alloy wheel at BA MKII)
• New shifter with six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Ruby Mahogany woodgrain finishes
• New paint colours : Kashmir, Wired and déjà vu.

BF Fairlane G8

• New sports-luxury model, replacing G220. The new G8 nomenclature reflects its Ghia heritage and standard V8 emgine
• New tail lamps
• New 17’’ alloy wheels (16’’ alloy wheel at BA MKII)
• New shifter with six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New paint colours : Kashmir, Wired and déjà vu.

BF LTD

• New tail lamps
• New 17’’ alloy wheels (16’’ alloy wheel at BA MKII)
• New shifter with six-speed automatic transmission
• New soft feel door grab handles with satin chrome inserts
• New Rabbit Rose woodgrain finishes
• New paint colours : Kashmir, Wired and déjà vu.

MODEL BY MODEL

Ford BF Falcon Ute

BF XL Ute

• New front bumper
• New optional 16’’ alloy wheel
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colour Déjà vu.

BF XLS Ute

• New front bumper
• New 16’’ alloy wheel
• New leather wrapped steering wheel
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colour Déjà vu.

BF RTV Ute

• New front bumper
• New soft feel door grab handles with satin chrome inserts
• New Titanium Stone Metallic finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colour Déjà vu.

BF XR6 Ute

• New sports front bumper
• New 16’’ alloy wheel
• New optional 18’’ alloy wheel
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colours : Menance, Toxic, Fantasy and Déjà vu.

BF XR6 Turbo Ute

• New sports front bumper
• New 16’’ alloy wheel
• New optional 18’’ alloy wheel
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colours : Menance, Toxic, Fantasy and Déjà vu.

BF XR8 Ute

• New sports front bumper
• New 16’’ alloy wheel
• New optional 18’’ alloy wheel
• New soft feel door grab handles with satin chrome inserts
• New Liquid Metal finish on Interior Command Centre fascia, centre console.
• New seat fabrics and trim inserts
• New paint colours : Menance, Toxic, Fantasy and Déjà vu.

MODEL BY MODEL

Ford SY Territory

SY Territory TX RWD

• Auto Headlamps on
• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

SY Territory TS RWD

• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

SY Territory Ghia RWD

• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

SY Territory TX RWD

• New shifter with six speed automatic transmission
• Auto Headlamps on
• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

SY Territory TS RWD

• New shifter with six speed automatic transmission
• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

SY Territory Ghia RWD

• New shifter with six speed automatic transmission
• New paint colours: Kashmir, Wired, Déjà vu and Mercury Silver (previously only on Falcon and Fairlane models)

[DFB FGXR6]

2005 Australian International Motor Show – FPV’s Emission Possible

Thursday, October 13, 2005

Ford Performance Vehicles has introduced a cleaner, leaner but still just as mean range of Australian-built high-performance cars.

Its complete new BF model line, which includes the GT, GT-P, Pursuit and Super Pursuit that are powered by the high-tech quad-cam 5.4-litre Boss 290 V8 and the F6 Typhoon and F6 Tornado with the F6 270 Turbo 4.0-litre in-line six-cylinder, all comply with the strict Euro III emission regulations months ahead of their formal introduction by the Federal Government.

The modifications introduced to meet the new emission regulations, and combined with the addition of the new six-speed automatic, has resulted in better fuel economy for both the Boss 290 V8 and F6 270 Turbo engines.

“High performance cars are perceived to be the most harmful to the environment because of their inherent nature, but that is not necessarily the case,” David Flint, Managing Director of Ford Performance Vehicles.

“The advances made in emission control over the last decade have been quite dramatic. Our engineering partners at Prodrive were handed the challenge of making sure our vehicles complied with the toughest emission regulation ever imposed on Australian-built cars. They have achieved the task and counteracted the tougher restrictions without ant loss in the performance outputs of our engines.

“These modifications have also resulted in improved efficiency of our engines. It’s a double win for our customers.”

Euro III

All FPV models in the BF model range now comply with Euro III emission regulations as dictated by the Australian Design Rule ADR 79/01 that is due to come into effect for all new petrol powered passenger vehicles sold from January 1, 2006.

The strict new regulations enforce a significant reduction in the …..

A major pathway in achieving the requirements of the new regulations is the introduction of a number of strict tests, including for the first time a sub-zero emission test at minus seven degrees centigrade, that all emissions are recorded from start-up, an evaporative heat soak test that measures emissions from the fuel system under high-ambient temperatures and that the catalytic converters must still perform above regulations for longer than 80,000km.

On Board Diagnostics

As part of the Euro III standards, all vehicles must also be fitted with a sophisticated on-board diagnostics (OBD) system that constantly monitors the emission control systems to ensure the vehicle complies with the regulations.

The OBD is linked to the engine management system with a number of sensors that monitor the condition and performance of specific components related to controlling the emission output.

The OBD system measure the emission output through the addition of an extra oxygen sensor that monitors the operation of the catalytic converters and provides more accurate control of the fuel-air ratio. There is also a misfire monitor that detects any changes in the acceleration of the crankshaft.

If either of these sensors record an event that results in emissions exceeding those prescribed under the Euro III regulations, the OBD system logs the event within the ECU. If a similar event occurs within the same driving period, or if the system detects the issue when the engine is restarted, the driver is made aware of a potential issue via the engine warning light on the instrument panel.

“The adoption of On Board Diagnostics through the Euro III regulations provides our customers with greater peace of mind that their vehicle is operating correctly at all times,” Flint adds.

“The system is completely invisible to the owner up to the point when a potential issue has been recorded. If this occurs, the owner should take the vehicle to their FPV dealership to have the event investigated.”

Boss 290

The high-tech quad cam Boss 290 – the only V8 production engine to built in Australia – has a number of upgraded features that coincide with the introduction of the new BF range.

In conjunction with the Euro III emission regulations, another new design standard will be introduced from 2006: a reduction in drive-by noise (ADR 83/00) from 77db to 75db. To achieve this, the 5.4-litre quad cam Boss 290 V8 is now fitted with dual-entry ram airbox that was introduced on the F6 Typhoon and F6 Tornado and a bold new twin exhaust system exclusively available on GT and GT-P.

The dual entry ram airbox provides more efficient airflow into the induction system. This offsets the increase in exhaust back pressure imposed by the emission regulations, and also provides a significant reduction in induction noise. The airbox volume has increased from five cubic liters to 13 cubic liters.

The new twin exhaust system on the GT and GT-P not only lifts the aesthetic presence of the iconic V8 powered models, but also generates a traditional muscle car inspired exhaust note. The system has four-into-one extractors from each bank of cylinders joining into a twin 2 inch exhaust with an intermediate silencer box. The exhaust gases pass through new tri-flow silencers before exiting via the six inch twin-outlets that feature a design reminiscent of iconic muscle cars of the 1970’s.

The tri-flow silencers replace conventional absorption silencers and create a definitive V8 exhaust note while being able to comply with the ADR 83/00 drive-by noise regulations.

Other detail changes include the addition of an extra knock sensor, camshaft timing improvements and relocating the front oxygen sensor from the manifold to the catalyst downpipe. The twin knock control system ensures efficient engine management under a wider range of conditions. The camshaft timing adjustment has resulted in a lower idle speed and better idle stability. And the relocation of the oxygen system improves the accuracy of measuring the air/fuel ratio for the OBD system.

The engine management system also required modification to the calibration to meet the Euro III standards as well as the fitment of the dual entry ram airbox and twin exhaust system.

Despite the restrictions imposed by the Euro III regulations, Prodrives powertrain engineering team has maintained the power and torque outputs of the 5.4-Litre quad cam Boss 290 V8. It produces 290kW at 5500rpm and 520Nm or torque at 4500rpm.

The Boss 290 is now up to 2.6 per cent more fuel efficient, with the GT and GT-P manual sedans recording 14.9 litres/100km/h under official ADR requirements for combined city/urban driving cycle. The lower gearing of the six-speed automatic records 15.0 litres/100km/h in GT and GT-P and 15.1 in Pursuit.

F6 270 Turbo

The intercooled and turbo-charged F6 270 Turbo six cylinder engine has also received a host of detail changes in line with the introduction of the Euro III emission standards.

As with the Boss 290, it now features twin knock sensors and a revised engine calibration.

It also receives new camshaft profiles on the dual variable cam timing system with five degrees longer duration on the inlet and 10 degrees longer on exhaust to maintain consistent at high engine speeds.

The F6 Typhoon also has a new exhaust outlet, replicating the trapezoidal design on the GT and GT-P with the single pipe on the right-hand side.

Peak power and torque outputs have been maintained, with the DOHC 4.0-litre turbo-charged six-cylinder producing peak power of 270kW at 5250rpm and maximum torque of 550Nm – the highest torque figure of any Australian-built production engine – produced from 2000-4250rpm.

The F6 Turbo is up to 3.6 per cent more fuel efficient compared to the BA MK II model with the six-speed manual versions of the F6 Typhoon and F6 Tornado recording official fuel economy figures of 13.5 litres/100km/h. With the six speed automatic, both models have fuel economy figures of 13.0 litres/100km/h.