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With the new developments in electronics, use of electronic sensors is becoming more common in today's vehicles. Oil level monitoring using electronic level sensor is one of them. In this paper, an algorithm developed for Ecotorq heavy duty diesel engines is presented and software measures developed to overcome typical application challenges are described. The sensor used on the engine has a damping tube in which the oil flows through a very small hole to dampen the oil flow. The sensing method is ultrasonic sensing. Direct calculation of total amount of oil from oil level is not possible anytime, since a portion of the oil circulated in the engine varies with engine speed and some part of the oil trapped in the different regions of the engine changes with road conditions. Additionally, lubrication oil is not still while the engine and/or vehicle is running due to effect of crankshaft oil spill and vehicle movements.

This study mainly focuses on oil consumption behavior of laser textured cylinder bores. The results of an experimental study performed on a six cylinder, 9.0 L capacity diesel engine is presented. The engine has Compacted Graphite Iron (CGI) cylinder block, and parent bore power cylinder design. Both an instantaneous oil consumption measurement method, sulfur-tracing, and a conventional oil consumption measurement method, “drain and weigh”, are used in determining the effects of different laser texture parameters at different running conditions. Oil consumption measurement results with the conventional plateau honed surface in comparison with the laser honed surface are also discussed.

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.

Both current exhaust emission legislations and continuously growing customer demand of less oil consumption drive the diesel engine manufacturers to develop more efficient crankcase ventilation and oil mist separation systems. In recent years, integrated design concepts are also considered for almost all sub-systems to achieve compact solutions fulfilling the tightened packaging requirements and more challenging cost targets. This paper presents crankcase ventilation and oil mist separator unit of new generation Ford Otosan Ecotorq Heavy Duty Diesel engines and all work to reach its final configuration, the three-layer filter element with an integrated impactor design. The unit has a compact design as it is integrated to engine valve cover.