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Recently, Ford Motor Company announced the introduction of EcoBoost engines in its Ford, Lincoln and Mercury vehicles as an affordable fuel-saving option to millions of its customers. The EcoBoost engine is planned to start production in June of 2009 in the Lincoln MKS. The EcoBoost engine integrates direct fuel injection with turbocharging to significantly improve fuel economy via engine downsizing. An application of this technology bundle into a 3.5L V6 engine delivers up to 12% better drive cycle fuel economy and 15% lower emissions with comparable torque and power as a 5.4L V8 PFI engine. Combustion system performance is key to the success of the EcoBoost engine. A systematic methodology has been employed to develop the EcoBoost engine combustion system.

This report describes the dynamometer testing portion of the combustion system development of a direct-injection stratified-charge gasoline engine. The engine used in this study is a single-cylinder, direct-injection engine with a newly designed cylinder head comprised of 4-valves per cylinder, an intake-side-mounted DI fuel injector and a bowl-in-piston wall-guided stratified-charge combustion system. Test results detailed in this report include evaluation of four piston designs, two combustion chamber designs, and two injector spray angles. Tests were run at stratified-charge part-load, homogeneous-charge part-load, and WOT conditions. The program had aggressive goals in improving both WOT performance and part-load fuel economy while achieving Stage IV emission requirements. Tests results showed that the engine was able to meet these program goals.