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Old 10-27-2013, 02:21 PM  
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Originally Posted by joshuafail View Post
If you read the article, that's exactly what happened. They put the engine on a dyno at max power for 300 hours included repeated cooling to 20 below and heated to 235 degrees, then installed in an F150. That truck was then put to work towing 11k pounds, towing Richard Petty's racecars around Miami Speedway for 1600 miles (averaging over 80mph), and several other real-world testing scenarios.

I'm a little skeptical of torture tests, and this one actually impressed me. For a rough equivalent of over 400,000 consumer miles, I was very shocked at the condition of the engine, being cleaner than I expected it to be. Gotta give props to the engineering team at Ford for that one.

The Ford engineers want to see how the 3.5L EcoBoost "Hero" engine # 448AA parts and components held up after being tortured with test after test. The team will disassemble the engine and check measurements on components to assess the wear for long term durability. They are expected to complete this task in approximately 1 hour in front of the public in Cobo Hall.

“Customers will be able to see for themselves how the components fared during a regime of tests that, when taken together, are far more extreme than even the harshest-use customer could dish out,” said Jim Mazuchowski, V6 engines programs manager. “This EcoBoost truck engine received no special treatment, and now we’re going to see how it did.”

The F-150 EcoBoost engine saw its first action on the dyno in July. Engineers punished it in temperature and load extremes simulating nearly 10 years of use – a regimen tougher than any consumer could ever subject a truck to. At this point, most engines would be ready to be rebuilt or retired, but the EcoBoost testing engine was just beginning.

The engine was dropped into a regular production 2011 F-150 at Kansas City Assembly Plant Then it hit the road and saw some of the most severe use Ford engineers have ever dreamed up.

• It hauled 55 tons of lumber
• It ran at full throttle for 24 straight hours towing 11,300 pounds
• Beat competitors’ larger engines in an uphill towing competition
• Completed the world’s toughest desert endurance race, the SCORE Tecate Baja 1000 in Mexico
While at Homestead-Miami Speedway, the 2011 F-150 EcoBoost:
Turned 1,061 laps
Compiled 1,606 miles
Had a fast lap of 99 mph
Averaged 82 mph

“The engine and the truck performed flawlessly,” said Eric Kuehn, chief engineer of the 2011 Ford F-150. “These demonstrations reinforce that every engine we put under the hood of a Ford F-Series has to pass all of our Built Ford Tough testing – and pass it readily.”

Of particular importance to maximum towing customers is the performance of the stock turbochargers and cooling systems tested during this demonstration.

“The twin turbochargers were pushed to the absolute limit multiple times every single lap with no problems whatsoever,” said Kuehn. “The stock cooling systems were outstanding as well. The engine coolant, transmission temperatures and oil temperatures ran at or below where we expected throughout the entire test.”

The perception of power is being displaced by modern technology. The advances in supplying fuel at high pressures by direct injection, turbocharging, and electronic ignition control are putting to rest the ages old adage, “There is no replacement for displacement!”
It's certainly not the first time an automaker has torture tested their own products internally through dyno testing as well as climate testing in the real world and in the laboratory. However it was one of the most public facing campaigns in years in order to try to demonstrate that truck guys don't have to have a V8 to have a durable and reliable truck.

For as many miles on the engine and as dirty and battered it was by the desert at the end the internals sure didn't look like they suffered much from all of the thermal stresses and cycles put into the parts.
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