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Click above to view the video after the jump

Ford will officially unveil its revised 2011 Super Duty pickups Thursday at the State Fair of Texas, and the all-new, Ford-designed and produced 6.7-liter Power Stroke (aka Scorpion) diesel is the star of the show. We've already given you the details on the Scorpion, as well as a description of how quiet it is, and now Ford has now posted a video of one of the diesels on a dynamometer switching from the old single injection pulse control to the new multi-pulse strategy.

The difference in sound levels is quite startling. By splitting the fuel delivery into multiple pulses (and ignition events) the pressure impulse on the piston is flattened out and spread over a larger time, mitigating the knocking sound. The new engine will be available in production trucks in the second quarter of 2010 and you can check it out for yourself in the video after the jump.

[Source: Ford]


6.7-liter Power Stroke V-8 Turbocharged Diesel Engine
Click here to download related images.

VIDEO: Quiet New Ford 6.7-liter Power Stroke Turbocharged Diesel Engine

DEARBORN, Mich., Sept. 23, 2009 – People who know diesel engines are familiar with, and expect, the noisy clatter generally associated with diesels. That is, until now. When Ford's new 6.7-liter Power Stroke® diesel engine debuts in the 2011 Super Duty lineup, it's expected to be the quietest, smoothest diesel on the market, outperforming its closest competitors by several decibels.

Engineering and design improvements to the all-new Ford-engineered, Ford-tested and Ford-built 6.7-liter Power Stroke® turbocharged diesel engine – debuting in the 2011 F-Series Super Duty – eliminate the harsh sounds of the typical diesel to make it one of the quietest and smoothest diesels on the market. Significantly quieter than its toughest competitor, the 6.7-liter diesel challenges traditional views about how diesels should sound.

"Historically, consumer perception has been that diesels should sound rough and tough, but from a sound quality perspective they were actually loud and unrefined," said Scott DeRaad, engine NVH (noise, vibration and harshness) engineer. "At Ford, we approached the new diesel development as though it was more than a work truck and something that people wanted to drive, making 'quieter' a reason to buy."

Most of the improvement in NVH comes from changes made to the combustion system and the structural integrity of the compacted graphite iron block, as well as from mounting one turbocharger on the engine block instead of two.

Specific design upgrades were made to both the piston and the piston bowl to optimize the combustion process, which features a two-stage combustion event instead of a single-injection event, causing harsh, sudden and loud combustion. Instead, a starter or pilot injection of fuel begins the compression process before the main injection.

The result is a smoother combustion and a more refined sound for the customer. When at idle, two pilot injection events are used to make the firing process even smoother and aid in quietness. The "ticking" of the high-speed injectors also is masked by specially designed covers on the engine.

Mounting the turbocharger from the center housing directly to the block provided several advantages as well in terms of NVH performance.

"When turbochargers vibrate, it can lead to other parts of the vehicle vibrating," said DeRaad. "The exhaust system, for example, is directly attached to the turbocharger. So when the turbocharger vibrates a lot, the exhaust system vibrates too and that's disturbing to the customer. Bolting the turbocharger directly to the block eliminates that concern."

Using one turbocharger, instead of two operating in series or sequentially, helped solve some NVH challenges as well.

"Having one turbocharger eliminates the air-handling noises – the whooshes – as the engine switches from one turbo to the next turbo," DeRaad said. "Our turbocharger also has ball bearings that pilot the shaft in the turbo, which helps eliminate the potential for the shaft of the turbocharger to gyrate in its housing, which can create noise."

Other improvements include the addition of two resonators in the intake system as well as a third resonator near the air cleaner.

"We've been able to tune the diesel intake system to give us the sound we wanted," DeRaad said. "It's now a nice complement to the engine."

The new diesel will also deliver other significant improvements including better torque and horsepower, class-leading fuel economy and best-in-class towing and payload for unparalleled performance.

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    • 1 Second Ago
      • 5 Years Ago
      oooh well done Ford!

      Only everyone in Europe has been running twin pilot injection strategies for the past 4 years... including Ford Europe.

        • 5 Years Ago
        Uh, the PowerStroke has done this since 1999. The '99 Super Duty introduced the "Split-shot" HEUI injectors on the 7.3 liter PowerStroke Diesel.

        But, don't let facts keep you from being an ass.
      • 5 Years Ago
      Wow, that's quiet. I would love that in my truck.
      • 5 Years Ago
      Personally I like my diesel loud.
        • 5 Years Ago
        Why are so many folks so quick to insist that a liking for big trucks or powerful cars has something to do with penises? Don't project your insecurities on the rest of us.

        As it turns out, these types of vehicles are FUN.
        • 5 Years Ago
        "Personally, I don't care to hear your penis-substitute."

        At first I though that was kinda rude but it actually was witty! So I won't - you!

        For the record: I like loud in a truck too! But it's still funny! LOL
        • 5 Years Ago
        that's because your a dodge guy and they can't seem to make a quiet diesel ;) lol

        but this is goo news. i mean .. nothing is more annoying than having to turn off your engine at the drive thru window. pain in the ass.

        the 6.4 PS is already the quietest diesel on the road, and it is quiet. put this motor under some insulated metal, and you won't be able to hear a thing!

        congratulations Ford on engineering your own diesel engine. something the other two can't and never will do.
        • 5 Years Ago
        Andy: Is this your official coming out announcement?
        • 5 Years Ago
        So are penises!
      • 5 Years Ago
      If its as easy to work on (relative to the 6.0) and as reliable as the 7.3, its a winner!
      • 5 Years Ago
      say what you want about Ford of the late 90's and early 2000's...but they have their heads on straight now and are putting out some quality products
        • 5 Years Ago
        It seems to me as far as their trucks go, they've always been pretty dependable save for the supplier's diesel issue they had recently. Every Ford truck owner, including myself, that I've known has had very high mileage with little to no problems. Just my own observation, but *to me* they've done really well with their trucks for a long time all the way to now with the Ranger getting highest ranked dependability for a small/mid-size pick-up.
        • 5 Years Ago
        Actually with their trucks, its kinda reversed.

        The 90's era F-series and Superduty's were at their prime. Reliable and versatile.

        Then to meet emissions criteria in 2002, International threw out their trusted 7.3L tD and started fresh with an exploding 6.0L tD. And followed that up with an exploding 6.4L twin-tD.

        Now Ford has decided to build its own diesel, and hopefully their Superduty's will go back to being a friend of the working man.
      • 5 Years Ago
      This technology was first developed by FIAT in Italy and was called Multi-Jet.

      Also the common-rail technology (that allows current diesel engined cars to be the most sold here in europe) was developed by FIAT: the first production diesel common rail car was the Alfa Romeo (owned by fiat) 156 JTD.

      see: http://en.wikipedia.org/wiki/MultiJet

        • 5 Years Ago
        Good data, thanks!
      • 5 Years Ago
      The common rail system prototype was developed in the late 1960s by Robert Huber of Switzerland and the technology further developed by Dr. Marco Ganser at the Swiss Federal Institute of Technology in Zurich, later of Ganser-Hydromag AG (est.1995) in Oberägeri. In the mid-1990s Dr. Shohei Itoh and Masahiko Miyaki of the Denso Corporation, a Japanese automotive parts manufacturer, developed the common rail fuel system for heavy duty vehicles and turned it into practical use on their ECD-U2 common-rail system mounted on the Hino Rising Ranger truck and sold for general use in 1995.[1] Denso claims the first commercial high pressure common rail system in 1995.[2]

      Modern common rail systems, whilst working on the same principle, are governed by an engine control unit (ECU) which opens each injector electronically rather than mechanically. This was extensively prototyped in the 1990s with collaboration between Magneti Marelli, Centro Ricerche Fiat and Elasis. After research and development by the Fiat Group the design was acquired by the German company Robert Bosch GmbH for completion of development and refinement for mass-production. In hindsight the sale appeared to be a tactical error for Fiat as the new technology proved to be highly profitable. The company had little choice but to sell, however, as it was in a poor financial state at the time and lacked the resources to complete development on its own.[3] In 1997 they extended its use for passenger cars. The first passenger car that used the common rail system was the 1997 model Alfa Romeo 156 1.9 JTD,[4] and later on that same year Mercedes-Benz C 220 CDI.

        • 5 Years Ago
        You should post that on Wikipedia... oh, never mind.
      • 5 Years Ago
      Audi technology!
        • 5 Years Ago
        WTF are you talking about?
        • 5 Years Ago
        What? Making diesels quiet? They aren't the only ones who make quiet diesels.... Just about every manufacturer who sells in Europe has at least one model with a quiet diesel.
        • 5 Years Ago
        And, unit injectors don't even have anything to do with this. Unit injectors have a camshaft-actuated pump for each cylinder, this has one or two pumps for all eight.
        • 5 Years Ago
        If anything it's Bosch technology. But neither of them invented direct injection and I'd be surprised if they invented multiple pulses either.
        • 5 Years Ago
        "eat my man, bitches:"

        1) that doesn't make a damn bit of sense

        2) get a clue. Unit injectors (a.k.a. Pumpe Duse) were well known since the 1930s. Electronic unit injectors existed long before Audi started using them. and Denso was largely responsible for high-pressure common-rail systems (http://www.sae.org/technical/papers/910252)

        You LOSE.
      • 5 Years Ago
      Good job.
      • 5 Years Ago
      "pickup trucks", "Thursday", "state fair" - sounds like a real hick event!
        • 5 Years Ago
        What is that avatar? A ghetto Tails from Sonic the Hedgehog? Sounds like a real nerd event! (I kid... I'm a game developer and long-time gamer. :P) But really, what a dumb comment... :
        • 5 Years Ago
        I can't imagine what "Thursday" has to do with "hick" but the rest of your comment suggests that you're not very perceptive so perhaps no link exists.

        Texas is a huge market for pickups, and the F150 was very popular here before it became fashionable for people all over the country to drive a pickup to their white-collar job. The auto show at the State Fair of Texas has been an important marketing event for car makers for decades, so it's a natural fit.
        • 5 Years Ago
        or good marketing....i too, can also judge you by your avatar.
        • 5 Years Ago
        I'd lean towards "furry" myself, if we're going 100% by the avatar.
        • 5 Years Ago
        Has anyone ever told you to yiff in hell because of your furry avatar on this site?
        So why stereotype other people?
      • 5 Years Ago
      I fail to see how a loud diesel is a penis substitute, let alone a big truck.
        • 5 Years Ago
        It's not. But people who have no self confidence, or self worth, want to try and spread their distaste with their life and how they feel about themselves on other people. Simple hatred with no basis is all. Anyone worried about someones penis size has problems.
      • 5 Years Ago
      Why doesn't Ford offer it for F150 too?
        • 5 Years Ago
        I second that notion! Same for the ranger! too! but I would prefer a Tacoma with a diesel above them all!
        • 5 Years Ago
        that engine is way too heavy for a 1/2 ton.
        • 5 Years Ago
        Because they hate me :(
        • 5 Years Ago
        It would be awesome if they did, but it would steal sales from the F250+.
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