Ford Showcases EcoLPi Technology in Falcon

[russellw]

July 1 2011

• Introduction of EcoLPi liquid phase injection LPG system to Australian market continues a year of technological innovation for Ford Australia
• State-of-the-art EcoLPi engine utilises the most advanced LPG technology currently available to deliver across-the-board improvements
• EcoLPi produces 27 per cent more power and 10 per cent more torque than the previous E-Gas LPG system

Ford Australia's next-generation EcoLPi liquid injection LPG system will be on show for the first time at the Australian International Motor Show.
EcoLPi will be showcased in the latest FG Falcon. It is the most advanced LPG technology available on the market and arrives at a time when rising petrol prices are forcing motorists to seek alternative fuel sources.

The new EcoLPi powertrain will be available on both Falcon sedan and Falcon Ute, with both model line-ups featuring distinctive "EcoLPi" badging. In addition to the G6E EcoLPi on show at AIMS, the sedan EcoLPi line-up includes Falcon XT, G6, and XR6 variants, while EcoLPi on Falcon Ute extends to XL, R6 and XR6 variants, in both Cab Chassis and Styleside Box body configurations.

The new EcoLPi in-line six-cylinder engine is a state-of-the-art, liquid phase injection, dedicated LPG power-plant that delivers impressive fuel efficiency and reduced CO2 emissions, as well as no compromise engine performance compared to Falcon's existing petrol I6 engine.

"The introduction of EcoLPi represents another key pillar in Ford's plan to bring a range of sustainability initiatives to market, following the launch of Australia's first locally-produced diesel vehicle with the new SZ Territory, as well as the introduction of Ford's patented EcoBoost engine technology on Mondeo," Bob Graziano, President and CEO, Ford Australia said.

"Awareness of the climate change issue and the importance of cost of ownership to consumers has seen Ford deliver a range of product actions in recent years, which have introduced sustainable technologies that are conscious of both the environment and our customers.
"Improvements in fuel economy, CO2 emissions and cost of ownership have been achieved through a combination of engineering developments, the introduction of a new range of small and light cars, and the expanded availability of alternative fuel vehicles such as diesel and LPG."

Liquid injection LPG is the most advanced LPG technology currently available and delivers significant driveability and operating improvements compared to the previous E-Gas venturi-style vapour system offered by Ford, including better fuel economy and substantial increases in both power and torque outputs.

"LPG is an alternative fuel that is readily available right across Australia and provides real benefits for Australian consumers, with reduced fuel costs contributing to a significant improvement in cost of ownership," Graziano added.
"Falcon EcoLPi offers customers the power, torque and overall engine performance they expect from a traditional Aussie six, coupled with all the space, comfort and towing capability of a family sedan, while at the same time delivering the fuel costs of a smaller car."

The cornerstone of the EcoLPi engine is the new injection system, which follows a similar fuel induction configuration to the petrol I6 engine courtesy of a new injector-based, high-pressure fuel rail that delivers liquid-state LPG fuel directly into the intake port.
Whereas traditional vapour LPG systems turn liquefied gas into vapour form before feeding it into the engine via a venturi in the throttle body, the liquid phase injection system takes the gas in liquid state all the way to the injectors.

Injecting the LPG fuel in a liquid state directly into the intake port in a more precise and controlled manner generates improved engine volumetric efficiency, which delivers better fuel economy, reduced CO2 emissions and greater engine performance.

As the LPG fuel is no longer under pressure once it is released from the injector, its sudden expansion and rapid cooling of the incoming air charge creates the ideal conditions for maximum fuel burning efficiency. This enables the engine to produce more power and torque, economically, and with fewer CO2 emissions.

The new EcoLPi engine develops 198 kW of power at 5000 rpm and 409 Nm of torque at 3250 rpm, which is identical to the petrol I6 engine when operating on higher octane 95 RON unleaded fuel (versus regular 91 RON unleaded).

For EcoLPi that represents a 27 per cent improvement in maximum power and a 10 per cent improvement in peak torque compared to the previous generation E-Gas LPG engine, which produced 156 kW and 371 Nm. Despite the significant increases in power and torque, fuel efficiency has also improved, along with a corresponding reduction in CO2 emissions.

Official ADR 81/02 fuel consumption certification testing on EcoLPi has returned combined cycle results of 12.5 L/100km on Falcon XT and 12.6 L/100km on G6, G6E and XR6 models, which represent improvements of 16.1 per cent and 15.4 per cent respectively.
Similar reductions have also been achieved on CO2 emissions, with Falcon XT coming in at 203 g/km and G6, G6E and XR6 models at 204 g/km – down from 240 g/km on the previous E-Gas system – representing improvements of 15.4 per cent and 15 per cent respectively.

Technical highlights of the new EcoLPi powertrain include:

• New fuel rail, including injectors, designed and developed specifically for the Ford EcoLPi engine
• New design lightweight pistons, including low-friction ring pack
• Higher compression ratio (12.0:1) to improve engine thermal efficiency and fuel consumption
• New polymer fuel lines with a low thermal mass to keep the LPG fuel liquefied
• New fuel line filter and in-tank filter added to prevent system/component contamination
• Significant modifications to the fuel tank, including all-new internals and sub-level components, as well as a new high-pressure fuel pump
• New catalytic converter – high density brick and new washcoat (common with I6 petrol engine)
• Major calibration and engine management system modifications, including a new fuel priming strategy
• Transmission upgrade to the acclaimed ZF six-speed automatic on all EcoLPi variants

The introduction of the EcoLPi engine option on Falcon – with its improved power and torque and reduced fuel consumption and CO2 emissions, combined with the upgrade from a four-speed to a six-speed automatic transmission – will attract a modest $500 increase to the recommended option price over the previous E-Gas LPG system.

The EcoLPi engine option is available for the recommended Manufacturer's List Price of $2,500.
More than 100,000 LPG-powered Falcon vehicles have been produced since a dedicated LPG system was first introduced in mid-2000, cementing Ford's position as one of the leading alternative fuel vehicle suppliers in Australia.
With the introduction of the next-generation EcoLPi system, Ford will continue to be the only manufacturer to offer dedicated LPG technology to the Australian market.

Source: Ford Media

[Polyal]

$2500 is cheap for what the system is...thats great news.

[fou_bleu]

Wow, that's impressive power and torque!!! A shame LPG will cost the same as petrol in a handful of years! :(

[Polyal]

Originally Posted by 4RD4TW

Wow, that's impressive power and torque!!! A shame LPG will cost the same as petrol in a handful of years! :(

Bah hearsay. Lets not go down the track of what ifs...even with the full excise tomorrow (12.5 cents) LPG is a great alternative for now, not technology thats "upcoming" and in the works.

[Mechan1k]

Wow ... $2500 premium is worth it really. Especially when the Diesel in the Territory is a $5000 premium.
Look forward to seeing these in showrooms.

[PoweredByCNG]

FWIW, $2,500 (minus $2,000 if you're eligible for the federal rebate) gets you better performance and significantly lower running costs, even with the new LPG excise. Well worth it in my books. For most applications, it would now be stupid to pick a petrol over an LPG Falcon.

[FGII-XR6]

impressive it's actually more powerful than the petrol I6 on 91 and even more so with them forcing this E10 on us. I see these selling like hotcakes, this may be what Ford need to kick start their production

[Mechan1k]

Originally Posted by PoweredByCNG

FWIW, $2,500 (minus $2,000 if you're eligible for the federal rebate) gets you better performance and significantly lower running costs, even with the new LPG excise. Well worth it in my books. For most applications, it would now be stupid to pick a petrol over an LPG Falcon.

You know what ... I completely forgot about the rebate actually. Makes it even more worthwhile.

[naddis01]

I thought the rebate was $1000 for new vehicles? And private only?

[PoweredByCNG]

Originally Posted by naddis01

I thought the rebate was $1000 for new vehicles? And private only?

Private only, and $2,000 for the next couple of years at least.

[redxm]

Awesome news. Now all they need to do is market it................................................ .......

[Mr Hardware]

I'm hanging for pics.

[mik]

there`s no down side i can see, if buying new 6 banger you`d have to pick the the new gassed falcon over petrol.

[Doodlemax]

Originally Posted by Mechan1k

Wow ... $2500 premium is worth it really. Especially when the Diesel in the Territory is a $5000 premium.
Look forward to seeing these in showrooms.

Um, $3250 for Diesel?

[EDManual]

http://www.caradvice.com.au/125785/2...-in-australia/

[Yellow_Festiva]

Originally Posted by Polyal

Bah hearsay. Lets not go down the track of what ifs...even with the full excise tomorrow (12.5 cents) LPG is a great alternative for now, not technology thats "upcoming" and in the works.

Exactly. It may take several years for increases in LPG to come close to the price of regular petrol. And ULP may also go up in price as well. Who knows.

From that link posted above, the LPI system will pay for itself in 2-3 years anyway, so before anything may happen in the distant future in regards to fuel prices, you will still be in front financially much earlier.

Any news on this system making its way into Territory?? Would be pretty easy seeing as all the hard work has been done for Falcon.

[EDManual]

Wonder what the economy breakdown is?

Surely under 10 litres on the hwy?

i hear straight gas wagons were able to do over 1000km on a tank on the hwy.

What is the tank size in these sedans?

[Polyal]

My AU SVI does 10 or under on the highway...this will do that easy I would have thought (yes it has more weight, but its power and gearing will help immensely).

[PoweredByCNG]

If you multiply the figures for the E-gas engine by 0.839, you get the approximate figures for the EcoLPI:

11.9L/100km vs. 9.9L/100km - extra urban

14.9L/100km vs. 12.5L/100km - combined

20.1L/100km vs. 16.9L/100km - urban

[FGII-XR6]

get a set of the pistons and put them in a petrol engine running 98 it would scream

[Buntz]

Originally Posted by redxm

Awesome news. Now all they need to do is market it................................................ .......

This is the only area that they can go wrong from here. As long as they promote the benefits of LPG, and how efficient it is. The car will sell very well.

They need to stress: "Running costs of a small car."

Originally Posted by au3xr6

get a set of the pistons and put them in a petrol engine running 98 it would scream

Wouldn't be that easy. Every change these days needs engine remapping.

[FGII-XR6]

Originally Posted by Buntz93ED

Wouldn't be that easy. Every change these days needs engine remapping.

any good tuner would fix that with a flash tune

[Buntz]

Originally Posted by au3xr6

any good tuner would fix that with a flash tune

I didn't realise you could flash the factory ECU. And how much do those cost?

[Mechan1k]

Originally Posted by PoweredByCNG

If you multiply the figures for the E-gas engine by 0.839, you get the approximate figures for the EcoLPI:

11.9L/100km vs. 9.9L/100km - extra urban

14.9L/100km vs. 12.5L/100km - combined

20.1L/100km vs. 16.9L/100km - urban

I'd say you aren't far off the mark there.
Will be interesting to see real-world figures after a bit of run-in.
Urban may be less with the ZF though and the short 1st gear making getting off the mark easier.

[PoweredByCNG]

Originally Posted by Mechan1k

I'd say you aren't far off the mark there.
Will be interesting to see real-world figures after a bit of run-in.
Urban may be less with the ZF though and the short 1st gear making getting off the mark easier.

As usual, fuel consumption will depend on the end user as much as the engine and car design itself. I would say that with a bit of careful driving, you'd be able to achieve under 9L/100km quite easily on a long-distance non-stop run.

For the majority of drivers who don't drive for economy (and I don't blame you), I would say that you would be using somewhere around 13-14L/100km in the suburbs.

[Bossxr8]

We're fortunate to have this LPi engine at all, original planning for Orion had no LPG engine option, but petrol prices soared and LPG was returned to the program late in the game, essentially why the E Gas FG engine was basically carry over from BF.

[Buntz]

Originally Posted by Bossxr8

We're fortunate to have this LPi engine at all, original planning for Orion had no LPG engine option, but petrol prices soared and LPG was returned to the program late in the game, essentially why the E Gas FG engine was basically carry over from BF.

That mind set needs some explanation. Why would Ford have been stupid enough to cancel LPG?

[Bossxr8]

This would have been in probably 2004, early planning stages of Orion. BA was selling every car they could build, and petrol was what, 90c a litre.

Only fleets were buying E Gas.

When petrol soared and sales dropped off in 2006 it all changed.

[Paxton]

There was to be no LPG option come Duratec. The biggest reason why the BF engine debuted in FG was because it cost them very little to introduce. With Wagon still on sale at that stage, the engine cost was amortised across two vehicles.

Burela changing the engine plan half way through Orion's life is one reason why we had to wait until now for the Injected LPG engine. If the I6 was to continue right from the start, we'd have seen LPG earlier.

[Smoke Pursuit]

Originally Posted by Paxton

There was to be no LPG option come Duratec. The biggest reason why the BF engine debuted in FG was because it cost them very little to introduce. With Wagon still on sale at that stage, the engine cost was amortised across two vehicles.

Burela changing the engine plan half way through Orion's life is one reason why we had to wait until now for the Injected LPG engine. If the I6 was to continue right from the start, we'd have seen LPG earlier.

Yep... The V6 program has really hurt Ford :(