How Ford tests its locally-built engines

Following a R600-million investment into its Struandale plant in Gqeberha, Ford South Africa has commenced the production of the host of engines that will be fitted to the next-generation Ranger.

This includes the slightly revised 2.0-litre single and bi-turbo motors, the 2.2-litre and 3.2-litre Duratorq units, as well as the all-new 3.0-litre, V6 which will power the range-topping variants of the bakkie.

This makes Ford South Africa’s engine plant “the only facility of its kind in the Ford world that produces both V-configuration and in-line engines on the same line,” said plant manager Shawn Govender.

Tested to the limit

As is customary with new powerplants, each of them is put through rigorous testing procedures both in-process and off-line to ensure dependability and that the new tooling used is within specification.

The investment went into installing a more advanced engine dynamometer specifically for the new V6 to perform 10 “conformity of production” (COP) tests spanning 20 hours each, “a standardised control test used to qualify vehicles or components throughout the world,” said Ford.

Additionally, these motors are put through three 275-hour engine fatigue tests (EFTs) to evaluate their robustness against structural fatigue and high speeds and cylinder pressures, followed by another 100-hour EFT “as part of the validation process.”

After this, a 115-hour “GloTherm” assessment is conducted to check the engine sealing system, and finally, a 150-hour “GloSys” test evaluates the durability and reliability of the block under simulated driving conditions.

In total, this adds up to 1,390 hours, or 16.25 days, of testing for the plant’s flagship motor.

For the revised 2.0-litre specifications, the procedures include four 20-hour COP tests, three 275-hour EFTs, and two 100-hour GloSys tests.

And for the Duratorqs, it comprises three 20-hour COP tests and a 154-hour durability test.

“The extensive and rigorous dynamometer tests are essential in validating the training of our employees, the application of the production processes and systems, as well as the performance and durability of the engines as part of our commitment to delivering world-class quality for our customers,” said Govender.

R600-million investment

Ford’s massive investment in its Struandale plant has seen the facility’s output grow to 130,000 engines per year for the Duratorq and V6 derivatives combined, and 120,000 for the 2.0-litre single and bi-turbos.

The facility has gained highly-accurate GPS tool positioning systems, torque-to-turn monitoring for every bolt, and multiple camera stations that validate and record the accurate fitment of parts during the assembly process.

Moreover, the plant now operates for two-and-a-half shifts at a time instead of the previous two shifts in order to support the additional demand for the 2.0-litre models.

Struandale is also responsible for machining the cylinder heads for the V6, which is performed in a completely revamped facility updated with the latest tooling, operating, and quality control systems.

“Most of the updates introduced were to accommodate the design of the next-gen Ranger, while further improvements have been made to the noise, vibration, and harshness (NVH) characteristics of the engines for even greater comfort and refinement,” said Govender.

“The quality, reliability, and durability of this engine program are exceptional, matched to superb fuel economy, and these are traits that will shine through in the next-gen Ranger.”