The Engine V6 Duratec While Ford has reaped the Duratec's benefit, it was not an original design. The primary input for the design of this engine was Porsche, which was already developing the configuration for other purposes. Porsche sold the engineering to Ford and Cosworth, the dominant force behind the cylinder head design. There is actually a 6.0L V-12 Duratec configuration used in the Aston Martin, which is custom built for each vehicle by Cosworth in England The Duratec engines have rapidly become Ford's finest engine launch in history. The engine ranked second in J.D. Power & Associates' satisfaction survey for 1996 and boasts zero claims against oil consumption. The Duratec 30 is a 60 degree V6.It has an aluminum block with cast iron liners, aluminum DOHC cylinder head with four valves per cylinder, fracture-split (cracked) forged powder metal connecting rods, and a forged steel crankshaft. There are two versions of the Duratec 30: DAMB - Lincoln LS, Jaguar, Mazda 6 and MPV, which use direct-acting mechanical bucket (DAMB) tappets. Here the camshaft sits directly above the valves with different thickness pucks for adjustment. Output is 232 hp. RFF-Taurus/Sable/Escape/Tribute use roller finger followers (RFF) with the camshaft offset acting on the roller, which pivot on a hydraulic lash compensator. Output is 208 hp. Jaguar AJ-V6 engine/aj-30 The Jaguar AJ-V6 engine is a specialized version of Ford's Duratec 25/30 V6. One notable addition is the use of variable valve timing, a feature also shared with http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (1 of 7) [3/14/2009 12:07:10 PM]
Mazda's version of the engine. It is available in 2.0 L, 2.5 L and 3.0 L displacements. Jaguar's AJ-V6 engine has an aluminium engine block and aluminium DOHC cylinder heads. It uses SFI fuel injection, has 4 valves per cylinder with VVT and features fracture-split forged powder metal connecting rods and a one-piece cast camshaft, another differentiator from the Ford and Mazda versions. AJ30 The AJ30 is a 3.0 L (2967 cc) version and is the most common, especially considering the Duratec 30. It has an 89 mm bore and shares the 2.5's 79.5 mm stroke. In the S-Type, it produces 240 hp and 216 ft-lb. Amongst others this engine is used in:- 2000 present Jaguar S-Type, 240 hp (179 kw) and 216 ft-lb (293 N m) 2002 present Jaguar X-Type, 231 hp (172 kw) and 209 ft-lb (283 N m) 2009 present Jaguar XF, 240 hp (179 kw) and 221 ft-lb (300 N m) The Jaguar XF will debut a refined version of the AJ30 with continuously variable cam-phasing and variable geometry air intakes to increase power and broaden the power band up to its 6800 rpm redline. http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (2 of 7) [3/14/2009 12:07:10 PM]
Esprit v6 The reason for choosing this engine for the Esprit is because it seemed to tick all the right boxes. I was looking for a replacement unit that had to meet certain criteria in that it needed to be, powerful, light and compact, but also, reliable and economical to run. The Jaguar AJ30 is the engine I used for this conversion. Mine came from a 2001 S-Type with about 60K on it. Due to the more traditional layout of the Jaguar being, front engine/rear wheel drive, meant this engine being longitudinally mounted in the S-Type, as opposed to transverse mounted as in the X-Type, was designed to face the same way as in the Esprit, (north-south) This meant the exhaust manifolds were usable as they were both facing towards the rear, the engine mounts were roughly in the right place and the cooling system is all fed from the front by a separate and easily removable water pump. Also, maybe this variant could be the better choice due to Jaguar's engineering input in it's final design, and with the inclusion of variable valve timing amongst other things. http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (3 of 7) [3/14/2009 12:07:10 PM]
These pictures show the engine after being cleaned up, painted and fitted to the Esprit's UN1 transaxle. This was done using a machined alloy adaptor plate between the engine and bell housing, and a mixture of Jaguar and Lotus clutch parts. Another modification needed was the original Jaguar sump and oil pickup pipe had to be removed and replaced with one from a 2.5L V6 Ford variant. This was due to clearance needed around one of the Esprit's lower chassis cross members. Also a modified 2.5L inlet manifold was used due to height restrictions in the engine bay, and because the Jaguar manifold was to big. These V6's share a very similar basic engine design, this meant that both sump bolt patterns were identical and it was a straight swap between them without any problems. The inlet manifold however did require adapter plates to be made due to the heads being slightly different,although the inlet openings are spaced the same. The throttle opening was also widened to help cope with the slightly larger engine capacity. There were some other modifications needed along the way, and I shall try to cover these in more detail in the installation section. http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (4 of 7) [3/14/2009 12:07:10 PM]
Here's the Engine in its final resting place in the back of the Esprit. http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (5 of 7) [3/14/2009 12:07:10 PM]
Duratec 35 http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (6 of 7) [3/14/2009 12:07:10 PM]
The Duratec 35 (code-name Cyclone) is a new 3.5 liter V6 that will appear in 2005. It is an all-aluminum engine based on the Duratec 30, and adds variable valve timing, a feature already found on the Jaguar AJ30 and Mazda AJ versions of the 3.0. Its displacement can be increased to 3.8 liters, meaning a Duratec 38 could come soon after. The aluminum block is made by Teksid in Alabama, while the heads come from Newmak in Mexico, and the crankshaft comes from Bharat Forge of India. The engine will be assembled in Lima, Ohio The Duratec 35 3.5-liter V6 engine is capable of pumping out an output of 265 hp (198 kw) and 250 ft lbf (339 Nm) of peak torque. It also offers an impressive fuel economy and low exhausts emissions. Ford's Lima Engine Plant in Ohio is currently producing about 325,000 of the 3.5-liter Duratec 35 engine, and the plant will be a model for Ford Motor Company s flexible manufacturing that will allow different models and products to be produced faster and with less cost in a single assembly line. Ford also said the Duratec 3.5 V6 engine will power as many as 20 percent of its vehicles by the end of the decade. Ward s Auto World named it as one of the 10 best engines of the year 2007 the first time a debut engine received such an honor. Ward s called it a "brilliant performer" with class leading refinement. http://www.espritv6.co.uk/index.php?option=com_content&view=article&id=22&itemid=29 (7 of 7) [3/14/2009 12:07:10 PM]