Ford is adding a new 3.0L V6 engine to its Ranger range.

To accommodate the demand for these engines, Ford has invested R600m in the Struandale Engine Plant.

“The modernisation and upgrades to the Struandale Engine Plant began in July 2021, and the construction was completed on time in December, ready to begin our tooling trials and pre-production runs this year in preparation for Job 1 for both engine programmes commencing in August,” said Shawn Govender, Ford Struandale Engine Plant’s manager.

“In its updated and extended format, the assembly line that is now producing the new 3.0L V6 turbodiesel continues with production of the existing 2.2 and 3.2 Duratorq TDCi engines, making it the only facility of its kind in the Ford world that produces both V-configuration and in-line engines on the same line,” Govender said. “Although this was a major challenge for our team and required a lot of creative and innovative thinking, it was essential to make optimal use of our facilities to contain the total investment required, and ensure that we are competitive from a cost-per-unit perspective.”

The new line incorporates 40 stations that are common to both units, and a further 25 stations that are unique to the 3.0L V6 diesel. The total installed capacity for this line is 130 000 engines per year.

2.0L single turbo and bi-turbo

The highly rated 2.0L single turbo and 2.0L bi-turbo diesel engines have undergone 23 design changes, while the number of derivatives produced on the dedicated assembly line for this engine programme has increased from nine to 13.

To support the increased demand for the 2.0-litre diesel engines, the plant has gone from the previous two shifts to 2.5 shifts, with a total installed capacity for producing up to 120 000 engines per year.

As with any new or updated engine programme, the new 3.0L V6 diesel and latest specification 2.0L single turbo and bi-turbo engines are subjected to exhaustive in-process and off-line testing. Additionally, the existing Duratorq TDCi engines have also undergone extensive tests to ensure that the advanced production systems, tooling and technologies used on the modernised flexible assembly line are within specification.

Three 275-hour engine fatigue tests were conducted. A further 100-hour engine fatigue test was also completed as part of the validation process. Thereafter, a 115-hour GloTherm accelerated dynamometer test was done to validate the engine sealing system (including the cylinder head gasket) and certain structural engine components through exposure to extreme thermal cycling. And, finally, a 150-hour GloSys test was performed to evaluate the durability and reliability of the engine under simulated customer driving conditions.

On the updated 2.0L SiT/BiT engines, a total of four 20-hour COP tests were done, along with three 275-hour engine fatigue tests, and two 100-hour GloSys tests. Similarly, the Duratorq TDCi engines underwent three 20-hour COP tests and a 154-hour durability test. Source: QuickPic

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