Ford Unveils New Duratec V-6 at Lima

Ford Motor Co. announces it will invest $335 million in its engine plant in Lima, OH, where it will build a 3.5L DOHC V-6.

While Ford doesn't say which vehicle programs will benefit from the all-aluminum engine, the auto maker confirms it will have applications in the passenger car and cross/utility segments. A source tells Ward's it will be available in at least two vehicles when it begins production in late 2005.

Developed under codename Cyclone, it will be marketed as Duratec 35 as Ford seeks synergies from its successful 3L Duratec, which now goes by the moniker Duratec 30. Same for Ford's 2L, 2.3L and its PZEV I-4 programs, which will be known, respectively, as the Duratec 20, Duratec 23 and Duratec E.

The new engine, which features variable-valve timing to boost fuel economy, also has the distinction of being globally sourced. Its die-cast blocks will be supplied by a new Teksid operation in Alabama. Linda Miller, Ford's manufacturing director-powertrain operations, says Duratec 35's heads will come from Nemak in Mexico, and its crankshafts will be supplied by India's Bharat Forge.

Bharat Forge supplies castings to Ford of Europe, but Duratec 35 marks its first foray into the auto maker's North American manufacturing network.

Lima will join the ranks of Ford's flexible manufacturing plants with the installation of CNC lines to machine the new engine's head and crankshaft; its block machining will use a state-of-the-art transfer line.

Significant aid from state and local governments helps finance Lima's retooling. If the auto maker qualifies for all available aid, it could receive more than $41 million over 15 years in business development grants, training funds and job retention and investment tax credits.

Maximum annual Duratec 35 volume is pegged at 325,000 units, but Roman Krygier — group vice president-manufacturing and quality — says the ramp-up will be gradual.

Currently, Lima produces the 3L Vulcan OHV V-6 for Ford Taurus and Mercury Sable, as well as the 3.9L V-8 that powers Ford Thunderbird and Lincoln LS. The plant employs more than 1,600 hourly workers.