The new EcoBoost engine also features an exhaust manifold cast into the cylinder head, which lowers the temperature of the exhaust gases and in turn enables the engine to run with the optimum fuel-to-air ratio across a wider rev band.

An advanced “split cooling” system reduces fuel consumption by warming the engine more quickly and—unique to the 1.0 engine&madsh;cast iron has been selected for the block, reducing the amount of energy needed for warm-up by up to 50% compared with aluminum.

Intelligent ancillaries such as a variable air-conditioning compressor and oil pump also reduce demand on the engine, thereby improving economy and emissions while special coatings for engine components and intricate development of engine geometry result in minimal frictional losses.

Like its larger-capacity siblings, the 1.0-liter EcoBoost engine will use twin independent variable camshaft timing (Ti-VCT) to further improve performance and economy. Ford has also employed an all-new camshaft actuator to speed up response times without sacrificing durability.

Engine refinement is improved thanks to an innovative design that immerses the two main engine drive belts in oil, resulting in quieter and more efficient running but with the durability of a chain. Careful attention has also been paid to mitigating the natural vibrations of the three-cylinder design.

Rather than employ the traditional method of adding energy-draining balancer shafts, Ford engineers have deliberately “unbalanced” the flywheel and pulley to offset the engine configuration. Ford believes these innovations combined with optimized engine mounts will deliver a refined performance feel perfected during 720,000 kilometers of tests (447,000 miles), including 360,000 (224,000 miles) kilometers of durability trials and 10,000 kilometers (6,200 miles) of environmental testing.

EcoSport. Created as the latest One Ford global product, the EcoSport will be a key model in expanding Ford’s presence in major worldwide growth markets, including India, Brazil and the ASEAN markets. It will eventually be sold in nearly 100 markets worldwide.

The new EcoSport was developed on Ford’s new global B-segment platform, which will be the basis for an array of new small-car products from Ford in the coming years. By mid-decade, the new Ford B-platform family of vehicles will represent more than 2 million units of annual production as compact cars continue to drive global growth.

Ford developed the EcoSport in South America at one of its eight global product development centers in conjunction with teams from Asia, Europe and North America. The project was led by Ford’s Development Center in Camaçari, Brazil, one of the most specialized in the development of compact cars.

The EcoSport was originally launched in South America in 2003 and sold 700,000 vehicles in nine years. The new EcoSport will be produced at flexible assembly plants in Brazil, India, and other markets to be announced at a later time.

The new EcoSport is a significant milestone for our global product development process. It proves that great small-car models for growth markets can be created in growth markets, using One Ford to leverage our global design and engineering expertise

—Derrick Kuzak, group vice president, Global Product Development

Ford plans to increase total worldwide sales by nearly 50% by mid-decade to 8 million vehicles a year. Of that figure, 60 to 70% is expected to come from the Asia Pacific and Africa region.

The EcoSport is the second of eight products slated to be launched in India by mid-decade. Ford India’s shift from niche automaker to volume player is supported by several new investments in the country.

Ford recently broke ground in Sanand, Gujarat as part of an investment of approximately US$1 billion to build new vehicle manufacturing and engine plants. Ford also announced earlier an investment of US$72 million by this year (2012) to expand its already operating powertrain facility in Chennai. Ford’s total investment in India to date is approximately US$2 billion.

The new EcoSport will be produced in the integrated Chennai manufacturing facility which has been transformed with an annual production capacity of 200,000 units and is now positioned as a Ford regional center of excellence for compact-car engineering and production. Ford EcoSport models will be also produced at the plant for export to international markets.