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Ford finds flex-fuel engine design plays big role in emissions output

How bad is ethanol for your engine? There's been a lot of debate on this issue as the US considers upping the biofuel content in the national gasoline supply from 10 percent (E10) to 15 percent (E15). The ethanol industry and some scientists say higher ethanol blends show no "meaningful differences" in new engines while the oil industry says ethanol creates health risks. Researchers working at the Ford Research and Innovation Center decided to take a closer look at how a wide range of gas-ethanol blends - E0, E10, E20, E30, E40, E55 and E80 - affected the emissions coming out of a flex-fuel 2006 Mercury Grand Marquis. To see the full report, printed in the journal Environmental Science & Technology, requires payment, but there is an abstract and Green Car Congress has some more details. The gist is that, "with increasing ethanol content in the fuel, the tailpipe emissions of ethanol, acetaldehyde, formaldehyde, methane, and ammonia increased." At least NOx and NMHC emissions decreased. The researchers say that the effects are due to the fuel and "are expected for all FFVs," but that the way that a manufacturer calibrates the engine will affect NOx, THC, and NMOG emissions. It's this last bit that's important, since the researchers found, "Higher ethanol content in gasoline affects several fundamental fuel properties that can impact emissions. ... These changes can have positive or negative effects that can depend on engine design, hardware, and control strategy. In addition to direct emissions impacts, higher ethanol content fuel can also provide more efficient combustion and overall engine operation under part-load conditions and under knock-limited higher-load conditions." So, as we head towards more ethanol in our fuel supply (maybe), manufacturers are going to need to learn how to burn it most efficiently.

Ford recalls 600,000 older-model sedans for braking issue

Ford is recalling 600,166 older-model Ford, Lincoln and Mercury vehicles over an issue that could affect braking and increase the risk of a crash. The safety recall covers certain Ford Fusion, Mercury Milan and Lincoln MKZ sedans from the 2006 through 2010 model years that were built at Ford’s Hermosillo Assembly Plant in Mexico between Feb. 22, 2006, and July 15, 2009. Ford says a valve that is normally closed inside the hydraulic control unit may get stuck in the open position or be slow to close, which could make it harder to engage the brakes and increase risk of a crash. Ford says itÂ’s aware of 15 reports of accidents and two injuries possibly related to the issue. Dealers will inspect the hydraulic control unit for signs of the problem and replace it, if necessary. The dealers will pressure-flush the system with brake fluid and replace the reservoir cap with a new one. Ford is also issuing a small recall of 33 of its 2020 F-150 trucks in the U.S. and 51 in Canada over potentially damaged spare tires. It says the bead area on the tires may have been damaged when it was mounted onto the wheel assembly, leaving it vulnerable to corrosion, separation of the bead wire and ultimately a rapid loss of air pressure and detachment from the wheel. Dealers will replace the spare tire. Affected vehicles were built at the Dearborn Truck Plant from Nov. 10-21 of this year.

Ford's J Mays feels vindicated by Fusion reception

It's hard to think back now, but the same man overseeing the design of the 2013 Ford Fusion also presided over a rather lackluster period in Ford design, highlighted by vehicles like the Five Hundred and Freestyle. With the redesigned Fusion receiving high praise, J Mays tells Automotive News that he feels vindicated from criticisms suggesting he's not a daring enough designer.
When Mays took over as lead of design in 1997, he admits to having quite an ego ("My head would barely fit through the door some days. I've long since gotten over myself") and the workload to match. With the Blue Oval's portfolio full of premium brands like Aston Martin, Jaguar, Land Rover and Volvo at that point, along with the bread-and-butter Ford, Lincoln and Mercury models, Mays certainly had quite the challenge.
It was in the mid-2000s that Mays took over just the premium brands, and took on the new title of Chief Creative Officer. At the time, Mays endured some criticism for looking backwards to retro styling, rather than setting a new standard for American car design - criticism that Mays says he is free from with the all-new Fusion.