Ford Sigma engine

Ford Sigma engine
Overview
Manufacturer Ford Motor Company
Also called Zetec
Duratec
Duratec Ti-VCT
Production 1995-
Layout
Configuration DOHC straight 4
Displacement 1.25 L
1.4 L
1.5 L
1.6 L
1.7 L
Cylinder block alloy aluminium
Cylinder head alloy aluminium
Combustion
Supercharger none
Turbocharger none
Fuel system EFI
Fuel type gasoline
Dimensions
Dry weight

1.6 L Zetec - 81 kg

1.6 L Duratec - 90 kg
Chronology
Predecessor Ford CVH engine
Ford Kent engine
Successor Ford EcoBoost engine

Introduced in 1995, the Ford Sigma is a small straight-4 automobile engine sold by Ford Motor Company. First evolution of engines were sold as the "Zetec-S" (not to be confused with the trim level), then Zetec SE and finally in later years, Ford renamed it Duratec.[1] Last upgrade of engine is named Duratec Ti-VCT. The engine was introduced in the mid-1990s and production continues through the present. Like the SHO V6 and SHO V8, the Sigma was designed with help from Yamaha. Conceived for Ford's smaller models, it was intended to replace the older HCS (a derivative of the even older Kent unit) and smaller capacity CVH units.

The Zetec-SE has no common parts or design with the larger Zetec-E engines apart from the name. This gives rise to some confusion since it suggests that they are members of the same family, but are in fact, completely different. Zetec-E units are mounted transversely with the inlet manifold at the rear, whereas the Zetec-SE units are mounted with the inlet manifold at the front.

Introduction and Innovations

When the Zetec-SE first arrived in 1995 it included many firsts, such as a plastic inlet manifold, a "ladder" style main bearing and crankcase assembly, and big-end bearing caps which are forged in one piece and subsequently split. It also incorporates powder metal connecting rods, which were quite exotic and notable at the time. The engine first appeared in the Mk4 Ford Fiesta and the virtually identical Mazda 121 in 1.25 L (1242 cc) capacity, with 1.4 L (1388 cc), 1.6 L (1596 cc) and 1.7 L (1679 cc) derivatives coming later.

Difference between Zetec-SE/Zetec-S/Duratec/Duratec Ti-VCT

Sigma engined is introduced under Zetec-SE name, after the upgrade it was renamed to Duratec. Latest upgrade of Sigma is called Duratec Ti-VCT.

Zetec-S/SE

CodeYearsDisplacement (bore x stroke)/TypePower@rpmtorque@rpmCompression (:1)
1.25 Zetec-S/SE1995-1,242 cc (1.242 L; 75.8 cu in) (71.9 mm (2.83 in)x76.5 mm (3.01 in)) I475 PS (55 kW; 74 hp)@5200110 N⋅m (81 lb⋅ft)@400010
1.4 Zetec-S/SE1998-1,388 cc (1.388 L; 84.7 cu in) (76 mm (3.0 in)x76.5 mm (3.01 in)) I475 PS (55 kW; 74 hp)@5000124 N⋅m (91 lb⋅ft)@350011
1.4 Zetec-S/SE1995-1,388 cc (1.388 L; 84.7 cu in) (76 mm (3.0 in)x76.5 mm (3.01 in)) I490 PS (66 kW; 89 hp)@5500123 N⋅m (91 lb⋅ft)@400010.3
1.6 Zetec-S/SE1998-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in)x81.4 mm (3.20 in)) I4100 PS (74 kW; 99 hp)@6000145 N⋅m (107 lb⋅ft)@400011

Zetec-S

1.7 Zetec-S VCT1997-1,679 cc (1.679 L; 102.5 cu in) (80 mm (3.1 in)x83.5 mm (3.29 in)) I4126 PS (93 kW; 124 hp)@6300157 N⋅m (116 lb⋅ft)@450010.3
1.7 Zetec-S VCT1999-1,679 cc (1.679 L; 102.5 cu in) (80 mm (3.1 in)x83.5 mm (3.29 in)) I4155 PS (114 kW; 153 hp)@7000162 N⋅m (119 lb⋅ft)@450010.3

The 1,679 cc (1.679 L; 102.5 cu in) engines uses a heavily modified 1.6 L engine block and features Variable Cam Timing on the inlet camshaft. This displacement has only been used in Ford Puma. 155 PS engine has only been used for the Ford Racing Puma with only 500 units built.

Zetec RoCam

In 2000, Ford of Brazil developed a cheaper version of the Zetec-SE engine, to compete with the classic Volkswagen EA827 engine series known locally as AP (from "Alta Performance", "High Performance", in English) engine in Brazil. It is 8v SOHC instead of 16v DOHC and its block is made of iron instead of aluminum. Also, its camshaft is driven by a chain instead of a belt. As a result this engine exhibits rougher behaviour, producing more vibration and noise.

On the other hand, it has a superb torque output thanks to the addition of the RoCam (Rollifinger Camshaft) feature. It's also a much smaller engine than the SE version, which allowed it to be installed on the Ford Ka, replacing the Endura-E engine which by that time was considered underpowered and outdated.

The engine also featured a new patented process for the aluminum head production, which resulted in a better alloy than those produced in Spain and UK, and at a lower production cost.

In 2002 a supercharged 1.0 litre (94 hp; 95 PS) version was released for the Ford Fiesta, to compete with the 1.0 Turbo 16v (111 hp; 112 PS) version of the VW Gol.

In 2003 the Zetec RoCam engine was introduced in Europe, but labeled as Duratec 8v, for the SportKa, StreetKa and Fiesta. Later a 1.3 litre version was also released as an option for the standard model, but the European versions of the engine are produced in the South Africa plant.

In October/2004 a newer bi-fuel version was introduced labeled "1.6L Flex", capable of running on both petrol and ethanol, even mixed at any proportion. This version also featured a high compression ratio (11.8:1) and "Compound High Turbulence" chambers, as used on the CHT engine.

Currently, this engine powers nearly all Brazilian Ford models – except those with 2.0 litre engines – in many different variants:

Applications

1.6 L (1596 or 1597 cc/97 cu in) applications:

  • –present Latin America Ford SportsKa 1.6, 95 PS (94 hp; 70 kW) and 100 lb⋅ft (140 N⋅m)
  • –present Latin America Ford StreetKa 1.6, 95 PS (94 hp; 70 kW) and 100 lb⋅ft (140 N⋅m)

Duratec

Ford upgraded Sigma and renamed it to Duratec.

CodeYearsDisplacement (bore x stroke)/TypePowerTorqueCompression
1.25 Duratec2008-1,242 cc (1.242 L; 75.8 cu in) (71.9 mm (2.83 in)x76.5 mm (3.01 in)) I460 PS (44 kW; 59 hp) @109 N⋅m (80 lb⋅ft) @11.0:1
1.25 Duratec2008-1,242 cc (1.242 L; 75.8 cu in) (71.9 mm (2.83 in)x76.5 mm (3.01 in)) I480 PS (59 kW; 79 hp) @114 N⋅m (84 lb⋅ft) @11.0:1
1.4 Duratec2002-1,388 cc (1.388 L; 84.7 cu in) (76 mm (3.0 in)x76.5 mm (3.01 in)) I480 PS (59 kW; 79 hp) @ 5700124 N⋅m (91 lb⋅ft) @ 350011.0:1
1.4 Duratec2008-1,388 cc (1.388 L; 84.7 cu in) (76 mm (3.0 in)x76.5 mm (3.01 in)) I496 PS (71 kW; 95 hp) @125 N⋅m (92 lb⋅ft) @11.0:1
1.6 Duratec2004-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in)x81.4 mm (3.20 in)) I4100 PS (74 kW; 99 hp) @ 6000150 N⋅m (110 lb⋅ft) @ 400011.0:1

Duratec Ti-VCT

The 1,596 cc (1.596 L; 97.4 cu in) Ti-VCT (Twin independent Variable Camshaft Timing) version includes variable valve timing, and generates more power and torque than non-VVT counterparts. Latest versions comply with the Euro5 emission level.

CodeYearsDisplacement (bore x stroke)/TypePowerTorqueCompression
1.5 Duratec Ti-VCT2013-1,499 cc (1.499 L; 91.5 cu in) (79 mm (3.1 in) x 76.5 mm (3.01 in)) I4112 PS (82 kW; 110 hp) @ 6300140 N⋅m (100 lb⋅ft) @ 430011.0:1
1.6 Duratec Ti-VCT2004-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4115 PS (85 kW; 113 hp) @ 6000155 N⋅m (114 lb⋅ft) @ 415011.0:1
1.6 Duratec Ti-VCT2007-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4110 PS (81 kW; 110 hp) @ 6000152 N⋅m (112 lb⋅ft) @ 405011.0:1
1.6 Duratec Ti-VCT2007-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4125 PS (92 kW; 123 hp) @ 6300160 N⋅m (120 lb⋅ft) @ 410011.0:1
1.6 Duratec Ti-VCT2008-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4120 PS (88 kW; 120 hp) @ 6300160 N⋅m (120 lb⋅ft) @ 410011.0:1
1.6 Duratec Ti-VCT2010-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4105 PS (77 kW; 104 hp) @ 6000150 N⋅m (110 lb⋅ft) @ 4000-450011.0:1
1.6 Duratec Ti-VCT2011-1,596 cc (1.596 L; 97.4 cu in) (79 mm (3.1 in) x 81.4 mm (3.20 in)) I4134 PS (99 kW; 132 hp) @ 6700160 N⋅m (120 lb⋅ft) @ 425011.0:1

Crate engine versions

Crate engine versions of Zetec-SE engines are sold by Ford Power Products under the name ZSG Range.

CodeYearsDisplacement (bore x stroke)/TypePower@rpmtorque@rpmCompression (:1)
ZSG 414?-1,388 cc (1.388 L; 84.7 cu in) (76 mm (3.0 in)x76.5 mm (3.01 in)) I475 PS (55 kW; 74 hp)@5700124 N⋅m (91 lb⋅ft)@350011
ZSG 416?-1,595 cc (1.595 L; 97.3 cu in) (79 mm (3.1 in)x81.4 mm (3.20 in)) I4100 PS (74 kW; 99 hp)@6000146 N⋅m (108 lb⋅ft)@400011

Applications

Engine typeratingsvehicles
1,242 cc (1.242 L; 75.8 cu in) I4 60 PS (44 kW; 59 hp), 109 N⋅m (80 lb⋅ft)
75 PS (55 kW; 74 hp)@6000, 110 N⋅m (81 lb⋅ft)@4000
80 PS (59 kW; 79 hp), 114 N⋅m (84 lb⋅ft)
1,388 cc (1.388 L; 84.7 cu in) I4 75 PS (55 kW; 74 hp), 124 N⋅m (91 lb⋅ft)
80 PS (59 kW; 79 hp)@5700, 124 N⋅m (91 lb⋅ft)@3500
90 PS (66 kW; 89 hp), 125 N⋅m (92 lb⋅ft)
96 PS (71 kW; 95 hp), 125 N⋅m (92 lb⋅ft)
1,499 cc (1.499 L; 91.5 cu in) I4 Ti-VCT 112 PS (82 kW; 110 hp), 140 N⋅m (100 lb⋅ft)
1,596 cc (1.596 L; 97.4 cu in) I4 100 PS (74 kW; 99 hp)@6000, 145 N⋅m (107 lb⋅ft)@4000
100 PS (74 kW; 99 hp)@6000, 150 N⋅m (110 lb⋅ft)@4000
1,596 cc (1.596 L; 97.4 cu in) I4 Ti-VCT 115 PS (85 kW; 113 hp)@6000, 155 N⋅m (114 lb⋅ft)@4150
120 PS (88 kW; 120 hp)@6000, 152 N⋅m (112 lb⋅ft)@4050
105 PS (77 kW; 104 hp)@6000, 150 N⋅m (110 lb⋅ft)@4000-4500
110 PS (81 kW; 110 hp)@6300, 160 N⋅m (120 lb⋅ft)@4100
125 PS (92 kW; 123 hp)@6000, 159 N⋅m (117 lb⋅ft)@4000
1,679 cc (1.679 L; 102.5 cu in) I4 VCT 126 PS (93 kW; 124 hp)@6300, 157 N⋅m (116 lb⋅ft)@4500
155 PS (114 kW; 153 hp)@7000, 162 N⋅m (119 lb⋅ft)@4500
  • 1999-2000 Ford Racing Puma 1.7

Current use

The Ford Sigma engine is produced at Bridgend Ford in Wales.

Today Sigma engines are used by Focus, Fiesta, C-Max and Mondeo. A 110 bhp (82 kW) version is used by Morgan for their 4/4 Roadster since 2009, albeit coupled to a Mazda transmission driving the rear wheels.[2]

1.25/1.4/1.6 L Sigma

These engines in the first generation Focus produced 75 and 100 bhp (75 kW; 101 PS) respectively, but for MkII Focus the 1.4 variant was slightly modified and produced 80 bhp (60 kW; 81 PS). Both engines have belt driven camshafts and Electronic Fuel Injection systems. They weigh 90 kilograms. The 1.6 Ti-VCT was introduced in 2004, it features Variable Cam Timing; this 115 bhp (86 kW; 117 PS) version is used in MkII Focus. A new 105/125 bhp EU5 version is used in the MkIII Focus, also a 1.6 L 120 hp (89 kW) version is used in Ford Fiesta Zetec-S. The Sigma is usually coupled to the Ford IB5 five-speed manual transmission.

Brazil

Today the Sigma engine is present in Brazilian versions of the Fiesta, Focus and Ecosport (1.6L TI-VCT version) and a 1.5 version is used by Ka. This engine is able to use the flex technology.

Power with ethanol:

  • 1.5L Sigma (non TI-VCT) - IB5+ manual transmission
    • Fiesta (2014-2016) - 112 PS
    • Ka (2014-Present) - 110 PS
  • 1.6 Sigma (non TI-VCT) - IB5+ manual transmission (both) and PowerShift (Fiesta Only).
    • Fiesta (2008-2014) - 116 PS
    • Ecosport (2012-Present) - 116 PS
  • 1.6 Sigma TI-VCT - IB5+ manual transmission and PowerShift.
    • Focus (2013-Present) - 135 PS
    • Fiesta (2008-2014) - 128PS
    • Ecosport (2012-Present) - 131 PS

Caterham usage

Some Caterham Cars use modified Ford Sigma engines[3] such as the Caterham Seven 270, which uses a tuned Sigma engine producing 135 hp (101 kW) at 6,800 rpm as a modern equivalent to the original Ford Kent Crossflow engine used in the Lotus 7 from 1957 to 1972.
Ford Sigma 1.6-litre overview Technical features:

  • a high level of running refinement and low emission levels
  • aluminium alloy cylinder block and head
  • cross flow cylinder head
  • structural aluminium oil-pan for increased engine stiffness
  • individual throttle bodies in place of the standard intake manifold
  • twin overhead camshafts each with five bearings
  • sequential multi-port fuel injection system
  • long life, glass fibre reinforced camshaft drive belt with automatic tensioner
  • state-of-the-art Twin Independent Variable Camshaft Timing (on Ti-VCT variant)
CodeDisplacement (bore x stroke)/TypePower@rpmtorque@rpmCompression (:1)
Ford Sigma 1.6 125 hp1,595 cc (1.595 L; 97.3 cu in) (79 mm (3.1 in)?x81.4 mm (3.20 in)?) I4125 PS (92 kW; 123 hp)@6100162 N⋅m (119 lb⋅ft)@535011.0:1
Ford Sigma 1.6 150 hp1,595 cc (1.595 L; 97.3 cu in) (79 mm (3.1 in)?x81.4 mm (3.20 in)?) I4150 PS (110 kW; 150 hp)@6900162 N⋅m (119 lb⋅ft)@560011.0:1
Caterham Sigma 1.6 Ti-VCT EU41,595 cc (1.595 L; 97.3 cu in) (79 mm (3.1 in)?x81.4 mm (3.20 in)?) I4115 PS (85 kW; 113 hp)@6000155 N⋅m (114 lb⋅ft)@415011.0:1

SCCA Spec Racer

The third generation of the SCCA Spec Racer was introduced in 2015,[4] and uses the 1.6 L Sigma engine. The engine is sold by SCCA Enterprises as a sealed unit.

Replacement

In 2012 Ford replaced the Sigma engine with a brand new 3-cylinder 1.0 litre EcoBoost engine for some markets and models. The new engine provides more power and torque with less fuel consumption and less CO2 emissions.[5]

See also

References

  1. ↑ Fuel, performance and emissions Ford Fiesta, Ford.co.uk, 21 April 2009.
  2. ↑ "4/4: Specifications". The Morgan Motor Company. Retrieved 2013-06-05.
  3. ↑ caterhamcars.com
  4. ↑ "Spec Racer Ford". SCCA Enterprises. Retrieved 2016-11-12.
  5. ↑ Ecoboost replaces Duratec, themotorreport.com.au, 05. February 2012.
  • "ZSG Range Leaflet" (PDF). Ford Power Products.
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