Ford Sigma engine
The Ford Sigma is a small straight-4 automobile engine introduced in 1995 by Ford Motor Company. Its first evolution was sold as the Zetec-S (not to be confused with the trim level), then Zetec-SE and finally, in later years, renamed Duratec.[3] The last upgrade of the engine is named Duratec Ti-VCT. Conceived for Ford's smaller models, the motor was intended to replace the older HCS (a derivative of the even older Kent unit) and smaller capacity CVH units.
| Ford Sigma engine | |
|---|---|
 | |
| Overview | |
| Manufacturer | Ford Motor Company, Yamaha Motor Company[1][2] |
| Also called | Zetec-S Zetec-SE Duratec Duratec Ti-VCT |
| Production | 1995–present |
| Layout | |
| Configuration | Straight-4 |
| Displacement | 1.2 L; 75.8 cu in (1,242 cc) 1.4 L; 84.7 cu in (1,388 cc) 1.5 L; 91.5 cu in (1,499 cc) 1.6 L; 97.4 cu in (1,596 cc) 1.7 L; 102.5 cu in (1,679 cc) |
| Cylinder bore | 71.9 mm (2.83 in) 76 mm (2.99 in) 79 mm (3.11 in) 80 mm (3.15 in) |
| Piston stroke | 76.5 mm (3.01 in) 81.4 mm (3.20 in) 83.5 mm (3.29 in) |
| Cylinder block material | aluminium |
| Cylinder head material | aluminium |
| Valvetrain | SOHC 2 valves x cyl. DOHC 4 valves x cyl. w/Ti-VCT |
| Compression ratio | 10.0:1, 10.3:1, 11.0:1, 11.8:1 |
| Combustion | |
| Supercharger | On 2002 1.0–litre Ford Fiesta |
| Fuel system | Electronic fuel injection Sequential multi-port FI |
| Management | PCM, Siemens |
| Fuel type | gasoline |
| Oil system | Pressure-fed with full flow oil filter |
| Cooling system | Water-cooled |
| Output | |
| Power output | 60–155 PS (44–114 kW; 59–153 hp) |
| Torque output | 109–162 N⋅m (80–119 lb⋅ft) |
| Dimensions | |
| Dry weight | 1.6 L Zetec - 81 kg (179 lb) 1.6 L Duratec - 90 kg (198 lb) |
| Emissions | |
| Emissions target standard | Euro 4, Euro 5 |
| Emissions control systems | Close-coupled, closed loop, three-way catalyst with oxygen sensor |
| Chronology | |
| Predecessor | CVH Engine Valencia-HCS engine |
| Successor | Ford EcoBoost engine |
Introduction and production
As with the Ford Taurus SHO's SHO V6 engine, development of the Zetec-S was a collaborative effort between Ford, Mazda and Yamaha.[1][2] The engine's sounds were refined in the Ford acoustics center in Cologne-Merkenich, Germany.[1] Production of the Zetec-SE was carried out in the Ford Valencia Engine Plant, with Yamaha building the 1.7 L engine blocks in Japan.[1][2]
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. This feature however makes the engine more challenging to rebuild at the end of its working life, since it is not possible to re-machine the bearing ladder as would be the case with a conventional cylinder block - the entire assembly has to be renewed. Despite this however, engine tuners have found novel ways to increase the power of the unit through use of different valves and increasing the compression ratio of the engine through skimming of the cylinder head.
The engine first appeared in the Mk4 Ford Fiesta and the virtually identical Mazda 121 in 1.2 L (1,242 cc) capacity, with 1.4 L (1,388 cc), 1.6 L (1,596 cc) and 1.7 L (1,679 cc) derivatives coming later.
Difference between Zetec-SE/Zetec-S/Duratec/Duratec Ti-VCT
1.25-Litre-Duratec-Engine in a 2009 Ford Fiesta
1.7-Litre-Zetec-S-Engine in a Ford Puma
1.6-Litre-Duratec-Engine with TI-VCT in a 2012 Ford Focus
The Sigma engine was introduced under the Zetec-S name; after the upgrade it was renamed to Zetec-SE, Duratec and Duratec Ti-VCT. The latest upgrade of Sigma is called Ecoboost 1.6 engine (Not to be confused with the smaller 1.0 or larger 2.0/2.3 engines)
Zetec-S/SE
| Code | Years | Displacement | Bore x stroke | Power@rpm | Torque@rpm | Compression |
|---|---|---|---|---|---|---|
| 1.25 Zetec-S/SE | 1995- | 1.2 L; 75.8 cu in (1,242 cc) | 71.9 mm × 76.5 mm (2.83 in × 3.01 in) | 75 PS (55 kW; 74 hp)@5200 | 110 N⋅m (81 lb⋅ft)@4000 | 10.0:1 |
| 1.4 Zetec-S/SE | 1998- | 1.4 L; 84.7 cu in (1,388 cc) | 76 mm × 76.5 mm (2.99 in × 3.01 in) | 75 PS (55 kW; 74 hp)@5000 | 124 N⋅m (91 lb⋅ft)@3500 | 11.0:1 |
| 1995- | 90 PS (66 kW; 89 hp)@5500 | 123 N⋅m (91 lb⋅ft)@4000 | 10.3:1 | |||
| 1.6 Zetec-S/SE | 1998- | 1.6 L; 97.4 cu in (1,596 cc) | 79 mm × 81.4 mm (3.11 in × 3.20 in) | 100 PS (74 kW; 99 hp)@6000 | 145 N⋅m (107 lb⋅ft)@4000 | 11.0:1 |
Zetec-S
| 1.7 Zetec-S VCT | 1997- | 1.7 L; 102.5 cu in (1,679 cc) | 80 mm × 83.5 mm (3.15 in × 3.29 in) | 125 PS (92 kW; 123 hp)@6300 | 157 N⋅m (116 lb⋅ft)@4500 | 10.3:1 |
| 1999- | 155 PS (114 kW; 153 hp)@7000 | 162 N⋅m (119 lb⋅ft)@4500 | ||||
The 1.7 L; 102.5 cu in (1,679 cc) engines uses a heavily modified 1.4 L engine block and features Variable Cam Timing on the inlet camshaft. This displacement has only been used in the Ford Puma. A 155 PS (114 kW; 153 hp) version of this engine was developed 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 Volkswagen 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 cast 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 95 PS (70 kW; 94 hp) version was released for the Ford Fiesta, to compete with the 1.0 Turbo 16v 112 PS (82 kW; 110 hp) version of the Volkswagen Gol.
In 2001 the Zetec RoCam engine was introduced in Europe, but labeled as Duratec 8v, for the Ka and Fiesta. Later a 1.6–litre version was also released for the SportKa and StreetKa. 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 of 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:
- 101/106 hp 1.6L Flex (Ford Ka)
- 65/68 hp 1.0L Flex (Ford Fiesta)
- 105/111 hp 1.6L Flex (Ford Fiesta/ Fiesta Sedan), (Ford Focus), Ford EcoSport)
Applications
1.6 or 1.6 L; 97.4 or 97.5 cu in (1,596 or 1,597 cc) applications:
- 2003—2008 Ford SportKa 1.6, 95 PS (70 kW; 94 hp) and 100 lb⋅ft (136 N⋅m)
- 2003—2006 Ford StreetKa 1.6, 95 PS (70 kW; 94 hp) and 100 lb⋅ft (136 N⋅m)
Duratec
After an upgrade to the Sigma, Ford renamed it the Duratec.
| Code | Years | Displacement | Bore x stroke | Power | Torque | Compression |
|---|---|---|---|---|---|---|
| 1.25 Duratec | 2008- | 1.2 L; 75.8 cu in (1,242 cc) | 71.9 mm × 76.5 mm (2.83 in × 3.01 in) | 60 PS (44 kW; 59 hp) | 109 N⋅m (80 lb⋅ft) | 11.0:1 |
| 80 PS (59 kW; 79 hp) | 114 N⋅m (84 lb⋅ft) | |||||
| 1.4 Duratec | 2002- | 1.4 L; 84.7 cu in (1,388 cc) | 76 mm × 76.5 mm (2.99 in × 3.01 in) | 80 PS (59 kW; 79 hp) at 5700 | 124 N⋅m (91 lb⋅ft) @ 3500 | |
| 2008- | 96 PS (71 kW; 95 hp) | 125 N⋅m (92 lb⋅ft) | ||||
| 1.6 Duratec | 2004- | 1.6 L; 97.4 cu in (1,596 cc) | 79 mm × 81.4 mm (3.11 in × 3.20 in) | 100 PS (74 kW; 99 hp) at 6000 | 150 N⋅m (111 lb⋅ft) at 4000 |
| Engine | 2008 1.25 Duratec 60/82 hp (61 kW; 83 PS) 2008 1.4 Duratec 96 hp (72 kW; 97 PS) | 2007 1.4 Duratec 80 hp (60 kW; 81 PS) | 2007 1.6 Duratec 100 hp (75 kW; 101 PS) |
|---|---|---|---|
| Vehicle | Fiesta Mk6 | Focus MkII face-lift | Focus MkII face-lift |
| Valve gear | DOHC, mechanical tappets, belt drive | DOHC, mechanical tappets, belt drive | DOHC, mechanical tappets, belt drive |
| Valves per cylinder | 4 | 4 | 4 |
| Camshaft drive | Belt | Belt | Belt |
| Crankshaft | Spheroidal | Spheroidal | |
| Crankshaft bearings | 5 | 5 | 5 |
| Engine management | Siemens | Siemens | Siemens |
| Fuel injection | EFI | EFI | EFI |
| Ignition | Electronic distributor-less, wasted spark | Electronic distributor-less, wasted spark | Electronic distributor-less, wasted spark |
| Emission control | Close-coupled, closed loop, three-way catalyst with oxygen sensor | Close-coupled, closed loop, three-way catalyst with oxygen sensor | Close-coupled, closed loop, three-way catalyst with oxygen sensor |
| Emission level | Euro4 | Euro4 | Euro4 |
| Lubrication system | Pressure-fed lubrication system with full flow oil filter | Pressure-fed lubrication system with full flow oil filter | Pressure-fed lubrication system with full flow oil filter |
| Lubrication system capacity with/without filter (L) | 3.8/3.5 | 3.8/3.5 | 4.1/3.75 |
| Cooling system | Water pump with thermostat and valves | Water pump with thermostat and valves | Water pump with thermostat and valves |
| Cooling system capacity, incl. heater | 5.5 | 5.5 | 5.8 |
| Fuel type | ULP | ULP | ULP |
| Fuel grade | 95 RON | 95 RON | 95 RON |
Duratec Ti-VCT
The 1.6 L; 97.4 cu in (1,596 cc) 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.
| Code | Years | Displacement | Bore x stroke | Power | Torque | Compression |
|---|---|---|---|---|---|---|
| 1.5 Duratec Ti-VCT | 2013- | 1.5 L; 91.5 cu in (1,499 cc) | 79 mm × 76.5 mm (3.11 in × 3.01 in) | 112 PS (82 kW; 110 hp) @ 6300 | 140 N⋅m (103 lb⋅ft) @ 4300 | 11.0:1 |
| 1.6 Duratec Ti-VCT | 2004- | 1.6 L; 97.4 cu in (1,596 cc) | 79 mm × 81.4 mm (3.11 in × 3.20 in) | 115 PS (85 kW; 113 hp) @ 6000 | 155 N⋅m (114 lb⋅ft) @ 4150 | |
| 2007- | 110 PS (81 kW; 108 hp) @ 6000 | 152 N⋅m (112 lb⋅ft) @ 4050 | ||||
| 125 PS (92 kW; 123 hp) @ 6300 | 160 N⋅m (118 lb⋅ft) @ 4100 | |||||
| 2008- | 120 PS (88 kW; 118 hp) @ 6300 | |||||
| 2010- | 105 PS (77 kW; 104 hp) @ 6000 | 150 N⋅m (111 lb⋅ft) @ 4000-4500 | ||||
| 2011- | 134 PS (99 kW; 132 hp) @ 6700 | 160 N⋅m (118 lb⋅ft) @ 4250 |
| Engine | 2007 1.6 Duratec Ti-VCT 110 hp (82 kW; 112 PS) 2007 1.6 Duratec Ti-VCT 125 hp (93 kW; 127 PS) 2008 1.6 Duratec Ti-VCT 120 hp (89 kW; 122 PS) 2010 1.6 Duratec Ti-VCT 120 hp (89 kW; 122 PS) | 2007 1.6 Duratec Ti-VCT 115 hp (86 kW; 117 PS) | 2011 1.6 Duratec Ti-VCT 105 hp (78 kW; 106 PS)/125 hp (93 kW; 127 PS) |
|---|---|---|---|
| Vehicle | Mondeo Mondeo face-lift Fiesta Mk6 | Focus MkII face-lift | Focus MkIII |
| Valve gear | DOHC, tappets | DOHC | DOHC, twin independent variable cam timing |
| Valves per cylinder | 4 | 4 | 4 |
| Included angle between valves | 41.75° | ||
| Valve sizes | Intake 30 mm (1.2 in), exhaust 24.1 mm (0.95 in) | ||
| Camshaft drive | Belt | Belt | Belt with dynamic tensioner |
| Crankshaft | 4 counter-weights | Cast iron, 4 counter-weights | |
| Crankshaft bearings | 5 | 5 | |
| Engine management | Siemens ECM EMS2101 16-bit | Siemens | Siemens ECM EMS2101 16-bit |
| Fuel injection | EFI | EFI | EFI |
| Ignition | Tower coil | Electronic distributor-less | |
| Emission control | Hego/CMS dual binary sensors | Close-coupled, closed loop, three-way catalyst with oxygen sensor | Close-coupled, closed loop, three-way catalyst with oxygen sensor |
| Emission level | Euro4 | Euro4 | Euro5 |
| Lubrication system | Pressure-fed lubrication system with full flow oil filter | Pressure-fed lubrication system with full flow oil filter | |
| Lubrication system capacity with/without filter (L) | 4.1/3.75 | 4.1/ | |
| Cooling system | Water pump with thermostat and valves | Water pump with thermostat and valves | |
| Cooling system capacity, incl. heater | 6.0 | 5.5 | |
| Fuel type | ULP | ULP | ULP |
| Fuel grade | 95 RON | 95 RON | 95 RON |
Crate engine versions
Crate engine versions of Zetec-SE engines are sold by Ford Power Products under the name ZSG Range.
| Code | Years | Displacement | Bore x stroke | Power@rpm | torque@rpm | Compression |
|---|---|---|---|---|---|---|
| ZSG 414 | ?- | 1.4 L; 84.7 cu in (1,388 cc) | 76 mm × 76.5 mm (2.99 in × 3.01 in) | 75 PS (55 kW; 74 hp)@5700 | 124 N⋅m (91 lb⋅ft)@3500 | 11.0:1 |
| ZSG 416 | 1.6 L; 97.3 cu in (1,595 cc) | 79 mm × 81.4 mm (3.11 in × 3.20 in) | 100 PS (74 kW; 99 hp)@6000 | 146 N⋅m (108 lb⋅ft)@4000 | ||
Applications
| Displacement | ratings | vehicles |
|---|---|---|
| 1.2 L; 75.8 cu in (1,242 cc) | 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) |
| |
| 1.4 L; 84.7 cu in (1,388 cc) | 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) |
| |
| 1.5 L; 91.5 cu in (1,499 cc) (with Ti-VCT) | 112 PS (82 kW; 110 hp), 140 N⋅m (103 lb⋅ft) |
|
| 1.6 L; 97.4 cu in (1,596 cc) | 100 PS (74 kW; 99 hp)@6000, 145 N⋅m (107 lb⋅ft)@4000 |
|
| 100 PS (74 kW; 99 hp)@6000, 150 N⋅m (111 lb⋅ft)@4000 |
| |
| 1.6 L; 97.4 cu in (1,596 cc) (with Ti-VCT) | 115 PS (85 kW; 113 hp)@6000, 155 N⋅m (114 lb⋅ft)@4150 |
|
| 120 PS (88 kW; 118 hp)@6000, 152 N⋅m (112 lb⋅ft)@4050 |
| |
| 105 PS (77 kW; 104 hp)@6000, 150 N⋅m (111 lb⋅ft)@4000-4500 |
| |
| 110 PS (81 kW; 108 hp)@6300, 160 N⋅m (118 lb⋅ft)@4100 |
| |
| 125 PS (92 kW; 123 hp)@6000, 159 N⋅m (117 lb⋅ft)@4000 |
| |
| 1.7 L; 102.5 cu in (1,679 cc) (with 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 |
|
Current use
The Ford Sigma engine is produced at Bridgend Ford in Wales, U.K. and at Taubate Engine & Transmission Plant, Taubate, São Paulo, Brazil. Today Sigma engines are used by Focus, Fiesta, C-Max and Mondeo. A 110 bhp (82 kW; 112 PS) version is used by Morgan for their 4/4 Roadster since 2009, albeit coupled to a Mazda transmission driving the rear wheels.[4]
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 kg (198 lb). 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 bhp (78 kW; 106 PS)/125 bhp (93 kW; 127 PS) EU5 version is used in the MkIII Focus, also a 1.6 L 120 hp (89 kW; 122 PS) version is used in Ford Fiesta Zetec-S. The Sigma is usually coupled to the Ford IB5 five-speed manual transmission.
Brazil
Recently the Sigma engine was present in modern Brazilian versions of the Fiesta, Focus and Ecosport (1.6L TI-VCT version) and a 1.5 version was used by Ka. This engine was able to use the flex technology.
Power with ethanol:
- 1.5L Sigma (non TI-VCT) - IB5+ manual transmission
- Fiesta (2014-2016) - 112 PS (82 kW; 110 hp)
- Ka (2014–Present) - 110 PS (81 kW; 108 hp)
- 1.6 Sigma (non TI-VCT) - IB5+ manual transmission (both) and PowerShift (Fiesta Only).
- Fiesta (2008-2014) - 116 PS (85 kW; 114 hp)
- Ecosport (2012–Present) - 116 PS (85 kW; 114 hp)
- 1.6 Sigma TI-VCT - IB5+ manual transmission and PowerShift.
- Focus (2013–Present) - 135 PS (99 kW; 133 hp)
- Fiesta (2008-2014) - 128 PS (94 kW; 126 hp)
- Ecosport (2012–Present) - 131 PS (96 kW; 129 hp)
- In 2018 the Sigma engine was replaced in all Ford compact/subcompact cars to the newer and stronger "Dragon" engine, displacing 1.5L with a 3-Cylinder layout and with a power output of 136HP.
Caterham usage
Some Caterham Cars use modified Ford Sigma engines[5] such as the Caterham Seven 270, which uses a tuned Sigma engine producing 135 hp (101 kW; 137 PS) 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)
| Code | Displacement | Bore x stroke | Power@rpm | torque@rpm | Compression |
|---|---|---|---|---|---|
| Ford Sigma 1.6 | 1.6 L; 97.3 cu in (1,595 cc) | 79 mm × 81.4 mm (3.11 in × 3.20 in)? | 125 PS (92 kW; 123 hp)@6100 | 162 N⋅m (119 lb⋅ft)@5350 | 11.0:1 |
| 150 PS (110 kW; 148 hp)@6900 | 162 N⋅m (119 lb⋅ft)@5600 | ||||
| Caterham Sigma 1.6 Ti-VCT EU4 | 115 PS (85 kW; 113 hp)@6000 | 155 N⋅m (114 lb⋅ft)@4150 | |||
SCCA Spec Racer
The third generation of the SCCA Spec Racer, commonly known as the Gen3 was introduced in 2015,[6] and uses the 1.6 L Sigma engine. The engine is sold by SCCA Enterprises as a sealed unit.
Zetec-E comparison
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 when they 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.
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 lower CO2 emissions.[7]
See also
References
- Binon, Pascal (March 16, 1996). "Un moteur Zetec léger, original et au bruit raffiné" [A light Zetec engine, original and with a refined sound]. Le Soir (in French). Archived from the original on 2022-03-15.
- Lewin, Tony (July 7, 1997). "Yamaha coats cylinders for Ford Puma". Automotive News. Archived from the original on 2019-03-17.
- Fuel, performance and emissions Ford Fiesta, Ford.co.uk, 21 April 2009.
- "4/4: Specifications". The Morgan Motor Company. Retrieved 2013-06-05.
- caterhamcars.com
- "Spec Racer Ford". SCCA Enterprises. Retrieved 2016-11-12.
- Ecoboost replaces Duratec, themotorreport.com.au, 05. February 2012.
- "ZSG Range Leaflet" (PDF). Ford Power Products.