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IKCO EF engines

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IKCO EF Engines
Overview
ManufacturerIran Khodro
Also calledNational engine
Production2008–present
Layout
ConfigurationStraight-4
Displacement1.6 L (1,648 cc) EF7
1.5 L (1,497 cc) EFD
1.4 L (1,397 cc) EF4
Cylinder bore78.56 mm (3.09 in)
76 mm (2.99 in)
Piston stroke85 mm (3.35 in)
82.5 mm (3.25 in)
Cylinder block materialCast iron
Cylinder head materialAluminium
ValvetrainDOHC
Compression ratio11:1 - 16.5:1
Combustion
TurbochargerSingle & Twin
Fuel systemMPFI, Diesel Direct Injection & CNG Direct Injection (From late 2011)
Fuel typePetrol, CNG & Diesel
Oil systemWet sump
Cooling systemWater cooling
Output
Power output115 PS (85 kW) - 160 PS (118 kW)
Torque output111 N⋅m (82 lb⋅ft) - 300 N⋅m (221 lb⋅ft)

IKCO EF Engines, also known as National Engines, are a family of four-cylinder engines produced by the Iranian car manufacturer Iran Khodro (IKCO). The first engines in this family, the EF7 series, were designed jointly by Iran Khodro Powertrain Company (IPCO) and F.E.V GmbH of Germany. The later models were designed by IPCO alone. IPCO is the powertrain design and production company of IKCO.[1][2][3]

The first phase of the IKCO EF Engines project, the EF7 Dual-Fuel, was estimated at $80,000,000 US.[4] IKCO aimed to supply 800,000 powertrains by 2010.[5]

EF engines share most of their parts with each other. The EF4 and EF7 are bi-fuel engines that primarily use compressed natural gas (CNG) but can also operate on gasoline. The EFD is a single-fuel diesel engine.

The EF family dual-fuel and petrol-fuel engines have achieved the Euro IV emission standard and are able to achieve the Euro V emission standard with some minor changes.[1] EFD will be the first engine of the family which comes with the Euro IV emission standard as its first release, and is able to achieve the Euro VI emission standard with alterations.

Some prominent suppliers for EF engines are INA for critical variable valve timing (VVT) and other mechanical parts; MAHLE, which supplies some integral components of the engine family such as pistons; and Bosch, which supplies the ECU, electrically controlled pedal (Drive-by-wire), and many other sensitive electronic parts. All of the parts (except high-tech and sensitive parts) from worldwide companies are produced in Iran under license.

EF7 and EF7+

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The engine's general structure is similar to that of the PSA Group's Peugeot TU5JP4. It has a displacement of 1648cc with a bore of 78.560mm and a stroke of 85mm. This engine was introduced as EF7 dual-fuel in 2008 at Engine Expo Stuttgart, Germany.[6] It is a 16-valve engine incorporating CVVT technology on its intake valves (IPS type).

It features both a lubrication and liquid-cooling system. The EF7 has a direct-drive oil pump[7] that, along with the water pump, oil pump, and oil coolant system, is integrated in one place with the intention to reduce the need for removal of parts for maintenance compared to other engines. Other parts are re-engineered to provide ease in changing the oil filter.

The engines use a three-way Catalytic Converter in order to reach higher emission standards.[7]

All the EF7 variants have passed the NVH tests on their head cylinder and cylinder block.[7] Also, the engines have a blow-by system which provides ventilation for the crankcase and oil pan.[7]

The EF7 assembly line is in Tehran, Iran.

EF7-NA (Dual-Fuel)

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EF7 Dual-Fuel engine (Rear view)
EF7 Dual-Fuel engine (Front view)
Without intake manifold

The EF7-NA reaches its maximum power output at 6000 rpm and maximum torque at 3250 rpm while using either CNG or petrol.

IKCO has indicated an engine timing belt change interval of 180,000 km. IKCO states that if the engine runs only on CNG, it will not need any special maintenance until 250,000 km (on average),[8] and if the engine runs on both CNG and gasoline, the number will increase to more than 250,000 km.

Due to challenges in feasibility, numerous requests for single-fuel Samand with EF7 engine and petrol-based EF7 engine could not be me. In late 2009, IKCO wanted IPCO to start a project to remove CNG-necessary engine parts. Thus, the project was completed in about 3 months, and the tests were completed in the second quarter of 2010. Only the ECU program is changed in this engine version, and CNG functions are disabled. This ECU program supports immobilisers, too. Currently, consumers are able to purchase the Samand with a single-fuel EF7 engine.

In September 2010, IKCO announced the design and production of a modified EF7 engine with reduced fuel consumption and air pollution.[9] The engine was envisioned to use direct fuel injection technology for both petrol and CNG, which would have made IKCO the first manufacturer in the world to employ this technology for CNG engines.[9]

Technical details

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  • EF7 Dual-Fuel engine piston[13]
    EF7 Dual-Fuel engine piston[13]
  • EF7 Cylinder head[14] (Another view)
    EF7 Cylinder head[14]
    (Another view)
  • EF7 Intake Manifold[14]
    EF7 Intake Manifold[14]

EF7 turbocharged (TC7)

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A new variant of the EF7 family was introduced in 2009 with a turbocharger and named EF7-TC or TC7. It is installed on the Soren ELX and Dena Plus.

To resist the high temperature of engine combustion, about 35 kg of nickel is used in the cylinder block alloy.[7]

In addition, a new lubricant will be produced for the engine by the Behran Oil company.

IP-Co has estimated the engine's life cycle to be around 5 years.[16]

EF7 petrol based

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In an interview[17] with one of the EF7 project managers, the manager confirmed the rumors of an upcoming EF7 engine.

The project of the new engine is currently in its first phases, and in the end, there will be an EF7 fully compatible with gasoline.

The new engine will have many changes compared to the EF7 dual-fuel engine. Some of the changes will be: Reducing the engine compression ratio from 11:1 to 10.5:1, replacing parts that are resistant and compatible with high temperature of combustion of CNG with parts with weaker resistance to reduce production costs (new parts are fully compatible with the temperature rising from the combustion of petrol) and some other changes.

In addition, the new engine will use a newer ECU program and functions.

Another part of the engine that has changed in comparison to his father, EF7, will be the catalytic converter. The change is due to making the engine petrol-based and there is no need to use a CNG-compatible catalytic converter for the engine.

The engine output is estimated to be between 118 PS (87 kW)-126 PS (93 kW). It depends on the company strategy, decisions and plans.

It is expected that the engine will be shown to the public in mid-2011.

EF7 Plus

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The EF7 Plus (or EF7+) series of engines reduces fuel consumption and pollution emission from Euro IV to Euro V standard.[18]

The series include the EF7+ NA (or EF7P-NA) and the EF7+ TC (or EF7P-TC or TC7+).[18]

Performance

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Model Power Torque Production since Utilisation on Compression Ratio FC(Urban) FC(Combined) FC(Extra Urban) Notes
EF7-NA Petrol: 112 PS (82 kW)
CNG: 100 PS (74 kW)
at 6000 rpm[19]		 Petrol: 151 N⋅m (111 lb⋅ft)
CNG: 134 N⋅m (99 lb⋅ft)
3500-4500 rpm[19]		 Early 2009 Samand
Soren
Dena
Dena Plus		 11:1 8.9 L, 7Kg* 7.5 L, 5.6 kg [19] 4.9 L [20]
3.9 kg		 Bi-fuel (petrol-CNG), Euro IV

16-valve, DOHC, HLA Tappets, CVVT, MPFI, Catalytic converter

EF7-TC 149 PS (110 kW)
at 5500 rpm[19]		 215 N⋅m (159 lb⋅ft)
2000-4500 rpm[19]		 Late 2010 Soren
Dena Plus		 9.8:1 TBD 7.3 L, 5.4 kg [19][21] TBD Bi-fuel (petrol-CNG), Euro IV

16-valve, DOHC, HLA Tappets, MPFI, Turbocharger, Catalytic converter

EF7P-NA Petrol: 113 PS (83 kW)
CNG: ?
at 6000 rpm[18] 		Petrol: 153 N⋅m (113 lb⋅ft)
CNG: ?
at 3500 rpm[18] 		Late 2024 Dena Plus 10.8:1 6.8 L[18] Euro V
EF7P-TC Petrol: 163 PS (120 kW)
CNG: ?
at 5000 rpm[18] 		Petrol: 240 N⋅m (177 lb⋅ft)
CNG: ?
1600-4500 rpm[18] 		Late 2024 Rira

(coming soon) Dena Plus

9.1:1 6.8 L[18] Euro V
    • Fuel consumption in kg for CNG

EF4

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EF4 has displacement of 1397 cc with a bore of TBD mm and a stroke of TBD mm. The engine was introduced to the public in 2009 in Iran. It uses the EF7 cylinder head.

The engine reaches maximum power at 6000 rpm and the maximum torque at 3250 rpm for both CNG and petrol.

It shares almost all of its technologies with the big brother, EF7.

The EF4 assembly line will be in Esfahan, Iran.

The EF4 engine never made it to production nor was it installed in any vehicle.

Performance

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Model Power Torque Utilisation on Compression Ratio FC(Urban) FC(Combined) FC(Extra Urban) Notes
EF4-NA Petrol: 103 PS (76 kW)
CNG: 84 PS (62 kW)
at 6000 rpm[19]		 Petrol: 125 N⋅m (92 lb⋅ft)
CNG: 110 N⋅m (81 lb⋅ft)
3500-4500 rpm[19]		 Runna

(it stopped)

11:1 8.4 L, 6.5 kg 6.9 L, 5.1 kg[19] 4.7 L, 3.7 kg Bi-fuel (petrol-CNG), Euro V

16-valve, DOHC, HLA Tappets, CVVT, MPFI, Catalytic converter

EF4-TC Petrol: 129 PS (95 kW)
CNG: ?
at 6000 rpm[19] 		Petrol: 190 N⋅m (140 lb⋅ft)
CNG: ?
3500-4500 rpm[19] 		6.8 L[19] Bi-fuel (petrol-CNG), Euro V

EFD engines

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EFD diesel engines have a displacement of 1497 cc with a bore of 76 mm and a stroke of 82.5 mm.

EFD engines have a 16-valve design and feature a range of new diesel engine technologies.[22]

Because EFD engines are the first engines from the family to use alternative fuel, this makes a necessity for changing most parts which means there are just some parts of other EF family engines used in them.

Since the initial talks about the project in mid 2008, NIOPDC was the main sponsor of the project (EFD)[22][23] and has supported the project up to 20 million US$.[24]

Iran Khodro and the company wanted to design diesel engines with the properties of being modern, technological and comparable with other new diesel engines in their range, Iran Khodro made a partnership in designing the engines and consulted with AVL in many aspects for gaining the new required technologies to reach to the goals.[24]

IP-Co says production of the non-turbocharged EFD engine costs about 1.7 times more than other EF family engines; but if a customer buys a car using the engine, after not a long time, these costs will be paid back to the consumers due to less fuel consumption and fewer maintenance needs.[23]

Due to the inefficiencies of the Peugeot BE3/5 gearbox and the need for a new gearbox for other IKCO engines, the company started designing a new gearbox for the EFD engines. This new gearbox will handle higher torque and offer greater efficiency compared to the BE3/5.

On November 30, 2010, IKCO announced they would finalise the gear ratios of the new gearbox for EFD in the near future.[25]

Here are IP-Co reasons for initiating the development of a diesel engine (EFD engines):

  • Respond to new territory's fuel policies and changing the domestic fuel basket from Petrol and CNG to Petrol, CNG and Diesel
  • Owning an efficient diesel powertrain which is on the knowledge edges of sufficiency, fuel consumption, and pollution
  • Making the Diesel engines technologies native in Iran
  • Using the maximum R & D knowledge of combustion engines which is gained from designing other engines
  • Designing the engines based on the EF family engines to reduce costs of development and investments

These are some of the technologies that are used in the implementation of EFD engines:

EFD-NA

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The EFD-NA (natural aspiration) is the first variant of the EFD family, which was unveiled on November 17, 2009, by the president of Iran Mahmoud Ahmadinejad in Amol and mobilised with mentioned technologies listed above.

The engine reaches its maximum power at 4000 rpm and maximum torque at 1750 rpm.

It is currently installed on some Samands and Sorens to pass the last required tests.

Other specifications are listed in the Performance section below.

EFD turbocharged

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It will be a double-stage turbocharged engine.

IP-Co has no plans to develop it until its counterpart, the EFD engine, comes to market.

Performance

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Model Power Torque Compression Ratio Maximum Combustion Chamber Pressure Redline Max rpm FC(Combined) Notes
EFD-NA 122 PS (90 kW) @ 4000 rpm 256 N⋅m (189 lb⋅ft) @ 1750 rpm 16.5:1 165 bar 4500 rpm 5500 rpm 5 L Diesel, Euro V

16-valve, DOHC, HLA Tappets, Direct Injection, Common Rail, Turbodiesel, VGT, InterCooler, Glow Plug, EGR, DPF, DOC

EFD-TC 149 PS (110 kW) @ TBD rpm 300 N⋅m (221 lb⋅ft) @ TBD rpm TBD TBD TBD rpm TBD rpm TBD Diesel, Euro V

16-valve, DOHC, HLA Tappets, Direct Injection, Common Rail, 2 x Turbodiesel, VGT, InterCooler, Glow Plug, EGR, DPF, DOC

See also

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References

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  1. ^ a b "Iran to unveil National Engine at Engine Expo 2008". tehran times. 2008-05-05. Archived from the original on 2011-06-14. Retrieved 2010-12-01.
  2. ^ Video on YouTube
  3. ^ "IKCO Acquires Powertrain Technology - Automotives Insight". Autosinsight.com. Archived from the original on 2011-05-24. Retrieved 2010-12-01.
  4. ^ "::: Iran-Tejarat.com :::". iran-tejarat.com. Retrieved 2023-02-02.
  5. ^ "IKCO Acquires Powertrain Technology". Corporate Financing Week. 2010-03-21. Archived from the original on 2011-07-08. Retrieved 2010-12-01.
  6. ^ "IKCO". Ikcopress.com. 2010-01-06. Retrieved 2010-12-01.
  7. ^ a b c d e http://www.kntu-mech.blogfa.com/post-321.aspx Archived 2009-10-03 at the Wayback Machine (in Persian)
  8. ^ Khabar Khodro (Persian)
  9. ^ a b http://www.khabarkhodro.com/detail.asp?id=121819 (Persian)
  10. ^ "Bosch Motorsport" (PDF). Archived from the original (PDF) on 2011-07-08. Retrieved 2010-12-01.
  11. ^ a b c d e f g h i j "Iranian National Engine (EF7)". Valapart.com. Archived from the original on 2010-11-23. Retrieved 2010-12-01.
  12. ^ a b c "Product list". Stam-sanat.com. Archived from the original on 2010-12-03. Retrieved 2010-12-01.
  13. ^ a b "Gasoline engine pistons". Archived from the original on 2011-07-13. Retrieved 2010-08-08.
  14. ^ a b c d "Continental Engines Limited". Baxy.com. Retrieved 2010-12-01.
  15. ^ "Tara Zob". Tzmco.com. Archived from the original on 2011-07-17. Retrieved 2010-12-01.
  16. ^ CarNP Archived 2011-02-25 at the Wayback Machine (Persian)
  17. ^ PHalls (Persian)
  18. ^ a b c d e f g h "EF7+ engine family" (PDF).
  19. ^ a b c d e f g h i j k l "EF7 engine family" (PDF).
  20. ^ "FarsNews". FarsNews. 2009-12-21. Archived from the original on 2011-09-28. Retrieved 2010-12-01.
  21. ^ "IKCO". Ikcopress.com. 2009-11-17. Retrieved 2010-12-01.
  22. ^ a b http://www.naftnews.net/print-7145.html (in Persian)
  23. ^ a b http://www.asriran.com/fa/print/90910 (Persian)
  24. ^ a b "بازگشت به‌خودروهای سواری دیزلی". Hamshahrionline.ir. Archived from the original on 2011-07-26. Retrieved 2010-12-01.
  25. ^ IKCO Archived 2016-09-14 at the Wayback Machine (Persian)
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