The Vulcan was optional in the L and GL sedans, and standard in the L and GL wagons and all LX models. The standard engine in the L and GL sedans and the only engine offered in the MT-5 sedan and wagon was the HSC four cylinder. By the end of its first year of sales, the Taurus was offered in four trim levels: L, MT-5, GL, LX.
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The Vulcan was the only engine available in the Taurus when it launched Ford introduced the 2.5 L (152.6 cu in) HSC inline four as the base engine on certain models late in the Taurus' first year and later offered a model with a 5-speed manual transmission. Another set of about thirty prototype engines were installed in a fleet of trucks that logged between 100,000 and 200,000 mi (161,000 and 322,000 km), after which the engines were torn down and inspected, deficiencies noted and parts redesigned, after which the engines were remanufactured and returned to service for a second phase of testing. These were driven approximately 100,000 mi (161,000 km), roughly twice the usual test distance, and evaluated in both hot and cold environments. : 120 Later test engines were installed in a group of Ford LTDs and Mercury Marquis. Some of the first engines were installed in front wheel drive Chevrolet Celebritys. : 119 In their efforts to produce a lightweight block, the walls had been made very thin, while the structure was quite rigid, which caused the cracking.
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In the spring of 1982 forty phase one prototype engines blocks were cast, all of which cracked when they were assembled. The engine block was cast at Ford's Cleveland Casting Plant with tooling built by Sherwood Metal Products, the intake came from Ford's Essex Aluminum Casting, and the engine was assembled at Ford's Lima engine plant in Lima, Ohio. The intake was redesigned to make it more appealing, which had the side effect of allowing it to flow more air. : 118 The appearance of the engine was also important. : 119įord's parts and service division asked that the oil filter, sparkplugs, oil dipstick be up front and accessible, and that key underhood touchpoints be colored yellow for easy identification. During development various different technologies were evaluated, including two different fuel injection systems, a turbocharged version, an engine with two sparkplugs per cylinder, a variable displacement model with cylinder deactivation, and one using Ford's experimental programmed combustion (PROCO) technology. : 117 Displacement grew from an original 2.8 L to 3.0 L. Fitting the engine into the Taurus' engine bay was a challenge, and resulted in the engine's 60° vee angle. The resulting Vulcan V6 was a clean-sheet, all metric, engine design. : 117 Market studies indicated that American buyers were more interested in having a reliable, low maintenance engine that in owning a sophisticated engine for its own sake. The engine was to develop no less than 130 hp (97 kW), travel 7,500 mi (12,100 km) before requiring an oil change, go 100,000 mi (161,000 km) before requiring major maintenance, run for five minutes after a major cooling system failure, and offer a "limp home" mode. The car was expected to be able to accelerate from 0–60 mph (0–97 km/h) in a maximum time of 11.5 seconds. Performance goals were set for both the car and its engine. Two years into the project, Thomas Howard was chosen to head up internal engine development. : 54, 55 Neither of Ford's existing V6 engines were appropriate for this use their 3.8 L Essex V6 was too wide and produced excessive vibration, while their 2.8 L Cologne V6 was too large and heavy. As the project progressed, the future car's size and weight increased to the point where a V6 of 2.8 L was added to the powertrain options. The four cylinder was also expected to be provided by a supplier outside of Ford. The Sigma/DN5 car was originally to be powered by a straight-four engine, with no provision for a V8 and no expectation that a V6 would be needed. Originally called Sigma, the project was renamed DN5 and resulted in the 1986 Ford Taurus and Mercury Sable. The project was led by vice president and head of product planning and research Lewis Veraldi. The Vulcan V6 engine was developed as part of a project at Ford to replace their mid-size LTD and Marquis sedans and wagons.
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